Boiler Book 2010

The Boiler Book
Produced by the Employees of
Cleaver-Brooks 2008, 2010
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.
e-mail: info@cleaver-brooks.com
Web Address: http://www.cleaver-brooks.com
Printed in the U.S.A.
The Boiler Book is intended for use by qualified engineering

professionals. All information contained herein is subject to
change without notice. Cleaver-Brooks is responsible only 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.
TABLE OF CONTENTS
Firetube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
A1 Promethean Boilers Model CB-LE (Dry-Back) 125-800 HP Low NOx
A2 Promethean Boilers Model 4WI (Wet-Back) 100-800 HP Low NOx
A3 Criterion Boilers Model 4WG (Wet-Back) 100-800 HP Low NOx
A4 Criterion Boilers Model ICB (Intercooled Back) 100-800 HP Low NOx
A5 Model CBL (Wet-Back) 900-1500 HP Low NOx
A6 Model CB (Dry-Back) 15-100 HP
A7 Model CBE (Dry-Back) 60-80 HP
A8 Model CB Ohio Special (Dry-Back) 100-225 HP
A9 Model CEW Ohio Special Boilers (Wet-Back) 100-225 HP
A10 Model CBR Boilers 125-800 HP
A11 Optimized Boiler Package
Commercial Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B

B1 Model FLX Boilers
B2 Model 4 Boilers
B3 Model 5 Boilers
B4 Electric Boilers
B5 ClearFire Model CFC Condensing Hot Water Boilers
B6 ClearFire Model CFH Steam Boilers
B7 ClearFire Model CFV Steam Boilers
B8 CEJS Electrode Boiler
Industrial Watertube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
Economizers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G
Feedwater Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section H
H1 Spraymaster Deaerators (Single Tank)
H2 Spraymaster Deaerators (Duo Tank)
H3 Traymaster Deaerators
H4 Boilermate Deaerators
H5 Surge Tanks
H6 Boiler Feed Systems
H7 Chemical Feed Systems and Metering Pumps
H8 Filters
H9 Softeners
H10 Dealkalizers
H11 Blowdown Separators
H12 Blowdown Heat Recovery Systems
H13 Flash Tank Heat Exchangers
H14 Sample Coolers
System Fundamentals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section I

I1 Boiler Selection Considerations
I2 Hot Water Systems
I3 Steam Systems
I4 General Engineering Data
I5 Alternative Fuels
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section J
Firetube Boilers
FEATURES AND BENEFITS

The Cleaver-Brooks line of firetube boilers include the following features and benefits:
Packaged Design with
Integral Front Head:
Integral front head provides proper burner/boiler compatibility for maximum

efficiency and ease of maintenance.
Packaged boiler is factory assembled, wired, and tested for guaranteed
performance and reliability.
Packaged design allows for easy connection of utilities, minimum start-up
requirements, and lower long-term operational requirements.
Built and tested to ASME standards.
Fully UL cUL approved package.
Single Point
Positioning
Combustion Control
Package:
Accurate, repeatable combustion control for responsiveness to load swings.

Single point linkage assembly for air and fuel simplifies adjustments and reduces
start-up and maintenance costs.
Unique variable contour.cam assembly allows accurate adjustment and enhances
safe operation of the boiler.
Micro-Processor based burner control provides accurate sequencing and
continuous monitoring for optimum safety, efficiency, and reliability.
Low Stack
Temperatures:
Guaranteed efficiency (Promethean) at 25, 50, 75 and 100% firing rate.
Low Excess Air:
Operates at 3% O2 with less than 200 ppm CO for maximum combustion

efficiency.
Reduced fuel and operating costs.
High efficiency and low maintenance requirements.

High Steam Quality:
Large steam space and liberal surface area ensure high steam quality, free from
entrained particles of moisture (98.5% dry).
Quiet Operation:
Integral front head with vibration free combustion air fan provides quiet operation.
Ideal for sound critical applications, like hospitals and schools.
Heavy duty motor with direct drive, maintenance free, case-less fan.
Integral forced draft fan diminishes the need for:
Large diameter breeching.
High chimneys.
Induced draft fans.
Barometric dampers.
Sequencing draft controls.
Thick Fiberglass
Insulation:
2" insulation covered with sturdy sheet metal lagging provides maximum efficiency
and durable construction.
All units finished with hard enamel paint coating.
A-2
09-09
Firetube Boilers
Customer Service and
Support:
Boiler start-up, final adjustment, and operator training provided with all firetube
boilers.
Emergency service response 24 hours a day, 7 days a week, from the industrys
most advanced worldwide computerized parts/service distribution network.
Largest network of factory trained technicians provide:
System trouble shooting.
Operator training.
Customized factory-backed planned maintenance programs.
Total after-sale support.
PRODUCT OFFERING
The firetube product offering is available in the following models.
The Promethean Boiler Model CB-LE 125-800 HP is also a firetube

product offering with the integral burner and low NOx emission.
Four-pass dryback design.
125-800 hp.
150-300 psig high pressure steam.
15 psig low pressure steam.
30 or 125 psig hot water.
Natural gas, light oil, or heavy oil firing.
Gas - NOx reductions options 60, 30 ppm (LE), 15-<9 ppm (NT) and
70 ppm NOx with No. 2 oil and 0.015% fuel bound nitrogen.
The Promethean Boiler Model 4WI 100-800 HP (standard offering)
is a firetube product with integral burner providing maximum boiler efficiency, a wide range of size, pressures and premium control packages.
Four-pass Wet-Back design.
100 hp through 800 hp.
Gas - NOx reductions options 60-30 ppm (LE), 15-<9 ppm (NT) and
A-3
09-09
Firetube Boilers
The Criterion Boiler Model 4WG 100-800 (standard offering) provides the advantages of the Cleaver-Brooks four-pass wetback design with a
gun burner.
four-pass wetback design.
Natural gas, light oil.
Gas - NOx reductions options 60, 30 ppm (LE), 15-<9 ppm (NT) and
The Criterion Model ICB Boiler 100-800 is a firetube product,
designed to provide high quality steam or hot water. Its revolutionary design
incorporates the key features and benefits of both the Wet-Back and DryBack firetube boilers.
Three or four-pass Intercooled design.
100 800 hp.
150 300 psig high pressure steam.
30 and 125 psig hot water.
Natural gas or light oil firing.
Gas - NOx reductions options 60, 30 ppm (LE) and 70 ppm NOx with
No. 2 oil and 0.015% fuel bound nitrogen.
The CB Model CBL 800-1500 HP Boiler (standard offering) line provides high quality steam utilizing a boiler/burner package (consult factory for
applications over 1500 HP).
Three or four-pass wetback design.
900-1800 hp.
Gas - Low NOx 30 ppm (LE).
A-4
09-09
Firetube Boilers
The Model CB Boiler is the original firetube product offering providing
excellent boiler efficiency, covering the smaller size range.
The Model CBE Boiler (standard offering) provides high quality steam or
hot water, utilizing a baseline boiler/burner design.
Three-pass dryback design.
60-80 hp.
Natural gas or light oil.
The Model CB Ohio Special Boiler (standard offering) design is based
on operator requirements for the state of Ohio, under the rules and regulations for unattended units.
Four-pass dryback design (100 hp).
Two-pass dryback design (125-225 hp).
150, 200 and 250 psig high pressure steam.
The Model CEW Ohio Special Boiler (standard offering) baseline design
is based on operator requirements for the state of Ohio, under the rules and
regulations of unattended units.
Three-pass wetback design.
100-225 hp.
A-5
09-09
Firetube Boilers
Natural gas or light oil.
The Model CBR Ohio Special Boiler
125-800hp.
Steam and hot water.
Same available pressures as equivalent Model CB/CBLE/CBW/4WI.
Capable of firing natural gas, #2-#6 oil, bio-gas, digester gas or town
gas.
Low NOx capabilitiesnatural gas only.
Containerization from 125-800hp will reduce delivered to jobsite
price for large boilers that would otherwise be shipped on flatracks.
Enhanced heat transfer through the use of rifled tubes enables
Cleaver-Brooks to reduce the number of tubes, thus reducing the
overall weight and shell diameters while maintaining high fuel-to steam
efficiency.
MODEL NUMBER, FUEL SERIES NUMBER, HORSEPOWER, AND DESIGN PRESSURE

The model designation for Cleaver-Brooks firetube boilers includes the following:
Light Oil: Series 100
Natural Gas: Series 700
Heavy Oil: Series 600
Light Oil and Natural Gas: Series 200
Heavy Oil and Natural Gas: Series 400
For example, a model CB700-100-150ST would represent a model CB boiler, natural gas fired, 100 hp, 150 psig steam design pressure.
All Cleaver-Brooks firetube boilers are built in accordance with ASME Codes and,
with the exception of the Ohio Special Boilers and CBL Boilers, UL/cUL standards.
Insurance requirements (e.g., Industrial Risk Insurance IRI, Factory Mutual FM,
etc.) or special local code requirements may dictate additional controls or equipment to be included. Please contact your local Cleaver-Brooks authorized representative for assistance in completing your specification or for additional information
and optional equipment.
A-6
09-09
09-09
03-08
60" 125-200 hp
78" 250-350 hp
96" 400-800 hp
No. 2 Oil,
Gas,
Combination
Oil/Gas
Full Modulation
Rotary
Blue
UL & ULC
Boiler/Burner
Shell Size
Fuel
Firing Method
Air Damper Type
Paint Color
Approvals
100-225 hp
UL & ULC
Boiler/Burner
Blue
Rotary
100-800 hp
Full Modulation
UL & cUL Boiler/

Burner
Blue
Rotary p
Full Modulation
UL & cUL
Boiler/Burner
Blue
Rotary
Full Modulation
800-1000 hp
UL & CSA
(Burner Only)
Blue
Rotary & Louvers
Full Modulation
800-1000 hp
No. 6 Oil, Gas,
Combination
Oil/Gas
800-1500 hp
Gas
Blue
UL & cUL
Boiler/Burner
Blue
Multi-Blade
Full Modulation
UL & ULC
Boiler/Burner
Single Blade
15-40 hp
Rotary 50100 hp
50-100 hp
Full Modulation
30-40 hp
Low-HighLow-Off
15-20 hp
On-off
50-100 hp
No. 6 OilB,
Gas,
Combination
Oil/Gas
N/A
Blue
Rotary
Full Modulation
100 hp
No. 6 Oil,
Gas,
Combination
Oil/Gas
N/A
Blue
Multi-Blade
Full Modulation
UL & ULC
Boiler/Burner
Blue
Rotary
Full Modulation
No. 2 Oil,
Gas,
Combination
Oil/Gas
No. 2 Oil,
Gas,
Combination
Oil/Gas
100-225 hp
No. 2 Oil,
Gas,
Combination
Oil/Gas
No. 2 Oil,
Gas,
Combination
Oil/Gas
15-100 hp
No. 2 Oil,
Gas,
Combination
Oil/Gas
900-1800 hp
No. 2 Oil, Gas,
Combination
Oil/Gas
No. 2 Oil,
Natural Gas
Combination Oil/
Gas
No. 2 Oil,
Gas,
Combination
Oil/Gas
100-800 hp
No. 2 Oil, Gas,
Combination
Oil/Gas
100-800 hp
No. 6 OilB,
Gas,
Combination
Oil/Gas
60" 125-200 hp
78" 250-350 hp
96" 400-800 hp
60" 100-225 hp
48" 100 hp
60" 125-225
hp
48" 60-80 hp
36" 15-40 hp
48" 50-100
hp
2- Pass
Dry-Back
Hot Water
30 & 125 psig
Steam
15-300 psig
125-800 Hp
114" or 126"E
3 Pass
Wet-Back
Steam
15-250 psig
100-225 hp
55" 100-125 hp
60" 150-200 hp
72" 250-300 hp
78" 350-400 hp
92" 500-600 hp
106" 700-800 hp
Passes Vary
Steam Only
15-250 psig
CEW Ohio
Special
100-225 HP
(SECTION A9)
60" 100-125 hp
67" 125-200 hp
78" 250-300 hp
85" 350-400 hp
96" 500-600 hp
106" 400-800 hp
3-Pass
Dry-Back
Hot Water
30 & 125 psig
Steam
15-300 psig
60-80 hp
Model CBE
60-80 HP
(SECTION A7)
60" 100-125 hp
67" 125-200 hp
78" 250-300 hp
85" 350-400 hp
96" 500-600 hp
106" 400-800
hp
4-Pass
Dry-Back
Hot Water
30 & 125
psig
Steam
15-300 psig
15-100 hp
Model CB
15-100 HP
(SECTION
A6)
4-Pass Intercooled
3-Pass Option
3 or 4-Pass
Wet-Back
Steam
150-250 psig
900-1800 hp
Model CBL**
900-1800 HP
(SECTION A5
CBR
125-800 HP
International
Only
(SECTION
A10)
4-Pass
Wet-Back
Hot Water
30 & 125 psig
Steam
15-300 psig
100-800 hp
Criterion
Model ICB***
100-800 HP
(SECTION A4)
CB Ohio
Special
100-225 HP
(SECTION
A8)
4-Pass
Wet-Back
Hot Water
30 & 125 psig
Steam
15-300 psig
100-800 hp
Criterion
Model 4WG**
100-800 HP
(SECTION A3)
* Standard NOx reduction to 60 ppm. ** Standard NOX reduction to 75 ppm. ***Contact factory for NOx reduction.
4-Pass
Dry-Back
Hot Water
30 & 125 psig
Hot Water
30 & 125 psig
Boiler Type
Steam
15-300 psig
Steam
15-300 psig
Design
Pressure
100-800 hp
125-800 hp
MODEL
Rated Capacity
Promethean
Model 4WI*
100-800 HP
(SECTION A2)
125-800 HP
(SECTION A1)
(Dry-Back)
Promethean
Model CB-LE*
Table A-1. Quick Comparison of Standard Features for Cleaver-Brooks FIretube Boilers
Firetube Boilers
A-7
Firetube Boilers
Steam Trim-Low
Water Control
(High Pressure
Steam)
Steam Trim-Low
Water Control
(15# Steam)
McD&M
PS 750-MT-120
Warrick 3C-2
Level Master
McD&M 157,
McD&M 193
125-800 HP
(SECTION A1)
Hi Limit (MR),
Oper. Limit,
Firing Rate
30-800 hp
McD&M
PS 750-MT120
Warrick 3C-2
Level Master
McD&M 157,
McD&M 193
Promethean
Model 4WI*
100-800 HP
(SECTION A2)
HPS-Std
LPS-Conn. Only
Hi Limit (MR),
Oper. Limit,
Firing Rate
McD&M
PS 750-MT-120
Warrick 3C-2
McD&M 157
McD&M 157,
McD&M 193
Criterion
Model 4WG**
100-800 HP
(SECTION A3)
HPS-Std
LPS-Conn. Only
Hi Limit (MR),
Oper. Limit,
Firing Rate
McD&M
PS 750-MT-120
Warrick 3C-2
McD&M 157
McD&M 157,
McD&M 193
Criterion
Model ICB***
100-800 HP
(SECTION A4)
HPS-Std
Hi Limit (MR),
Oper. Limit,
Firing Rate
N/A
Warrick 3C-2
Level Master
McD&M 193-7
Model CBL**
900-1800 HP
(SECTION A5
HPS-Std
LPS-Conn.
Only
Hi Limit
(MR),
Oper. Limit,
Firing Rate
30-80 hp
McD&M
PS 750-MT120
Warrick 3C-2
Level Master
McD&M 157
Model CB
15-100 HP
(SECTION
A6)
Hi Limit (MR),
Oper.Limit,
Firing Rate
McD&M
PS 750-MT120
Warrick 3C-2
McD&M 157
McD&M 157
Model CBE
60-80 HP
(SECTION A7)
Hi Limit
(MR),
Oper.Limit,
Firing Rate
N/A
Warrick 3C-2
Level Master
McD&M 157
CB Ohio
Special
100-225 HP
(SECTION
A8)
Hi Limit (MR),
Oper.Limit,
Firing Rate
N/A
Warrick 3C-2
McD&M 157
McD&M 157
CEW Ohio
Special
100-225 HP
(SECTION A9)
Hi Limit (MR),
Oper. Limit,
Firing Rate
McD&M
PS 750-MT-120
Warrick 3C-2
Level Master
McD&M 157
CBR
125-800 HP
International
Only
(SECTION
A10)
Table A-1. Quick Comparison of Standard Features for Cleaver-Brooks FIretube Boilers (Continued)
Steam Trim Aux

Low Water Control
Hi Limit (MR),
Oper. Limit,
Firing Rate
HPS-Std
LPS-Conn.
Only
Promethean
Model CB-LE*
Water Trim-Low
Water Control
HPS-Std
LPS-Conn. Only
HW-Std.
Air Vent
Connection
No
Yes
No
Yes
No
No
HW-Std.
No
No
HW-Std
N/A
Yes
N/A
No
Yes
HW-Std.
No
No
HW-Std.
HPS-Std
LPS-Conn.
Only
Hinge
No
Yes
N/A
HPS-Std
LPS-Conn.
Only
Davit
No
No
N/A
HPS-Std
LPS-Conn.
Only
No
Yes
HW-Std.
HPS-Std
LPS-Conn.
Only
(Dry-Back)
Controls
Steam & Hot
Water Controls
HW-Std.
Stack
Thermometer
Davit
09-09
MODEL
Surface Blowoff
Conn. & Dip
Tube on top C/L
Drain Valve-HW
&
15 psig-Steam
Davit
Hinge 15100 HP
2 inch
Davit
Davit
3 Phase
Davit
2 Inch
Davit
Hinge 100 hp
Davit 125225 hp
3 Phase
Front Door
2 inch
Hinge 125-200
hp
Davit /Hinge
250-800 hp
Davit
3 Phase
Hinge 100-125
hp
Davit/Hinge
150-800 hp
2 inch
Hinge 125-200
hp
Davit /Hinge
250-800 hp
2 inch
60-80 hp1 Phase
Hinge 15100 hp
2 Inch
3 Phase
Davit
2 inch
3 Phase
Davit
2 Inch
3 Phase
Davit
2 inch
3 Phase
Davit 100-800
hp
2 inch
3 Phase
Davit
Insulation
3 Phase
Rear Door
Standard
Voltage
Requirements
A-8
03-08
09-09
03-08
Yes
Cleaver-Brooks
CB780E
Infrared
Front Head with

Key Lock
LD, FV, LW, FF
Interrupted Gas
Pilot-Gas, No. 2
Oil & All Combination
High Radiant
Multi-PortAll Except
125-200 hpAnnular Entry
Control Circuit
Transformer
Flame Safeguard
Control
Scanner Type
Control Panel
Location
Indicating Lights
Type of Pilot
Gas Burner Type
High Radiant
Multi-Port-
High Radiant
Multi-Port 100
hp
Annular 125225 hp
High Radiant
Multi-Port
100 hp
Annular 125225 hp
High Radiant
Multi-Port
High Radiant
Multi-PortAll Except
125-200 hpAnnular Entry
High Radiant
Multi-Port
High Radiant
Multi-Port-
High Radiant
Multi-Port
Spark Ignited
Oil Pilot No.2
Oil
No. 2 Oil
Direct Spark
Ignition
60-100 hp
Direct Spark
Ignition-No.
2 Oil 15-40
hp
High Radiant
Multi-Port
Interrupted Gas
Pilot-Gas, No. 2
Interrupted
Gas Pilot-Gas,
No. 2 Oil & All
Combination
Interrupted
Gas PilotGas, No. 6
Oil & All
Combination
Interrupted
Gas Pilot-Gas,
No. 2 Oil & All
Combination
Interrupted
Gas PilotGas,
No. 6 Oil &
All
Combination
15-80 hp
Interrupted
Gas Pilot-Gas,
No. 2 Oil,
No. 6 Oil
&
All Combination
Interrupted Gas
Pilot-Gas, No. 2
Oil All Combination
Interrupted Gas
Pilot-Gas, No. 2
Interrupted
Gas Pilot-Gas,
No. 2 Oil, No. 6
Oil & All
Combination
100-800 hp
Spark Ignited
Oil Pilot-No.
2 Oil
50-80 hp
LD, FV, LW, FF
LD, FV, LW, FF
Front Head with

Key Lock
LD, FV, LW,
FF
Burner without
Key Lock
Infrared
LD, FV, LW, FF
Front Head
with Key
Lock
Burner without
Key Lock
Ultraviolet
50-80 hp
LD, FV, LW,
FF
Front Head
with
Key Lock
Infrared
Ultraviolet
Infrared
LD, FV, LW,

FF
Burner without
Key Lock
Ultraviolet
(Gas & No. 2
Oil)
Infrared (No. 6
Oil)
Cleaver-Brooks
CB780E
CleaverBrooks
CB120E
CleaverBrooks
CB780E
CleaverBrooks
CB120E
CleaverBrooks
CB780E
LD, FV, LW, FF
On Burner
without Key
Lock
Ultraviolet
CleaverBrooks
CB120E
LD, FV, LW, FF
Burner without
Key Lock
Ultraviolet
Cleaver-Brooks
CB120E
Cleaver-Brooks
CB120E
Yes
Yes
Control Circuit
&
All 3 Phase
Loads
Except Remote
Oil Pump
Yes
Control Circuit
&
All 3 Phase
Loads
Except Remote
Oil Pump
CEW Ohio
Special
100-225 HP
(SECTION A9)
Yes-3 Phase
Only
Control Circuit &

All 3 Phase
Loads
Except
Remote
Oil Pump
CBR
125-800 HP
International
Only
(SECTION
A10)
Yes
Control Circuit
&
All 3 Phase
Loads
Except
Remote
Oil Pump
Control Circuit &

All 3 Phase
Loads
Except
Remote
Oil Pump
Control Circuit
&
All 3 Phase
Loads
Except
Remote
Oil Pump
Yes
Model CBE
60-80 HP
(SECTION A7)
Model CB
15-100 HP
(SECTION
A6)
Model CBL**
900-1800 HP
(SECTION A5
CB Ohio
Special
100-225 HP
(SECTION
A8)
50-800 hp
LD, FV, LW, FF
Front Head
with
Key Lock
Infrared
CleaverBrooks
CB780E
Yes
Yes
Control Circuit &

All 3 Phase
Loads
Except Remote
Oil Pump
Control Circuit &

All 3 Phase
Loads
Except Remote
Oil Pump
Control Circuit
&
All 3 Phase
Loads
Except Remote
Oil Pump
Yes
Criterion
Model ICB***
100-800 HP
(SECTION A4)
Criterion
Model 4WG**
100-800 HP
(SECTION A3)
Promethean
Model 4WI*
100-800 HP
(SECTION A2)
Control Circuit &

All 3 Phase
Loads
Except Remote
Oil Pump
125-800 HP
(SECTION A1)
Fuse Protection
MODEL
(Dry-Back)
Promethean
Model CB-LE*
Firetube Boilers
A-9
Solenoid
Metering Valve
Main Oil Valves
Oil Control
System
A-10
09-09
03-08
Yes
Yes
Yes
Yes
Yes
Yes
Start-Up Included
50-800 hp
+ or-0.50"
W.C.
+ or-0.25"
W.C.
With FGR
Yes
Yes
+ or-0.25"
W.C.
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.
100-800 hp
+ or-0.25" W.C.
.
+ or-0.25" W.C.
Maximum Stack
Pressure
Variation
Uncontrolled
120-140 ppm
NOx
Uncontrolled
120-140 ppm
NOx
Uncontrolled
120-140 ppm
NOx
OptionalInduced FGR
30 ppm
Uncontrolled 75
ppm NOx
75-30 ppm LE
Uncontrolled 75
ppm NOx
75-30 ppm LE
15-<9 ppm NT
100-800 hp
60-20 ppm LE
15-<9 ppm NT
No. 6 Oil
100-225 hp
Remote
N/A
No. 6 Oil
50-800 hp,
Remote
Yes
+ or-0.25" W.C.
Uncontrolled
20-140 ppm
NOx
Yes
+ or-0.25" W.C.
Induced FGR
(LE Option)
125-800 hp
20-60 ppm
(Natural Gas)
15-<9 ppm NT
Included
No. 2 Oil
125-800 hp
Remote
Included
No. 2 Oil
100-225 hp
Remote
Included
Metering Valve
No. 2 Oil
100-225 hp
Remote
Metering System
Solenoid
Air Atomizing
Yes
Yes
Regulating
actuator
Butterfly Valve
Motorized
CBR
125-800 HP
International
Only
(SECTION
A10)
Included
Metering
Valve
Solenoid
Air Atomizing
Air Atomizing
Solenoid
Yes
Yes
Included
Butterfly Valve
Solenoid,
Motorized
Yes
Yes
Regulating
actuator
Butterfly
Valve
Motorized
CEW Ohio
Special
100-225 HP
(SECTION A9)
No. 2 Oil 60200 hp Burner

Mounted
Metering System
Solenoid
Pressure
Atomizing
60-80 hp
Air Atomizing
Yes
Yes
Included
Butterfly Valve
Solenoid,
Motorized
Model CBE
60-80 HP
(SECTION A7)
CB Ohio
Special
100-225 HP
(SECTION
A8)
No. 6 Oil
Mounted on
Oil Pump/Oil
Heater Skid
Induced FGR
(LE Option)
125-800 hp
20-60 ppm
(Natural Gas)
15-<9 ppm NT
No. 6 Oil
50-800 hp,
Remote
Included
No. 2 Oil 1540 hp on
Front Head;
50-80 hp
Remote
Included
No. 2 Oil
Remote
Included
Metering
Valve
No. 2 Oil
100-150 hp
Burner Mounted
No. 2 Oil
200-800 hp
Remote
Metering System
Solenoid
Included
Metering System
Motorized
Air Atomizing
Air Atomizing
Pressure
Atomizing
100-150 hp
Air Atomizing
200-800 hp
Solenoid
No-15-50 hp
Yes-60-80 hp
Yes
Included
Butterfly
Valve
Yes
Yes
Regulating
Actuator
Butterfly Valve
Motorized
Yes
Yes
Included
Butterfly Valve
Motorized
Model CBL**
900-1800 HP
(SECTION A5
Model CB
15-100 HP
(SECTION
A6)
No. 2 Oil
100-150 hp
Burner Mounted
No. 2 Oil
200-800 hp
Remote
Metering System
Solenoid
Pressure Atomizing
100-150 hp
Air Atomizing
200-800 hp
Air Compressor
Shipped loose
Yes
Yes
Included
Butterfly Valve
Solenoid, Motorized
Criterion
Model ICB***
100-800 HP
(SECTION A4)
Included
Metering Valve
Solenoid
Air Atomizing
Regulating
actuator
Butterfly Valve
Solenoid, Motorized
Criterion
Model 4WG**
100-800 HP
(SECTION A3)
No. 2 Oil
100-800 hp
Remote
NOx Control
Air Atomizing
Oil Burner Type
Included
Yes
High & Low Gas

Pressure
Switches
No. 2 Oil
125-800 hp
Remote
Yes
Gas Pilot
Regulator
Oil Pump
Yes
Regulating
actuator
Gas Pressure
Regulator
Location of Oil
Pump
Yes
Butterfly Valve
Main Gas
Control System
Motorized
Motorized
MODEL
Main Gas Valve
Promethean
Model 4WI*
100-800 HP
(SECTION A2)
125-800 HP
(SECTION A1)
(Dry-Back)
Promethean
Model CB-LE*
Firetube Boilers
Section A1
Promethean Series Model CB-LE Boilers
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-4
True Boiler/Burner/Low NOx Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-4
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-4
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-4
Available Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-4
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-4
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-24
Specifying Boiler Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-24
Efficiency Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-24
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-25
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-28
Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-28
Gas-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-29
Oil-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-33
General Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-33
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-33
Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-33
Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-33
Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-33
Sample Specifications (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-43
Sample Specifications (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-55
A1-1
09-09
Promethean Series Model CB-LE
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Firetube Boilers
ILLUSTRATIONS
A1-1. CB-LE Steam - 125-200 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1-2. CB-LE Steam - 250-350 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1-3. CB-LE Steam - 400-800 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1-4. CB-LE Hot Water - 125-200 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1-5. CB-LE Hot Water 250-350 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1-6. CB-LE Hot Water 400-800 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1-7. Space Required to Open Rear Head on Model CB-LE Boilers Equipped with Davits . .
A1-8. Model CB-LE Boiler Mounting Piers (60 and 78) . . . . . . . . . . . . . . . . . . . . . . . . .
A1-9. Model CB-LE Boiler Mounting Piers (96) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1-10. Lifting Lug Location, Model CB-LE Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1-11. Predicted Stack Temperature Increase for Pressure Greater Than 125 psig . . . . . . .
A1-12. Standard Gas Train Connection Size and Location . . . . . . . . . . . . . . . . . . . . . . . .
A1-13. Typical Gas Piping Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1-14. Model CB-LE Gas Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1-15. No.2 Oil Connection Size, Location, and Recommended Line Sizes . . . . . . . . . . . .
A1-16. No. 2 Oil Piping, Single Boiler Installation, Remote Oil Pump . . . . . . . . . . . . . . . .
A1-17. No. 2 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . .
A1-18. No. 2 Oil Piping, Multiple Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1-19. No. 2 Oil Transfer Tank Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1-20. Typical Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1-21. Boiler Room Length (Typical Layouts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1-22. Boiler Room Width (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1-23. Breeching Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLES
Table A1-1. Model CB-LE Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A1-2. Model CB-LE Hot Water Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A1-3. Model CB-LE Steam Boiler Dimensions,
60 (15 - 150 psig Design Pressure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A1-6. Model CB-LE Hot Water Boiler Dimensions,
60 (30 and 125 psig Design Pressure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A1-9. Blower Motor Selection - Steam Boilers O 150 psig, all HW boilers . . . . . . . . . . . . . .
Table A1-10. Blower Motor Selection - Steam Boilers >150 psig . . . . . . . . . . . . . . . . . . . . . . . .
Table A1-11. Blower Motor Selection CB-LE NTI Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A1-12. Model CB-LE Boiler Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A1-13. Steam Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A1-14. Hot Water Boiler Relief Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A1-15. Predicted Fuel-to-Steam Efficiencies - Natural Gas A1-26
A1-2
09-09
A1-6
A1-8
A1-10
A1-12
A1-14
A1-16
A1-21
A1-21
A1-22
A1-23
A1-26
A1-32
A1-35
A1-36
A1-36
A1-37
A1-37
A1-38
A1-38
A1-39
A1-41
A1-41
A1-42
A1-5
A1-5
A1-6
A1-8
A1-10
A1-12
A1-14
A1-16
A1-18
A1-18
A1-18
A1-19
A1-20
A1-20
Firetube Boilers
Table A1-16. Predicted Fuel-to-Steam Efficiencies - No. 2 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-27

Table A1-17. CB-LE Boilers - Natural Gas, Emission Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-27
Table A1-18. CB-LE Boilers - No. 2 Oil, Emission Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-27
Table A1-19. Model CB-LE Predicted Sound Levels 30 ppm NOx Systems . . . . . . . . . . . . . . . . . . A1-28
Table A1-20. Standard, Undersize, and Oversize Gas Trains, Model CB-LE Boilers . . . . . . . . . . . . A1-30
Table A1-21. Recommended NTI Gas Train Sizes & Pressure Ranges . . . . . . . . . . . . . . . . . . . . . . A1-31
Table A1-22. Minimum Required Regulated Gas Pressure Altitude Conversion . . . . . . . . . . . . . . . A1-32
Table A1-23. Maximum Gas Consumption (CFH) for Natural Gas and Propane Vapor. . . . . . . . . . . A1-32
Table A1-24. Model CB-LE Blowdown Tank Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-39
Table A1-25. Heating Surface, Model CB-LE Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-39
Table A1-26. Steam Volume & Disengaging Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-40
Table A1-27. Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-40
Table A1-28. Recommended Non-Return Valve Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-40
Available as an option to the Model CB Firetube Dryback Boiler (125 - 800 hp), the Low Emission Option provides NOx
control, top performance, and reliable Cleaver-Brooks efficiency. The Low Emission Option combines the packaging of
induced flue gas recirculation with the Cleaver-Brooks integral front head. The front head routes the flue gases from
the fourth pass to the fan and burner assembly for reliable low NOx performance. The enhanced burner design assures
maximum NOx reduction at all firing rates while maintaining top of the line boiler performance.
Standard Low Emission Options include 60, 30, 25, or 20 ppm packages (all NOx emission levels are given on a dry
volume basis and corrected to 3% 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.
A1-3
09-09
Firetube Boilers

The Cleaver-Brooks Model CB Boiler - the premium firetube on the market today includes the four-pass dryback design, five square feet of heating surface per boiler
horsepower, and maximum boiler efficiency. In addition to the features of the Model
CB Boiler, the Low Emission Option provides the following
Integral Front Head Design
Single-piece front door.
Fan cassette assembly for easy access to fan and motor.
Guaranteed low nitrogen oxide (NOx) performance.
Enhanced burner performance.
Improved flame stability and combustion control.
Intimate mixing of air and fuel assures minimum CO levels at low NOx levels.
True Boiler/Burner/Low NOx Package.

UL/ULC approved package.
Assures highest fuel-to-steam efficiency.
Eliminates the need for field installation of burner, controls, or NOx equipment.
Single point positioning of fuel and air ensures ease of startup and provides
reliable operation.
PRODUCT OFFERING
The Low Emission Option currently is available on:
Standard Equipment
Available Options
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.
Model CB Firetube Boiler.
New integral front head with internal low NOx system.
Enhanced burner design.
For option details, contact your local Cleaver-Brooks authorized representative.
Full line of Model CB Firetube options.
Additional NOx reduction packages.
DIMENSIONS AND RATINGS

The Model CB-LE dimensions and ratings are provided inTable A1-1 through Table
A1-8, and in Figure A1-1 through Figure A1-6.
A1-4
09-09
Firetube Boilers
Table A1-1. Model CB-LE Steam Boiler Ratings

BOILER HP
125
150
200
250
300
350
400
500
Rated Steam Cap. (lbs/hr

from and @ 212 F)
4313
5175
6900
8625
10350
12075
13800
Btu Output (1000 Btu/hr)
4184
5021
6695
8369
10043
11716
13390
600
700
750
800
17250
20700
24150
25875
27600
16738
20085
23432
25106
26779
RATINGS SEA LEVEL TO 700 FT
APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITY

Light Oil (gph)A
36.4
43.7
58.3
72.9
87.5
102.1
116.6
145.8
175.0
204.1
218.7
233.3
Natural Gas (cfh) MBtu
5103
6124
8165
10206
12247
14288
16329
20412
24494
28576
30618
32659
Gas (Therm/hr)
51.0
61.2
81.7
102.1
122.5
142.8
163.3
204.2
245.0
285.8
306.2
326.6
POWER REQUIREMENTS - SEA LEVEL TO 700 FT, 60 HZ

Blower Motor hp
Refer to Tables A1-9 and A1-10
Oil Pump Motor, hp No. 2 Oil
1/2
1/2
1/2
1/2
3/4
3/4
3/4
3/4
3/4
Air Compressor Motor hp (Oil

firing Only)
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
NOTES:
A. Based on 140,000 Btu/gal.
Table A1-2. Model CB-LE Hot Water Boiler Ratings

BOILER HP
125
150
200
250
300
350
400
500
600
700
750
800
Rated Cap. 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
20415
Gas (Therm/hr)
51.0
61.2
81.7
102.1
122.5
142.9
163.3
204.2
24494
28576
30618
32659
245.0
285.8
306.2
326.6
APPROXIMATE FUEL CONSUMPTON AT RATED CAPACITY

Blower Motor hp
Air Compressor Motor hp (Oil firing Only)
Refer to Tables A1-9 and A1-10

1/2
1/2
1/2
1/2
3/4
3/4
3/4
3/4
3/4
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
NOTES:
A1-5
09-09
Firetube Boilers
A
B
D
E
BB
CC
DD EE
KK
FF
AA
GG
JJ
L
JJ
FF
GG
GG
V
HH
HH
H
W
X
N
I
Figure A1-1. CB-LE Steam - 125-200 HP

60 (15 - 150 psig Design Pressure) - Sheet 1 of 2
(measurements shown in inches)
Description
DIM
125
Boiler HP
150
200
LENGTHS
Length Overall
Shell
Front Head Extension
Front Ring Flange to Nozzle - 15#
Rear Head Extension
Front Ring Flange to Panel
Ring Flange to Base
Base Frame
Rear Flange Ring to Base
A
B
C
D
D
E
G
H
I
J
173
125
28
88
84
19.5
17
0.5
112
12.5
196.5
149
28
90
84
19.5
17
0.5
136
12.5
228.5
180
29
96
96
19.5
17
0.5
167
12.5
HEIGHTS
Ht Overall
Base to Vent Outlet
Base to Boiler Centerline
Base to Gas Train
K
L
M
N
86
85
46
6
86
85
46
8.5
86
85
46
8.5
A1-6
09-09
Firetube Boilers

Description
DIM
125
Boiler HP
150
200
HEIGHTS (continued)
Base to Panel Top
Base to Panel Bottom
Height of Base
T
U
V
75
15
12
75
15
12
77
17
12
WIDTHS
Width Overall
Center to ALWCO
Center to Outside Control Panel
Center to Lagging
Center to WC
Base Inside
Base Outside
Boiler I.D.
O
P
Q
R
S
W
X
F
89.88
38.75
48.5
33
44.5
44.5
52.5
60
89.875
38.75
48.5
33
45
44.5
52.5
60
90.5
38.75
48.5
33
45
44.5
52.5
60
CONNECTIONS
Electric - Main Power Supply
Surface Blowoff (with collector pipe)
Steam Outlet 15# (150# Flange)
Chemical Feed
Feed Water (2)
Blowdown/Drain (2)
Water Column Blowdown
Gauge Glass Blowdown
AA
BB
CC
CC
FF
GG
HH
JJ
KK
460 / 3 / 60
1
4
4
1
1.5
1.5
0.75
.025
460 / 3 / 60
1
4
4
1
1.5
1.5
0.75
0.25
460 / 3 / 60
1
4
4
1
2
1.5
0.75
0.25
VENT STACK
Diameter (OD) (flgd. connection)
16
16
16
CLEARANCES
Rear Door Swing (Davited)
Front Door Swing
Tube Removal, Rear
Tube Removal, Front
32
67
115
103
32
67
139
127
32
67
170
158
MINIMUM BOILER ROOM LENGTH ALLOWING FOR DOOR SWING AND TUBE REMOVAL:
From Rear of Boiler
307
355
From Front of Boiler
260
308
Through Window or Doorway
224
248
WEIGHT IN LBS
Normal Water Capacity
Approx. Ship Wt. 15 psig
5750
11300
12400
13000
7250
12600
13500
14200
417
370
279
8625
14600
15600
16400
A1-7
09-09
Firetube Boilers
A
B
C
O
P
CC
DD
EE
BB
KK
Y
G
K
L
JJ
JJ
AA
FF
GG
FF
GG
GG
HH

Description
DIM
250
Boiler HP
300
350
LENGTHS
Length Overall
Shell
Rear Head Extension
Ring Flange to Base
Base Frame
A
B
C
D
D
E
G
H
I
J
191.5
144
23.5
90
88
24
17
0.5
131
12.5
220
171
25
98
98
24
23
0.5
158
12.5
250
201
25
112
112
24
23
0.5
188
12.5
HEIGHTS
Ht Overall
Base to Vent Outlet
K
L
115
106
115
106
115
106
A1-8
09-09
Firetube Boilers

Description
DIM
250
Boiler HP
300
350
HEIGHTS (continued)
Base to Gas Train
Base to Panel Top
Height of Base
M
N
T
U
V
56
10
77
17
12
56
10
77
17
12
56
10
77
17
12
WIDTHS
Width Overall
Center to ALWCO
Center to Lagging
Center to WC
Base Inside
Base Outside
Boiler I.D.
O
P
Q
R
S
W
X
F
106.5
48.5
58
42
53.75
56
64
78
106.5
48.5
58
42
53.75
56
64
78
108.75
48.5
58
42
53.75
56
64
78
CONNECTIONS
Chemical Feed
Feed Water (2)
Blowdown/Drain (2)
AA
BB
CC
CC
FF
GG
HH
JJ
KK
460 / 3 / 60
1
6
6
1
2
1.5
0.75
0.25
460 / 3 / 60
1
6
6
1
2
1.5
0.75
0.25
460 / 3 / 60
1
6
6
1
2.5
1.5
0.75
0.25
VENT STACK
20
20
20
CLEARANCES
Rear Door Swing
Front Door Swing
Tube Removal, Rear
Tube Removal, Front
43
89
131
116
43
89
157
142
43
89
187
172
MINIMUM BOILER ROOM LENGTH ALLOWING FOR DOOR SWING AND TUBE REMOVAL
From Rear of Boiler
364
417
477
303
356
416
275
302
332
WEIGHT IN LBS
10670
21500
22800
24600
13000
23600
25200
27200
15465
26800
27800
29300
A1-9
09-09
Firetube Boilers
A
O
R
Q
S
DD
BB
EE
CC
KK
F
Y
FF
FF
JJ
GG
JJ
GG
GG
AA
HH
HH

Description
LENGTHS
Length Overall
Shell
Rear Head Extension
Ring Flange to Base
Base Frame
DIM
A
B
C
D
D
E
G
H
I
J
400
500
205.75
146.75
27
98
96
32
26
0.5
133.75
12.5
227.75
167.5
28
101
100
32
26
0.5
154.75
12.5
A1-10
09-09
Boiler HP
600
700
259.75
199.75
28
96
96
32
26
0.5
186.75
12.5
298.75
232.75
34
112
112
32
26
0.5
219.75
12.5
750
800
298.75
232.75
34
112
112
32
26
0.5
219.75
12.5
298.75
232.75
34
112
112
32
26
0.5
219.75
12.5
Firetube Boilers

Table A1-5 Model CB-LE Steam Boiler Dimensions,
Description
DIM
400
500
Boiler HP
600
700
750
800
HEIGHTS
Ht Overall
Base to Vent Outlet
Base to Gas Train
Base to Panel Top
Height of Base
K
L
M
N
T
U
V
134
126
67
12
75
15
12
134
126
67
12
75
15
12
134
126
67
12
75
15
12
134
126
67
12
75
15
12
134
126
67
12
75
15
12
134
126
67
12
75
15
12
WIDTHS
Width Overall
Center to ALWCO
Center to Lagging
Center to WC
Base Inside
Base Outside
Boiler I.D.
O
P
Q
R
S
W
X
F
124
57.5
66.5
51
63
58.88
71.88
96
124.25
57.5
66.5
51
63
58.88
71.88
96
124
57.5
66.5
51
63
58.88
71.88
96
124
57.5
66.5
51
63
58.88
71.88
96
124
57.5
66.5
51
63
58.88
71.88
96
124
57.5
66.5
51
63
58.88
71.88
96
CONNECTIONS
Chemical Feed
Feed Water (2)
Blowdown/Drain (2)
AA 460 / 3 / 60 460 / 3 / 60 460 / 3 / 60 460 / 3 / 60 460 / 3 / 60 460 / 3 / 60

BB
1
1
1
1
1
1
CC
12
12
12
12
12
12
CC
6
8
8
8
8
8
FF
1
1
1
1
1
1
GG
2.5
2.5
2.5
2.5
2.5
2.5
HH
2
2
2
2
2
2
JJ
0.75
0.75
0.75
0.75
0.75
0.75
KK
0.25
0.25
0.25
0.25
0.25
0.25
VENT STACK
24
24
24
24
24
24
CLEARANCES
Rear Door Swing
Front Door Swing
Tube Removal, Rear
Tube Removal, Front
53
108
131
114
53
108
152
135
53
108
184
167
53
108
53
108
53
108
217
200
217
200
217
200
MINIMUM BOILER ROOM LENGTH ALLOWING FOR DOOR SWING AND TUBE REMOVAL
From Rear of Boiler
386
428
492
558
558
314
356
420
486
486
308
329
361
394
394
558
486
394
WEIGHT IN LBS
14810
33500
36570
39680
15950
37110
39970
43580
19270
42300
45025
49400
23000
49500
52050
57315
23000
49600
52150
57415
23000
49600
52150
57415
A1-11
09-09
Firetube Boilers
Figure A1-4. CB-LE Hot Water - 125-200 HP

60 (30 and 125 psig Design Pressure) - Sheet 1 of 2
BOILER HP
DIM
125
150
200
171-1/2
196-1/2
228-1/2
Shell
125
149
180
Base Frame
112
136
167
Front Head Extension (60 ppm System)
27
28
29
Rear Head Extension
19-1/2
19-1/2
19-1/2
Front Ring Flange to Outlet
HH
114
136
167
Front Ring Flange to Return
89
102
131
Ring Flange to Base
1/2
1/2
1/2
Over Tubesheets
113
137
168
LENGTHS
Overall (60 ppm System)
Shell Extension
12
12
12
12-1/2
12-1/2
12-1/2
A1-12
09-09
Firetube Boilers

BOILER HP
DIM
125
150
200
Overall
75-1/2
75-1/2
75-1/2
I.D. Boiler
60
60
60
Center to Entrance Box
42-1/2
42-1/2
42-1/2
Center to Outside Hinge
KK
35
35
35
WIDTHS
Center to Lagging
33
33
33
Base, Outside
52-1/2
52-1/2
52-1/2
44-1/2
44-1/2
44-1/2
Base, Inside
HEIGHTS
Overall
OO
86
86
86
85
85
85
Base to Return and Outlet
82-3/8
82-3/8
82-3/8
Height of Base
12
12
12
16
16
16
Waterfill Conn. Right & Left
1-1/2
1-1/2
Auxiliary Connection
6A
6A
6A
Base to Vent Outlet
Base to Bottom of Boiler

BOILER CONNECTION
Water Return Flange

Water Outlet Flange (2" Dip Tube Included)
6A
6A
6A
Drain, Front and Rear
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
BB
16
16
16
32
Air Vent
VENT STACK
Diameter (flgd. connection)
MINIMUM CLEARANCES
Rear Door Swing
DD
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
Water Capacity Flooded
7670
9295
11130
Approx. Ship. Wgt. 30 psig

11400
11800
12500
12900
14500
14900
NOTES: All connections are threaded unless indicated.

A. ANSI 150 psig flange.
A1-13
09-09
Firetube Boilers
Figure A1-5. CB-LE Hot Water 250-350 HP

BOILER HP
DIM
250
300
350
191-1/2
220
252
Shell
144
171
201
Base Frame
131
158
188
23-1/2
25
27
Rear Head Extension
24
24
24
103-1/2
130
160
188
LENGTHS
HH
131
158
Ring Flange to Base
1/2
1/2
1/2
Over Tubesheets
129
156
186
Shell Extension
15
15
15
12-1/2
12-1/2
12-1/2
A1-14
09-09
Firetube Boilers

BOILER HP
DIM
250
300
350
93
93
93
I.D. Boiler
78
78
78
51
51
51
KK
51
51
51
Center to Lagging
42
42
42
Base, Outside
64
64
64
Base, Inside
52
52
52
OO
115
115
115
WIDTHS
Overall
HEIGHTS
Overall
Base to Vent Outlet
106
106
106
101-1/2
101-1/2
101-1/2
Height of Base
10
10
10
17
17
17
BOILER CONNECTION
2-1/2
1-1/4
1-1/4
1-1/4
Water Return Flange (2" Dip Tube included)
8A
8A
8A
8A
8A
8A
Air Vent
1-1/2
1-1/2
1-1/2
BB
20
20
20
Water Outlet Flange (2" Dip Tube Included)
VENT STACK
MINIMUM CLEARANCES
Rear Door Swing
DD
43
43
43
Front Door Swing
EE
89
89
89
Tube Removal, Rear
FF
131
157
187
GG
116
142
172
Rear of Boiler
RR
364
417
477
Front of Boiler
RF
303
356
416
RD
275
302
332
13880
16840
20090

21400
22200
23500
24300
26700
27500
WEIGHT IN LBS
NOTES: All connections are threaded unless indicted.

A1-15
09-09
Firetube Boilers
Figure A1-6. CB-LE Hot Water 400-800 HP

BOILER HP
DIM
400
500
600
700
750
800
LENGTHS
206
228
262
299
300
300
Shell
147
168
200
233
233
233
Base Frame
134
155
187
220
220
220
27
28
30
34
35
35
Rear Head Extension
32
32
32
32
32
32
Shell Ring Flange to Base
1/2
1/2
1/2
1/2
1/2
1/2
Rear Ring Flange to Base
12-1/2
12-1/2
12-1/2
12-1/2
12-1/2
12-1/2
Shell Flange to Outlet
HH
139-1/2
156-1/2
182-1/2
216-1/2
216-1/2
216-1/2
Shell Flange to Return
107
125
151-1/2
185
185
185
Over Tubesheets
130
151
183
216
216
216
Shell Extension
17
17
17
17
17
17
A1-16
09-09
Firetube Boilers

BOILER HP
DIM
400
Overall
113
I.D. Boiler
96
62
500
600
700
750
800
113
113
113
115
115
96
96
96
96
96
62
62
62
64
64
62
WIDTHS
KK
62
62
62
62
62
Center to Lagging
51
51
51
51
51
51
Base, Outside
72
72
72
72
72
72
Base, Inside
56
56
56
56
56
56
OO
134
134
134
134
134
134
Base to Vent Outlet
126
126
126
126
126
126
Height of Base
12
12
12
12
12
12
19
19
19
19
19
19
121-9/16
121-9/16
121-9/16
121-9/16
121-9/16
121-9/16
Waterfill Connection, Right and Left
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
Water Return
10A
10A
12A
12A
12A
12A
Water Outlet (2 Dip Tube Included)
10A
10A
12A
12A
12A
12A
Air Vent
24
24
24
24
HEIGHTS
Overall
BOILER CONNECTIONS
VENT STACK
Diameter (Flanged Connection)
BB
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
RD
308
329
361
394
394
394
WEIGHT IN LBS
20015
23300
28260
33360
33360
33360

33300
37270
36900
40780
42150
46005
49650
53300
49750
53400
49750
53400
NOTES: All connections are threaded unless indicated:

A1-17
09-09
Firetube Boilers
Table A1-9. Model CB-LE Blower Motor Selection Operating Pressures 150 psig and Less, and All Hot
Water Boilers
Table A1-10. Model CB-LE Blower Motor Selection Operating Pressures Greater than 150 psig (Steam
Boilers)
MOTOR HP
BOILER HP
MOTOR HP
60
PPM
30
PPM
25
PPM
20
PPM
125
10
10
150
7.5
10
10
200
15
15
250
7.5
300
BOILER HP
60
PPM
30
PPM
25
PPM
20
PPM
125
10
10
10
10
150
10
10
10
15
20
NA
200
15
20
20
NA
10
15
15
250
7.5
10
15
20
10
15
20
25
300
10
20
30
40
350
15
25
40
40
350
20
30
40
50
400
10
15
20
20
400
10
15
20
25
500
15
20
25
30
500
20
25
30
40
600
25
30
50
60
600
25
40
60
60
700
30
50
75
75
700
40
60
75B
75C
750
50
60
75
NA
750
50
75
NA
NA
800
50
75
NA
NA
800
60
75A
NA
NA
NOTES: For elevations above 700 - contact your local

Cleaver-Brooks authorized representative.
NOTES: For elevation above 700 - contact your local

A. Downrate to 770 hp.
B. Downrate to 675 hp.
C. Downrate to 660 hp.
Table A1-11. Blower Motor Selection CB-LE NTI Boilers

Altitude: 700 ft and less - Design Pressure: 150 psi and less
Nominal
Boiler Size
15 ppm
Blower Motor HP
9 ppm
Blower Motor HP
* 800 HP - to be de-rated to 720 HP for 9 ppm and to 750 HP for 15 ppm.
A1-18
09-09
09-09
Firetube Boilers
Table A1-12. Model CB-LE Boiler Weights
BOILER HP
125
150
200
250
300
350
400
500
600
700
800
HOT WATER
STEAM
FUEL
SERIES
30 PSIG
125 PSIG
15 PSIG
150 PSIG
200 PSIG
100
11200
11600
11300
12000
12600
200
11400
11800
11500
12400
13000
700
11300
11700
11400
12300
12900
100
12300
12700
12400
13200
13900
200
12500
12900
12600
13500
14200
700
12300
12700
12400
13300
14000
100
14400
14800
14500
15500
16300
200
14500
14900
14600
15600
16400
700
14500
14900
14600
15600
16400
100
20700
21500
20800
22000
23800
200
21400
22200
21500
22800
24600
700
20900
21700
21000
22500
24300
100
23100
23900
23200
24800
26800
200
23500
24300
23600
25200
27200
700
23400
24200
23500
25000
27000
100
26200
27000
26300
27600
29100
200
26700
27500
26800
27800
29300
700
26400
27200
26500
27700
29200
100
33000
36970
33200
36270
39380
200
33300
37270
33500
36570
39680
700
33200
37170
33400
36470
39580
100
36600
40470
36810
39670
43480
200
36900
40780
37110
39970
43580
700
36800
40680
37010
39870
43280
100
41850
45905
42000
44725
49100
200
42150
46005
42300
45025
49400
700
42050
45915
42200
44925
49300
100
49450
53000
49300
51850
57015
200
49750
53300
49600
52150
57315
700
49650
53200
49500
52050
57215
NOTES:
1. Weights shown are based on standard product offering for current listed boilers. If units are of special design and construction, actual weight
will be determined at time of shipment. Shipment will then be made on shippers weight and count. All weights are in US pounds.
A1-19
09-09
Firetube Boilers
Table A1-13. Steam Boiler Safety Valve Openings
VALVE
SETTING
15 PSIG STEAM
100 PSIG STEAM
125 PSIG STEAM
150 PSIG STEAM
200 PSIG STEAM
250 PSIG STEAM
BOILER HP
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
125
1-1/2
(1) 1-1/2
(1) 1-1/4
(1) 1-1/2
(1) 1-1/4
(1) 1-1/4
(1) 1
150
(1) 2
(1) 1-1/2
1-1/2
(1) 1-1/2
(1) 1-1/4
1-1/4
(1) 1
(1) 1-1/4
200
2-1/2
(1) 2
(1) 1-1/2
1-1/2
(1) 1-1/2
(1) 1-1/4
1-1/4
250
(1) 2-1/2
(1) 3
(1) 2-1/2
(1) 2
(1) 2
(1) 1-1/2
1-1/2
(1) 1-1/2
(1) 1-1/4
300
(1) 2-1/2
(1) 2
(1) 2-1/2
(1) 2
(2) 2
(1) 2
(1) 1-1/2
1-1/2
350
(1) 2
(2) 3
(1) 2-1/2
(2) 2
2-1/2
(1) 2-1/2
(1) 2
(1) 1-1/2
(1) 2
400
(2) 3
(1) 2-1/2
(1) 2
(2) 2-1/2
2-1/2
(1) 2-1/2
(1) 2
(1) 2
(1) 1-1/2
500
(3) 3
2-1/2
(2) 2-1/2
(1) 2
(2) 2-1/2
(1) 2-1/2
(1) 2
(2) 2
600
(3) 2-1/2
(1) 2
2-1/2
(2) 2-1/2
(1) 2
2-1/2
(1) 2
(1) 2-1/2
700, 750 &

800
(3) 3
(2) 2-1/2
(3) 2-1/2
(2) 2
(3) 2-1/2
(1) 2
(2) 2-1/2
(1) 2
2-1/2
2-1/2
NOTES: Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on availability.
Table A1-14. Hot Water Boiler Relief Valve Openings

VALVE
SETTING
BOILER HP
30 PSIG HW
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
60 PSIG HW
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
100 PSIG HW
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
125 PSIG HW
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
125
2-1/2
1-1/4
150
2-1/2
2-1/2
200
(1) 2-1/2
(1) 1-1/4
2-1/2
250
(1) 2
(1) 2-1/2
2-1/2
2-1/2
300
2-1/2
(1) 1
(1) 2-1/2
2-1/2
2-1/2
350
(2) 2-1/2
(1) 1
(1) 2-1/2
(1) 2
2-1/2
2-1/2
400
(1) 2
(2) 2-1/2
(1) 2
(2) 2-1/2
(1) 1
(1) 2-1/2
2-1/2
500
(1) 1
(3) 2-1/2
2-1/2
(1) 2-1/2
(1) 1-1/4
(1) 1
(1) 2-1/2
600
(3) 2-1/2
(1) 2
(1) 1-1
(2) 2-1/2
(1) 2
1) 2-1/2
(1) 2-1/2
(1) 1-1/4
700, 750 &

800
(1) 1
(4) 2-1/2
(1) 2
(2) 2-1/2
2-1/2
(1) 2-1/2
(1) 2
NOTES: Hot water relief valves are Kunkle #537.
A1-20
09-09
Firetube Boilers
DIMENSIONS (INCHES)
BOILER HP
A
CB-125 THRU CB-200
33
55
45
68
32
CB-250 THRU CB-350
42
69
58
86
43
CB-400 THRU CB-800
51
88
71
10
9
53
Figure A1-7. Space Required to Open Rear Head on Model CB-LE Boilers Equipped with Davits
BOILER HP
X1
X2
X3
125
112
39-1/2
57-1/2
44-1/2
10
9-3/4
22-1/2
150
136
39-1/2
57-1/2
44-1/2
10
9-3/4
22-1/2
200
167
39-1/2
57-1/2
44-1/2
10
9-3/4
22-1/2
250
12
131
46
70
56
10
22
22-1/2
300
12
158
46
70
56
10
22
22-1/2
350
12
188
46
70
56
10
22
22-1/2
NOTE:
All numbers in table are in inches.
6-inch high mounting piers recommended for use beneath the boiler base frame. The use of these piers provides increased inspection
accessibility to the piping beneath the boiler and added height for washing down the area beneath the boiler.
Figure A1-8. Model CB-LE Boiler Mounting Piers (60 and 78)
A1-21
09-09
Firetube Boilers
BOILER HP
400
14
134
50
78
6-1/2
58-7/8
500
14
155
50
78
6-1/2
58-7/8
600
14
187
50
78
6-1/2
58-7/8
700-750-800
14
220
50
78
6-1/2
58-7/8
NOTE:
1. All numbers in table are in inches.
2. 6-inch high mounting piers recommended for use beneath the boiler base frame. The use of these piers provides increased inspection accessibility to the piping beneath the boiler and added height for washing down the area beneath
the boiler.
Figure A1-9. Model CB-LE Boiler Mounting Piers (96)
A1-22
09-09
Firetube Boilers
FRONT
FLANGE
E DIA. HOLE
CL
VIEW A
FAR
SIDE
NEAR
SIDE
D
D
VIEW B
BOILER
HP
VIE
W
ALL DIMENSIONS IN INCHES

A
125
All
80-1/4
29-3/4
70-1/2
10
150
All
80-1/4
29-3/4
83-1/2
10
200
All
80-1/4
29-3/4
114-1/2
10
Steam
99
36
72
10
Hot Water
99
36
81
10
Steam
99
36
99
10
Hot Water
99
36
108
10
Steam
99
36
129
10
Hot Water
99
36
138
10
Steam
119
35-3/4
78
11
Hot Water
119
35-3/4
78
11
Steam
119
35-3/4
99
11
Hot Water
119
35-3/4
99
11
Steam
119
35-3/4
131
11
Hot Water
119
35-3/4
131
11
Steam
119
35-3/4
164
11
Hot Water
119
35-3/4
164
11
250
300
350
400
500
600
700, 750 &

800
NOTE: A, B and C dimensions may vary by 1/2 inch.
Figure A1-10. Lifting Lug Location, Model CB-LE Boilers
A1-23
09-09
Firetube Boilers
PERFORMANCE DATA
The Low Emission Option provides NOx reduction at current published and
predicted fuel-to-steam efficiencies.
Specifying Boiler
Efficiency
Cleaver-Brooks offers an industry leading fuel-to-steam boiler efficiency guarantee

for Model CB-LE Firetube Boilers. The guarantee is based on the fuel-to-steam
efficiencies shown in the efficiency tables and the following conditions. The
efficiency percent number is only meaningful if the specific conditions of the
efficiency calculations are clearly stated in the specification (see Cleaver-Brooks
publication CB-7768 for a detailed description of efficiency calculations).
When specifying the efficiencies in the tables, be sure to include the specific
guarantee conditions to maximize the effectiveness of your efficiency specification. If
you have any questions regarding the efficiency specifications, please contact your
local Cleaver-Brooks authorized representative.
Efficiency
Specification
The boiler manufacturer shall guarantee that, at the time of startup, the boiler will
achieve fuel-to-steam efficiency (as shown in Table A1-15 and Table A1-16) at
100% firing rate (add efficiency guarantees at 25%, 50%, and 75% of rating, if
required). If the boiler(s) fail to achieve the corresponding guaranteed efficiency as
published, the boiler manufacturer will rebate, to the ultimate boiler owner, five
thousand dollars ($5,000) for every full efficiency point (1.0%) that the actual
efficiency is below the guaranteed level.
The specified boiler efficiency is based on the following conditions.
1. Fuel specification used to determine boiler efficiency:
Natural Gas
Carbon,% (wt) = 69.98

Hydrogen,% (wt) = 22.31
Sulfur,% (wt) = 0.0
Heating value, Btu/lb. = 21,830
No. 2 Oil
Carbon,% (wt) = 85.8

Sulfur,% (wt) = 0.2
No. 6 Oil
Sulfur,% (wt) = 2.09
2. Efficiencies are based on ambient air temperature of 80 F, relative humidity of
30%, and 15% excess air in the exhaust flue gas.
3. Efficiencies are based on manufacturers published radiation and convection
losses. (For Cleaver-Brooks radiation and convection losses, see Boiler
Efficiency Facts Guide, publication number CB-7767).
4. Any efficiency verification testing will be based on the stack loss method.
For efficiencies and stack temperatures at operating pressures not listed, follow
these procedures:
A1-24
09-09
Firetube Boilers

When the operating steam pressure is between 10 psig and 125 psig, interpolate
the values from the efficiency tables.
When the operating steam pressure is above 125 psig, estimated efficiency can be
calculated as follows:
Example:
Boiler: 350 hp.
Fuel: natural gas.
Operating steam pressure: 200 psig.
Find the fuel-to-steam efficiency at 100% firing rate. From Table A1-15 for a 350
hp boiler operating at 100% firing rate and an operating steam pressure of 125
psig, the efficiency is 82.5%.
Using Figure A1-11, note that the stack temperature increases 36 F at the higher
operating pressure. To estimate boiler efficiency, use this rule of thumb: For every
40 F increase in stack temperature, efficiency decreases by 1%. Since the stack
temperature rise is 36 F, the decrease in the boiler efficiency at 200 psig operating
pressure is calculated as follows: 36/40 =.9%. Therefore, the boiler efficiency at
200 psig operating pressure is 82.5 -.9 = 81.6%
Emissions
The emission data included in this section consists of typical emission levels for
Model CB boilers equipped with 60, 30, 25, and 20 ppm LE Options when firing
natural gas and No. 2 oil.
Notice
The data in Table A1-17 and Table A1-18 represent typical emission levels only.
Guaranteed emission levels are available from your local Cleaver-Brooks authorized
representative.
A1-25
09-09
Firetube Boilers
Table A1-15. Predicted Fuel-to-Steam Efficiencies - Natural Gas

OPERATING PRESSURE = 10 psig
% OF LOAD
% OF LOAD
BOILER
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 A1-11. Predicted Stack Temperature Increase for Pressure Greater Than 125 psig
A1-26
09-09
Firetube Boilers
Table A1-16. Predicted Fuel-to-Steam Efficiencies - No. 2 Oil

% OF LOAD
% OF LOAD
BOILER
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 A1-17. CB-LE Boilers - Natural Gas, Emission Levels

ESTIMATED LEVEL
POLLUTANT
60 ppm
30 ppm
25 ppm
20 ppm
15 ppm
9 ppm
ppmA
50/150B
50/150B
50/150B
50/150B
lb./MMBtu
0.04/0.11
0.04/0.11
0.04/0.11
0.04/0.11
50
0.04
50
0.04
NOx
ppmA
lb/MMBtu
60
0.07
30
0.035
25
0.03
20
0.024
15
0.018
9
0.011
SOx
ppmA
lb/MMBtu
1
0.001
1
0.001
1
0.001
1
0.001
1
0.001
1
0.001
HC/VOC5
ppmA
lb/MMBtu
10
0.004
10
0.004
10
0.004
10
0.004
10
0.004
10
0.004
PM
ppmA
lb/MMBtu
0.01
0.01
0.01
0.01
0.01
0.01
CO
A. ppm levels are given on a dry volume basis and corrected to 3% oxygen (15% excess air).
B. CO emission for 60, 30, 25 & 20 ppm system is 50 ppm (0.04 lb/MMBtu) when boiler is operating above 50% of rated capacity.
CO emission is 150 ppm (0.11 lb/MMBtu) when boiler is operating below 50% of rated capacity.
Table A1-18. CB-LE Boilers - No. 2 Oil, Emission Levels

ESTIMATED LEVEL
POLLUTANT
60 ppm LE Option
30, 25, 20 ppm LE Option
15 ppm
9 ppm
lb/MMBtu
50
0.039
50
0.039
50
0.039
50
0.039
NOx
ppmA
lb/MMBtu
140
0.186
90
0.120
85
0.113
70
0.093
SOx
ppmA
lb/MMBtu
278
0.52
278
0.52
278
0.52
278
0.52
HC/VOCs
ppmA
lb/MMBtu
4
0.002
4
0.002
4
0.002
4
0.002
PM
ppmA
lb/MMBtu
0.025
0.025
0.025
0.025
CO
ppmA
A. ppm levels are given on a dry volume basis and corrected to 3% oxygen (15% excess air).
BASED ON THE FOLLOWING CONSTITUENT LEVELS:
Fuel-bound Nitrogen content = 0.015% by weight.
Sulfur content = 0.5% by weight.
Ash content = 0.01% by weight.
A1-27
09-09
09-09
Firetube Boilers
ENGINEERING DATA
Table A1-19 gives a summary of predicted sound pressure levels for Model CB
boilers with 30 ppm LE Options. Contact your local Cleaver-Brooks authorized
representative for sound levels or other LE Options.
Sound Level
Units
The units for the sound level tables are dbA (decibels, measured on the A-weighted
scale) in reference to 0.0002 microbars (20 micro-Newtons per square meter).
Their reference are standardly used in specifying and reporting sound pressure levels
on industrial equipment.
Test Method
The sound pressure levels in the above tables were obtained from tests in
accordance with the ABMA Test Code for the Measurement of Sound from
Packaged Boilers. In accordance with this code the sound pressure levels reported
were measured on the boiler centerline 4-1/2 feet vertically above the bottom of the
base rails and 3 feet horizontally in front of the end of the blower motor or front
surface of the electrical cabinet.
Sound Level Meter
The sound level meter used complies with ANSI S1.4, Type 1 (Precision). The
readings are taken with the meter set for slow response and corrected for
background levels.
Sound Pressure
The large size boilers, the need for auxiliary equipment, and the necessary
interconnecting piping make it impractical (and sometimes impossible) to provide a
boiler testing environment which is suitable for taking the data needed to develop
Sound Pressure Power levels.
Typical Values
Sound pressure levels (dbA) for the same boiler will vary between boiler rooms.
Sound levels will vary with motor type, NOx levels, and altitudes. In addition,
variations will occur between different people using different sound meters on the
same boiler. And finally, no two boilers can be expected to give precisely the same
sound levels. For these reasons, we can only predict, but not guarantee, sound
levels (dbA).
Table A1-19. Model CBLE Predicted Sound Levels 30 ppm NOx Systemss
BOILER HP
125
150
200
250
300
350
400
500
600
700
750
800
HFO, dbA
84
84
84
83
84
85
84
85
85
88
89
90
LFO, dbA
82
82
83
81
82
83
82
83
83
84
87
89
HFG, dbA
82
82
83
82
83
84
83
83
85
87
89
90
LFG, dbA
81
81
82
81
82
83
81
81
82
84
86
88
NOTES
1. Sound pressure levels measured on boilers operating in various locations and expressed in dbA are as shown:
2. Based on standard altitude fans and fan motors, 60 Hz.
3. Contact your local Cleaver-Brooks authorized representative for sound levels of 60, 25,
or 20 ppm LE Options.
A1-28
09-09
ABBREVIATIONS:
HF = High Fire
LF = Low Fire
O = Oil
G = Gas
Firetube Boilers
Gas-Fired Burners
Table A1-20 shows gas pressure with standard, over- and undersized gas trains.
Table A1-21 shows recommended NTI gas train sizes and pressure ranges.
Table A1-22 shows minimum required gas pressure altitude conversion.
Figure A1-12 shows standard gas train sizes and locations for Model CB Firetube
Boilers.
Figure A1-13 shows typical gas train piping layouts for multiple boiler applications.
Figure A1-14 shows standard gas train components.
A1-29
09-09
Firetube Boilers
Table A1-20. Standard, Undersize, and Oversize Gas Trains
Boiler HP
125
CBLE 20 PPM
Gas Train
Pressure
Size, in
PSI
1.5
0.8 - 3.0
CBLE 30 PPM
Gas Train
Pressure
Size, in
PSI
1.5
0.7 - 3.0
CBLE 60 PPM
Gas Train
Pressure
Size, in
PSI
1.5
0.7 - 3.0
150
1.5
1.0 -3.0
1.5
0.9 - 3.0
1.5
0.9 - 3.0
200
NA
NA
1.5
2
1.5 - 4.0
1.0 - 1.5
1.5
2
1.5 - 4.0
1.0 - 1.5
250
1.5
2
2.4 - 5.0
1.6 - 2.4
1.5
2
2.4 - 5.0
1.5 - 2.4
1.5
2
2.3 - 5.0
1.5 - 2.3
1.5-2
2
3
3.0 - 5.0
2.0 - 3.0
1.3 - 2.0
1.5-2
2
3
3.0 - 5.0
2.0 - 3.0
1.3 - 2.0
1.5-2
2
3
3.0 - 5.0
1.9 - 3.0
1.2 - 1.9
1.5-2
2
2.5
3
4.2 - 6.5
3.2 - 4.2
2.5-3.2
1.8 - 2.5
1.5-2
2
2.5
3
4.2 - 6.5
3.1 - 4.2
2.5-3.1
1.7 - 2.5
1.5-2
2
2.5
3
3.8 2.8 2.1 1.4 -
5.0
3.8
2.8
2.1
1.5-2
2
2.5
3
4.6 3.1 2.5 1.4 -
1.5-2
2
2.5
3
4.6 3.1 2.5 1.4 -
1.5-2
2
2.5
3
4.6 3.1 2.3 1.4 -
7.0
4.6
3.1
2.3
300
350
400
7.0
4.6
3.1
2.3
7.0
4.6
3.1
2.3
1.5-2.5
2-2.5
2.5
3
6.9 - 10.0
5.0 - 6.9
3.6 - 5.0
2.2 - 3.6
1.5-2.5
2-2.5
2.5
3
6.9 - 10.0
5.0 - 6.9
3.5 - 5.0
2.2 - 3.5
1.5-2.5
2-2.5
2.5
3
6.8 - 10.0
4.9 - 6.8
3.5 - 4.9
2.2 - 3.5
1.5-2.5
2-2.5
2.5
2.5-3
3
9.7 - 10.0
7.0 - 9.7
5.0 - 7.0
4.3 - 5.0
2.9 - 4.3
1.5-2.5
2-2.5
2.5
2.5-3
3
9.6 - 10.0
6.9 - 9.6
4.9 - 6.9
4.2 - 4.9
2.9 - 4.2
1.5-2.5
2-2.5
2.5
2.5-3
3
9.5 - 10.0
6.8 - 9.5
4.9 - 6.8
4.2 - 4.9
2.8 - 4.2
2-3
2.5-3
3
4
8.7 - 10.0
5.6 - 8.7
3.8 - 5.6
2.9 - 3.8
2-3
2.5-3
3
4
8.6 - 10.0
5.5 - 8.6
3.7 - 5.5
2.8 - 3.7
2-3
2.5-3
3
4
8.6 - 10.0
5.5 - 8.69
3.7 - 5.5
2.8 - 3.7
750
NA
NA
2.5-3
3
4
6.9 - 10.0
4.6 - 6.9
3.2 - 4.6
2.5-3
3
4
6.9 - 10.0
4.6 - 6.9
3.2 - 4.6
800
NA
NA
2.5-3
3
4
7.2 - 10.0
5.0 - 7.2
3.7 - 5.0
2.5-3
3
4
7.1 - 10.0
4.9 - 7.1
3.6 - 4.9
500
600
700
UNDERSIZE
STANDARD
OVERSIZE
Note: Some units list two diameters because the gas train
increases in size after the regulating valve. The first number is
the customer connection size.
Table is based on Siemens gas train, which includes a
regulating actuator.
A1-30
09-09
Firetube Boilers
Table A1-21. Recommended NTI Gas Train Sizes and Pressure Ranges
Boiler HP
125
150
200
250
300
350
400
500
600
700
LE 15 PPM
Gas Train
Pressure Range
Size, in
PSI
1.5
3.3 - 6.0
1.5
3.9 - 6.0
1.5
4.5 - 7.0
1.5 - 2
4.4 - 7.0
1.5 - 2
6.1 - 9.0
2
1.5 - 2
2
2.5
1.5 - 2
2
2.5
3
1.5 - 2
2
2.5
3
2 - 2.5
2.5
3
2.5 - 3
4.8 - 6.1
5.1 - 7.5
4.1 - 5.1
3.4 - 4.1
7.3 - 10.0
5.8 - 7.3
5.0 - 5.8
4.1 - 5.0
8.1 - 10.0
6.1 - 8.1
4.7 - 6.1
3.4 - 4.7
7.8 - 10.0
5.8 - 7.8
4.4 - 5.8
7.7 - 10.0
2
1.5 - 2
2
2.5
1.5 - 2
2
2.5
3
1.5 - 2
2
2.5
3
2 - 2.5
2.5
3
2.5 - 3
4.6 - 5.9
6.2 - 9.0
5.2 - 6.2
4.5 - 5.2
7.2 - 10.0
5.7 - 7.2
4.9 - 5.7
4.0 - 4.9
8.1 - 10.0
6.1 - 8.1
4.7 - 6.1
3.4 - 4.7
7.8 - 10.0
5.8- 7.8
4.4 - 5.8
8.0 - 10.0
5.9 - 7.7
3
2.5 - 3
6.2 - 8.0
8.2 - 10.0
6.3 - 8.2
2.5 - 3
3
8.6 - 10.0
6.7 - 8.6
720
750
LE 9 PPM
Gas Train
Pressure Range
Size, in
PSI
1.5
3.3 - 6.0
1.5
4.1 - 6.0
1.5
4.5 - 7.0
1.5 - 2
4.1 - 7.0
1.5 - 2
5.9 - 9.0
Note: Some units list two diameters because the gas train increases in size
after the regulating valve. The first number is the customer connection size.
UNDERSIZE
STANDARD
OVERSIZE
Table is based on Siemens gas train, which includes a regulating actuator.
A1-31
09-09
Firetube Boilers
Table A1-22. Minimum Required Regulated Gas Pressure

Altitude Conversion
ALTITUDE
(FT)
CORRECTION
FACTOR
ALTITUDE
(FT)
CORRECTION
FACTOR
1000
1.04
6000
1.25
2000
1.07
7000
1.30
3000
1.11
8000
1.35
4000
1.16
9000
1.40
5000
1.21
Table A1-23. Maximum Gas Consumption (CFH)

for Natural Gas and Propane Vapor
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.
CONNECTION
SIZE
(IN. NPT)
LOCATION
DIMENSION
A (IN.)
125-200
1-1/2
52
250-350
56
400
58
500
2-1/2
60
600
2-1/2 - 3
71
65
700-800
NATURAL GAS
1000 (Btu/cu-ft)
PROPANE GAS
2550 (Btu/cu-ft)
125
5103
2000
150
6124
2402
200
8165
3202
250
10206
4002
300
12247
4802
350
14280
5600
400
16329
6404
500
20415
8006
600
24494
9605
700
28576
11206
750
30618
12007
800
32659
12807
MODEL CB
BOILER
HP
TYPE OF GAS AND HEAT CONTENT
BOILER
HP
BOILER
FRONT
PLAN VIEW
Figure A1-12. Standard Gas Train Connection Size and Location

A1-32
09-09
Firetube Boilers
Oil-Fired Burners
Fuel oil consumption information is shown on the boiler rating sheets in the
Dimensions and Rating Section.
Figure A1-15 shows the oil connection sizes and locations for Model CB Boilers
firing No. 2 oil.
Figure A1-16 through Figure A1-18 show typical oil systems and layouts.
Figure A1-19 and Figure A1-20 show the detail of an oil transfer tank (day tank)
typically utilized to provide a storage reservoir between the oil system supply pump
and the boiler oil pump.
General Boiler
Information
Table A1-24 shows blowdown tank sizing information.

Table A1-25 provides heating surface information.
Table A1-26 provides steam volume and disengaging area information
Table A1-27 provides recommended steam nozzle sizes.
Table A1-28 provides recommended non-return valve sizes.
Boiler Room
Information
Figure A1-21 shows typical boiler room length requirements.

Figure A1-22 shows typical boiler room width requirements.
Figure A1-23 shows typical breeching arrangements.
Stack Support
Capabilities
All standard Cleaver-Brooks Firetube Boilers with an LE option can support up to

2,000 lbs without additional support.
LE Boilers 250 hp through 800 hp can be reinforced to support 3,000 lbs.
Stack/Breeching
Size Criteria
The design of the stack and breeching must provide the required draft at each boiler
flue gas outlet. Proper draft is critical to burner performance.
Although constant pressure at the flue gas outlet of the Model CB-LE is not required,
it is necessary to size the stack/breeching to limit flue gas pressure variation. The
allowable pressure range is 0.25" W.C. to +0.25" W.C.
For additional information, please review Section I4, General Engineering Data
(Stacks) and Section F, Stacks. Stack and breeching sizes should always be provided
by a reputable stack supplier who will design the stack and breeching system based
on the above criteria. Your local Cleaver-Brooks authorized representative is capable
of assisting in your evaluation of the stack/breeching design.
Boiler Room
Combustion Air
When determining boiler room air requirements, the size of the room, air flow, and
velocity of air must be reviewed as follows:
1. Size (area) and location of air supply openings in boiler room.
A. Two (2) permanent air supply openings in the outer walls of the boiler room
are recommended. Locate (1) at each end of the boiler room, preferably
below a height of 7 feet. This allows air to sweep the length of the boiler.
B. Air supply openings can be louvered for weather protection, but they should
not be covered with fine mesh wire, as this type of covering has poor air flow
qualities and is subject to clogging by dust or dirt.
C. A vent fan in the boiler room is not recommended, as it could create a slight
vacuum under certain conditions and cause variations in the quantity of
combustion air. This can result in unsatisfactory burner performance.
A1-33
09-09
Firetube Boilers
D. Under no condition should the total area of the air supply openings be less
than (1) square foot.
E. Size the openings by using the formula:
Area (sq-ft) = CFM/FPM
2. Amount of air required (cfm).
A. Combustion Air = Rated bhp x 8 cfm/bhp.
B. Ventilation Air = Maximum bhp x 2 cfm/bhp
C. Total recommended air = 10 cfm/bhp - up to 1000 feet elevation. Add 3
percent more per 1000 feet of added elevation.
3. Acceptable air velocity in Boiler Room (fpm).
A. From floor to (7) foot height - 250 fpm
B. Above (7) foot height - 500 fpm
Example: Determine the area of the boiler room air supply openings for (1) 300 hp
boiler at 800 feet altitude. The air openings are to be 5 feet above floor level.
Air required: 300 x 10 = 3000 cfm (from 2B above).

Air velocity: Up to 7 feet = 250 fpm (from 3 above).
Area Required: Area = cfm = 3000/250 = 12 sq-ft total.
Area/Opening: 12/2 = 6 sq-ft/opening (2 required).
Notice
Consult local codes, which may supersede these requirements.
A1-34
09-09
Firetube Boilers
This figure illustrates the basic gas valve arrangement on Cleaver-Brooks

Model CB boiler and shows the contractor's connection point. The valves and
controls between the contractor connection point and the gas main in the
street are representative of a typical installation. Actual requirements may
vary depending on local codes or local gas company requirements which
should be investigated prior to preparation of specifications and prior to construction.
STREET GAS MAIN
MODEL
CB-LE
BOILERS
PLUG
COCK
MODEL
CB-LE
BOILERS
A
B
C
CONTRACTOR
CONNECTION
POINT
GAS TRAIN
ON BOILER
A. Utilities service valve.

B. Utilities service regulator.
C. Gas meter.
D. Piping from meter to boiler.
The size of the gas line from the meter to the gas pressure regulator at the
boiler can be very important if gas pressures are marginal. The gas line sizing
is dependent on:
1.
2.
3.
4.
Gas pressure at outlet of gas meter (C)

Rate of gas flow required, CFH
Length of pipe run (D)
Pressure required at contractor connection point.
The local gas utility will advise the pressure that is available at the outlet of
their meter.
Figure A1-13. Typical Gas Piping Layout
A1-35
09-09
Firetube Boilers
UL
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
DESCRIPTION
Pilot Shut Off Cock
Pilot Pressure Regulator
Pilot Pressure Gauge
Gas Pilot Valve
Pilot Vent Valve
Gas Pilot Valve
Manual Shut Off Valve
Low Gas Pressure Switch
Main Gas Valve w/o POC
Main Gas Valve w/ POC
Vent Valve or Valve Proving Switch
Regulating Gas Valve w/ POC
High Gas Pressure Switch
Butterfly Valve
CSD-1
NFPA-85
125 hp 300 hp
350 hp 800 hp
125 hp 300 hp
FM
350 hp 800 hp
125 hp 300 hp
350 hp 800 hp
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
10
2
11
12
13
14
15
S
S
PILOT GAS LINE
Gas
Supply
To
Burner
FLOW
FLOW
MAIN GAS LINE
Figure A1-14. Model CB-LE Gas Train Components
MODEL CB
A
(IN.)
125
150
200
3/4
12-1/2
250
300
350
3/4
34
400
500
600
3/4
11-3/4
700
750
800
11-3/4
BOILER
HP
CONTRACTOR
CONNECTIONS
BOILER
FRONT
BOILER BASE FRAME
A
RIGHT HAND SIDE VIEW
RECOMMENDED OIL LINEA

SIZES
(STANDARD PIPE)
(IN. - IPS)
SUPPLY
AND
RETURN
CONN
SIZES
(IN.)
(NPT)
STORAGE
PUMP
TANK TO
TO
BOILER
BOILER
OR PUMP
CONNECT
RETURN
LINE TO
TANK
NOTE: See No. 2 Oil Line Sizing Instruction for systems with other
conditions.
A. For suction line condition with a maximum of 10 Feet of lift and a
total of 100 feet of suction line.
Figure A1-15. No.2 Oil Connection Size, Location, and Recommended Line Sizes
A1-36
09-09
Firetube Boilers
CHECK
VALVE
VACUUM
GAUGE
OIL PUMP
UNION
GATE VALVE
STRAINER
GATE VALVE
F.O.S.
RELIEF VALVE
F.O.R.
GATE VALVE
CHECK VALVE
BOILER
FRONT
BOILER
BASE FRAME
F.O.S.
F.O.R.
Figure A1-16. No. 2 Oil Piping, Single Boiler

Installation, Remote Oil Pump
CONTRACTOR
CONNECTIONS
AT THIS POINT
VACUUM GAUGE
CHECK VALVE
GATE VALVE
STRAINER
GATE VALVE
F.O.S.
OIL
PUMP
NO. 2
F.O.R.
OIL PUMP NO. 1

UNION
GATE VALVE
RELIEF
VALVE
(100 PSIG)
GATE VALVE
CHECK VALVE
BOILER
FRONT
Figure A1-17. No. 2 Oil Piping, Multiple Boiler

Installation, Remote Oil Pumps
BOILER
BASE FRAME
F.O.S.
F.O.R.
CONTRACTOR
CONNECTIONS
AT THIS POINT
A1-37
09-09
Firetube Boilers
VACUUM GAUGE
STRAINER
GATE VALVE
CHECK
VALVE
STANDBY
OIL PUMP
F.O.S.
GATE
VALVE
F.O.R.
ADJUSTABLE
PRESSURE
RELIEF VALVE
(75 PSIG)
UNION
GATE VALVE
RELIEF
VALVE
(100 PSIG)
PRESSURE
GAUGE
GATE
VALVE
CHECK
VALVE
USE LAYOUT FOR: MODEL CB. . . . . . . 50 THRU 800 HP

Relief valve on the boiler
must be set at 100 psig so
that adjustable pressure
relief valve in the loop
system is in control.

Installation
BOILER
FRONT
BOILER
BASE FRAME
F.O.S.
CONTRACTOR
CONNECTIONS
AT THIS POINT
VENT
OIL TRANSFER TANK

AT LOCATION NEAR
BOILER
OIL LEVEL
TEST VALVE
F.O.R.
F.O.S.
OIL TRANSFER PUMP

NEAR STORAGE TANK
F.O.R.
GATE
CHECK
VALVE
VALVE STRAINER
F.O.S.
SUPPLY TO BOILER
TERMINAL BLOCK OR
TO BOILER OIL PUMP
RELIEF VALVE
(100 PSIG)
ITEM
SIZE
F.O.R.
GATE
UNION VACUUM VALVE
GAUGE
DESCRIPTION
1/2" NT 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
NOTE: Connections should be

sized using recommended sizes in
oil line sizing instructions.
G A
B
2"
5"
3"
22"
60"
E
4" OR 6"
STD
BLACK
PIPE
33"
3"
3/8" MTL
Figure A1-19. No. 2 Oil Piping

(For elevated boiler room locations
using an oil transfer pump and tank)
A1-38
09-09
Firetube Boilers
CONDENSATE OR HOT WATER

OIL RETURN
OIL SUCTION
STEAM OR HOT WATER
MANHOLE
OIL STORAGE
TANK
NOTE: OBSERVE ALL LOCAL AND NATIONAL

(EG. FIRE UNDERWRITERS) CODE REQUIREMENTS GOVERNING THE INSTALLATION OF FUEL OIL STORAGE TANKS
AND SUPPLY SYSTEMS.
Figure A1-20. Typical Arrangement
Table A1-24. Model CB-LE Blowdown

Tank Sizing
BOILER HP
125
Table A1-25. Heating Surface, Model CB-LE
WATER (GAL)
BOILER
HP
97
125
HEATING SURFACE (SQ-FT)

FIRESIDE
WATERSIDE
625
679
150
118
150
750
820
200
145
200
1000
1092
250
146
250
1250
1346
300
1500
1623
300
176
350
1750
1932
350
210
400
2000
2151
400
177
500
2500
2691
600
3000
3262
700, 750, 800
3500
3810
500
209
600
250
700, 750, 800
296
NOTE: Quantity of water removed from boiler by lowering

normal water line 4".
A1-39
09-09
Firetube Boilers
Table A1-26. Steam Volume and Disengaging Area

STEAM DISENGAGING AREA
SQ-IN
STEAM VOLUME CU-FT

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
NOTE: Based on normal water level.

A. Based on 150 psig design pressure.
B. Based on 15 psig design pressure.
Table A1-28. Recommended Non-Return Valve Size

Table A1-27. Recommended Steam Nozzle Size (for
4000 to 5000 fpm nozzle velocity)
BOILER
CAPACITY
(LBS/HR)
100
3450
125
4313
Boiler HP
OPERATING
PRESSURE
PSIG
OPERATING PRESSURES (PSIG)
BOILER
HP
125 150 200 250 300 350 400 500 600 700 750 800
50
75
2-1/2 2-1/2
100
125
150
175
200
250
NA
NA
NA
NA
NA
NA
NA
NA
2-1/2 2-1/2 2-1/2
NA
NA
NA
15
10
10
12
12
12
12
12
12
12
12
150
5175
30
10
10
10
12
12
12
12
200
6900
3*
40
10
10
10
12
12
12
250
8625
3*
50
10
10
10
12
12
300
10350
3*
75
10
10
10
3*
10
12025
350
100
125
400
13800
3*
150
500
17210
200
2.5
600
20700
250
2.5
700
24150
800
27600
NOTES:
1. Steam nozzle sizes given in inches.
2. Recommended steam nozzle sizes based on 4000 to 5000 fpm steam velocity.
3. All standard steam nozzle sizes for 150 psig design pressure or greater are the same
as 125 psig operating pressure on the above table. To increase or decrease the standard
size, request the change with your local Cleaver-Brooks authorized representative.
4. Shaded area denotes special surge load baffles must be installed to avoid possible
water carry-over.
5. For incremental operating pressures, see Table I3-1 Steam Systems Fundamentals.
2-1/2 2-1/2 2-1/2 2-1/2
NA
2-1/2 2-1/2 2-1/2
NOTE: Valve sizes (300 # Flanges) given in inches.

Standard Non-Return valve selections limited to a maximum 2 to 1 turndown
(50% of full load); selections based on typical non-return valve sizing recommendations. For final valve selection contact your C-B authorized representative. For
high turndown applications see Boiler Book Section I3, Table I3-3.
* Indicates pressure drop of less than 7.5 psig. All other selections are less than
6 psig pressure drop.
A1-40
09-09
Firetube Boilers
FRONT
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
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.
If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and working
space.
2. Next shortest boiler room length (Dwg B) is obtained by allowing for possible future tube replacement from the
front of the boiler. Allowance is only made for minimum door swing at the rear.
If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and working
space.
3. A slightly longer boiler room (Dwg C) is obtained by allowing for possible future tube replacement from the rear of
the boiler. Allowance for door swing at the front provides sufficient aisle and working space at the front.
Figure A1-21. Boiler Room Length (Typical Layouts)
125-200
250-350
400-800
Dimension A
BOILER HP
82"
93"
102"
Dimension B
115"
141"
171"
NOTES:
1. Recommended Minimum Distance Between Boiler and Wall. Dimension A allows for a clear 42" aisle between the water column on the boiler and the wall. If space permits, this aisle
should be widened.
2. Recommended Minimum Distance Between Boilers.
Dimension B between boilers allows for a clear aisle of:
42" - 125 -200 hp
48" - 250-350 hp
60" - 400-800 hp
If space permits, this aisle should be widened.
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
Figure A1-22. Boiler Room Width (Typical Layout)
A1-41
09-09
Firetube Boilers
TIGHT SEAL
CLEANOUT
STACK
MANUAL
DAMPER
LOCK (OPEN)
CLEANOUT
DRAIN
CONNECTION
MULTIPLE BOILERS WITH A COMMON STACK
MAXIMUM 10
CONE ANGLE
NOTE: These stack breeching arrangements for multiple

boilers are generic and not intended for your specific
design requirements. For additional information, review
Section F, Stacks.
MAXIMUM 10 CONE ANGLE

EVEN WITH LIMITED SPACE
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.
TIGHT SEAL
CLEANOUT
DETAIL OF TRANSITION PIECES
TIGHT SEAL
CLEANOUT
STACK
MANUAL
DAMPER
LOCK (OPEN)
STACK
MANUAL
DAMPER
LOCK (OPEN)
CLEANOUT
CLEANOUT
DRAIN
CONNECTION
MULTIPLE BOILERS WITH INDIVIDUAL STACKS
Figure A1-23. Breeching Arrangement

A1-42
09-09
DRAIN
CONNECTION
Section A1
Model CB-LE Steam Boiler Specifications
(125-800 hp, Steam 15-300 psig)
Table Of Contents
Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-44
General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-44
Boiler Shell (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-44
Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-45
Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-46
Boiler Flame Safeguard Controller and Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-49
Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-51
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-52
Performance Criteria: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-52
Shop Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-53
Start-up Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-53
A1-43
09-09
Section A1

(125-800 hp, Steam 15-300 psig)
PART 1 GENERAL
The LE Option specification includes information on the base low emissions package for 60 or 30
ppm NOx (dry volume basis and corrected to 3% 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)
1.1
Boiler Characteristics (Steam)

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

A. The boiler shall be a four pass horizontal firetube updraft boiler with five (5) square
feet (except 750 or 800 hp) of heating surface per rated boiler horsepower. It shall be
mounted on a heavy steel frame with integral forced draft burner and burner controls.
1. The boiler shall be completely preassembled and fire tested at the factory. The
unit shall be ready for immediate mounting on floor or simple foundation and
ready for attachment of water, steam, fuel, electrical, vent and blowdown
connections.
2. The boiler shall be built to comply with the following insurance and codes
__________________(Factory Mutual, GE-GAP Insurance, ASME CSD-1).
PART 2 PRODUCTS
Notice
The complete package boiler shall be approved as a unit by Underwriters Laboratories and shall bear
the UL/ULC label, except in the case where 50 Hz has been selected.
2.1
Boiler Shell (Steam)

A. The boiler shell must be constructed in accordance with ASME Boiler Code and must
receive authorized boiler inspection prior to shipment. A copy of the inspection report
shall be furnished to the purchaser.
B. Two lifting eyes shall be located on top of the boiler.
C. Front and rear doors on the boiler shall be hinged or davited. Doors are to be sealed
with fiberglass tadpole gaskets and fastened tightly using heavy capscrews that
thread into replaceable brass nuts.
D. Rear refractory and insulation shall be contained in the formed door, which must
swing open for inspection of brick work.
E. The boiler tubes shall not include turbulators, swirlers or other add-on
appurtenances.
A1-44
09-09
Section A1

F.
G.
H.
I.
J.
K.
L.
2.2
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.
For boilers 125 horsepower and over, a manhole shall be provided.
The exhaust gas vent shall be located near the front of the boiler on the top center
line and shall be capable of supporting:
1. 15-100 hp. 1000 lbs and shall contain a stack thermometer
2. 125-800 hp. 2000 lbs and shall contain a stack thermometer
The boiler shell shall contain a chemical feed connection.
Observation ports for the inspection of flame conditions shall be provided at each end
of the boiler.
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.
The entire boiler base frame and other components shall be factory painted before
shipment using a hard finish enamel coating.
Steam Boiler Trim

A. Water Column
A water column shall be located on the right hand side of the boiler complete with
gauge glass set and water column blowdown valves.
1. Feedwater Pump Control
The boiler feedwater pump control shall be included as an integral part of the
water column to automatically actuate a motor driven feed water pump
maintaining the boiler water level within normal limits.
2. WATER COLUMN/LOW WATER CUTOFF AND WATER LEVEL CONTROL
SYSTEM
(150-250 psig design): Shall be a CB LEVEL MASTER Water level control
system and shall be comprised of a microprocessor-based electronic controller, a
non-contact, non-wearing, continuously reading absolute level sensor and
pressure chamber. The control system shall be designed as follows: The
electronic controller shall be mounted in the common control panel (see 2.4
below) and operate in ambient temperatures from 32 degrees F to 125 degrees
F. The pressure chamber shall be boiler mounted and operate to pressures of
250 PSIG and the level sensor shall operate to pressures of 250 PSIG and
temperatures to 400 degrees F. The pressure-containing components shall be
constructed in accordance with ASME Code. A shielded, four conductor cable
with ground shall be run in metal conduit between the level sensor and the
controller. Supply power shall be 115VAC-1 phase- 60 Hz. All wiring shall be in
compliance with the National Electrical Code.
The pressure chamber shall have a sight glass mounted on the side. The level
sensor shall have an accuracy of .01" or greater. The electronic controller shall
have level and error indicating lights, alphanumeric display for messaging, reset/
menu switch and the following features:
a.
b.
c.
d.
Continuous Level Indication

Low Water Cutoff & Alarm
High Water Alarm
Low & High Water Warning
A1-45
B.
C.
D.
E.
2.3
Section A1
e. Full Modulating Control of Modulating Feedwater Control Valve

f.
Continuous Monitoring of Float Operation
g. Column Blowdown Detection and Reminder
h. Auto or Manual Reset
i.
Real Time Clock
j.
Alarm Annunciation
k. Alarm History Files with Time Stamp
l.
Water Column Blowdown Record
m. Auxiliary Low Water Cutoff Check
n. RS 232 Interface
o. Maximum Contacts Rating 15 amps Resistive Load
3. Low Water Cutoff (15 psig design)
The low water cutoff shall be included as an integral part of the boiler feedwater
control wired into the burner control circuit to prevent burner operation if the
boiler water level falls below a safe level.
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.
Steam Pressure Gauge
The steam pressure gauge shall be located at the front of the boiler and include cock
and test connection.
Safety Valves
Safety valves of a type and size to comply with ASME Code requirements shall be
shipped loose.
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).
Burner and Controls

A. Mode of Operation
Burner operation shall be full modulation principle. The burner shall always return to
low fire position for ignition.
B. Blower
1. Air for combustion shall be supplied by a forced draft blower mounted in the
front boiler door, above the burner, to eliminate vibration and reduce noise level.
2. Maximum sound level of the boiler/burner package shall not exceed _____ dbA
(when measured in accordance with ABMA Sound Test Standards).
3. The impeller shall be cast aluminum, radial blade, carefully balanced, and
directly connected to the blower motor shaft.
C. Combustion Air Control
Combustion air damper and cam operated fuel metering valves shall be operated by a
single damper control motor that regulates the fire according to load demand.
Potentiometer type position controls shall be provided to regulate operation of the
damper control motor (remove this sentence when CB-HAWK flame safeguard is
used).
A1-46
09-09
Section A1

D.
Fuel Specification and Piping

Select one of the following fuel types:
Fuel series 700 - Gas fired (4.4.1).
Fuel series 100 - Light oil (No. 2) fired (4.4.2).
Fuel series 200 - Light oil or gas fired (4.4.3).
1.
2.
Fuel Series 700 - Gas Fired

a. Burner Type - The burner shall be integral with the front head of the boiler
and of high radiant multi-port type for gas. The burner shall be approved
for operation on natural gas fuel and equipped with an LE option.
b. Gas Pilot - The gas pilot shall be a premix type with automatic electric
ignition. An electronic detector shall monitor the pilot so that the primary
gas valve cannot open until pilot flame has been established. The pilot
train shall include two manual shut-off valves, solenoid valve, pressure
regulator and pressure gauge.
c. Gas Burner Piping - Gas burner piping on all units shall include pressure
regulating gas shutoff valve, motor operated with proof of closure switch
and plugged leakage test connection. The main gas valve(s) shall be wired
to close automatically in the event of power failure, flame failure, low water
or any safety shutdown condition. A lubricating plug cock or butterfly
shutoff valve shall be provided as a means for a tightness check of the
primary shut off valve. An additional plug cock on butterfly valve shall be
furnished at entrance to gas train. Select one of the following:
1) 125-300 hp. High and low gas pressure switches shall be provided.
A second motorized safety shutoff valve, plus an additional plugged
leakage test connection shall be provided.
leakage test connection shall be provided. A valve proving switch
shall be located between the safety shutoff valves.
d. Burner Turndown - Select one of the following:
1) 125-200 hp. Turndown range of burner shall be 4:1 when firing
natural gas.
2) 250-800 hp. Turndown range of the burner shall be 10:1 when firing
natural gas with a 60 or 30 ppm LE option. (Consult with CleaverBrooks Representative regarding high turndown capability based on
available gas pressure and 25 and 20 ppm LE options.)
Fuel Series 100 - Light Oil Fired
a. Burner Type - The burner shall be integral with the front head of the boiler,
and shall be a low pressure air atomizing type approved for operation with
CS12-48, Commercial No. 2 oil and equipped with an LE option.
b. Gas Pilot - The gas pilot shall be premix type with automatic electric
fuel valve cannot open until flame has been established. The pilot train
shall include two manual shut-off valves, solenoid valve, pressure regulator
and pressure gauge.
c. Oil Pump - An oil pump with a capacity of approximately twice the
maximum burning rate shall be included. Separate motor driven pump set,
shipped loose to be installed in a location favorable to the oil storage tank,
shall be provided.
A1-47
Section A1
d.
3.
Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure
regulating devices, oil metering controls, solenoid shutoff valves, pressure
gauges and fuel strainer, all integrally mounted on the unit. A fuel oil
controller shall be provided to combine all of the fuel oil controls into a
single casting which is mounted on the front door of the unit. A single tip
retractable nozzle shall be used for the low pressure air atomizing burner. A
low oil pressure switch shall be included in the oil piping.
e. Low Pressure Air Atomizing
Separate air compressor module mounted on boiler base rail with low
atomizing air pressure switch.
f.
Burner Turndown.
Select one of the following:
1) A. 125 hp through 200 hp. Turndown range shall be 4:1 when firing
No. 2 oil.
2) B. 250 hp through 800 hp Turndown range shall be 8:1 when firing
No. 2 oil. (Consult your local Cleaver-Brooks authorized
representative regarding No. 2 oil turndown capabilities when utilizing
LE Options to achieve NOx levels of 25 or 20 ppm when firing natural
gas.)
Fuel Series 200 - Light Oil or Gas Fired
a. Burner Type - The burner, integral with the front head of the boiler, shall be
a combination of the low pressure air atomizing type for oil and high
radiant multi-port type for gas. The burner shall be approved for operation
with either CS12-48 Commercial No. 2 Oil or natural gas. The burner shall
be equipped with an LE option.
and pressure gauge.
c. Oil Burner
1) Oil Pump - An oil pump with a capacity of approximately twice the
maximum burning rate shall be included. Separate motor driven
pump set, shipped loose, to be installed in a location favorable to the
oil storage tank, shall be provided.
2) Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure
regulating devices, oil metering controls, solenoid shutoff valves,
pressure gauges and fuel strainer, all integrally mounted on the unit. A
fuel oil controller shall be provided to combine all of the fuel oil
controls into a single casting which is mounted on the front door of
the unit. A single tip retractable nozzle shall be used for the low
pressure air atomizing burner. A low oil pressure switch shall be
included in the oil piping.
3) Low pressure air atomizing - Separate air compressor module
mounted on boiler base rail with low atomizing air pressure switch.
A1-48
09-09
Section A1

d.
e.
2.4
Gas Burner
Gas Burner Piping - gas burner piping on all units shall include pressure
regulatinggas shutoff valve, motor operated with proof of closure switch
primary shut off valve. An additional plug cock or butterfly valve shall be
A second motorized safety shutoff valve, plus and additional plugged
Burner Turndown - Select one of the following:
1) 125-200 hp. Turndown range of the burner shall be 4:1.
natural gas and 8:1 on No. 2 oil. (Consult your local Cleaver-Brooks
authorized representative regarding high turndown capability based
on available gas pressure and No. 2 oil turndown capabilities when
utilizing LE Options to achieve NOx levels of 25 or 20 ppm when
firing natural gas.)
Boiler Controls and Control Panel

A. Control/Entrance Panel
A common enclosure shall house the control panel and the entrance panel. Enclosure
shall be NEMA 4 rated and shall be mounted at the side of the boiler in a location
convenient to the operator. Enclosure shall consist of upper and lower sections
divided by a partition with a separate hinged door for each section. Upper section
(low voltage) will house boiler controls including flame safeguard, water level system
controller, and Hawk ICS if so equipped. Lower panel section (high voltage) will
house entrance panel.
B.
CB780E Flame Safeguard

1. Boilers with CB780E Control - Each boiler shall be factory equipped with flame
safeguard controller providing technology and functions equal to the CleaverBrooks Model CB780E.
Controller shall be computerized solid state having sequence and flame-on lights
and digital first out fault code indications of flame safeguard trip functions. It
shall include dynamic self-check logic. The controller shall have a fixed
operating sequence incapable of being manually altered. The sequence shall
include start, pre-purge, pilot and main fuel ignition run and post-purge cycles.
Controller shall be the non-recycle type for maximum safety that shall shutdown
the burner and indicate as a minimum the following trip functions: pilot and
main flame failure, high and low fire proving switch faults, running interlocks
open, false flame signal and fuel valve open (when proof of closure switch is
furnished).
The controller shall have a run/test switch. It shall allow interruptions to
A1-49
Section A1
sequence just after pre-purge, during pilot ignition trial and run cycles for
adjustments to firing rate motor, damper linkages and pilot flame for minimum
turndown tests.
2.
Lights
White - load demanded.
White - fuel valve open.
Red - low water.
Red - flame failure.
3.
Control Switches
Burner On-Off.
Manual-Automatic.
Manual Firing Rate Control.
4.
C.
Oil, heat and moisture resistant wire shall be used and identified with circuit
numbers corresponding to the electrical wiring diagram.
5. All electrical equipment and wiring shall be in conformance with Underwriters
Laboratories requirements.
6. Boiler to be supplied with a control circuit transformer and fuse protection for
the control circuit.
CB-HAWK ICS Integrated Boiler Control and Management System:
Boiler Control System combining a Digital Burner Management System for flame
safety and a Programmable Logic Controller for boiler modulation and operator
interface functions.
The factory pre-configured Boiler Control System shall integrate the Burner
Management functions and the PLC based modulation and operator interface
functions. The logic of the Burner Management System and the modulating controls
will not be run in the same processor or powered by the same DC supply. The PLC
and Operator Interface Hardware shall be as manufactured by Allen Bradley.
Major system components shall include:
Programmable Logic Controller
Touch Screen HMI
One Burner Management Controller with Wiring Sub-Base
One Flame Scanner and amplifier
Various Temperature and Pressure Sensors
Major functions provided by the Boiler Control System shall be:
Automatic sequencing of the boiler through standby, pre-purge, pilot
flame establishing period, main flame establishing period, run, flame
proving and lockout and post-purge
Full modulating control of fuel and air
Utilize solid state controls and sensors to provide various control
functions, such as:
Modulating control (algorithm shall be Proportional-lntegral-Derivative (PID) type)
Thermal shock protection
High and Low limit alarms and shutdowns
Touch Screen graphical operator interface and monitoring

Manual control of the boiler firing rate using control screens on the HMI to increment
or decrement the firing rate
A1-50
09-09
Section A1

On screen indication of burner management controller status and diagnostics
On screen display of system alarms and faults
On screen history of alarms and faults
On screen recommendations for troubleshooting of fault conditions
On screen water level indication and alarm(s)
Stack Flue Gas, Combustion Air and Shell (water) temperature indication
Boiler efficiency calculation
Low Fire Hold with Minimum Temperature Control
Assured Low Fire Cut-Off (ALFCO)
The Boiler Control System shall incorporate the following safety provisions:
Examine all load terminals to assure it is capable of recognizing the true status
of the external controls, limits and interlocks. If any input fails this test, the
Burner Management System shall lockout on safety shutdown.
Closed-loop logic test of critical loads (ignition, pilot and main fuel valves) and
must be able to lockout on safety.
Pre-ignition interlocks (fuel valve proof of closure, etc.) and flame signal
checked during Standby and Pre-Purge.
Dynamic checking of the flame signal amplifier.
Safe start check and expand check to include monitoring flame signal during
standby.
High and Low fire switches checked for proper sequencing.
The Boiler Control System shall provide the ability to communicate with external digital
devices via Ethernet as standard. OPC compliant Internet communications shall be
supported, with the Boiler Control System supplied with its own IP address.
2.5
Efficiency Guarantee
A. The boiler manufacturer shall guarantee that, at the time of startup, the boiler will
achieve ________ fuel-to-steam efficiency at 100% firing rate when burning natural
gas and ________ fuel-to-steam efficiency at 100% firing rate when burning oil (add
efficiency guarantees at 25%, 50%, and 75% of rating, if required). If the boiler(s)
fail to achieve the corresponding guaranteed efficiency as published, the boiler
manufacturer will rebate, to the ultimate boiler owner, five thousand dollars ($5,000)
for every full efficiency point (1.0%) that the actual efficiency is below the guaranteed
level.
B.
Natural Gas
Fuel specification used to determine boiler efficiency:
Carbon,% (wt) = 69.98

Sulfur,% (wt) = 0.0
No. 2 Oil
Sulfur,% (wt) = 0.2
No. 6 Oil
A1-51
Section A1

C.
D.
E.
Efficiencies are based on ambient air temperature of 80 F, relative humidity of 30%,

and 15% excess air in the exhaust flue gas.
Efficiencies are based on manufacturers published radiation and convection losses.
(For Cleaver-Brooks radiation and convection losses, see Boiler Efficiency Facts
Guide, publication number CB-7767).
Any efficiency verification testing will be based on the stack loss method.
2.6
Warranty
All equipment is to be guaranteed against defects in materials and/or workmanship for a
period of 12 months from date of start-up or 18 months from date of shipment, whichever
comes first.
2.7
Performance Criteria:
Performance Criteria
Manufacturer:
CLEAVER-BROOKS
Model:
Promethean Line
Horsepower:
________HP
Output:
________#/hr (from and at 212F)
Gas Input:
________MBH
Oil Input:
________GPH
Design Pressure:
________PSIG
Operating Pressure
________PSIG
Steam Disengaging Area (minimum)
________Sq. Inches
Steam storage area (minimum)
________Cu. Ft.
Heating Surface (minimum):
________Sq. Ft. Fireside
Heating Release (maximum):
________BTU/Cu. Ft.
Burner Turndown Ratio Natural Gas:

Overall Efficiency (Fuel to Steam)
Natural Gas (%):
No. 2 Oil (%):
________% at High Fire

NOX Emission (maximum)

Gas (Natural):
Oil (No. 2):
________PPM (corrected to 3%O2)

CO Emissions (maximum)
Gas (Natural):
Oil (No. 2):

A1-52
09-09
Section A1

Electrical:
Fan Motor:
Air Compressor Motor:
Oil Pump Motor:
Noise Level (3' from burner):
____ V / ____ H / ____ P

____HP
____HP
____HP
____dBA
Available Gas Supply Pressure:
____PSIG
Weight
Dry:
Flooded:
____
____
Seismic Zone:
____
Altitude:
____
Code Requirements:
ASME / NATIONAL BOARD

CSD-1 NFPA 8501
Underwriters Lab (UL)
State Of _______
Factory Mutual (FM)
Industrial Risk Insurers (IRI)
ASL
PART 3 EXECUTION
3.1
Shop Tests
A. The packaged boiler must receive factory tests to check the construction, controls,
and operation of the unit. All tests may be witnessed by the purchaser, if desired.
3.2
Start-up Service
A. After boiler installation is completed, the manufacturer shall provide the services of a
field representative for starting the unit and training the operator at no additional
costs.
1. A factory approved and authorized start-up report shall be submitted to the
customer/user at the time of start-up.
A1-53
Firetube Boilers
Notes
A1-54
Section A1
Model CB-LE Hot Water Specifications
(125-800 hp, 30 psig, 125 psig)
Table Of Contents
Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-57
Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-57
Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-63
Performance Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-64
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-65
Shop Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-65
A1-55
09-09
Section A1
PART 1 GENERAL
1.1
Boiler Characteristics (Hot Water)

A. The Hot Water Boiler shall be Cleaver-Brooks Model CB, Fuel Series ______ (100,
200, 700), _____ hp designed for _____ psig (30, 125 psig, or other hot water). The
maximum water temperature shall be _____ degree F, and the maximum system
temperature drop shall be _____ degrees F.
available shall be _____Volt _____ Phase _____ Cycle.
PART 2 PRODUCTS
2.1

feet (except 750 or 800 hp) of heating surface per rated boiler horsepower. It shall be
mounted on a heavy steel frame with integral forced draft burner and burner controls.
The complete package boiler shall be approved as a unit by Underwriters
Laboratories and shall bear the UL/ULC label.
connections.
____________________ (Factory Mutual, Industrial Risk Insurance, ASME CSD1).
B. Boiler Shell (Hot Water)
1. The boiler shell must be constructed in accordance with ASME Boiler Code and
must receive authorized boiler inspection prior to shipment. A copy of the
inspection report shall be furnished to the purchaser.
2. The hot water return and outlet connections shall be located on the top center
line of the boiler. The boiler shall be designated to rapidly mix the return water
with the boiler water. Forced internal circulation shall be used.
3. A dip tube shall be included as an integral part of the water outlet.
4. Two lifting eyes shall be located on top of the boiler.
5. Front and rear doors on the boiler shall be hinged or davited. Doors are to be
sealed with fiberglass tadpole gaskets and fastened tightly using heavy
capscrews that thread into replaceable brass nuts.
6. Rear refractory and insulation shall be contained in the formed door, which must
7. The boiler tubes shall not include turbulators, swirlers or other add-on
appurtenances.
8. Front and rear tube sheets and all flues must be fully accessible for inspection
and cleaning when the doors are swung open. The shell must be furnished with
adequate handholes to facilitate boiler inspection and cleaning.
9. A manhole shall be provided.
10. The exhaust gas vent shall be located near the front of the boiler on the top
center line and shall be capable of supporting 2000 lbs and shall contain a
stack thermometer.
A1-56
09-09
Section A1
C.
D.
E.
F.
Observation ports for the inspection of flame conditions shall be provided at each end
of the boiler.
The entire boiler based frame and other components shall be factory painted before
shipment using a hand finish enamel coating.
Emission Controls
1. Boiler shall be equipped with a low emission (LE) option for guaranteed NOx
performance at ________ ppm, dry volume basis and corrected to 3% O2 when
firing natural gas.
2. The low emission option shall include an integral front head, burner, and boiler
package, providing NOx reduction through an internal flue gas recirculation
system using the combustion air fan, internal recirculation valve, and enhanced
boiler design to achieve the guaranteed NOx levels. The emission control system
shall not use an external fan, control valve, and piping. Boiler fuel-to-steam
efficiency and rated boiler capacity shall be guaranteed while the boiler is
operating at the low NOx performance levels.
3. Burner, boiler, and low NOx system shall be manufactured as a package by a
single manufacturer. The Low Emission Option to the CB Boiler shall included
factory testing as a package, and shall bear the UL packaged label. The boiler
nameplate shall include the approved UL low NOx boiler model designation. No
field assembly of the burner or low NOx equipment shall be required.
2.2
Hot Water Boiler Trim

A. Low Water Cutoff
A low water cutoff control (manual reset) shall be mounted on the top centerline of
the boiler wired into the burner control circuit to prevent burner operation if boiler
water falls below a safe level.
B. Pressure and Temperature Gauges
Pressure and temperature gauges shall be mounted on the boiler with temperature
sensing element located adjacent to the hot water outlet.
C. Relief Valves
Water relief valves of a type and size to comply with ASME Code requirements shall
be shipped loose.
D. Temperature Controls
Temperature controls to regulate burner operation shall be mounted on the unit with
temperature sensing elements located adjacent to the hot water outlet. Controls shall
be high limit (manual reset), operating limit (auto reset), and firing rate control.
2.3
Burner and Controls

Burner operation shall be full modulation principle. The burner shall always return to
low fire position for ignition.
B. Blower
front boiler door, above the burner, to eliminate vibration and reduce noise level.
A1-57
09-09
Section A1
3.
C.
D.
The impeller shall be cast aluminum, radial blade, carefully balanced, and
Combustion Air Control
Potentiometer type position controls shall be provided to regulate operation of the
damper control motor (remove this sentence when CB-HAWK flame safeguard is
used).
Fuel series 700 - Gas fired.
Fuel series 100 - Light oil (No. 2) fired.
Fuel series 200 - Light oil or gas fired.
1.
2.

and of high radiant multi-port type for gas. The burner shall be approved
for operation on natural gas fuel and equipped with an LE option.
primary shut off valve. An additional plug cock on butterfly valve shall be
natural gas.
natural gas when equipped with a 60 or 30 ppm LE option. (Consult
with Cleaver-Brooks Representative regarding high turndown
capability based on available gas pressure and 25 and 20 ppm LE
options.)
a. Burner Type - The burner shall be integral with the front head of the boiler,
and shall be a low pressure air atomizing type approved for operation with
A1-58
09-09
Section A1
3.
CS12-48, Commercial No. 2 oil and equipped with an LE option.

and pressure gauge.
c. Oil Pump - An oil pump with a capacity of approximately twice the
shipped loose to be installed in a location favorable to the oil storage tank,
shall be provided.
d. Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure
gauges and fuel strainer, all integrally mounted on the unit. A fuel oil
controller shall be provided to combine all of the fuel oil controls into a
single casting which is mounted on the front door of the unit. A single tip
retractable nozzle shall be used for the low pressure air atomizing burner. A
low oil pressure switch shall be included in the oil piping.
e. Low Pressure Air Atomizing - Separate air compressor module mounted on
boiler base rail with low atomizing air pressure switch.
f.
1) 125 hp through 200 hp. Turndown range shall be 4:1 when firing
No. 2 oil.
2) 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.)
a. Burner Type - The burner, integral with the front head of the boiler, shall be
a combination of the low pressure air atomizing type for oil and high
radiant multi-port type for gas. The burner shall be approved for operation
with either CS12-48 Commercial No. 2 Oil or natural gas. The burner shall
be equipped with an LE option.
and pressure gauge.
c. Oil Burner
maximum burning rate shall be included. Separate motor driven
pump set, shipped loose, to be installed in a location favorable to the
A1-59
09-09
Section A1
2)
fuel oil controller shall be provided to combine all of the fuel oil
controls into a single casting which is mounted on the front door of
the unit. A single tip retractable nozzle shall be used for the low
pressure air atomizing burner. A low oil pressure switch shall be
included in the oil piping.
3) Low pressure air atomizing - Separate air compressor module
d. Gas Burner
1) Gas Burner Piping - Gas burner piping on all units shall include
pressure regulating gas shutoff valve, motor operated with proof of
closure switch and plugged leakage test connection. The main gas
valve(s) shall be wired to close automatically in the event of power
failure, flame failure, low water or any safety shutdown condition. A
lubricating plug cock or butterfly shutoff valve shall be provided as a
means for a tightness check of the primary shut off valve. An
additional plug cock or butterfly valve shall be furnished at entrance
to gas train. Select one of the following:
125-300 hp. High and low gas pressure switches shall be provided. A second motorized
safety shutoff valve, plus an additional plugged leakage test connection shall be provided.
350-800 hp. High and low gas pressure switches shall be provided. A second motorized
safety shutoff valve, plus and additional plugged leakage test connection shall be provided. A
valve proving switch shall be located between the safety shutoff valves.
e. Burner Turndown - Select one of the following:
125-200 hp. Turndown range of the burner shall be 4:1.
250-800 hp. Turndown range of the burner shall be 10:1 when firing natural gas and 8:1 on
No. 2 oil. (Consult your local Cleaver-Brooks authorized representative regarding high
turndown capability based on available gas pressure and No. 2 oil turndown capabilities
when utilizing LE Options to achieve NOx levels of 25 or 20 ppm when firing natural gas.)
E.
Boiler Controls and Control Panel

1. CB780E Flame Safeguard
a. Boilers with CB780E Control - Each boiler shall be factory equipped with
flame safeguard controller providing technology and functions equal to the
Cleaver-Brooks Model CB780E.
Controller shall be computerized solid state having sequence and flame-on
lights and digital first out fault code indications of flame safeguard trip
functions. It shall include dynamic self-check logic. The controller shall
have a fixed operating sequence incapable of being manually altered. The
sequence shall include start, pre-purge, pilot and main fuel ignition run
and post-purge cycles.
Controller shall be the non-recycle type for maximum safety that shall
shutdown the burner and indicate as a minimum the following trip
functions: pilot and main flame failure, high and low fire proving switch
faults, running interlocks open, false flame signal and fuel valve open
(when proof of closure switch is furnished).
A1-60
09-09
Section A1
b.
c.
adjustments to firing rate motor, damper linkages and pilot flame for
minimum turndown tests.
Control Panel - The control panel shall be mounted on the front door of the
boiler in a location convenient to the operator. The hinged metal cabinet
shall have NEMA 1A rating that includes a neoprene dust seal and a Yale
cabinet key type lock.
The panel shall contain the boiler flame safeguard controller, blower motor
starter, indicating lights and selector switches.
The panel shall have a removable sub-base for mounting the flame
safeguard controller, blower motor starter, and terminal blocks. For
combination gas-oil fired boilers the panel shall contain the fuel selector
switch.
The panel shall contain the following lights and switches:
Lights
Red - low water.
d.
Control Switches
Burner On-Off.
Manual-Automatic.
e.
Oil, heat and moisture resistant wire shall be used and identified with
circuit numbers corresponding to the electrical wiring diagram.
f.
All electrical equipment and wiring shall be in conformance with
Underwriters Laboratories requirements.
g. Boiler to be supplied with a control circuit transformer and fuse protection
for the control circuit.
2. CB-HAWK ICS Integrated Boiler Control and Management System:
Boiler Control System combining a Digital Burner Management System for flame
safety, and a Programmable Logic Controller for boiler modulation and operator
interface functions.
The factory pre-configured Boiler Control System shall integrate the Burner
Management functions and the PLC based modulation and operator interface
functions. The logic of the Burner Management System and the modulating controls
will not be run in the same processor or powered by the same DC supply. The PLC
and Operator Interface Hardware shall be as manufactured by Allen Bradley.
Touch Screen HMI
Automatic sequencing of the boiler through standby, pre-purge, pilot
A1-61
09-09
Section A1
flame establishing period, main flame establishing period, run, flame
proving and lockout and post-purge
Utilize solid state controls and sensors to provide various control
functions, such as:

Manual control of the boiler firing rate using control screens on the HMI to increment
Examine all load terminals to assure it is capable of recognizing the true status
of the external controls, limits and interlocks. If any input fails this test, the
Burner Management System shall lockout on safety shutdown.
Closed-loop logic test of critical loads (ignition, pilot and main fuel valves) and
must be able to lockout on safety.
Pre-ignition interlocks (fuel valve proof of closure, etc.) and flame signal
checked during Standby and Pre-Purge.
Safe start check and expand check to include monitoring flame signal during
standby.
The Boiler Control System shall provide the ability to communicate with external digital via Ethernet
as a standard. OPC compliant Internet communications shall be supported, with the Boiler Control
System supplied with its own IP address.Efficiency Guarantee
F.
achieve ________ fuel-to-steam efficiency at 100% firing rate when burning natural
gas and ________ fuel-to-steam efficiency at 100% firing rate when burning oil (add
efficiency guarantees at 25%, 50%, and 75% of rating, if required). If the boiler(s)
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.
G.
Natural Gas
Carbon, % (wt) = 69.98
Hydrogen, % (wt) = 22.31
A1-62
09-09
Section A1
Sulfur, % (wt) = 0.0
Heating value, Btu/lb = 21,830
No. 2 Oil
Carbon, % (wt) = 85.8
No. 6 Oil
Carbon, % (wt) = 86.6
Sulfur, % (wt) = 2.09
H.
I.
J.
2.4

Manufacturer:
CLEAVER-BROOKS
Model:
Promethean Line
Horsepower:
________HP
Output:
________#/hr (from and at 212F)
Gas Input:
________MBH
Oil Input:
________GPH
Design Pressure:
________PSIG
Operating Pressure
________PSIG
Operating Temperature
________degrees F

Natural Gas (%):
No. 2 Oil (%):
Gas (Natural):
Oil (No. 2):

A1-63
09-09
Section A1
Gas (Natural):
Oil (No. 2):

Electrical:
Fan Motor:
Oil Pump Motor:
____ V / ____ H / ____ P

____HP
____HP
____HP
____dBA
____PSIG
Weight
Dry:
Flooded:
____
____
Seismic Zone:
____
Altitude:
____
Code Requirements:

CSD-1 NFPA 85 (optional)
State Of _______
Factory Mutual (FM) (optional)
GE-GAP (optional)
ASL
PART 3 EXECUTION
3.1
Warranty
All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12
months from date of start-up or 18 months from date of shipment, whichever comes first.
3.2
Shop Tests
B. Start-up Service
1. After boiler installation is completed, the manufacturer shall provide the services
of a field representative for starting the unit and training the operator at no
additional costs.
a. A factory approved and authorized start-up report shall be submitted to the
A1-64
09-09
Section A1
A1-65
09-09
Firetube Boilers
Notes
A1-66
Section A2
Promethean Series Model 4WI
100 - 800 HP
4 pass Wet-Back Integral Burner (4WI)
TABLE OF CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-4
Promethean Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-4
Specifying Boiler Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-13
Efficiency Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-13
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-14
Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-19
Gas-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-19
Oil-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-20
General Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-26
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-26
A2-1
09-09
Promethean Series - 4WI

Stack Support Capabilities . . . .
Stack/Breeching Size Criteria . . .
Boiler Room Combustion Air . . .
Sample Specifications - Steam. . . . .
Sample Specifications - Hot Water . .
Firetube Boilers
............................................
............................................
............................................
............................................
............................................
A2-26
A2-26
A2-26
A2-33
A2-45
LIST OF FIGURES
A2-1. Model 4WI Steam Boiler 100-800 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A2-2. Model 4WI Hot Water Boiler 100-800HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A2-3. Predicted stack temp. increase for pressure greater than 125 psig - Model 4WI . . . .
A2-4. Typical Gas Piping Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A2-5. No. 2 Oil Piping, Single Boiler Installation, Remote Oil Pump . . . . . . . . . . . . . . . . .
A2-6. No. 2 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . . .
A2-7. No. 2 Oil Piping, Multiple Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A2-8. No. 2 Oil Transfer Tank Detail (for consideration with elevated boiler rooms) . . . . . . .
A2-9. Typical Fuel Storage Tank Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A2-10. Boiler Room Length (Typical Layouts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A2-11. Boiler Room Width (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A2-12. Breeching Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A2-6
A2-8
A2-15
A2-22
A2-24
A2-24
A2-25
A2-25
A2-26
A2-30
A2-30
A2-31
LIST OF TABLES
Table A2-1. Horsepower -vs- Shell Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A2-2. Model 4WI Steam Boiler Ratings 100 to 800 HP . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A2-3. Model 4WI Steam Boiler Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A2-4. Model 4WI Hot Water Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A2-5. 4WI Hot Water Boiler Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A2-6. Steam Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A2-7. Hot Water Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A2-8. Space required to open rear head on boilers equipped with davits (4WI) . . . . . . . . . .
Table A2-9. Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A2-10. Lifting Lug Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A2-11. Firing Rates 4WI Boilers with Integral Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A2-12. Predicted Fuel-to-Steam Efficiencies - Natural Gas - Model 4WI . . . . . . . . . . . . . . .
Table A2-13. Predicted Fuel-to-Steam Efficiencies - No. 2 Oil - Model 4WI . . . . . . . . . . . . . . . . .
Table A2-14. Promethean Boilers - Natural Gas, Emission Levels - Model 4WI . . . . . . . . . . . . . .
Table A2-15. Promethean Boilers - No. 2 Oil, Emission Levels - Model 4WI 17 . . . . . . . . . . . . . .
Table A2-16. Standard, undersized, and oversized gas trains - sizes and pressure ranges . . . . . . . .
Table A2-17. Recommended NTI Gas Train Sizes and Pressure Ranges . . . . . . . . . . . . . . . . . . . .
Table A2-18. Predicted Sound Levels (30 ppm NOx system) at High Fire - Model 4WI . . . . . . . . .
Table A2-19. Minimum Required Gas Pressure Altitude Conversion . . . . . . . . . . . . . . . . . . . . . . .
Table A2-20. Maximum Gas Consumption (CFH) for Natural Gas and Propane Vapor . . . . . . . . . .
Table A2-21. Standard Gas Train Connection Size and Location . . . . . . . . . . . . . . . . . . . . . . . . .
Table A2-22. Gas Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A2-23. N0. 2 Oil Connection Size, Location and Recommended Line Sizes . . . . . . . . . . . . .
A2-3
A2-6
A2-7
A2-8
A2-9
A2-10
A2-10
A2-11
A2-11
A2-12
A2-14
A2-15
A2-16
A2-16
A2-16
A2-17
A2-18
A2-18
A2-21
A2-21
A2-21
A2-23
A2-23
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
A2-2
09-09
Firetube Boilers
Table A2-24. Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table A2-25. Heating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A2-26. Steam Volume Disengaging Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A2-27. Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity .
Table A2-28. Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A2-29. Blower Motor Selection 4WI NTI Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A2-27
A2-28
A2-28
A2-29
A2-29
A2-29
Table A2-1. Horsepower vs Shell Diameter
Wet-Back Boilers
HP
Dia. (IN)
4WI 100-125
60
4WI 150-200
67
4WI 250-300
78
4WI 350-400
85
4WI 500-600
96
4WI 700-800
106
A2-3
09-09
Firetube Boilers
GENERAL
The Promethean Boiler Model 4WI (100 - 800 hp), provides NOx control, top
performance, and reliable Cleaver-Brooks efficiency. The Low Emission capabilities
combines the packaging of induced flue gas recirculation with the Cleaver-Brooks
integral front head and the Nat-Com burner internal components to gain the ultralow NOx of 15 to <9 ppm levels on natural gas demanded by the environmental
concerns of today. The burner head combines advanced burner technology to
match the geometric and aerodynamic parameters to meet the stringent NOx and
CO standards for all applications. The front head routes a portion of the flue gases
from the fourth pass to the fan and burner assembly for reliable low NOx
performance. The enhanced burner design assures maximum NOx reduction at all
firing rates while maintaining top of the line boiler performance.
Low Emission Options include packages from 60 ppm to ultra-low < 9 ppm.(all
NOx emission levels are given for natural gas and on a dry volume basis and
corrected to 3% O2):
Fan diameters and motor horsepower will vary in size depending on NOx
reduction requirements with the lower NOx levels requiring larger fans and
more horsepower.
Cleaver-Brooks' commitment to lowering emissions is based on more than 2000

low NOx installations - all passing guaranteed emission performance levels.

The Cleaver-Brooks Promethean Firetube Boiler model 4WI, is a 4 pass wet-back
design including five square feet of heating surface per boiler horsepower, and
maximum guaranteed efficiencies. The shell sizes can be found in Table A2-1.
The Promethean model 4WI includes a complete package; pressure vessel, integral
burner and controls including the revolutionary Level Master water level control on
High pressure steam units. Additionally, options can be added to further enhance
the package...
One such option is the CB Hawk ICS, integrated control system providing boiler
control, monitoring, communication and system integration in a single PLC based
package. To this system you may also add a VSD (variable speed drive) for
controlling combustion air, parallel positioning for independent control of fuel and
air, modulating feed water valve, and Oxygen trim for additional energy savings in
an integrated package.
The Promethean model 4WI is offered with;
Promethean Boilers
4-pass wetback design
100-800 boiler horsepower, steam or hot water
Compact footprint; optimized shell and furnace geometry
Lower furnace heat release
Integral burner
Low emissions on natural gas; selections from 60 to Ultra-low NOx reduction

(ULNOx(tm)) of 15 - <9 PPM
Low emissions on #2 oil; 70 PPM with 0.015% fuel bound nitrogen.
A2-4
09-09
Firetube Boilers
Level Master water level control on high pressure steam units
Multiple fuel firing
CB 780E burner management control
UL/ULC approved package.
Single point positioning of fuel and air ensures ease of startup and reliable
operation.

The 4 pass Wet-Back boiler ratings for the steam boiler are on Table A2-2 and the
4 pass Wet-Back hot water boilers ratings are on Table A2-1. Dimensions and
weights for the 4 pass Wet-Back steam boiler is on Table A2-1. The 4 pass WetBack hot water boiler dimension and weights are on Table A2-2.
Notes:
A2-5
09-09
Firetube Boilers
H
N
I
K
G
AA
CC
DD
FF
BB
T
P
O
EE
EE
60" D IA . (100/125 H P ) U S E S HING E D

F RO N T D O O R ( NO T DA V IT A S S H O W N) .
Figure A2-1. Model 4WI Steam Boiler 100-800 HP
Table A2-2. Model 4WI Steam Boiler Ratings 100 to 800 HP

BOILER H.P.
100
125
150
200
250
300
350
400
500
600
700
800
RATINGS - SEA LEVEL TO 700 FT.

Rated Capacity
(lbs-steam/hr from and at 212F)
3450
4313
5175
6900
8625
10350
12075
13800
17250
20700
24150
27600
3347
4184
5021
6694
8368
10042
11715
13389
16736
20083
23430
26778
APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITY BASED ON NOMINAL 82% EFFICIENCY

Light Oil gph (140,000 Btu/gal)
29.2
36.4
43.7
58.3
72.9
87.5
102.0
116.6
145.8
174.9
204.1
233.3
Gas CFH (1000 Btu)
4082
5102
6123
8164
10205
12246
14287
16328
20410
24492
28574
32656
Gas (Therm/hr)
40.8
51.0
61.2
81.6
102.0
122.5
142.9
163.3
204.1
244.9
285.7
326.6
POWER REQUIREMENTS - SEA LEVEL TO 700 FT. (60 HZ)

Blower Motor hp (60 ppm)
(See Note A)
7-1/2
10
15
15
20
15
25
30
50

(See Note A)
7-1/2
7-1/2
15
10
15
20
25
25
40
50
75
Oil Pump Motor, No. 2 Oil
1/2
1/2
1/2
1/2
1/2
3/4
3/4
3/4
3/4
3/4
Air Compressor Motor hp

(No. 2 Oil firing Only)
7-1/2
7-1/2
7-1/2
7-1/2
500
625
750
1000
1250
1500
1750
2000
2500
3000
3500
See Note
"B"
BOILER DATA
Heating Surface sq-ft. (Fireside)
NOTE:
A. Blower motor size for boiler operating pressures 125 psig and less, contact your local Cleaver-Brooks authorized representative for higher pressures and altitude.
B. 800 hp boilers are available w/ 3500 or 4000 sq. ft. of heating surface
A2-6
09-09
Firetube Boilers
Table A2-1. Model 4WI Steam Boiler Dimensions

BOILER H.P.
DIM
100
125
150
200
250
300
350
400
500
600
700/800
LENGTHS
*800
See Note "C"
Overall Length (60 PPM system)
161.63
185.63
175
208
200
220.13
223.5
238.75
245.75
270.75
297.75
161.63
185.63
175
208
200
220.13
223.5
247
253.5
286.25
276.75
303.75
Shell
131
155
143
176.5
172.3
196.1
189.75
207.75
213.75
248.75
232.75
259.75
Base Frame
110
134.13
122
156
150.1
174.1
167.25
185.25
188.25
223.25
207.25
234.25
Front Head Extension (60 PPM system)
27
27
27.63
27.63
24
24
28
27
28
34
34
27
27
28
27.63
24
24
28
35.25
35.75
34
40
40
Shell Ring Flange to Panel
17
17
17
17
17
23
23
26
26
26
26
26
20.5
20.5
20.63
20.5
22
22
22.5
22
25
25
25
25
Shell Flange to Steam Nozzle 15 psi
78.38
88.38
87.38
93.38
84.38
98.38
94.5
104.5
101.5
124.5
110.5
128.5
70.38
90.38
73.38
87.38
92.38
98.38
95.5
104.5
106.5
124.5
115.5
128.5
Overall Width
90.25
90.25
94.38
94.38
107
107
114
114
124.75
124.75
134.68
134.68
Center to Panel
II
48.5
48.5
52
52
58
58
61.5
61.5
67
67
72
72
I.D. Boiler
60
60
67
67
78
78
85
85
96
96
106
106
Center to Water Column
44.38
44.38
48.5
48.5
54
54
57.5
57.5
63
63
68
68
Center to Outside Davit/Hinge
35
35
41.5
41.5
51
51
58
56.5
62
64.65
67
67
Center to Lagging
32.5
32.5
36.75
36.75
42
42
45
45
50.46
50.46
56
56
Center to Auxiliary LWCO
38.75
38.75
42.38
43.38
49
49
52
52
59
57.68
62.68
62.68
Base Outside
52.5
52.5
51
51
64
64
60
60
71.88
71.88
74.75
74.75
Base Inside
44.5
44.5
43
43
56
56
47
47
58.88
58.88
61.75
61.75
Overall Height
86
86
101.75
101.75
115
115
123.5
123.5
134
134
145.5
145.5
Base to Vent Outlet
85
85
92.63
92.63
106
106
115
115
126
126
135.63
135.63
46
46
50
50
56
56
61
61
67
67
71
71
Height of Base Frame
12
12
12
12
12
12
12
12
12
12
12.25
12.25
Base to Bottom of Panel
16.5
16.5
14.75
14.75
15.5
15.5
17
17
16.5
16.5
16.75
16.75
2.5
WIDTHS
HEIGHTS
BOILER CONNECTIONS
Feedwater Inlet (Both Sides)
BB
1.25
1.5
1.5
2.5
2.5
2.5
2.5
2.5
Surface Blowoff (150 lb only)
CC
Steam Nozzle 15 lb (See Note "A")
DD
10
10
12
12
12
12
12
12
12
Steam Nozzle 150 lb (See Note "B")
DD
Blowdown-Front & Rear (15 lb)
EE
1.5
1.5
1.5
EE
1.25
1.5
1.5
1.5
1.5
1.5
1.5
Chemical Feed
FF
AA
16
16
16
16
20
20
24
24
24
24
24
24
Rear Door Swing
36
36
40
40
46
46
50
50
55
55
60
60
Front Door Swing
67
67
78
78
89
89
97
97
108
108
118
118
Tube Removal - Front Only
96
120
108
142
132.5
156.5
148
166
169
204
188
215
VENT STACK
Vent Stack Diameter (Flanged)
MINIMUM CLEARANCES
Thru Window or Door
234
258
261
295
308
332
337
355
377
412
411
438
Front of Boiler
263
311
291
359
351
399
388
424
438
508
481
535
WEIGHTS IN LBS
Normal Water Weight
5,870
7,310
7,625
10,000
12,590
14,848
16,025
17,960
21,055
25,355
28,700
32,770
Approx. Shipping Weight - (15psig)
11,760
12,980
14,200
16,260
20,130
22,080
25,810
27,950
33,810
38,170
41,980
46,300
12,500
13,900
15,200
17,700
22,640
24,200
28,000
30,400
36,700
39,580
45,940
50,480
NOTES:
Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension diagram/drawing.
All Connections are Threaded Unless Otherwise Indicated:
NOTE "A": ANSI 150 psig Flange
NOTE "B": ANSI 300 psig Flange
NOTE "C": *800 hp w/ 4000 sq. ft. of heating surface
A2-7
09-08
09-09
Firetube Boilers
RF/RD
FF
A
D
I
L
Cl
eav
er
Br o
o
EE
BB
LWCO
T
U
DD
ks
E
OO
4"
HH
O
P
KK
Q
N
W
F
60" DIA. (100/125 HP) USES HINGED

FRONT DOOR (NOT DAVIT AS SHOWN).
Figure A2-2. Model 4WI Hot Water Boiler 100-800HP
Table A2-1. Model 4WI Hot Water Boiler Ratings

BOILER H.P.
100
125
150
200
250
300
350
400
500
600
700
800
13389
16736
20083
23430
26778

3347
4184
5021
6694
8368
10042
11715

29.2
36.4
43.7
58.3
72.9
87.5
102.0
116.6
145.8
174.9
204.1
233.3
Gas CFH (1000 Btu)
4082
5102
6123
8164
10205
12246
14287
16328
20410
24492
28574
32656
Gas (Therm/hr)
40.8
51.0
61.2
81.6
102.0
122.5
142.9
163.3
204.1
244.9
285.7
326.6
15
25
30
50
25
40
50
75

7-1/2
10
15
15
7-1/2
7-1/2
15
10
15
20
Oil Pump Motor, No. 2 Oil
1/2
1/2
1/2
1/2
1/2
3/4
3/4
3/4
3/4
3/4
7-1/2
7-1/2
7-1/2
7-1/2
2000
2500
3000
3500
See Note "A"
Air Compressor Motor hp (No. 2

Oil firing Only)
20
25
BOILER DATA
500
625
750
1000
1250
1500
NOTE 'A': 800 hp boilers are available w/ 3500 or 4000 sq. ft. of heating surface
A2-8
09-09
1750
Firetube Boilers

Table A2-2. 4WI Hot Water Boiler Dimensions
BOILER H.P.
DIM
100
125
150
200
250
300
350
400
500
600
700/800
LENGTHS
*800
See Note "C"
162
186
175
209
200
225.5 221.75 238.75
245.75
282.75
270.75
297.75
162
186
175
209
200
225.5 221.75
253.5
287.25
276.75
303.75
Shell
131
155
143
177
172.5
196.5 189.75 207.75
213.75
248.75
232.75
259.75
Base Frame
Front Head Extension (60 PPM
110
124
122
156
150.12 174.12 167.25 185.25
188.25
223.25
207.25
207.25
27
27
28
28
23.5
25
28
27
28
30
34
34
Front Head Extension (30 PPM
27
27
28
28
23.5
25
28
35.25
35.75
34.5
40
40
Shell Extension
12
12
12
12
14.5
14.5
16.75
16.75
16.25
16.25
16.75
16.75
0.5
247
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
20.5
20.5
20.5
20.5
22
22
22
22
25
25
25
25
78
99
87
121
113.5
137.5 130.75 148.75
143
151.75
146.75
173.75
HH
103
124
112
146
139.5
163.5 156.75 174.75
179
187.75
182.75
209.75
WIDTHS
Overall Width
75.5
75.5
82.75
82.75
93
93
102
102
113
113
123
123
I.D. Boiler
60
60
67
67
78
78
85
85
96
96
106
106
42.5
42.5
46
46
51
51
56.5
56.5
62
62
67
67
KK
35
35
41.5
41.5
51
51
56.5
56.5
62
62
67
67
Center to Lagging
33
33
36.75
36.75
42
42
45.5
45.5
51
51
56
56
Base Outside
52.5
52.5
51
51
64
64
60
60
71.88
71.88
74.75
74.75
Base Inside
44.5
44.5
43
43
56
56
47
47
58.88
58.88
61.75
61.75
OO
86
86
101.75 101.75
115
115
123.5
123.5
134
134
145.5
145.5
85
85
92.63
92.63
106
106
115
115
126
126
135.63
135.63
46
46
50
50
56
56
61
61
67
67
71
71
12
12
12
12
12
12
12
12
12
12
12
12
15.63
15.63
16.13
16.13
16.5
16.5
18
18
18.5
18.5
17.5
17.5
Base to Return & Outlet
82.38
82.38
89.88
89.88
101.5
101.5
110
110
121.5
121.5
130.5
130.5
HEIGHTS
Overall Height
Base to Vent Outlet
BOILER CONNECTIONS
Waterfill Connection (Both Sides)
1.25
1.5
1.5
2.5
2.5
2.5
2.5
2.5
2.5
Water Return (See Note "A")
10
10
12
12
12
Water Outlet (See Notes "A & B")
10
10
12
12
12
Drain-Front & Rear
1.5
1.5
1.5
Air Vent
1.5
1.5
1.5
1.5
1.5
1.5
1.5
BB
16
16
16
16
20
20
24
24
24
24
24
24
VENT STACK
MINIMUM CLEARANCES
Rear Door Swing
DD
36
36
40
40
46
46
50
50
55
55
60
60
Front Door Swing
EE
67
67
78
78
89
89
97
97
108
108
118
118

MINIMUM BOILER ROOM LENGTH
FF
96
120
108
142
132.5
156.5
148
166
169
204
188
215
Thru Window or Door
RD
234
258
261
295
308
332
337
355
377
412
411
438
Front of Boiler
RF
424
438
508
481
535
263
311
8,569
291
359
351
399
388
WEIGHTS IN LBS
Normal Water Weight
6,888
8,857 11,590 14,746 17,368 19,212 21,507
26,251
31,571
35,878
40,930
11,760 12,980 14,200 16,260 20,130 22,080 25,810 27,950
33,810
38,170
41,980
45,960
12,500 13,870 15,150 17,680 21,690 24,170 27,980 30,370
35,900
40,560
45,090
49,400
NOTES:
NOTE "B": Water Outlet includes 2" Dip Tube
NOTE C: 800 HP w/ 4000 sq. ft. of heating surface
A2-9
09-08
09-09
Firetube Boilers
VALVE SETTING 15 PSIG STEAM

NO. OF
OUTLET
BOILER HP
VALVES
SIZE (IN.)
REQ'D
150 PSIG STEAM

NO. OF
OUTLET
VALVES
SIZE (IN.)
REQ'D
100
2-1/2
125
150
200
2-1/2
250
(1) 2-1/2
(1) 3
300
350
400
500
(1) 2
(2) 3
(2) 3
(1) 2-1/2
3
250 PSIG STEAM

NO. OF
OUTLET
VALVES
SIZE (IN.)
REQ'D
1-1/2
1-1/4
(1) 1-1/4
(1) 1
1-1/4
(1) 1
(1) 1-1/4
1-1/2
(1) 1-1/2
(1) 1-1/4
1-1/4
(1) 2
(1) 1-1/2
1-1/2
(1) 1-1/2
(1) 1-1/4
(1) 2
(1) 1-1/2
1-1/2
(1) 2-1/2
(1) 2
2
2
2
1-1/2
200 PSIG STEAM

NO. OF
OUTLET
VALVES
SIZE (IN.)
REQ'D
(1) 1-1/2
(1) 1-1/4
(1) 1-1/2
(1) 1-1/4
(1) 2-1/2
(1) 2
(1) 2-1/2
(1) 2
2-1/2
(3) 3
(2) 2-1/2
3
2
2-1/2
2
(1) 2-1/2
(1) 2
(3) 3
(2) 2-1/2
3
2
2-1/2
2
700, 800
5
(2) 2-1/2
(1) 2
NOTE: Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on availability.
600
Table A2-4. Hot Water Boiler Safety Valve Openings

VALVE SETTING 30 PSIG HW
OUTLET
NO. OF
BOILER HP
VALVES
REQ'D
SIZE (IN.)
125 PSIG HW
OUTLET
NO. OF
VALVES
REQ'D
SIZE (IN.)
150 PSIG HTHW

OUTLET
NO. OF
VALVES
REQ'D
SIZE (IN.)
100
2-1/2
1-1/4
125
2-1/2
1-1/4
150
2-1/2
200
250
(1) 2
(1) 2-1/2
300
2-1/2
2-1/2
(1) 2-1/2
(1) 1-1/4
(1) 2
(1) 2-1/2
2-1/2
(2) 2-1/2
1
2-1/2
2
(1) 1
(1) 2
400
3
1
2-1/2
2
(2) 2-1/2
(1) 1
(1) 1
500
4
2
2
(3) 2-1/2
(1) 2-1/2
(1) 1-1/4
(3) 2-1/2
2
3
600
4
(1) 2
(1) 2-1/2
(1) 1
(1) 2-1/2
700, 800
5
2
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.
350
A2-10
09-09
2
(1) 1-1/2
(1) 2
(1) 1-1/2
(1) 2
(1) 2-1/2
(1) 3
(1) 2-1/2
(1) 3
3
(2) 3
(1) 2-1/2
3
(1) 1-1/2
(1) 2
(1) 1-1/2
(1) 2
2
(1) 2
(1) 2-1/2
2-1/2
Firetube Boilers
BOILER
HP
100-125
150-200
250-300
350-400
500-600
700-800
A
33
36.5
42
45.5
51
56

B
C
D
47
52
80
49
56
83
56
61
92
58
68
99
66
75
111
74
80
121
E
36
40
46
50
55
60
Table A2-5. Space Required to Open Rear Head on Promethean Boilers Equipped with Davits (4WI)
BOILER
HP
100
125
150
200
250
300
350
400
500
600
700-800
A
6
6
6
6
6
6
6
6
6
6
6
B
9
9
9
9
9
9
12
12
12
12
12

C
D
E
110
39.5
57.5
124
39.5
57.5
122
38
56
156
38
56
150.125
51
69
174.125
51
69
167.25
41.5
65.5
185.25
41.5
65.5
188.25
53.375
77.375
223.25
53.375
77.375
207.25
56.25
80.25
F
4
4
4
4
4
4
6.5
6.5
6.5
6.5
6.5
G
44.5
44.5
43
43
56
56
47
47
58.875
58.875
61.75
X1
12
12
12
12
16.125
16.125
17.75
17.75
18.75
18.75
18.75
X2
8
8
8
8
11.5
11.5
11.5
11.5
10.5
10.5
10.5
NOTE:
6-inch high mounting piers recommended for use beneath the boiler base frame. The use of these piers provides
increased inspection accessibility to the boiler and added height for washing down the area beneath the boiler.
Table A2-6. Boiler Mounting Piers
A2-11
09-08
09-09
Firetube Boilers
FRONT
FLANGE
E DIA. HOLE
CL
VIEW A
NEAR
SIDE
FAR
SIDE
VIEW B
BOILER
A
B
C
D
HP
100
79.5
21.375
84.75
10
125
79.5
21.375
108.75
10
150
87.125
21.375
96.75
10
200
87.125
21.375
130.75
10
250
99
28.75
104.25
10
300
99
28.75
128.25
10
350
107.625
33.25
126
10
400
107.625
33.25
144
10
500
125.375
34.5
145
10
600
125.375
34.5
180
10
700-800
134.5
34.5
164
10
NOTE: A, B, and C dimensions may vary by 1 inch.
Table A2-7. Lifting Lug Locations
A2-12
09-09
E
3
3
3
3
3
3
3
3
3
3
3
Firetube Boilers
PERFORMANCE DATA
The Low Emission Option provides NOx reduction at current published and
predicted fuel-to-steam efficiencies. Refer to Table A2-9 and Table A2-10.
Specifying Boiler
Efficiency
Cleaver-Brooks offers an industry leading fuel-to-steam boiler efficiency guarantee

for Promethean 4WI Firetube Boilers. The guarantee is based on the fuel-to-steam
efficiencies shown in the efficiency tables and the following conditions. The
efficiency percent number is only meaningful if the specific conditions of the
efficiency calculations are clearly stated in the specification (see Cleaver-Brooks
publication CB-7768 for a detailed description of efficiency calculations).
When specifying the efficiencies in the tables, be sure to include the specific
guarantee conditions to maximize the effectiveness of your efficiency specification.
If you have any questions regarding the efficiency specifications, please contact
your local Cleaver-Brooks authorized representative.
Efficiency
Specification
achieve fuel-to-steam/water efficiency (as shown in Table A2-9 and Table A2-10)
at 100% firing rate (Reference efficiency guarantees at 25%, 50%, and 75% of
rating, if required). If the boiler(s) fail to achieve the corresponding guaranteed
efficiency as published, the boiler manufacturer will rebate, to the ultimate boiler
owner, ten thousand dollars ($10,000) for every full efficiency point (1.0%) that
the actual efficiency is below the guaranteed level.
Natural Gas
Carbon,% (wt) = 69.98

Sulfur,% (wt) = 0.0
No. 2 Oil

Sulfur,% (wt) = 0.2
No. 6 Oil

2. Efficiencies are based on ambient air temperature of 80 F, relative humidity of

3. Efficiencies are based on manufacturers published radiation and convection
losses. (For Cleaver-Brooks radiation and convection losses, see Boiler Efficiency
Facts Guide, publication number CB-7767).
For efficiencies and stack temperatures at operating pressures not listed, follow
these procedures:
When the operating steam pressure is between 10 psig and 125 psig, interpolate
A2-13
09-09
Firetube Boilers
the values from the efficiency tables.

Example:
Boiler: 350 hp.
Fuel: natural gas.
Find the fuel-to-steam efficiency at 100% firing rate. From Table A2-9 a boiler
operating at 100% firing rate and an operating steam pressure of 125 psig, the
efficiency is 82.1%.
operating pressure. To estimate boiler efficiency, use this rule of thumb: For every
40 F increase in stack temperature, efficiency decreases by 1%. Since the stack
temperature rise is 36 F, the decrease in the boiler efficiency at 200 psig operating
pressure is calculated as follows: 36/40 =.9%. Therefore, the boiler efficiency at
200 psig operating pressure is 82.1 -.9 = 81.2%
Emissions
The emission data included in this section consists of typical emission levels for the
4WI boiler equipped with 60 & 30 ppm reduction with natural gas or No. 2 oil.
Table A2-8. Firing Rates 4WI Boilers with Integral Burner
BHP
100
125
150
200
250
300
350
400
500
600
700
750
800
Natural Gas, 1000 Btu/hr

Low
High
1021
4082
1276
5103
1531
6124
2041
8165
1021
10206
1225
12247
1428
14280
1633
16329
2042
20415
2449
24494
2858
28576
3062
30617
3266
32659
No. 2 Oil, GPH

Low
High
7.3
29.2
9.1
36.4
10.9
43.7
14.6
58.3
9.1
72.9
10.9
87.5
12.8
102.1
14.6
116.6
18.2
145.8
21.9
175
25.5
204.1
27.3
218.7
29.2
233.3
Notes:
Fuel input rates are based on nominal 82% efficiency.
No. 2 Oil = 140,000 Btu/Gal
A2-14
09-09
Firetube Boilers
Table A2-9. Predicted Fuel-to-Steam Efficiencies - Natural Gas - Model 4WI
BHP
100
125
150
200
250
300
350
400
500
600
700
800

% OF LOAD
25%
50%
75%
100%
84.4
84.6
84.1
83.6
84.6
85.0
84.7
84.3
84.5
84.8
84.4
83.9
84.7
85.2
85.1
84.8
84.7
85.1
84.9
84.5
84.8
85.3
85.2
85.0
84.7
85.2
85.1
84.8
85.4
85.6
85.5
85.2
85.4
85.6
85.5
85.3
85.5
85.8
85.7
85.6
85.5
85.7
85.7
85.6
85.5
85.8
85.7
85.6

% OF LOAD
25%
50%
75%
100%
81.6
82.0
81.7
81.3
81.8
82.3
82.2
82.0
81.6
82.0
81.7
81.3
81.8
82.4
82.3
82.2
81.8
82.4
82.3
82.1
81.9
82.6
82.6
82.5
81.8
82.4
82.3
82.1
82.6
82.9
82.8
82.6
82.6
83.0
82.9
82.8
82.7
83.2
83.2
83.1
82.7
83.1
83.1
83.0
82.7
83.1
83.1
83.0
Note: Using the ultra low NOx burner (15-<9ppm) will result in a slight reduction of fuel-to-steam efficiency.
Figure A2-3. Predicted Stack Temperature Increase for Pressure Greater Than 125 psig - Model 4WI
A2-15
09-09
Firetube Boilers
Table A2-10. Predicted Fuel-to-Steam Efficiencies - No. 2 Oil - Model 4WI

BHP
100
125
150
200
250
300
350
400
500
600
700
800

% OF LOAD
25%
50%
75%
100%
87.9
88.1
87.6
87.0
88.0
88.5
88.2
87.8
88.0
88.3
87.9
87.4
88.2
88.7
88.5
88.2
88.1
88.6
88.3
88.0
88.2
88.8
88.6
88.4
88.2
88.7
88.5
88.2
88.8
89.0
88.9
88.7
88.8
89.0
88.9
88.7
88.9
89.2
89.2
89.1
88.9
89.2
89.1
89.0
88.9
89.2
89.2
89.1

% OF LOAD
25%
50%
75%
100%
85.1
85.4
85.1
84.7
85.2
85.7
85.7
85.5
85.1
85.4
85.1
84.8
85.3
85.8
85.7
85.6
85.3
85.8
85.7
85.6
85.4
86.0
86.0
86.0
85.3
85.8
85.7
85.6
86.0
86.3
86.2
86.0
86.1
86.4
86.4
86.2
86.2
86.6
86.6
86.6
86.1
86.5
86.5
86.4
86.1
86.5
86.5
86.4
Note: Using the ultra low NOx burner (15-<9ppm) will result in a slight reduction of fuel-to-steam efficiency.
Table A2-11. Promethean Boilers - Natural Gas, Emission Levels - Model 4WI
POLLUTANT
UNITS
60 PPM SYSTEM
CO
ppm*
50/150**
50/150**
lb/MMbtu
0.04/0.11
0.04/0.11
NOx
SOx
HC/VOC5
PM
30 PPM SYSTEM
ppm*
60
30
lb/MMbtu
0.07
0.035
ppm*
lb/MMbtu
0.001
0.001
ppm*
10
10
lb/MMbtu
0.004
0.004
ppm*
lb/MMbtu
0.01
0.01
* ppm levels are given on a dry volume basis and are corrected to 3% oxygen (15% excess air)
** CO emission is 50 ppm when boiler is operating above 50% of rated capacity. CO emission is
150 ppm when boiler is operating below 50% of rated capacity.
Table A2-12. Promethean Boilers - No. 2 Oil, Emission Levels - Model 4WI
POLLUTANT
UNITS
60 PPM SYSTEM
CO
ppm*
50
50
lb/MMbtu
0.04
0.04
NOx
SOx
HC/VOC5
PM
30 PPM SYSTEM
ppm*
140
90
lb/MMbtu
0.186
0.12
ppm*
278
278
lb/MMbtu
0.52
0.52
ppm*
lb/MMbtu
0.002
0.002
ppm*
lb/MMbtu
0.025
0.025
* ppm levels are given on a dry volume basis and are corrected to 3% oxygen (15% excess air)
BASED ON THE FOLLOWING CONSTITUENT LEVELS:
Fuel-bound Nitrogen content = 0.015% by weight
Sulfur content = 0.5% by weight
Ash content = 0.01% by weght
A2-16
09-09
09-08
Firetube Boilers
Table A2-16. 4WI Gas Pressure at Entrance to Standard, Undersized, and Oversized Gas Trains
Boiler HP
Pipe Size
100
125
150
200
1.5
1.5
1.5
1.5
2
1.5
2
1.5 - 2
2
3
1.5 - 2
2
2.5
3
1.5 - 2
2
2.5
3
1.5 - 2.5
2 - 2.5
2.5
3
1.5 - 2.5
2 - 2.5
2.5
2.5 - 3
3
2 - 3
2.5 - 3
3
4
2.5 - 3
3
4
2.5 - 3
3
4
250
300
350
400
500
600
700
750
800
30 PPM
Pressure
Range PSI
0.6 - 2.0
0.8 - 3.0
1.0 - 3.0
1.7 - 4.0
1.1 - 1.7
2.4 - 5.0
1.5 - 2.4
2.9 - 5.0
1.9 - 2.9
1.2 - 1.9
3.8 - 5.0
2.8 - 3.8
2.1 - 2.8
1.4 - 2.1
5.0 - 7.0
3.5 - 5.0
2.7 - 3.5
1.8 - 2.7
6.6 - 10.0
4.7 - 6.6
3.3 - 4.7
1.9 - 3.3
9.5 - 10.0
6.8 - 9.5
4.8 - 6.8
4.1 - 4.8
2.8 - 4.1
8.5 - 10.0
5.4 - 8.5
3.6 - 5.4
2.7 - 3.6
6.4 - 10.0
4.6 - 6.4
3.1 - 4.6
6.8 10.0
4.6 - 6.8
3.3 - 4.6
Note: Some units list two diameters because the

gas train increases in size after the regulating
valve. The first number is the customer connection size.
60 PPM
Pressure
Range PSI
0.5 - 2.0
0.8 - 3.0
0.9 - 3.0
1.6 - 4.0
1.1 - 1.6
2.5 - 5.0
1.6 - 2.5
3.1 - 5.0
2.1 - 3.1
1.4 - 3.1
3.8 - 5.0
2.8 - 3.8
2.1 - 2.8
1.4 - 2.1
5.0 - 7.0
3.5 - 5.0
2.7 - 3.5
1.9 - 2.7
6.6 - 10.0
4.7 - 6.6
3.3 - 4.7
1.9 - 3.3
9.5 - 10.0
6.8 - 9.5
4.8 - 6.8
4.1 - 4.8
2.7 - 4.1
8.4 - 10.0
5.3 - 8.4
3.5 - 5.3
2.6 - 3.5
6.4 - 10.0
4.6 - 6.4
3.1 - 4.6
7.0 - 10.0
4.8 - 7.0
3.5 - 4.8
UNDERSIZE
STANDARD
OVERSIZE
Table is based on Siemens gas train, which includes a regulating

actuator.
A2-17
09-09
09-08
Firetube Boilers
Table A2-17. Recommended NTI Gas Train Sizes and Pressure Ranges
Boiler HP
100
125
150
200
250
300
350
400
500
600
700
4WI 15 PPM
Gas Train
Pressure Range
Size, in
PSI
1.5
2.3 - 5.0
1.5
3.3 - 6.0
1.5
3.9 - 6.0
1.5
4.5 - 7.0
1.5 - 2
4.5 - 7.0
1.5 - 2
6.1 - 9.0
2
1.5 - 2
2
4.8 - 6.1
5.1 - 7.5
4.0 - 5.1
1.5 - 2
2
2.5
3
1.5 - 2
2
2.5
3
2-3
2.5 -3
3
2.5 - 3
3
7.3 - 10.0
5.8 - 7.3
5.0 - 5.8
4.1 - 5.0
8.1 - 10.0
6.1 - 8.1
4.7 - 6.1
3.4 - 4.7
7.8 - 10.0
5.8 - 7.8
4.4 - 5.8
7.7 - 10.0
5.9 - 7.7
4WI 9 PPM
Gas Train
Pressure Range
Size, in
PSI
1.5
2.3 - 5.0
1.5
3.3 - 6.0
1.5
4.1 - 6.0
1.5
4.5 - 7.0
1.5 - 2
4.2 - 7.0
1.5 - 2
5.9 - 9.0
720
750
2.5 - 3
3
2
1.5 - 2
2
2.5
1.5 - 2
2
2.5
4.6 - 5.9
6.2 - 9.0
5.2 - 6.2
4.5 - 5.2
7.2 - 10.0
5.7 - 7.2
4.9 - 5.7
1.5 - 2
2
2.5
3
2-3
2.5 -3
3
2.5 - 3
3
2.5 - 3
8.1 - 10.0
6.1 - 8.1
4.7 - 6.1
3.4 - 4.7
7.8 - 10.0
5.8 - 7.8
4.4 - 5.8
7.9 - 10.0
6.1 - 7.9
8.1 - 10.0
6.3 - 8.1
8.6 - 10.0
6.7 - 8.6
increases in size after the regulating valve. The first number is the
customer connection size.
UNDERSIZE
STANDARD
OVERSIZE
Table A2-18. Predicted Sound Levels (30

ppm NOx system) at High Fire - Model 4WI
BHP
100
125
150
200
250
300
350
400
500
600
700
800
Sound Level-dbA
79
83
83
84
83
84
84
85
85
87
88
90
A2-18
09-09
Firetube Boilers
ENGINEERING DATA
Sound Level
Table A2-18 gives a summary of predicted sound pressure levels for the CB boilers
with 30 ppm LE Options. Contact your local Cleaver-Brooks authorized representative
for sound levels for other LE Options.
Units
The units for the sound level tables are dbA (decibels, measured on the A-weighted
scale) in reference to 0.0002 microbars (20 micro-Newtons per square meter). Their
reference are standardly used in specifying and reporting sound pressure levels on
industrial equipment.
Test Method
The sound pressure levels in the above tables were obtained from tests in accordance
with the ABMA Test Code for the Measurement of Sound from Packages Boilers. In
accordance with this code the sound pressure levels reported were measured on the
boiler centerline 4-1/2 feet vertically above the bottom of the base rails and 3 feet
horizontally in front of the end of the blower motor or front surface of the electrical
cabinet.
Sound Level Meter
The sound level meter used complies with ANSI S1.4, Type 1 (Precision). The
readings are taken with the meter set for slow response and corrected for background
levels.
Sound Pressure
With larger sized boilers, the need for auxiliary equipment, and the necessary
interconnecting piping make it impractical (and sometimes impossible) to provide a
boiler testing environment which is suitable for taking the data needed to develop
Sound Pressure Power levels.
Typical Values
Sound pressure levels (dbA) for the same boiler will vary between boiler rooms.
Sound levels will vary with motor type, NOx levels, and altitudes. In addition,
variations will occur between different people using different sound meters on the
same boiler. And finally, no two boilers can be expected to give precisely the same
sound levels. For these reasons, we can only predict, but not guarantee, sound levels
(dbA).
Gas-Fired Burners
Table A2-16 shows gas pressure ranges for standard, oversized, and undersized gas
trains.
C-B O2 Trim Systems: If a C-B O2 Trim system will be utilized, contact your local
Cleaver-Brooks authorized representative to be sure that a compatible regulator is
selected.
Table A2-20 shows maximum gas consumption for natural gas and propane vapor.
Table A2-21 shows standard gas train sizes and locations for Model CB Firetube
Boilers.
A2-19
09-09

Oil-Fired Burners
Firetube Boilers
Table A2-23 shows the oil connection sizes and locations for Model CB Boilers firing
No. 2 oil.
Figures Figure A2-5 through Figure A2-8 show typical oil systems and layouts.
Figure A2-8 show the detail of an oil transfer tank (day tank) typically utilized to
provide a storage reservoir between the oil system supply pump and the boiler oil
pump.
A2-20
09-09
Firetube Boilers
Table A2-19. Minimum Required Gas Pressure

Altitude Conversion
Table A2-20. Maximum Gas Consumption (CFH) for Natural

Gas and Propane Vapor
ALTITUDE
(FT)
CORRECTION
FACTOR
ALTITUDE
(FT)
CORRECTION
FACTOR
BOILER
HP
1000
1.04
6000
1.25
2000
1.07
7000
1.30
3000
1.11
8000
1.35
4000
1.16
9000
5000
1.21
NATURAL GAS
1000 (Btu/cu-ft)
PROPANE GAS
2550 (Btu/cu-ft)
125
5103
2000
150
6124
2402
200
8165
3202
1.40
250
10206
4002
300
12247
4802
350
14280
5600
400
16329
6404
500
20415
8006
600
24494
9605
700
28576
11206
750
30618
12007
800
32659
12807

Oz/sq-in x 1.732 = Inches WC
Psig x 27.71 = Inches WC
MODEL 4WI
BOILER
HP
CONNECTION
SIZE
(IN.) (NPT)
LOCATION
DIMENSION
A (IN.)
100-125
1-1/2
52
150-200
1-1/2
47-1/2
250-400
50
500
2-1/2
60
600
2-1/23
71
65
700-800
BOILER
FRONT
PLAN VIEW
Table A2-21. Standard Gas Train Connection Size and Location
A2-21
09-09
Firetube Boilers
This figure illustrates the basic gas valve arrangement on Cleaver-Brooks

Model 4WI boiler and shows the contractor's connection point. The valves
and controls between the contractor connection point and the gas main in
the street are representative of a typical installation. Actual requirements
may vary depending on local codes or local gas company requirements
which should be investigated prior to preparation of specifications and prior
to construction.
STREET GAS MAIN
MODEL
4WI
BOILERS
PLUG
COCK
MODEL
4WI
BOILERS
A
B
C
CONTRACTOR
CONNECTION
POINT
GAS TRAIN
ON BOILER

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:
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.
A2-22
09-09
Firetube Boilers
10
2
11
12
13
14
15
S
S
Gas
Supply
PILOT GAS LINE
To
Burner
FLOW
FLOW
MAIN GAS LINE
UL
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
DESCRIPTION
Pilot Shut Off Cock
Gas Pilot Valve
Pilot Vent Valve
Gas Pilot Valve
Main Gas Valve w/ POC
Vent Valve or Valve Proving Switch
Butterfly Valve
CSD-1
NFPA-85
125 hp 300 hp
350 hp 800 hp
125 hp 300 hp
FM
350 hp 800 hp
125 hp 300 hp
350 hp 800 hp
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Table A2-22. Gas Train Components
MODEL 4WI
A
(IN.)
100
150
200
3/4
12-1/2
250
300
350
3/4
34
400
500
600
3/4
11-3/4
700
750
800
11-3/4
BOILER
HP
CONTRACTOR
CONNECTIONS
BOILER
FRONT
BOILER BASE FRAME

A

SIZES
(STANDARD PIPE)
(IN. - IPS)
SUPPLY
AND
RETURN
CONN
SIZES
(IN.)
(NPT)
STORAGE
PUMP
TANK TO
TO
BOILER
BOILER
OR PUMP
CONNECT
RETURN
LINE TO
TANK
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.
Table A2-23. N0. 2 Oil Connection Size, Location and Recommended Line Sizes
A2-23
09-09
Firetube Boilers
CHECK
VALVE
VACUUM
GAUGE
OIL PUMP
UNION
GATE VALVE
STRAINER
GATE VALVE
F.O.S.
RELIEF VALVE
F.O.R.
Figure A2-5. No. 2 Oil Piping, Single

Boiler Installation, Remote Oil Pump
GATE VALVE
CHECK VALVE
BOILER
FRONT
BOILER
BASE FRAME
F.O.S.
F.O.R.
CONTRACTOR
CONNECTIONS
AT THIS POINT
VACUUM GAUGE
CHECK VALVE
GATE VALVE
STRAINER
GATE VALVE
F.O.S.
OIL
PUMP
NO. 2
F.O.R.
OIL PUMP NO. 1

UNION
GATE VALVE
Figure A2-6. No. 2 Oil Piping, Multiple

Boiler Installation, Remote Oil Pumps
RELIEF
VALVE
(100 PSIG)
GATE VALVE
CHECK VALVE
BOILER
FRONT
BOILER
BASE FRAME
F.O.S.
F.O.R.
CONTRACTOR
CONNECTIONS
AT THIS POINT
A2-24
09-09
Firetube Boilers

VACUUM GAUGE
STRAINER
CHECK
VALVE
STANDBY
OIL PUMP
F.O.S.
GATE
VALVE
UNION
GATE VALVE
GATE VALVE
RELIEF
VALVE
(100 PSIG)
F.O.R.
PRESSURE
GAUGE
Figure A2-7. No. 2 Oil Piping, Multiple

Boiler Installation
ADJUSTABLE
PRESSURE
RELIEF VALVE
(75 PSIG)
GATE
VALVE
CHECK
VALVE
USE LAYOUT FOR: MODEL 4WI 100 THRU 800 HP

that adjustable pressure relief
valve in the loop system is in
control.
BOILER
FRONT
CONTRACTOR
CONNECTIONS
AT THIS POINT
VENT
H
OIL LEVEL
TEST VALVE
F.O.S.
SUPPLY TO BOILER
TERMINAL BLOCK OR
TO BOILER OIL PUMP
RELIEF VALVE
(100 PSIG)
SIZE
F.O.S.
F.O.R.
OIL TRANSFER TANK

AT LOCATION NEAR
BOILER
OIL TRANSFER PUMP

NEAR STORAGE TANK
F.O.R.
GATE
CHECK
VALVE
VALVE STRAINER
F.O.S.
F.O.R.
ITEM
BOILER
BASE FRAME
GATE
UNION VACUUM VALVE
GAUGE
DESCRIPTION

level switch
pump
connection
H
McD
Figure A2-8. No. 2 Oil Transfer Tank

Detail (For consideration with elevated
boiler rooms)
G A
2"
5"
3"
22"
60"
E
4" OR 6"
STD
BLACK
PIPE
33"
3"

3/8" MTL
A2-25
09-09
Firetube Boilers

OIL RETURN
OIL SUCTION
STEAM OR HOT WATER
MANHOLE
OIL STORAGE
TANK

AND SUPPLY SYSTEMS.
Figure A2-9. Typical Fuel Storage Tank Arrangement

General Boiler
Information
Table A2-24 shows blowdown tank sizing information.

Table A2-25 provides heating surface information.
Table A2-26 provides steam volume and disengaging area information
Table A2-27 provides recommended steam nozzle sizes.
Table A2-28 provides recommended non-return valve sizes.
Boiler Room
Information

Stack Support
Capabilities
All standard Cleaver-Brooks Firetube Boilers can support up to 2,000 lbs without
additional support.
Boilers 250 hp through 800 hp can be reinforced to support 3,000 lbs.
Stack/Breeching
Size Criteria
Although constant pressure at the flue gas outlet is not required, it is necessary to
size the stack/breeching to limit flue gas pressure variation. The allowable pressure
range is 0.25" W.C. to +0.25" W.C.
Boiler Room
Combustion Air
A. Two (2) permanent air supply openings in the outer walls of the boiler room
are recommended. Locate (1) at each end of the boiler room, preferably below
a height of 7 feet. This allows air to sweep the length of the boiler.
qualities and is subject to clogging by dust or dirt. A vent fan in the boiler room
is not recommended, as it could create a slight vacuum under certain
A2-26
09-09
Firetube Boilers

conditions and cause variations in the quantity of combustion air. This can
result in unsatisfactory burner performance.
C. Under no condition should the total area of the air supply openings be less
than (1) square foot.
D. Size the openings by using the formula:
C. Total recommended air = 10 cfm/bhp - up to 1000 feet elevation. Add 3
percent more per 1000 feet of added elevation.
A. From floor to (7) foot height - 250 fpm
B. Above (7) foot height - 500 fpm
Area Required: Area = cfm = 3000/250 = 12 sq-ft total.
Notice
Table A2-24. Blowdown Tank Sizing Information

BOILER HP
100
125
150
200
250
300
350
400
500
600
700
800
WATER (GAL)
85
104
102
131
145
169
178
198
233
278
286
286

A2-27
09-09
Firetube Boilers
Table A2-25. Heating Surface
BOILER
HP

FIRESIDE
WATERSIDE
100
500
125
625
679
150
750
820
200
1000
1092
250
1250
1346
300
1500
1623
350
1750
1932
400
2000
2151
500
2500
2691
600
3000
3262
700 & 800
3500
3810
Table A2-26. Steam Volume Disengaging Area
BOILER HP
100
125
150
200
250
300
350
400
500
600
700
800
STEAM VOLUME CU-FT

HIGH PRESSURE LOW PRESSURE
(A)
(B)
16.5
22.3
20.3
27.4
19.9
26.8
25.7
34.6
34.8
49.5
40.6
57.9
51.3
69.6
57.2
77.5
83.6
107.6
100
128.6
115.6
144.9
115.6
144.9
NOTE:
1. Based on normal water level.
A2-28
09-09
STEAM RELIEVING AREA SQ-IN

(A)
(B)
4565
4954
5587
6077
5443
5918
7013
7632
7790
8597
9115
10051
9734
10570
10843
11779
12874
13781
15394
16474
15826
16819
15826
16819
Firetube Boilers
Table A2-27. Recommended Steam Nozzle Size (To Maintain 4000 to

5000 fpm Nozzle Velocity
Model 4WI Recommended Steam Nozzle Size
OPERATING PRESSURE
BOILER HP
PSIG
100
125
150
200
250
300
350
400
500
600
700
15
8
8
8
10
10
12
12
12
12
12
12
30
6
6
6
8
8
8
10
10
10
12
12
40
6
6
6
6
8
8
8
10
10
10
12
50
4
6
6
6
6
8
8
8
10
10
10
75
4
4
4
6
6
6
8
8
8
8
10
100
4
4
4
6
6
6
6
6
8
8
8
125
4
4
4
4
6
6
6
6
8
8
8
150
2.5
3
3
4
4
6
6
6
6
6
8
200
2.5
2.5
3
4
4
4
4
6
6
6
6
250
2
2.5
3
3
4
4
4
4
6
6
6
NOTES:
3. All standard steam nozzle sizes for 150 psig design pressure or greater are the same as 125 psig operating
pressure on the above table. To increase or decrease the standard size, request the change with your local
4. Shaded area denotes special surge load baffles must be installed to avoid possible water carryover.
5. For incremental operating pressure, see Table I3-1 Steam System Fundamentals.
800
12
12
12
12
10
10
8
8
6
6

BOILER
HP
BOILER CAPACITY
(LBS/HR)
100
3450

50
2-1/2
75
2-1/2
100
NA
125
NA
150
NA
175
NA
200
NA
250
NA
125
4313
2-1/2
2-1/2
2-1/2
NA
NA
NA
NA
150
5175
2-1/2
2-1/2
2-1/2
2-1/2
NA
NA
200
6900
3*
2-1/2
2-1/2
2-1/2
250
8625
3*
300
10350
3*
12025
3*
350
400
13800
3*
500
17210
600
20700
700
24150
800
27600

Standard Non-Return valve selections limited to a maximum 2 to 1 turndown (50% of full load); selections based on typical non-return valve sizing recommendations. For final valve selection contact your C-B authorized representative. For high turndown applications see Boiler Book Section I3, Table I3-3.
* Indicates pressure drop of less than 7.5 psig. All other selections are less than 6 psig pressure drop.
Table A2-29. Blower Motor Selection 4WI NTI Boilers

Altitude: 700 ft and less - Design Pressure: 150 psi and less
15 ppm
Nominal
9 ppm
Boiler Size
Blower Motor HP
Blower Motor HP
* 800 HP - to be de-rated to 720 HP for 9 ppm and to 750 HP for 15 ppm.
A2-29
09-09
Firetube Boilers
FRONT
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
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.
If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and working space.
2. Next shortest boiler room length (DWG B) is obtained by allowing for possible future tube replacement from the front of the boiler.
Allowance is only made for minimum door swing at the rear.
3. A slightly longer boiler room (DWG C) is obtained by allowing for possible future tube replacement from the rear of the boiler.
Allowance for door swing at the front provides sufficient aisle and working space at the front.
BOILER HP
100
125
150
200
250
300
350
400
500
600
700
800
Dimension A
87
91"
96"
100"
105
110
Dimension B
120
127"
144"
151"
174
184
NOTES:
1. Recommended Minimum Distance Between Boiler and Wall. Dimension A allows for a clear 42" aisle between the water column on the boiler and the wall. If space permits,
this aisle should be widened.
42" - 125 -200 hp
48" - 250-350 hp
60" - 400-800 hp
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH

A2-30
09-09
Firetube Boilers
TIGHT SEAL
CLEANOUT
STACK
MANUAL
DAMPER
LOCK (OPEN)
CLEANOUT
DRAIN
CONNECTION
MAXIMUM 10
CONE ANGLE
NOTE: These stack breeching arrangements for multiple

boilers are typical and not intended for your specific
design requirements. For additional information, review
Section F, Stacks.

Stack and breeching sizes should always be provided by a

reputable stack supplier who will design the stack and
local Cleaver-Brooks authorized representative is capable
of assisting in your evaluation of stack and breeching
design.
TIGHT SEAL
CLEANOUT
MANUAL
DAMPER
LOCK (OPEN)
TIGHT SEAL
CLEANOUT
STACK
MANUAL
DAMPER
LOCK (OPEN)
CLEANOUT
DRAIN
CONNECTION
STACK
CLEANOUT
DRAIN
CONNECTION

A2-31
09-09
Firetube Boilers
Notes
A2-32
09-09
Section A2
Promethean Series - Model 4WI
SAMPLE SPECIFICATIONS - Model 4WI STEAM BOILERS

PART 1
GENERAL
1.1
SCOPE
A. The work to be performed consists of providing all labor, equipment, materials, etc. to furnish
and install new factory assembled steam boiler(s) as described in the specifications herein.
1.2
REFERENCES
A. Product Data: Include rated capacities; shipping, installed, and operating weights; furnished
specialties; and accessories for each model indicated.
B. Shop Drawings: Detail equipment assemblies and indicate dimensions, required clearances, and
method of field assembly, components, and location and size of each field connection.
C. Wiring Diagrams: Detail wiring for power, signal, and control systems and differentiate between
manufacturer-installed and field-installed wiring.
D. Source Quality Control Tests and Inspection Reports: Indicate and interpret test results for
compliance with performance requirements before shipping.
E. Field Test Reports: Indicate and interpret test results for compliance with performance
requirements.
F.
Maintenance Data: Include parts list, maintenance guide, and wiring diagrams for each boiler.
G. ASME Section I or IV (Power boilers or Heating Boilers)
H. ANSI Z21.13 (Gas Fired Low Pressure Boilers)
I.
NFPA 54 (ANSI Z221.3) National Fuel Gas Code
J. Factory Mutual
K. ASME CSD-1 (Controls and Safety Devices)
L. XL-GAP (formerly GE-GAP GE Global Asset Protection)
M. UBC (Uniform Building Code)
N. UMC (Uniform Mechanical Code)
O. NEC (National Electrical Code)
P.
UL (Underwriters Laboratories)
Q. NFPA 85
1.3
QUALITY ASSURANCE
A. The equipment shall, as a minimum, be in strict compliance with the requirements of this
specification and shall be the manufacturer's standard commercial product unless specified
otherwise. Additional equipment features, details, accessories, appurtenances, etc. which are not
specifically identified but which are a part of the manufacturer's standard commercial product,
shall be included in the equipment being furnished.
B. The equipment shall be of the type, design, and size that the manufacturer currently offered for
sale and appears in the manufacturer's current catalogue. The equipment shall be new and
fabricated from new materials and shall be free from defects in materials and workmanship
C. The equipment must fit within the allocated space, leaving ample allowance for maintenance and
cleaning, and must leave suitable space for easy removal of all equipment appurtenances. Tube
pull clearance space from either the front or rear of boiler must be maintained.
D. All units of the same classification shall be identical to the extent necessary to insure
interchangeability of parts, assemblies, accessories, and spare parts wherever possible.
A2-33
09-09

E.
Section A2
In order to provide unit responsibility for the specified capacities, efficiencies, and performance,
the boiler manufacturer shall certify in writing that the equipment being submitted shall perform
as specified. The boiler manufacturer shall be responsible for guarantying that the boiler provides
the performance as specified herein.
1.4
SUBMITTALS
A. The contractor shall submit, in a timely manner, all submittals for approval by the engineer.
Under no circumstances shall the contractor install any materials until the engineer has made
final approval on the submittals.
B. The engineer shall review and stamp submittals. Work may proceed and equipment released for
fabrication after contractor receives returned submittals stamped with "NO EXCEPTIONS TAKEN"
or "MAKE CORRECTIONS NOTED".
C. The bidder must submit in writing to the engineer any request for a proposed deviation, omission,
modification, or substitution to this specification for evaluation no later than ten (10) days prior
to the bid date. A request for any substitution shall be accompanied by technical data, drawings,
product samples, and complete data substantiating compliance of proposed substitution with
these specifications. No materials shall be deemed acceptable if not in strict and full compliance
with these specifications. All bidders must bid solely on the specified materials unless
acceptance by the engineer of a deviation, omission, modification, or substitution is granted in
writing to all bidders prior to the bid date.
D. Shop Drawings - Shop drawings shall be submitted to the engineer for approval and shall consist
of:
E. General assembly drawing of the boiler including product description, model number,
dimensions, clearances, weights, service sizes, etc.
F.
Schematic flow diagram of gas valve trains.
G. Schematic wiring diagram of boiler control system of the ladder-type showing all components, all
interlocks, etc. Schematic wiring diagram shall clearly identify factory wiring and field wiring.
H. Installation Instructions: Manufacturer's printed instructions for installation shall be submitted to
the engineer for approval.
I.
Manufacturer's Warranties: Manufacturer's printed warranties, as specified hereinafter, shall be
submitted prior to final acceptance by the engineer.
J. Manufacturer's Field Service: Manufacturer's printed field service procedures and reports, as
specified hereinafter, shall be submitted prior to final acceptance by the engineer. Report forms
shall contain all information as required to do start-up and testing as specified in the products
section.
1.5
CERTIFICATIONS
A. Manufacturer's Certification: The boiler manufacturer shall certify the following:
1. The products and systems furnished are in strict compliance with the specifications.
2. The boiler, burner and other associated mechanical and electrical equipment have all been
properly coordinated and integrated to provide a complete and operable boiler.
3. ASME certification.
4. UL and CSD-1 certification.
5. The equipment furnished has been installed in accordance with the manufacturer's
installation instructions.
6. The specified factory tests have been satisfactorily performed.
7. The specified field tests have been satisfactorily performed.
A2-34
03-08
Section A2
B.
C.
D.
E.

Contractor's Certification: The contractor shall certify the following:
1. The products and systems installed are in strict compliance with the specifications.
Boiler Inspectors' Certification: All boiler inspections during hydrostatic testing shall be performed
by an authorized boiler inspector who is certified by the National Board of Boiler and Pressure
Vessel Inspectors and shall be submitted in writing prior to final acceptance by the engineer.
Test Reports: Factory and field test reports as described above and as specified hereinafter, shall
be submitted prior to final acceptance by the engineer.
Operation and Maintenance Manuals: Manufacturer's printed operation and maintenance
manuals shall be submitted prior to final acceptance by the engineer. Operation and maintenance
manuals shall contain shop drawings, product data, operating instructions, cleaning procedures,
replacement parts list, maintenance and repair data, complete parts list, etc.
1.6
DELIVERY, STORAGE, AND HANDLING

A. The contractor shall be responsible for the timely delivery of the equipment to the job site. The
contractor shall be responsible for unloading and rigging of the equipment. The contractor shall
be responsible for protecting the equipment from the weather, humidity and temperature
conditions, dirt, dust, other contaminants, as well as job site conditions during construction.
B. Equipment shall be unloaded, handled, and stored in accordance with the manufacturer's
handling and storage instructions.
C. The work to be performed consists of providing all labor, equipment, materials, etc. to furnish
and install new factory assembled, low pressure hot water boilers as described in the
specifications herein.
PART 2
PRODUCTS
2.1
MANUFACTURERS
A. Contractor shall furnish and install Cleaver Brooks Model 4WI natural gas (combination Gas/Oil
fired) steam boiler(s) with design pressure as scheduled on the drawings.
B. Alternate manufacturers complying with plans and specifications must be submitted and
approved by the consulting engineer within 10 days prior to bid date.
2.2
GENERAL DESCRIPTION
Factory packaged unit shall include boiler, burner, heavy duty skids, painted steel jacket with two inches of
fiberglass insulation, controls and accessories all piped and wired for single point field connections. Units shall
carry packaged label of Underwriters Laboratory (UL) and be in accordance with ASME/CSD-1, all codes
required by the local governing authorities and as indicated on the design performance data sheet. A certified
factory fire-test shall be provided on all fuels with data sheets furnished to Engineer and Owner. ASME certified,
labeled, stamped and designed for ____ PSIG steam in accordance with Section (I or IV) of ASME Code. Unit
shall be designed to Seismic Zone requirements and be provided with tie down clips and calculations showing
bolt diameter requirements. Manufacturer's Representative to provide services for field testing and adjusting of
boiler and controls to meet design requirements.
A2-35
09-09

2.3
Section A2
PERFORMANCE: BOILER SIZE AND RATINGS

A. The capacity of each unit shall be indicated on the drawing schedule.
B. Performance Criteria:
Manufacturer:
CLEAVER-BROOKS
Model:
Promethean Line
Horsepower:
________HP
Output:
________#/hr (from and at 212F)
Gas Input:
________MBH
Oil Input:
________GPH
Design Pressure:
________PSIG
Operating Pressure
________PSIG
________Sq. Inches
________Cu. Ft.
________BTU/Cu. Ft.

Natural Gas (%):
No. 2 Oil (%):


Gas (Natural):
Oil (No. 2):

Gas (Natural):
Oil (No. 2):

Electrical:
Fan Motor:
Oil Pump Motor:
____ V / ____ H / ____ P

____HP
____HP
____HP
____dBA
____PSIG
Weight
Dry:
Flooded:
____
____
Seismic Zone:
____
Altitude:
____
Code Requirements:

CSD-1 NFPA 8501
State Of _______
Factory Mutual (FM)
ASL
A2-36
03-08
Section A2
A.
Noise Sound Levels: Based on ABMA test code for packaged boilers measured 41/2 feet
vertically above the bottom of the base rail and 3'0" horizontally in front of the end of the blower
motor or front surface of control cabinet. Sound levels dBA on the scale in reference to 0.0002
microbars.
High Fire#2
#2 oil
____ dBA
Low Fire
#2 oil
____ dBA
High Fire
Nat Gas
____ dBA
Low Fire
Nat Gas
____ dBA
2.4
BOILER DESIGN
A. Four pass steel scotch marine firetube boiler for positive pressurized firing with forced draft
burner. Wet back design with a minimum five (5) square feet of heating surface per boiler
horsepower. Front and rear doors shall be davited and sealed with tad-pole gaskets using heavy
duty cap screws threaded into replaceable brass nuts. When opened, doors shall expose all
tubes, tubesheets and furnace for ease of inspection and maintenance. Lifting loops shall be
provided. Rear door shall be refractory lined with air cooled observation port. Tubes shall be
rolled, beaded and/or welded into tube sheets and tubes shall be cleanable and removable from
either front or back. Tubes shall be a minimum 2.5" O.D., with a tube wall thickness of not less
than.095".
B. The boiler pressure vessel shall be completely insulated with a minimum of 2" of insulation and
shall be encased in an 18 gauge metal cabinet with primer and finish coat of paint.
2.5
BURNER DESIGN
A. GENERAL: Forced draft burner mounted in and integral with boiler hinged front boiler door so
when door is opened burner head, furnace, tubesheet and tubes are exposed; reversed curve cast
aluminum blower fan; motor(s); ACCU-LINK single point positioning system consisting of rotary
air damper located on fan discharge, straight line linkage and characterized cams; air flow
switch; fuel trains and control panels. To conform to UL and other insurance requirements as
indicated.
B. GAS BURNER: Shall be of the high radiant multi-port type for natural gas. Minimum pilot safety
burner shall consist of gas-electric spark ignition with 100% safety shut-off pilot, solenoid gas
valve, pressure regulator and shut-off cock. Minimum main gas train shall include manual shutoff valve, pressure regulating valve, dual safety gas valves, manual test valve high-low pressure
switches, manifold pressure gauge and butterfly gas valve with (14) point characterized cam
assembly. Gas train shall be factory packaged to meet insurance requirements as indicated. Gas
turn down shall be minimum______. 4:1 up to 200 HP, 10:1 from 250 HP and above.
A2-37
09-09

C.
D.
E.
F.
G.
2.6
Section A2
OIL BURNER Oil burner shall be of the low pressure air atomizing type for No. 2 oil. Minimum
pilot safety burner shall consist of gas-electric spark ignition with 100% safety shut-off pilot,
solenoid gas valve, pressure regulator and shut-off cock. Oil train shall consist of retractable
nozzle with flexible hoses; gauges, manifold block; air purge valve; fuel-oil controller with (14)
point characterized cam assembly; dual oil solenoids; temperature switch, air compressor
assembly and oil pump assembly. (For heavy oil, an oil preheat system shall be provided to
include a water to water to oil safety type preheater and thermostatically controlled electric
preheater.) Oil train shall be factory packaged to meet insurance requirements as indicated. Oil
turn down shall be minimum 8:1(250 hp-800 hp), 4:1 (up to 200 hp).
COMBINATION BURNER: Provide gas-oil fuel selector switch to provide fuel switch over without
any required adjustments to burner linkage.
FUEL-AIR CONTROL: Modulating fire with proven low fire start. Provide manual potentiometer
with manual-auto switch on boiler control panel in addition to automatic fuel-air controller.
Linkage system shall be Cleaver-Brooks ACCU-LINK single point positioning with rotary air
damper, linkage and (14) point characterized cam assembly for all fuels. Provide automatic
operating control and manual reset high limit.
FORCED DRAFT BLOWER: All air for combustion shall be supplied by a blower mounted in the
front boiler door above the burner. The Backward curved cast aluminum radial impeller shall be
directly connected to a flanged type ODP motor. This rigid mounting with the blower wheel inside
the head shall eliminate vibration and reduce noise level. The balanced blower wheel shall be
cast aluminum with radial blades. The combustion air damper shall be an integral rotating
damper and shall be automatically adjusted for proper air quantity by a mod motor to maintain
proper fuel-air ratios.
EMISSION CONTROL: Boiler NOx shall be furnished with guaranteed internal induced NOx
control for 60 PPM (30, 15 & <9 PPM NOx systems are optional) corrected to3% 02 over the
entire turndown range. Boiler capacity, turndown, flame stability and efficiency shall not be
affected by the internal NOx control. External FGR piping shall not be allowed. Low NOx system
shall be part of the Boiler/Burner UL package label and manufacture shall have Twelve (12) years
of emission control experience in the state of_____.
BOILER TRIM
A. To include the following:
1. ______" diameter pressure gauge.
2. ASME safety relief valve(s).
3. Auxiliary Low Water Cutoff, Warrick 3C-2.
4. Primary low water cut-off.
5. Operating control.
6. Limit control with manual reset.
7. ______" stack thermometer.
8. Feedwater regulating valve with 3 valve bypass
9. Low fire hold controller (optional).
10. 1 Slow Opening Blowdown Valve, Size______ ", Class 200#
11. 2 Quick Opening Blowdown Valves, Size______ ", Class 490#
12. Feedwater Globe Valve, Size______ ", Class 240#
13. 1 Feedwater Check Valve, Size______ ", Class 240#
14. 1 ASME Spool Piece, Inlet Size______ ", Outlet Size______ ", Length______ "
15. 1 Stop Valve (Steam Header Valve), Size______, Flanged, Cast Iron, Class 250
A2-38
03-08
Section A2
B.

16. 1 Stop Check Valve (Non-Return Valve), Size______ ", Flanged, Cast Iron, Class 250",
Straight Pattern, with Free Blow Drain Valve
17. Factory mounted, installed, tested, and certified piping (by A, S, or PP ASME stamp holder)
and valves per ASME Code, including:
Water Column piping
Bottom Blowdown (from boiler to last code valve)
Feedwater assembly (shipped loose)
Surface Blowdown piping with stop valve and metering valve.
18. Modulating Feedwater Control Valve, including 3-Valve Bypass
19. Oil Pump, Mounted and Wired
20. Air Atomizing Compressor, Mounted and Wired
21. Platforms and ladder to access steam header and safety relief valves. Built to OSHA
requirements.
WATER COLUMN/LOW WATER CUTOFF AND WATER LEVEL CONTROL SYSTEM (150-250
psig design): Shall be a CB LEVEL MASTER Water level control system and shall be comprised of
a microprocessor-based electronic controller, a non-contact, non-wearing, continuously reading
absolute level sensor and pressure chamber. The control system shall be designed as follows: The
electronic controller shall be mounted in the common control panel and operate in ambient
temperatures from 32 degrees F to 125 degrees F, the pressure chamber shall be boiler mounted
and operate to pressures of 250 psig and the level sensor shall operate to pressures of 250 psig
and temperatures to 400 degrees F. The pressure containing components shall be constructed in
accordance with ASME Code. A shielded, four conductor cable with ground shall be run in metal
conduit between the level sensor and the controller. Supply power shall be 115VAC-1 phase- 60
Hz. All wiring shall be in compliance with the National Electrical Code.
The pressure chamber shall have a sight glass mounted on the side. The level sensor shall have
an accuracy of.01" or greater. The electronic controller shall have level and error indicating lights,
alphanumeric display for messaging, reset/menu switch and the following features:
1. Continuous Level Indication
2. Low Water Cutoff & Alarm
3. High Water Alarm
4. Low & High Water Warning
5. Full Modulating Control of Modulating Feedwater Control Valve
6. Continuous Monitoring of Float Operation
7. Column Blowdown Detection and Reminder
8. Auto or Manual Reset
9. Real Time Clock
10. Alarm Annunciation
11. Alarm History Files with Time Stamp
12. Water Column Blowdown Record
13. Auxiliary Low Water Cutoff Check
14. RS 232 Interface
15. Maximum Contacts Rating 15 amps Resistive Load
A2-39
09-09

2.7
Section A2
BOILER CONTROLS
A. A common enclosure shall house the control panel and the entrance panel. Enclosure shall be
NEMA 4 rated and shall be mounted at the side of the boiler in a location convenient to the
operator. Enclosure shall consist of upper and lower sections divided by a partition with a
separate hinged door for each section. Upper section (low voltage) will house boiler controls
including flame safeguard, water level system controller, and Hawk ICS if so equipped. Lower
panel section (high voltage) will house entrance panel.
B. (OPTION 1) BURNER MANAGEMENT SYSTEM (CB 780E Standard): Mounted at side of boiler
in control panel enclosure. Microprocessor-based control to monitor all critical boiler and burner
interlocks control and supervise burner light off sequence, and initiate an orderly safety procedure
in the event of interlock or flame failure. Dynamic self checking. System to provide pre-post purge
status, fault history, and diagnostic information by means of a two-line alpha-numeric display
with alarm/status LEDS.
C. (OPTION 2) CB-HAWK ICS Boiler Control System (Optional upgrade): Integrated Boiler Control
and Management System:
Boiler shall be factory equipped with a Boiler Control System combining a Digital Burner
Management System for flame safety, and a Programmable Logic Controller for boiler modulation
and operator interface functions.
The factory pre-configured Boiler Control System shall integrate the Burner Management
functions and the PLC based modulation and operator interface functions. The logic of the Burner
Management System and the modulating controls will not be run in the same processor or
powered by the same DC supply. The PLC and Operator Interface Hardware shall be as
manufactured by Allen Bradley.
Touch Screen HMI
Automatic sequencing of the boiler through standby, pre-purge, pilot flame
establishing period, main flame establishing period, run, flame proving and lockout
and post-purge
Utilize solid state controls and sensors to provide various control functions, such as:

Manual control of the boiler firing rate using control screens on the HMI to increment or decrement
the firing rate
A2-40
03-08
Section A2

Examine all load terminals to assure it is capable of recognizing the true status of the
external controls, limits and interlocks. If any input fails this test, the Burner Management
System shall lockout on safety shutdown.
Closed-loop logic test of critical loads (ignition, pilot and main fuel valves) and must be
able to lockout on safety.
Pre-ignition interlocks (fuel valve proof of closure, etc.) and flame signal checked during
Standby and Pre-Purge.
Safe start check and expand check to include monitoring flame signal during standby.
The Boiler Control System shall provide the ability to communicate with external digital via Ethernet
as a standard. OPC compliant Internet communications shall be supported, with the Boiler Control
System supplied with its own IP address.
2.8
SHOP TEST
A. Shop test: The complete packaged boiler shall receive factory tests to check construction and
function of all controls. All shop tests may be witnessed by the purchaser at his own c upon
sufficient notice to the company.
2.9
ACCESSORIES - BOILER FLUE VENT
2.10
ACCESSORIES - FEEDWATER SYSTEM (BOILER FEEDSET OR DEAERATOR)
2.11
ACCESSORIES - FEEDWATER HEATER OR ECONOMIZER
2.12
ACCESSORIES - BLOWDOWN SEPARATOR AND/OR BLOWDOWN HEAT RECOVERY
2.13
ACCESSORIES - 02 TRIM SYSTEM
2.14
ACCESSORIES - CHEMICAL FEED SYSTEM AND/OR WATER TREATMENT
2.15
MANUFACTURER FIELD SERVICES
A. General: The boiler and accessories supplier shall be responsible for performance of inspections, start up and testing
of the package boiler and accessory equipment and materials furnished under this section. A detailed written record
of the start up performance, including burner setting data entire load range shall be furnished to the test engineer
before test personnel leave the site. Equipment and test apparatus shall be furnished by the supplier. All equipment
defects discovered by the tests shall be rectified. The minimum time for two (2) boilers is five (5) days.
B. Equipment inspection: Boiler representative to provide ______hours of job site assistance to inspect boilers and other
equipment upon arrival, verifying completeness of equipment supplied ar damages. Responsibility of making freight
claims to be performed by contractor or owner personnel.
C. Pre start-up walk through: Boiler representative shall spend _____ hours at job site reviewing with mechanical
contractor to be conducted approximately 1 week prior to startup.
D. Start-up shall be conducted by experienced and factory authorized technician in the regular employment of the boiler
supplier, and shall include:
1. Demonstrate that boiler, burner, controls and accessories comply with requirement Section as proposed by the
boiler and accessories supplier. Pre-test all items prior to scheduling the final testing that will be witnessed by the
test engineer.
A2-41
09-09
Section A2
2. Readings at different firing rates (25, 50, 75 and 100%) of load for the modulating burner shall be taken with a
written report of the tests submitted to the test engineer. The reports shall include readings for each firing rate
tested and include stack temperatures, O2, CO, Nox and overall boiler efficiency.
3. Auxiliary Equipment and Accessories: Observe and check all valves, draft fans, electric motors and other accessories and appurtenant equipment during the operational and capacity tests for leakage, malfunctioning, defects,
and non compliance with referenced standards or overloading as applicable.
4. Commissioning Requirements:
a).Fireside inspection
b).Waterside inspection
c).Closing and resealing of doors, manways and hand holes
d).Set up fuel train and combustion air system
e).Set up operating set points
f).Check all safeties, including: Flame safeguard, LWCO, ALWCO, Air flow, Fuel pressures, High limits
g).Set up and verify efficiencies at 25%, 50%, 75%, and 100%
h).Set up and verify burner turndown.
i).Set up and verify feedwater/level controls
j).Set up and verify Emissions Compliance
E. Training to include all safety procedures, maintenance procedures, control operations, and diagnostic procedures.
Training to be provided in a single _ hour continuous session to accommodate operator's availability on site.
2.16
OPERATING & MAINTENANCE MANUALS
A. Provide two (2) Operating and Maintenance manuals including cut-away views of boiler and burner, schematics
including fuel trains, general instructions for maintenance and inspections, complete spare parts lists and trouble
shooting procedures.
B. A wiring diagram corresponding to the boiler shall be affixed to the boiler near the electrical panel.
2.17
WARRANTY DATA
A. The entire boiler/burner package shall be guaranteed and warranted by the boiler manufacturer. Warranty shall include
all parts for a period of (12) months from the date of start-up or beneficial use or 18 months from shipment, whichever
comes first.
PART 3
EXECUTION
3.1
GENERAL
A. Installation shall be provided by the contractor in accordance with the requirements of the codes specified
hereinbefore. All of the contractor's work shall be performed by experienced workman previously engaged in boiler
plant construction and shall be under the supervision of a qualified installation supervisor.
3.2
INSTALLATION
A. Install equipment in strict compliance with manufacturer's installation instructions.
B. Install equipment in strict compliance with state and local codes and applicable NFPA standards.
C. Maintain manufacturer's recommended clearances around sides and over top of equipment.
A2-42
03-08
Section A2
D. Install components that were removed from equipment for shipping purposes.
E. Install components that were furnished loose with equipment for field installation.
F. Provide all interconnecting electrical control and power wiring.
G. Provide all fuel gas vent and service piping.
H. Provide all piping for boiler pipe connections.
3.3
FIELD TESTING
A. The manufacturer's representative shall test all boiler and burner interlocks, actuators, valves, controllers, gauges,
thermometers, pilot lights, switches, etc. Any malfunctioning component shall be replaced.
B. All adjustments to boiler, burner, and boiler control system shall be performed by the manufacturer's representative.
3.4
START-UP, INSTRUCTION AND WARRANTY SERVICE
The manufacturer's representative shall provide start-up and instruction of each new boiler, including burner and boiler control system as specified herein. Start-up and instruction shall cover all components assembled and furnished by the manufacturer whether or not of his own manufacture.
A2-43
09-09
Section A2
NOTES
A2-44
03-08
Section A2
SAMPLE SPECIFICATIONS - Model 4WI HOT WATER BOILERS

PART 1
GENERAL
1.1
SCOPE
The work to be performed consists of providing all labor, equipment, materials, etc. to furnish and
install new factory assembled steam boiler(s) as described in the specifications herein.
1.2
REFERENCES
A. ASME Section IV (Heating Boilers)
B. ANSI Z21.13 (Gas Fired Low Pressure Boilers)
C. NFPA 54 (ANSI Z221.3)
D. National Fuel Gas Code
E. FACTORY MUTUAL
F.
ASME CSD-1 (Controls and Safety Devices)
G. GE-GAP (GE Global Asset Protection)
H. UBC (Uniform Building Code)
I.
UMC (Uniform Mechanical Code)
J. NEC (National Electrical Code)
K. UL (Underwriters Laboratories)
1.3
QUALITY ASSURANCE
A. The equipment shall, as a minimum, be in strict compliance with the requirements of this
specification and shall be the manufacturer's standard commercial product unless specified
otherwise. Additional equipment features, details, accessories, appurtenances, etc. which are
not specifically identified but which are a part of the manufacturer's standard commercial
product, shall be included in the equipment being furnished.
B. The equipment shall be of the type, design, and size that the manufacturer currently offered for
sale and appears in the manufacturer's current catalogue. The equipment shall be new and
fabricated from new materials and shall be free from defects in materials and workmanship
C. The equipment must fit within the allocated space, leaving ample allowance for maintenance and
cleaning, and must leave suitable space for easy removal of all equipment appurtenances.
D. All units of the same classification shall be identical to the extent necessary to insure
E. In order to provide unit responsibility for the specified capacities, efficiencies, and performance,
the boiler manufacturer shall certify in writing that the equipment being submitted shall perform
as specified. The boiler manufacturer shall be responsible for guarantying that the boiler
provides the performance as specified herein.
1.4
SUBMITTALS
A. The contractor shall submit, in a timely manner, all submittals for approval by the engineer.
Under no circumstances shall the contractor install any materials until the engineer has made
final approval on the submittals.
A2-45
09-09

C.
D.
E.
F.
1.5
Section A2
The bidder must submit in writing to the engineer any request for a proposed deviation, omission,
modification, or substitution to this specification for evaluation no later than ten (10) days prior
to the bid date. A request for any substitution shall be accompanied by technical data, drawings,
product samples, and complete data substantiating compliance of proposed substitution with
these specifications. No materials shall be deemed acceptable if not in strict and full compliance
with these specifications. All bidders must bid solely on the specified materials unless
acceptance by the engineer of a deviation, omission, modification, or substitution is granted in
writing to all bidders prior to the bid date.
Shop Drawings - Shop drawings shall be submitted to the engineer for approval and shall consist
of:
1. General assembly drawing of the boiler including product description, model number,
2. Schematic flow diagram of gas valve trains.
3. Schematic wiring diagram of boiler control system of the ladder-type showing all
components, all interlocks, etc. Schematic wiring diagram shall clearly identify factory
wiring and field wiring.
Manufacturer's Warranties: Manufacturer's printed warranties, as specified hereinafter, shall be
Manufacturer's Field Service: Manufacturer's printed field service procedures and reports, as
specified hereinafter, shall be submitted prior to final acceptance by the engineer. Report forms
shall contain all information as required to do start-up and testing as specified in the products
section.
CERTIFICATIONS
1. The products and systems furnished are in compliance with the specifications, except as
clarified in the bid package.
2. The boiler and burner have all been properly coordinated and integrated to provide a
complete and operable boiler.
4. UL and CSD-1 (if applicable) certification.
5. The equipment furnished has been installed in accordance with the manufacturer's
B. Contractor's Certification: The contractor shall certify the following:
C. Boiler Inspectors' Certification: All boiler inspections during hydrostatic testing shall be
performed by an authorized boiler inspector who is certified by the National Board of Boiler and
Pressure Vessel Inspectors and shall be submitted in writing prior to final acceptance by the
engineer.
D. Test Reports: Factory and field test reports as described above and as specified hereinafter, shall
be submitted prior to final acceptance by the engineer.
A2-46
09-09
Section A2
E.

Operation and Maintenance Manuals: Manufacturer's printed operation and maintenance
manuals shall be submitted prior to final acceptance by the engineer. Operation and
maintenance manuals shall contain, product data, operating instructions, cleaning procedures,
replacement parts list, maintenance and repair data, etc.
1.6
SHIPMENT, STORAGE, AND HANDLING

A. The contractor shall be responsible for the timely shipment of the equipment to the job site. The
contractor shall be responsible for unloading and rigging of the equipment. The contractor shall
be responsible for protecting the equipment from the weather, humidity and temperature
conditions, dirt, dust, other contaminants, as well as job site conditions during construction.
B. Equipment shall be unloaded, handled, and stored in accordance with the manufacturer's
handling and storage instructions.
C. The work to be performed consists of providing all labor, equipment, materials, etc. to furnish
and new factory assembled, low pressure hot water boilers as described in the specifications
herein.
PART 2
PRODUCTS
2.1
MANUFACTURERS
A. Contractor shall furnish and install Cleaver Brooks Model 4WI___________ natural gas
(combination Gas/Oil fired) hot water boiler(s) with design pressure as scheduled on the
drawings.
B. Alternate manufacturers complying with plans and specifications must be submitted and
approved by the consulting engineer within 10 days prior to bid date.
2.2
GENERAL DESCRIPTION
A. Factory packaged unit shall include boiler, burner, heavy duty skids, painted steel jacket with two
inches of fiberglass insulation, controls and accessories all piped and wired for single point field
connections. Units shall carry packaged label of Underwriters Laboratory (UL) and be in
accordance with ASME, all codes required by the local governing authorities and as indicated on
the design performance data sheet. A certified factory fire-test shall be provided on all fuels with
data sheets furnished to Engineer and Owner. ASME certified, labeled, stamped and designed for
_____ PSIG water in accordance with Section IV of ASME Code. Unit shall be designed to
Seismic Zone __ requirements applicable to boiler location. Manufacturer's Representative to
provide services for field testing and adjusting of boiler and controls to meet design requirements.
2.3

A2-47
09-09
Section A2
Manufacturer:
CLEAVER-BROOKS
Model:
Promethean Line
Horsepower:
________HP
Output:
________#/hr (from and at 212F)
Gas Input:
________MBH
Oil Input:
________GPH
Design Pressure:
________PSIG
Operating Pressure
________PSIG
Operating Temperature
________degrees F

Overall Efficiency
Natural Gas (%):
No. 2 Oil (%):
Gas (Natural):
Oil (No. 2):

Gas (Natural):
Oil (No. 2):

Electrical:
Fan Motor:
Oil Pump Motor:
____ V / ____ H / ____ P

____HP
____HP
____HP
____dBA
____PSIG
Weight
Dry:
Flooded:
____
____
Seismic Zone:
____
Altitude:
____
Code Requirements:

CSD-1 NFPA 85 (optional)
State Of _______
Factory Mutual (FM) (optional)
GE-GAP (optional)
ASL
A2-48
09-09
Section A2
C.

Noise Sound Levels: Based on ABMA test code for packaged boilers measured 41/2 feet
vertically above the bottom of the base rail and 3'0" horizontally in front of the end of the blower
motor or front surface of control cabinet. Sound levels dBA on the scale in reference to 0.0002
microbars.
High Fire#2
#2 oil
____ dBA
Low Fire
#2 oil
____ dBA
High Fire
Nat Gas
____ dBA
Low Fire
Nat Gas
____ dBA
2.4
EFFICIENCY GUARANTEE
The boiler manufacturer shall guarantee that, at the time of startup, the boiler will achieve ________
fuel-to- steam efficiency at 100% firing rate when burning natural gas and ________ fuel-to-steam
efficiency at 100% firing rate when burning oil (add efficiency guarantees at 25%, 50%, and 75% of
rating, if required). If the boiler(s) fail to achieve the corresponding guaranteed efficiency as published,
the boiler manufacturer will rebate, to the ultimate boiler owner, ten thousand dollars ($10,000) for
every full efficiency point (1.0%) that the actual efficiency is below the guaranteed level.
Natural Gas
Carbon, % (wt) = 69.98
No. 2 Oil
Carbon, % (wt) = 85.8
No. 6 Oil
Carbon, % (wt) = 86.6
Sulfur, % (wt) = 2.09
Efficiencies are based on ambient air temperature of 80 F, relative humidity of 30%, and 15% excess
air in the exhaust flue gas.
Efficiencies are based on manufacturers published radiation and convection losses. (For CleaverBrooks radiation and convection losses, see Boiler Efficiency Facts Guide, publication number CB7767).
Warranty
A2-49
09-09
Section A2
Shop Tests
The packaged boiler must receive factory tests to check the construction, controls, and operation of
the unit. All tests may be witnessed by the purchaser, if desired.
Start-up Service
After boiler installation is completed, the manufacturer shall provide the services of a field
representative for starting the unit and training the operator at no additional costs.
A factory approved and authorized start-up report shall be submitted to the customer/user at the time
of start-up.
2.5
GENERAL BOILER DESIGN

A. The boiler shall be a four pass horizontal firetube updraft boiler with five (5) square feet (except
750 or 800 hp) of heating surface per rated boiler horsepower. It shall be mounted on a heavy
steel frame with integral forced draft burner and burner controls.
B. The complete package boiler shall be approved as a unit by Underwriters Laboratories and shall
bear the UL/ULC label, except in the case where 50 Hz has been selected.
C. The boiler shall be completely pre assembled and fire tested at the factory. The unit shall be
ready for immediate mounting on floor or simple foundation and ready for attachment of water,
steam, fuel, electrical, vent and blowdown connections.
D. The boiler shall be built to comply with the following insurance and codes
____________________ (Factory Mutual, ASME CSD-1).
2.6
BOILER SHELL (HOT WATER)

A. The boiler shell must be constructed in accordance with ASME Boiler Code and must receive
authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished
to the purchaser.
B. The hot water return and outlet connections shall be located on the top center line of the boiler.
The boiler shall be designated to rapidly mix the return water with the boiler water. Forced
internal circulation shall be used.
C. A dip tube shall be included as an integral part of the water outlet.
D. Two lifting eyes shall be located on top of the boiler.
E. Front and rear doors on the boiler shall be hinged or davited. Doors are to be sealed with
fiberglass tadpole gaskets and fastened tightly using heavy capscrews that thread into
replaceable brass nuts.
F.
Rear refractory and insulation shall be contained in the formed door, which must swing open for
inspection of brick work.
G. The boiler tubes shall not include turbulators, swirlers or other add-on appurtenances.
H. Front and rear tube sheets and all flues must be fully accessible for inspection and cleaning when
the doors are swung open. The shell must be furnished with adequate handholes to facilitate
boiler inspection and cleaning.
I.
The exhaust gas vent shall be located near the front of the boiler on the top center line and shall
be capable of supporting 1000 lbs and shall contain a stack thermometer
2.7
EMISSION CONTROLS
A. Boiler shall be equipped with a low emission (LE) option for guaranteed NOx performance at
________ ppm, dry volume basis and corrected to 3% O2 when firing natural gas.
A2-50
09-09
Section A2
B.
C.

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.
Burner, boiler, and low NOx system shall be manufactured as a package by a single
manufacturer. The Low Emission Option to the CB Boiler shall included factory testing as a
package, and shall bear the UL packaged label. The boiler nameplate shall include the approved
UL low NOx boiler model designation. No field assembly of the burner or low NOx equipment
shall be required.
2.8
HOT WATER BOILER TRIM

A. Low Water Cutoff
A low water cutoff control (manual reset) shall be mounted on the top centerline of the boiler wired into the
burner control circuit to prevent burner operation if boiler water falls below a safe level.
Pressure and temperature gauges shall be mounted on the boiler with temperature sensing element located
adjacent to the hot water outlet.
C. Relief Valves
Water relief valves of a type and size to comply with ASME Code requirements shall be shipped loose.
Temperature controls to regulate burner operation shall be mounted on the unit with temperature sensing
elements located adjacent to the hot water outlet. Controls shall be high limit (manual reset), operating limit
(auto reset), and firing rate control (30-100 hp).
2.9
BURNER AND CONTROLS

B. Burner operation shall be full modulation principle. The burner shall always return to low fire
position for ignition.
2.10
BLOWER
A. Air for combustion shall be supplied by a forced draft blower mounted in the front boiler door,
above the burner, to eliminate vibration and reduce noise level.
B. Maximum sound level of the boiler/burner package shall not exceed _____ dbA (when measured
in accordance with ABMA Sound Test Standards).
C. The impeller shall be cast aluminum, radial blade, carefully balanced, and directly connected to
the blower motor shaft.
2.11
COMBUSTION AIR CONTROL

Combustion air damper and cam operated fuel metering valves shall be operated by a single damper
control motor that regulates the fire according to load demand. Potentiometer type position controls
shall be provided to regulate operation of the damper control motor (remove this sentence when CBHAWK flame safeguard is used).
2.12
FUEL SPECIFICATION AND PIPING

A2-51
09-09

1.
2.
3.
4.
Fuel
Fuel
Fuel
Fuel
Section A2
series 700 - Gas fired (4.4.1).

series 100 - Light oil (No. 2) fired (4.4.2).
series 200 - Light oil or gas fired (4.4.3).
Series 700 - Gas Fired
2.13
BURNER TYPE
The burner shall be integral with the front head of the boiler and of high radiant multi-port type for
gas. The burner shall be approved for operation on natural gas fuel and equipped with an LE option.
2.14
GAS PILOT
The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall
monitor the pilot so that the primary gas valve cannot open until pilot flame has been established.
The pilot train shall include two manual shut-off valves, solenoid valve, pressure regulator and
pressure gauge.
2.15
GAS BURNER PIPING

A. Gas burner piping on all units shall include pressure regulating gas shutoff valve, motor operated
with proof of closure switch and plugged leakage test connection. The main gas valve(s) shall be
wired to close automatically in the event of power failure, flame failure, low water or any safety
shutdown condition. A lubricating plug cock or butterfly shutoff valve shall be provided as a
means for a tightness check of the primary shut off valve. An additional plug cock on butterfly
valve shall be furnished at entrance to gas train. Select one of the following:
B. 125-300 hp. High and low gas pressure switches shall be provided. A second motorized safety
shutoff valve, plus an additional plugged leakage test connection shall be provided.
C. 350-800 hp. High and low gas pressure switches shall be provided. A second motorized safety
shutoff valve, plus an additional plugged leakage test connection shall be provided. A valve
proving switch shall be located between the safety shutoff valves.
2.16
BURNER TURNDOWN
1. 125-200 hp. Turndown range of burner shall be 4:1 when firing natural gas.
2. 250-800 hp. Turndown range of the burner shall be 10:1 when firing natural gas with a 60 or 30
ppm LE option. (Consult with Cleaver-Brooks Representative regarding high turndown capability
based on available gas pressure and 15 and 9 ppm LE options.)
2.17
FUEL SERIES 100

Light Oil Fired
2.18
BURNER TYPE
The burner shall be integral with the front head of the boiler, and shall be a low pressure air atomizing
type approved for operation with CS12-48, Commercial No. 2 oil and equipped with an LE option.
2.19
GAS PILOT
The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall
monitor the pilot so that the primary gas valve cannot open until pilot flame has been established.
The pilot train shall include two manual shut-off valves, solenoid valve, pressure regulator and
pressure gauge.
A2-52
09-09
Section A2
2.20
OIL PUMP
An oil pump with a capacity of approximately twice the maximum burning rate shall be included.
Separate motor driven pump set, shipped loose to be installed in a location favorable to the oil storage
tank, shall be provided.
2.21
OIL BURNER PIPING

Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid
shutoff valves, pressure gauges and fuel strainer, all integrally mounted on the unit. A fuel oil controller
shall be provided to combine all of the fuel oil controls into a single casting which is mounted on the
front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing
burner. A low oil pressure switch shall be included in the oil piping.
2.22
LOW PRESSURE AIR ATOMIZING

Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch.
2.23
BURNER TURNDOWN Fuel Series 200 Light Oil or Gas Fired

125 hp through 200 hp. Turndown range shall be 4:1 when firing No. 2 oil. When Firing natural gas
refer to section 2.23
2.24
BURNER TYPE
The burner, integral with the front head of the boiler, shall be a combination of the low pressure air
atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for
operation with either CS12-48 Commercial No. 2 Oil or natural gas. The burner shall be equipped
with an LE option.
2.25
GAS PILOT
The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor
the pilot so that the primary fuel valve cannot open until flame has been established. The pilot train
shall include two manual shut-off valves, solenoid valve, pressure regulator and pressure gauge.
2.26
OIL BURNER
Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be
included. Separate motor driven pump set, shipped loose, to be installed in a location favorable to the
2.27
OIL BURNER PIPING

Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid
shutoff valves, pressure gauges and fuel strainer, all integrally mounted on the unit. A fuel oil controller
shall be provided to combine all of the fuel oil controls into a single casting which is mounted on the
front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing
burner. A low oil pressure switch shall be included in the oil piping.
2.28
LOW PRESSURE AIR ATOMIZING

Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch.
A2-53
09-09
Section A2
2.29
GAS BURNER PIPING

Gas burner piping on all units shall include pressure regulating gas shutoff valve, motor operated with
proof of closure switch and plugged leakage test connection. The main gas valve(s) shall be wired to
close automatically in the event of power failure, flame failure, low water or any safety shutdown
condition. A lubricating plug cock or butterfly shutoff valve shall be provided as a means for a
tightness check of the primary shut off valve. An additional plug cock or butterfly valve shall be
2.30
BURNER
A. Boiler Flame Safeguard Controller and Control Panel
B. CB780E Flame Safeguard
C. Boilers with CB780E Control - Each boiler shall be factory equipped with flame safeguard
controller providing technology and functions equal to the Cleaver-Brooks Model CB780.
D. Controller shall be computerized solid state having sequence and flame-on lights and digital first
out fault code indications of flame safeguard trip functions. It shall include dynamic self-check
logic. The controller shall have a fixed operating sequence incapable of being manually altered.
The sequence shall include start, pre-purge, pilot and main fuel ignition run and post-purge
cycles.
E. Controller shall be the non-recycle type for maximum safety that shall shutdown the burner and
indicate as a minimum the following trip functions: pilot and main flame failure, high and low fire
proving switch faults, running interlocks open, false flame signal and fuel valve open (when proof
of closure switch is furnished).
F.
The controller shall have a run/test switch. It shall allow interruptions to sequence just after prepurge, during pilot ignition trial and run cycles for adjustments to firing rate motor, damper
linkages and pilot flame for minimum turndown tests.
2.31
CONTROL PANEL
A. The control panel shall be mounted on the front door of the boiler in a location convenient to the
operator. The hinged metal cabinet shall have NEMA 1A rating that includes a neoprene dust
seal and a Yale cabinet key type lock.
The panel shall contain the boiler flame safeguard controller, blower motor starter, indicating
lights and selector switches.
B. The panel shall have a removable sub-base for mounting the flame safeguard controller, blower
motor starter, and terminal blocks. For combination gas-oil fired boilers the panel shall contain
the fuel selector switch.
C. The panel shall contain the following lights and switches:
D. Lights
E. White - load demanded.
F.
G. Red - low water.
H. Red - flame failure.
I.
Control Switches
J. Burner On-Off.
K. Manual-Automatic.
L. Manual Firing Rate Control.
A2-54
09-09
Section A2
M.
Oil, heat and moisture resistant wire shall be used and identified with circuit numbers
corresponding to the electrical wiring diagram.
All electrical equipment and wiring shall be in conformance with Underwriters Laboratories
requirements.
Boiler to be supplied with a control circuit transformer and fuse protection for the control circuit.
N.
O.
2.32
BOILER CONTROLS
A. BOILER MANAGEMENT CONTROL SYSTEM CONTROL PANEL: Boiler mounted NEMA 1
enclosure(s) with key lock; fusing, magnetic starters; step-down control transformer; flame
safeguard and burner management system as indicated; annunciator lights for load demand, fuel
on , low water and flame failure; selector switches, required by dry contacts, relays and terminal
strips. Oil, heat and moisture resistant wire with circuit number corresponding to electrical
wiring diagrams. In accordance with UL and National Electric Code.
B. (OPTION 1) BURNER MANAGEMENT SYSTEM (CB 780E Standard): Boiler mounted in control
panel enclosure. Microprocessor-based control to monitor all critical boiler and burner interlocks
control and supervise burner light off sequence, and initiate an orderly safety procedure in the
event of interlock or flame failure. Dynamic self checking. System to provide pre-post purge
status, fault history, and diagnostic information by means of a two-line alpha-numeric display
with alarm/status LEDS.
C. (OPTION 2) CB-HAWK ICS Boiler Control System (Optional upgrade): Integrated Boiler Control
And Management System
Management System for flame safety, and a Programmable Logic Controller for boiler modulation
and operator interface functions.
The factory pre-configured Boiler Control System shall integrate the Burner Management
functions and the PLC based modulation and operator interface functions. The logic of the
Burner Management System and the modulating controls will not be run in the same processor or
powered by the same DC supply. The PLC and Operator Interface Hardware shall be as
manufactured by Allen Bradley.
a. Programmable Logic Controller
b. Touch Screen HMI
c. One Burner Management Controller with Wiring Sub-Base
d. One Flame Scanner and amplifier
e. Various Temperature and Pressure Sensors
Automatic sequencing of the boiler through standby, pre-purge, pilot flame establishing period, main
flame establishing period, run, flame proving and lockout and post-purge
1.
2.
3.

a. Modulating control (algorithm shall be Proportional-Integral-Derivative (PID) type)
b. Thermal shock protection
c. High and Low limit alarms and shutdowns
a. Manual control of the boiler firing rate using control screens on the HMI to increment
A2-55
09-09
Section A2

b. On screen indication of burner management controller status and diagnostics
c. On screen display of system alarms and faults
d. On screen history of alarms and faults
e. On screen recommendations for troubleshooting of fault conditions
f.
g. Stack Flue Gas, Combustion Air and Shell (water) temperature indication
4. Boiler efficiency calculation
5. Low Fire Hold with Minimum Temperature Control
6. Assured Low Fire Cut-Off (ALFCO)
7. The Boiler Control System shall incorporate the following safety provisions:
a. Examine all load terminals to assure it is capable of recognizing the true status of the
external controls, limits and interlocks. If any input fails this test, the Burner
Management System shall lockout on safety shutdown.
b. Closed-loop logic test of critical loads (ignition, pilot and main fuel valves) and must be
c. Pre-ignition interlocks (fuel valve proof of closure, etc.) and flame signal checked
during Standby and Pre-Purge.
d. Dynamic checking of the flame signal amplifier.
e. Safe start check and expand check to include monitoring flame signal during standby.
f.
The Boiler Control System shall provide the ability to communicate with external digital devices via
Ethernet as a standard. It shall be possible to communicate with any OPC compliant device. Internet
communications shall be supported, with the Boiler Control System supplied with its own IP address.
2.33
2.34
MANUFACTURER FIELD SERVICES

A. General: The boiler and accessories supplier shall be responsible for performance of inspections,
start up and testing of the package boiler and accessory equipment and materials furnished
under this Section. A detailed written record of the start up performance, including burner
setting data over the entire load range shall be furnished to the test engineer before test
personnel leave the site. All labor, equipment and test apparatus shall be furnished by the
supplier. All equipment defects discovered by the tests shall be rectified. The minimum time for
two (2) boilers is five (5) days.
B. Equipment inspection: Boiler representative to provide ___ hours of jobsite assistance to inspect
boilers and other equipment upon arrival, verifying completeness of equipment supplied and
potential damages. Responsibility of making freight claims to be performed by contractor or
owner personnel.
C. Pre start-up walk through: Boiler representative shall spend ___ hours at jobsite reviewing
installation with mechanical contractor to be conducted approximately 1 week prior to startup.
D. Start-up shall be conducted by experienced and factory authorized technician in the regular
employment of the boiler supplier, and shall include:
1. Demonstrate that boiler, burner, controls and accessories comply with requirements of this
Section as proposed by the boiler and accessories supplier. Pre-test all items prior to
scheduling the final testing that will be witnessed by the test engineer.
A2-56
09-09
Section A2

2.
E.
Readings at different firing rates (25, 50, 75 and 100%) of load for the modulating burner
shall be taken with a written report of the tests submitted to the test engineer. The reports
shall include readings for each firing rate tested and include stack temperatures, O2, CO,
NOx, and overall boiler efficiency.
3. Auxiliary Equipment and Accessories: Observe and check all valves, draft fans, electric
motors and other accessories and appurtenant equipment during the operational and
capacity tests for leakage, malfunctioning, defects, non compliance with referenced
standards or overloading as applicable.
a. Fireside inspection
b. Waterside inspection
c. Closing and resealing of doors, manways and hand holes
d. Set up fuel train and combustion air system
e. Set up operating set points
f.
Check all safeties, including: Flame safeguard, LWCO, ALWCO, Air flow, Fuel
pressures, High limits
g. Set up and verify efficiencies at 25%, 50%, 75%, and 100%
h. Set up and verify burner turndown.
i.
Set up and verify feedwater/level controls
Training to include all safety procedures, maintenance procedures, control operations, and
diagnostic procedures. Training to be provided in a single ____ hour continuous session to
accommodate operator's availability on site.
2.35

A. Provide two (2) Operating and Maintenance manuals including cut-away views of boiler and
burner, schematics including fuel trains, general instructions for maintenance and inspections,
complete spare parts lists and trouble shooting procedures.
B. A wiring diagram corresponding to the boiler shall be affixed to the boiler near the electrical
panel.
2.36
WARRANTY DATA
The entire boiler/burner package shall be guaranteed and warranted by the boiler manufacturer.
Warranty shall include all parts for a period of (12) months from the date of start-up or beneficial use
or 18 months from shipment, whichever comes first.
PART 3
EXECUTION
3.1
GENERAL
Installation shall be provided by the contractor in accordance with the requirements of the codes
specified hereinbefore. All of the contractor's work shall be performed by experienced workman
previously engaged in boiler plant construction and shall be under the supervision of a qualified
installation supervisor.
3.2
INSTALLATION
A. Install equipment in strict compliance with state and local codes and applicable NFPA standards.
B. Install components that were removed from equipment for shipping purposes.
A2-57
09-09

C.
D.
E.
F.
Section A2
Install components that were furnished loose with equipment for field installation.
Provide all interconnecting electrical control and power wiring.
Provide all fuel gas vent and service piping.
Provide all piping for boiler pipe connections.
3.3
FIELD TESTING
A. The manufacturer's representative shall test all boiler and burner interlocks, actuators, valves,
controllers, gauges, thermometers, pilot lights, switches, etc. Any malfunctioning component
shall be replaced.
B. All adjustments to boiler, burner, and boiler control system shall be performed by the
manufacturers representative.
3.4

The manufacturer's representative shall provide start-up and instruction of each new boiler, including
burner and boiler control system as specified herein. Start-up and instruction shall cover all
components assembled and furnished by the manufacturer whether or not of his own manufacture.
A2-58
09-09
Section A3
Criterion Series - Model 4WG
Steam and Hot Water
Table Of Contents
Criterion Model 4WG
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3--3
Four-Pass Wetback Design: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Hinged Burner, Front and Rear Doors: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Natural Gas, No. 2 Oil, or Combination Burners Available: . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-15
Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-17
Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-17
Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-18
Sample Specifications - Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-25
Sample Specifications - Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-37
A3-1
09-09
Section A3
List of Figures
4WG Dimensions - Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WG Dimensions - Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WG Low NOx Steam 100-800 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WG Low NOX Hot Water 100-800 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Space Required to Open Rear Head on Criterion Model 4WG . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 4WG Lift Lug Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 4WG Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Fuel Oil Supply Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler Room Length (Typical Layouts) - Model 4WG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler Room Width (Typical Layout) - Model 4WG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A3-5
A3-7
A3-9
A3-11
A3-13
A3-13
A3-14
A3-23
A3-24
A3-24
List of Tables
4WG Ratings Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WG Dimensions - Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WG Ratings - Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WG Dimensions - Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WG Low NOx Ratings Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WH Low NOx Dimensions Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WH Ratings Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WG Low NOx Dimensions Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WG Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WG Boilers: Predicted Sound Levels (30 ppm NOx systems) @ High Fire . . . . . . . . . . . . . . . . .
Steam Volume and Disengaging Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 4WG Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 4WG Hot Water Relief Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WG Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4WG Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Altitude Correction for Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 4WG, Standard and Low NOx, Mini. Req. Gas Pressure Standard, FM and IRI Gas Trains . .
A3-5
A3-6
A3-7
A3-8
A3-9
A3-10
A3-11
A3-12
A3-18
A3-18
A3-19
A3-19
A3-20
A3-20
A3-21
A3-21
A3-22
A3-2
09-09
Section A3
FEATURES AND
BENEFITS

The Cleaver-Brooks Criterion Model 4WG Boiler provides an integrated boiler
burner package with optimized pressure vessel and furnace working in
conjunction with a matching Profire gun burner. Additionally, the boiler/
burner package is fully UL and cUL approved and available from 100 - 800
hp. The following features apply:
Four-Pass Wetback Design:
Four-pass design provides high flue gas velocities and low stack
temperatures to maximize efficiency.
Five square feet of heating surface per boiler horsepower (except for the
750 and 800 hp unless otherwise specified) provides guaranteed
efficiency performance and long boiler life.
Hinged Burner, Front and Rear Doors:

Hinged burner assembly provides ease of access to the furnace.
Large rear access plug for turnaround and furnace access.
Rear door completely covers and insulates rear tube sheet.
Natural Gas, No. 2 Oil, or Combination Burners Available:

Combination gas/oil burners provide quick fuel changeover without burner
adjustment.
PRODUCT
OFFERING
Cleaver-Brooks Criterion Model 4WG Boilers are available in low pressure

steam, high pressure steam, and hot water designs. Burners are available to
fire natural gas, No. 2 oil, or a combination of oil and gas.
Standard product offering is:
100 - 800 hp.
15 - 250 psig steam.
Full modulation, all sizes.
Available options include the following (contact your local Cleaver-Brooks

authorized representative for option details).
Boiler Options:
Low NOx emission levels from 75, 30, 15 - <9PPM when burning
natural gas and 70 PPM on # 2 oil when the fuel bound nitrogen is at
0.02% or less.
Drain valves.
Additional screwed or flanged trappings.
Blowdown valves.
Non-return valves.
Feedwater valves and regulators.
Surface blowdown systems.
Blend pump.
Surge load baffles.
Seismic design.
A3-3
09-09
Section A3
Burner/Control Options:
Flame safeguard controllers.
Lead/lag system.
High altitude design.
Special insurance and code requirements (e.g., IRI, FM, CSD-1).
Alarm bell/silence switch.
Special motor requirements (TEFC, high efficiency).
Special indicating lights.
Main disconnect.
Elapsed time meter.
Voltmeter/micro-ammeter.
NEMA enclosures.
Low-fire hold control.
Remote emergency shut-off (115V).
Circuit breakers.
Day/night controls.
Special power requirements.
Stack thermometer.
Fuel Options:
DIMENSIONS AND
RATINGS
Air atomizing oil burner, 125 - 200 hp.
Gas strainer.
Gas pressure gauge.
Future gas conversion.
Oversized/undersized gas trains.
Dimensions and ratings for the Criterion Model 4WG Boilers are shown in the
following tables and illustrations. The information is subject to change
without notice.
Table A3-1 Model 4WG Steam Boiler Ratings
Table A3-3 Model 4WG Hot Water Boiler Ratings
Figure A3-1 Model 4WG Steam Boiler Dimensions
Figure A3-2 Model 4WG Hot Water Boiler Dimensions
Figure A3-5 Model 4WG Boiler Space Requirements to Open Rear

Door
Figure A3-6 Lifting Lug Location, Model 4WG Boilers
Figure A3-7 Model 4WG Boiler Mounting Piers
A3-4
09-09
Section A3

Table A3-1. 4WG Ratings - Steam
BOILER H.P.
BURNER MODEL
100
FP-3
125
FP-3
150
200
250
300
350
400
FP-3
FP-4
FP-4
FP-4 D145P D175P
500
D210P
600
D252P
700
D300P
Rated Capacity (lbs-steam/hr

3450
4313
5175
6900
8625 10350 12075 13800 17250 20700 24150
from and at 212 0F)
3347
4184
5021
6694
8368 10042 11715 13389 16736 20083 23430
29.2
36.4
43.7
58.3
72.9
87.5
102.0
116.6
145.8
174.9
204.1
Gas CFH (1000 Btu)
4082
5102
6123
8164 10205 12246 14287 16328 20410 24492 28574
Gas (Therm/hr)
40.8
51.0
61.2
81.6
102.0 122.5
142.9
163.3
204.1
244.9
285.7
Blower Motor hp
Circulating Oil Pump Motor hp
(Oil only)
Oil Metering Pump Motor hp
(Oil only)
800
D378P
27600
26778
233.3
32656
326.6
7-1/2
15
20
25
30
40
75
1/2
1/2
3/4
3/4
3/4
3/4
3/4
1/2
3/4
3/4
3/4
Integral Oil/Air Motor hp (Oil only)

only)
**
**
**
7-1/2
7-1/2
15
500
625
750
2500
3000
3500
See Note "B"
BOILER DATA
1000
1250
1500
1750
2000
* Integral oil pump

** No air compressor required (pressure atomized)
NOTES:
A. All fractional hp motors will be single phase voltage except oil metering pump motor(3-phase); integral hp motors will be 3-phase voltage.
RF/RD
LL
L
FF
D
DD
4
H
BB
J
OO
(NEARSIDE)
(BOTH SIDES)
P
R
Q
N
M
A
RIGHT SIDE VIEW
FRONT VIEW
W
G
Figure A3-1. 4WG - Steam 100-800 HP
A3-5
09-09
Section A3
Table A3-2. 4WG Dimensions - Steam

BOILER H.P.
LENGTHS
Overall Length
Shell
Base Frame
Burner Extension
Smokebox to Base
Smokebox to Steam Nozzle
WIDTHS
Overall Width
I.D. Boiler
Center to Lagging
Base Outside
Base Inside
HEIGHTS
Base to Rear Davit
Base to Vent Outlet
Base to Steam Outlet
BOILER CONNECTIONS
DIM
100
200
250
300
350
400
A
B
C
D
F
G
H
174
131
198
155
186
143
110
124
122
156
39
0.5
39
0.5
39
0.5
46.5
0.5
50.88 74.88 63.88 97.88 86.25 110.3 95.63 113.6
20.5
20.5
20.5
20.5
I
J
K
L
LL
M
N
85
60
45
33
40
52.5
44.5
85
60
45
33
40
52.5
44.5
500
600
700
800
*800
1.25
1
1.5
W
Z
1.25
1
1.5
1
227.5 220.3 244.3 245.3 263.3 276.8 311.8 296.5 304

331
177 172.5 196.5 189.8 207.8 213.8 248.8 232.8 232.8 259.8
92
92
67
67
48.5 48.5
36.75 36.75
43.5 43.5
51
51
43
43
OO 86.12 86.12 92.75

O
85
85 92.63
P
46
46
50
Q
12
12
12
R 15.63 15.63 16.13
X 82.38 82.38 89.88
S
T
Chemical Feed
VENT STACK
150
See Note "C
125
167.25
185.25
188.25
223.75
43.75 43.75 51.5

0.5
0.5
0.5
150.12
51.5
0.5
59
0.5
59
0.5
22
103
78
54
42
49
64
56
174.13
22
103
78
54
42
49
64
56
22
110
85
57.5
45.5
52.5
60
47
22
110
85
57.5
45.5
52.5
60
47
25
25
106
141
207.25
207.25
234.75
59.75 67.25 67.25

0.5
0.5
0.5
25
25
25
115.6 115.6 142.6
123
123
133
133
133
96
96
106
106
106
64
64
69
69
69
51
51
56
56
56
59
59
64
64
64
71.88 71.88 74.75 74.75 74.75
58.88 58.88 61.75 61.75 61.75
92.75 98.88 98.88 112.8 112.8 125.1 125.1 134.3 134.3 134.3
92.63 106
106
115
115
126
126 135.6 135.6 135.6
50
56
56
61
61
67
67
71
71
71
12
12
12
12
12
12
12
12
12
12
16.13 16.5 16.5
18
18
18.5 18.5 17.5 17.5 17.5
89.88 101.5 101.5 110
110 121.5 121.5 130.5 130.5 130.5
1.5
1
2
1
2
1
2
1
2.5
1
2.5
1
2.5
1
2.5
1
2.5
1
2.5
1
2.5
1
10
10
12
12
12
12
12
12
12
12
1.5
1.5
1.5
1
1.5
1
1.5
1
1.5
1
1.5
1
1.5
1
2
1
2
1
2
1
2
1
2
1
2
1
24
24
24
60
188
60
188
60
215
411
411
438
481
481
535
28,700
28,700
32,770
42,320
42,320
46,300
46,290
46,290
50,830
BB
16
16
16
16
20
20
24
24
24
24
MINIMUM CLEARANCES
Rear Door Swing
DD 36
36
40
40
46
46
50
50
55
55
FF
96
120
108
142 132.5 156.5 148
166
169
204
258
261
295
307.5
331.5
337
355
377
412
Thru Window or Door
RD 234
438
508
Front of Boiler
RF 263
311
291
359
351
399
388
424
WEIGHTS IN LBS
5,870
7,310
7,625
9,995
12,590
14,850
16,025
17,950
21,050
25,350
Normal Water Weight
10,860
12,080
13,090
15,260
19,110
21,050
24,760
27,640
33,295
38,150
11,320
12,920
13,980
16,620
21,620
23,970
26,850
29,650
36,190
39,560
NOTES:
A3-6
09-0909-09
Section A3
Table A3-3. 4WG Ratings - Hot Water

BOILER H.P.
BURNER MODEL
100
FP-3
150
200
250
300
350
400
500
600
700
FP-3
FP-4
FP-4
FP-4 D145P D175P D210P D252P D300P
3347
4184
5021
6694
8368
10042 11715 13389 16736 20083 23430
Light Oil gph (140,000 Btu/gal 29.2
36.4
43.7
58.3
72.9
87.5
102.0
116.6
145.8
174.9
204.1
Gas CFH (1000 Btu)
4082
5102
6123
8164
10205 12246 14287 16328 20410 24492 28574
Gas (Therm/hr)
40.8
51.0
61.2
81.6
102.0
122.5
142.9
163.3
204.1
244.9
285.7
Blower Motor hp
Circulating Oil Pump Motor
hp (Oil only)
(Oil only)
Integral Oil/Air Motor hp (Oil
only)
only)
Heating Surface sq-ft. (Firesid
125
FP-3
800
D378P
26778
233.3
32656
326.6
7-1/2
15
20
25
30
40
75
1/2
1/2
3/4
3/4
3/4
3/4
3/4
1/2
3/4
3/4
3/4
**
**
**
7-1/2
7-1/2
15
500
625
750
2500
3000
3500
See Note "B"
BOILER DATA
1000
1250
1500
1750
2000
* Integral oil pump

** No air compressor required (pressure atomized)
NOTES:
RF/RD
FF
D
I
L
H
LWCO Y
BB
LWCO
DD
4
HH
OO
X
S
(BOTH SIDES)
P
R
Q
N
M
A
RIGHT SIDE VIEW
FRONT VIEW
Figure A3-2. 4WG - Hot Water 100-800 HP
A3-7
09-09
Section A3
Table A3-4. 4WG Dimensions - Hot Water

BOILER H.P.
LENGTHS
Overall Length
Shell
Base Frame
Burner Extension
Smokebox to Base
Smokebox to Return
Smokebox to Outlet
WIDTHS
Overall Width
I.D. Boiler
Center to LWCO Controller
Center to Lagging
Base Outside
Base Inside
HEIGHTS
Base to Rear Davit
Base to Vent Outlet
BOILER CONNECTIONS
DIM 100
125
150
200
250
300
350
400
500
600
700
800
*800
See Note "C
A
B
C
D
F
G
H
HH
174
198
186
227.5
220.25
244.25
245.25
263.25
276.75
311.75
296.5
304
331
131
155
143
177
172.5
196.5
189.75
207.75
213.75
248.75
232.75
232.75
259.75
110
124
122
156
167.25
185.25
188.25
223.25
207.25
207.25
234.25
39
39
39
46.5
43.75
43.75
51.5
51.5
59
59
59.75
67.25
67.25
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
20.5
20.5
20.5
20.5
22
22
22
22
25
25
25
25
25
78
99
87
121
113.5
137.5
130.75
148.75
143
151.75
146.25
146.75
173.75
103
124
112
146
139.5
163.5
156.75
174.75
179
187.75
182.25
182.75
209.75
70
70
77.5
77.5
88
88
95
95
106
106
116
116
116
60
60
67
67
78
78
85
85
96
96
106
106
106
37
37
40.75
40.75
46
46
49.5
49.5
55
55
60
60
60
33
33
36.75
36.75
42
42
45.5
45.5
51
51
56
56
56
52.5
52.5
51
51
64
64
60
60
71.88
71.88
74.75
74.75
74.75
44.5
44.5
43
43
56
56
47
47
58.88
58.88
61.75
61.75
61.75
OO
O
P
Q
R
X
86.12
86.12
92.75
92.75
98.88
98.88
112.75
112.75
125.12
125.12
134.25
134.25
134.25
85
85
92.63
92.63
106
106
115
115
126
126
135.63
135.63
135.63
46
46
50
50
56
56
61
61
67
67
71
71
71
12
12
12
12
12
12
12
12
12
12
12
12
12
15.63
15.63
16.13
16.13
16.5
16.5
18
18
18.5
18.5
17.5
17.5
17.5
82.38
82.38
89.88
89.88
101.5
101.5
110
110
121.5
121.5
130.5
130.5
130.5
S
T
1.25
1.5
1.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
10
10
12
12
12
12
10
10
12
12
12
12
Drain-Front & Rear
1.5
1.5
1.5
Air Vent
1.5
1.5
1.5
1.5
1.5
1.5
1.5
24
24
24
24
I
J
K
L
M
N
150.125 174.125
VENT STACK
16
16
16
16
20
20
24
24
24
BB
MINIMUM CLEARANCES
36
36
40
40
46
46
50
50
55
Rear Door Swing
DD
96
120
108
142
132.5
156.5
148
166
169
FF
258
261
295
307.5
331.5
337
355
377
Thru Window or Door
RD 234
438
Front of Boiler
RF 263
311
291
359
351
399
388
424
WEIGHTS IN LBS
6,890
8,580
8,870
11,600
14,760
17,380
19,220
21,520
26,260
Normal Water Weight
10,860
12,080
13,090
15,260
19,110
21,050
24,760
27,640
33,295
11,600
12,980
14,040
16,680
20,670
23,140
26,930
30,060
35,390
NOTES:
55
60
60
60
204
188
188
215
412
411
411
438
508
481
481
535
31,580
35,900
35,900
40,930
38,150
42,320
42,320
46,300
40,550
45,430
45,430
49,750

A3-8
09-0909-09
Section A3
Table A3-5. 4WG Low NOx Ratings - Steam

BOILER H.P.
BURNER MODEL
100
125
LND54S
LND63P
150
200
250
300
350
400
500
600

Rated Capacity (lbs-steam/hr from
3450
4313
5175
6900
8625
10350
12075
13800
17250
20700
and at 212 0F)
3347
4184
5021
6694
8368
10042
11715
13389
16736
20083
29.2
36.4
43.7
58.3
72.9
87.5
102.0
116.6
145.8
174.9
Gas CFH (1000 Btu)
4082
5102
6123
8164
10205
12246
14287
16328
20410
24492
Gas (Therm/hr)
40.8
51.0
61.2
81.6
102.0
122.5
142.9
163.3
204.1
244.9
Blower Motor hp
Circulating Oil Pump Motor hp (Oil
only)
Oil Metering Pump Motor hp (Oil
only)
Air Compressor Motor hp (Oil only)
3
1/2
5
1/2
1
500
625
24150
27600
23430
26778
204.1
28574
285.7
233.3
32656
326.6
10
15
15
20
25
30
40
75
75
1/2
1/2
1/2
3/4
3/4
3/4
3/4
3/4
1/2
1/2
3/4
3/4
7-1/2
15
15
2500
3000
3500
See Note "B"
800
LND420P
7-1/2
700
LND84P LND105P LND145S LND145P LND175P LND210P LND252P LND300P LND378P
750
2
-
BOILER DATA
1000
1250
1500
1750
2000
NOTES:
Figure A3-3. 4WG Low NOx - Steam 100-800 HP
A3-9
09-09
Section A3
Table A3-6. 4WG Low NOx Dimensions - Steam

BOILER H.P.
LENGTHS
Overall Length
Shell
Base Frame
Burner Extension
Smokebox to Base
Smokebox to Steam Nozzle
WIDTHS
Overall Width
I.D. Boiler
Center to Lagging
Base Outside
Base Inside
Center to Outside of FGR Duct
FGR Duct Size

HEIGHTS
Base to Rear Davit
Base to Vent Outlet
BOILER CONNECTIONS
DIM
100
125
150
200
250
300
350
400
500
600
700/800
*800
See Note "C"
A
B
C
D
F
G
H
I
J
K
L
LL
M
N
NN
V
176
131
200
155
110
124
189.6 223.6 229.6 253.6 250 270.6 276.6 311.6 304

331
143
177 172.5 196.5 189.8 207.8 213.8 248.8 232.8 259.8
122
156
90.5
60
45
33
40
52.5
44.5
45.5
6
85
60
45
33
40
52.5
44.5
39.5
6
92
92
67
67
48.5
48.5
36.75 36.75
43.5
43.5
51
51
43
43
39.5
39.5
6
6
OO 86.12 86.12 92.75

O
85
85
92.63
P
46
46
50
Q
12
12
12
R 15.63 15.63 16.13
X 82.38 82.38 89.88
S
150.13 174.13 167.25 185.25 188.25 223.25 207.25 234.25
41
41
42.62 42.62 53.12 53.12 56.25 58.88 58.88 58.88 67.25 67.25
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
20.5
20.5
20.5
20.5
22
22
22
22
25
25
25
25
50.88 74.88 63.88 97.88 86.25 110.3 95.63 113.6 106
141 115.6 142.6
1.25
1.5
1.5
103
78
54
42
49
64
56
43.5
6
103
78
54
42
49
64
56
43.5
8
110
110
125
126
133
133
85
85
96
96
106
106
57.5
57.5
64
64
69
69
45.5
45.5
51
51
56
56
52.5
52.5
59
59
64
64
60
60
71.88 71.88 74.75 74.75
47
47
58.88 58.88 61.75 61.75
49.75 49.75
61
62
62.5
62.5
8
8
8
10
10
10
92.75 98.88 98.88 112.8 112.8 125.1 125.1 134.3 134.3

92.63 106
106
115
115
126
126 135.6 135.6
50
56
56
61
61
67
67
71
71
12
12
12
12
12
12
12
12
12
16.13 16.5
16.5
18
18
18.5
18.5
17.5
17.5
89.88 101.5 101.5 110
110 121.5 121.5 130.5 130.5
2
2.5
2.5
2.5
2.5
2.5
2.5
10
10
12
12
12
12
12
12
12
U
W
W
Z
4
1.5
1.25
1
4
1.5
1.5
1
4
1.5
1.5
1
4
2
1.5
1
6
2
1.5
1
6
2
1.5
1
6
2
1.5
1
6
2
2
1
8
2
2
1
8
2
2
1
8
2
2
1
8
2
2
1

Chemical Feed
VENT STACK
BB
16
16
16
16
20
20
24
24
24
24
24
24
MINIMUM CLEARANCES
Rear Door Swing
DD
36
36
40
40
46
46
50
50
55
55
60
60
FF
96
120
108
142 132.5 156.5 148
166
169
204
188
215
Thru Window or Door
RD 234
258
261
295 307.5 331.5 337
355
377
412
411
438
311
291
359
351
399
388
424
Front of Boiler
RF 263
438
508
481
535
WEIGHTS IN LBS
5,870
7,310
7,625
9,995 12,590 14,850 16,025 17,950 21,050 25,350 28,700 32,770
Normal Water Weight
- 10,860 12,080 13,090 15,260 19,110 21,050 24,760 27,640 33,295 38,150 42,320 46,300
- 11,320 12,920 13,980 16,620 21,620 23,970 26,850 29,650 36,190 39,560 46,290 50,830
NOTES:
A3-10
09-0909-09
Section A3
Table A3-7. 4WG Low NOx Ratings - Hot Water

BOILER H.P.
BURNER MODEL
100
125
LND54S
LND63P
150
200
250
300
350
400
500
600

3347
4184
5021
6694
8368
10042
11715
13389
16736
20083
29.2
36.4
43.7
58.3
72.9
87.5
102.0
116.6
145.8
174.9
Gas CFH (1000 Btu)
4082
5102
6123
8164
10205
12246
14287
16328
20410
24492
Gas (Therm/hr)
40.8
51.0
61.2
81.6
102.0
122.5
142.9
163.3
204.1
244.9
Blower Motor hp
Circulating Oil Pump Motor hp (Oil
only)
Oil Metering Pump Motor hp (Oil
only)
Air Compressor Motor hp (Oil only)
800
23430
26778
204.1
28574
285.7
233.3
32656
326.6
7-1/2
10
15
15
20
25
30
40
75
75
1/2
1/2
1/2
1/2
1/2
3/4
3/4
3/4
3/4
3/4
1/2
1/2
3/4
3/4
7-1/2
15
15
2500
3000
3500
See Note "B"
700
LND84P LND105P LND145S LND145P LND175P LND210P LND252P LND300P LND378P LND420P
1
-
1
-
500
625
750
2
-
BOILER DATA
1000
1250
1500
1750
2000
NOTES:
Figure A3-4. 4WG Low NOX - Hot Water 100-800 HP
A3-11
09-09
Section A3
Table A3-8. 4WG Low NOx Dimensions - Hot Water

BOILER H.P.
LENGTHS
Overall Length
Shell
Base Frame
Burner Extension
Smokebox to Base
Smokebox to Return
Smokebox to Outlet
WIDTHS
Overall Width
I.D. Boiler
Center to Lagging
Base Outside
Base Inside
Center to Outside of FGR Duct
FGR Duct Size
HEIGHTS
Base to Rear Davit
Base to Vent Outlet
BOILER CONNECTIONS
DIM
100
125
150
200
250
300
350
400
500
600
700/800
*800
See Note "C"
A
B
C
D
F
G
H
HH
176
131
110
41
0.5
20.5
78
103
200
155
124
41
0.5
20.5
99
124
189.62 223.62 229.62 253.62

250
270.63 276.63 311.63
304
331
143
177
172.5
196.5 189.75 207.75 213.75 248.75 232.75 259.75
122
156
150.13 174.13 167.25 185.25 188.25 223.25 207.25 234.25
42.62
42.62
53.12
53.12
56.25
58.88
58.88
58.88
67.25
67.25
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
20.5
20.5
22
22
22
22
25
25
25
25
87
121
113.5
137.5 130.75 148.75
143
151.75 146.75 173.75
112
146
139.5
163.5 156.75 174.75
179
187.75 182.75 209.75
I
J
K
L
M
N
NN
V
82.5
60
37
33
52.5
44.5
45.5
6
76.5
60
37
33
52.5
44.5
39.5
6
80.25
67
40.75
36.75
51
43
39.5
6
80.25
67
40.75
36.75
51
43
39.5
6
89.5
78
46
42
64
56
43.5
6
89.5
78
46
42
64
56
43.5
8
99.25
85
49.5
45.5
60
47
49.75
8
OO
O
P
Q
R
X
86.12
85
46
12
15.63
82.38
86.12
85
46
12
15.63
82.38
92.75
89.88
50
12
16.13
92.63
92.75
89.88
50
12
16.13
92.63
98.88
106
56
12
16.5
101.5
98.88
106
56
12
16.5
101.5
112.75 112.75 125.12 125.12 134.25 134.25

115
115
126
126
135.63 135.63
61
61
67
67
71
71
12
12
12
12
12
12
18
18
18.5
18.5
17.5
17.5
110
110
121.5
121.5
130.5
130.5
1.25
1.5
1.5
2.5
2.5
2.5
2.5
2.5
2.5
10
10
12
12
12
10
10
12
12
12
99.25
85
49.5
45.5
60
47
49.75
8
116
96
55
51
71.88
58.88
61
8
117
96
55
51
71.88
58.88
62
10
122.5
106
60
56
74.75
61.75
62.5
10
122.5
106
60
56
74.75
61.75
62.5
10
Drain-Front & Rear

W
1.5
1.5
1.5
2
2
2
2
2
2
2
2
2
Air Vent
Y
1.5
1.5
1.5
1.5
1.5
1.5
1.5
2
2
2
2
2
VENT STACK
BB
16
16
16
16
20
20
24
24
24
24
24
24
MINIMUM CLEARANCES
Rear Door Swing
DD
36
36
40
40
46
46
50
50
55
55
60
60
FF
96
120
108
142
132.5
156.5
148
166
169
204
188
215
Thru Window or Door
RD
234
258
261
295 307.5 331.5 337
355
377
412
411
438
263
311
291
359
351
399
388
424
Front of Boiler
RF
438
508
481
535
WEIGHTS IN LBS
Normal Water Weight
6,890
8,580
8,870 11,600 14,760 17,380 19,220 21,520 26,260 31,580 35,900 40,930
10,860 12,080 13,090 15,260 19,110 21,050 24,760 27,640 33,295 38,150 42,320 46,300
11,600 12,980 14,040 16,680 20,670 23,140 26,930 30,060 35,390 40,550 45,430 49,750
NOTES:
A3-12
09-0909-09
Section A3
BOILER
HP
100-125
150-200
250-300
350-400
500-600
700-800
A
33
36.5
42
45.5
51
56

B
C
D
47
52
80
49
56
83
56
61
92
58
68
99
66
75
111
74
80
121
E
36
40
46
50
55
60
Figure A3-5. Space Required to Open Rear Head on Criterion Model 4WG
NEAR SIDE
E DIA OF HOLE
B
C
FAIR SIDE
BOILER
HP
100
125
150
200
250
300
350
400
500
600
700-800
A
79.5
79.5
87.125
87.125
99
99
107.625
107.625
125.375
125.375
134.5

B
C
D
21.375
84.75
10
21.375
108.75
10
21.375
96.75
10
21.375
130.75
10
28.75
104.25
10
28.75
128.25
10
33.25
126
10
33.25
144
10
34.5
145
10
34.5
180
10
34.5
164
10
E
3
3
3
3
3
3
3
3
3
3
3
Figure A3-6. Model 4WG Lift Lug Locations
A3-13
09-0909-09
BOILER
HP
100
125
150
200
250
300
350
400
500
600
700-800
A
6
6
6
6
6
6
6
6
6
6
6
Section A3
B
9
9
9
9
9
9
12
12
12
12
12

C
D
E
110
39.5
57.5
124
39.5
57.5
122
38
56
156
38
56
150.125
51
69
174.125
51
69
167.25
41.5
65.5
185.25
41.5
65.5
188.25
53.375
77.375
223.25
53.375
77.375
207.25
56.25
80.25
F
4
4
4
4
4
4
6.5
6.5
6.5
6.5
6.5
G
44.5
44.5
43
43
56
56
47
47
58.875
58.875
61.75
X
8
8
8
8
11.5
11.5
11.5
11.5
10.5
10.5
10.5
NOTE:
increased inspection accessibility to the boiler and added height for washing down the area beneath the boiler.
Figure A3-7. Model 4WG Mounting Piers
PERFORMANCE
DATA
Contact your local Cleaver-Brooks authorized representative for efficiencies.

Cleaver-Brooks 4WG boilers are available with the standard burner package,
or optional model Profire LE or Profire NT if NOx reductions of between 75
and <9 PPM on natural gas are required, or 70 PPM on #2 oil with 0.02%
fuel bound nitrogen.
A3-14
09-09
Section A3
ENGINEERING DATA

The following engineering information is provided for Model 4WG Boilers.
Additional detail is available from your local Cleaver-Brooks authorized
representative.
Boiler Information
Table A3-11 shows steam volume and disengaging area for model
4WG boilers.
Table A3-12 lists quantity and outlet size for safety valves supplied on
Model 4WG steam boilers.
Table A3-13 lists quantity and outlet size for relief valves supplied on
Model 4WG hot water boilers.
Table A3-14 gives recommended steam nozzle sizes on Model 4WG

Boilers.
Table A3-15 shows recommended non-return valve sizes for Model

4WG Boilers.
Blowdown Water Requirements

Some local codes require blowdown tanks to be constructed in accordance
with recommendations of the National Board of Boiler and Pressure Vessel
Inspectors.
The National Board's recommendations base the size of the blowdown tank
on the removal of at least 4 inches of water from the boiler.
Table A3-9 lists the approximate quantity of water represented by 4 inches of
water at normal operating level for Cleaver-Brooks Model 4WG Boilers.
Burner/Control Information
Burner Characteristics
Maximum altitude for standard burners is shown in Table A3-16. Note that
altitude correction and burner changes are required for higher altitudes which
may alter dimensions, motor hp and gas pressures.
Gas-Fired Burners
Table A3-16 shows correction factors for gas pressure at elevations over 700
ft. above sea level.
Table A3-17 shows minimum and maximum gas pressure requirements for
Standard, FM and IRI 4WG Boiler gas trains upstream of the gas pressure
regulator.
For oversized or undersized gas trains or altitude above 2,000 feet, contact
A3-15
09-09
Section A3
Fuel Connections - Gas

The local gas company should be consulted for requirements and
authorization for installation and inspection of gas supply piping. Installation
of gas supply piping and venting must be in accordance with all applicable
engineering guidelines and regulatory codes. All connections made to the
boiler should be arranged so that all components remain accessible for
inspection, cleaning and maintenance.
A drip leg should be installed in the supply piping before the connection to
the gas pressure regulator. The drip leg should be at least as large as the inlet
fitting supplied with the boiler. Consideration must be given to both volume
and pressure requirements when choosing gas supply piping size. Refer to the
boiler dimension diagram provided by Cleaver-Brooks for the particular
installation. Connections to the burner gas train should be made with a union,
so that gas train components or the burner may be easily disconnected for
inspection or service. Upon completion of the gas piping installation, the
system should be checked for gas leakage and tight shutoff of all valves.
Fuel Connections - Oil
Oil-fired burners are equipped with an oil pump, which draws fuel from a
storage tank and supplies pressurized oil to the burner nozzle(s). The burner
supply oil pump has a greater capacity than the burner requires for the
maximum firing rate. Fuel not delivered to the nozzle is returned to the
storage tank. A two-pipe (supply and return) oil system is recommended for
all installations. Figure A3-8 shows a typical fuel oil supply arrangement. Oil
lines must be sized for the burner and burner supply oil pump capacities.
The burner supply oil pump suction should not exceed 10" Hg. If a transfer
pump is used, it must have a pumping capacity at least equal to that of the
burner pump(s). Supply pressure to the burner pump should not exceed 3
psig.
A strainer must be installed in the supply piping upstream of the burner
supply pump in order to prevent entry of foreign material into the pump, fuel
control valves, or burner nozzle(s). The strainer must be sized for the burner
supply pump capacity. A strainer mesh of 150 microns (0.005") is
recommended.
Install a check valve in the line to prevent draining of the oil suction line when
the burner is not in operation. Location of the check valve varies with the
system, but usually it is located as close as possible to the storage tank.
Installation of a vacuum gauge in the burner supply line between the burner
oil pump and the strainer is recommended. Regular observation and
recording of the gauge indication will assist in determining when the strainer
needs servicing.
Upon completion of the oil piping installation, the system should be checked
for oil or air leakage and tight shutoff of all valves.
Boiler Room Information
A3-16
09-09
Section A3

Stack Support Capabilities
100 - 800 hp Model 4WG Boilers can support up to 2000 lbs without
additional support.
100 - 800 hp Model 4WG Boilers can be reinforced to support up to 3000
lbs.
Boiler Room Combustion Air
When determining boiler room air requirements, the size of the room, air flow,
and velocity of air must be reviewed as follows:
A. Two (2) permanent air supply openings in the outer walls of the boiler
room are recommended. Locate one (1) at each end of the boiler
room, preferably below a height of 7 feet. This allows air to sweep the
length of the boiler.
B. Air supply openings can be louvered for weather protection, but they
should not be covered with fine mesh wire, as this type of covering
has poor air flow qualities and is subject to clogging by dust or dirt.
C. A vent fan in the boiler room is not recommended, as it could create
a slight vacuum under certain conditions and cause variations in the
quantity of combustion air. This can result in unsatisfactory burner
performance.
D. Under no condition should the total area of the air supply openings be
less than one (1) square foot.
Area (sq.-ft.) = CFM/FPM
B. Ventilation Air = Maximum bhp x 2 cfm/bhp or a total of 10 cfm/bhp
- up to 1000 feet elevation. Add 3 percent more per 1000 feet of
added elevation.
A. From floor to (7) foot height - 250 fpm.
B. Above (7) foot height - 500 fpm.
Example: Determine the area of the boiler room air supply openings for
(1) 300 hp boiler at 800 feet altitude. The air openings are to be 5 feet
above floor level.
Area Required: Area = cfm/fpm = 3000/250 = 12 Sq.-ft. total.
Area/Opening: 12/2 = 6 sq.-ft./opening (2 required).
Notice
A3-17
09-09
Section A3
Stack/Breeching Size Criteria
The design of the stack and breeching must provide the required draft at each
boiler flue gas outlet. Proper draft is critical to burner performance.
Although constant pressure at the flue gas outlet of the Model 4WG is not
required, it is necessary to size the stack/ breeching to limit flue gas pressure
variation. The allowable pressure range is -0.25" W.C. to +0.25" W.C.
For additional information, please review Section I4, General Engineering
Data (Stacks) and Section F, Stacks. Stack and breeching sizes should always
be provided by a reputable stack supplier who will design the stack and
breeching system based on the above criteria. Your local Cleaver-Brooks
authorized representative is capable of assisting in your evaluation of the
stack/breeching design.
Table A3-9. 4WG Blowdown Tank Sizing

Information
BOILER HP
100
125
150
200
250
300
350
400
500
600
700
800
Table A3-10. 4WG Boilers: Predicted Sound Levels

(30 ppm NOx systems) @ High Fire
WATER (GAL)
85
104
102
131
145
169
178
198
233
278
286
286
BHP
100
125
150
200
250
300
350
400
500
600
700
800
NOTE: Quantity of water removed from boiler

by lowering normal water line 4".
A3-18
09-09
Sound Level-dbA
81
83.5
89.5
88.6
88.5
91
94
91.5
93.5
93.5
93.7
93.5
Section A3

Table A3-11. Steam Volume and Disengaging Areas
BOILER HP
100
125
150
200
250
300
350
400
500
600
700
800
STEAM VOLUME CU-FT

(A)
(B)
16.5
22.3
20.3
27.4
19.9
26.8
25.7
34.6
34.8
49.5
40.6
57.9
51.3
69.6
57.2
77.5
83.6
107.6
100
128.6
115.6
144.9
115.6
144.9

(A)
(B)
4565
4954
5587
6077
5443
5918
7013
7632
7790
8597
9115
10051
9734
10570
10843
11779
12874
13781
15394
16474
15826
16819
15826
16819
NOTE:
Table A3-12. Model 4WG Steam Boiler Safety Valve Outlet Size
NO. OF
OUTLET
BOILER HP
VALVES
SIZE (IN.)
REQ'D
150 PSIG STEAM

NO. OF
OUTLET
VALVES
SIZE (IN.)
REQ'D
100
2-1/2
125
150
200
2-1/2
250
(1) 2-1/2
(1) 3
300
350
400
500
(1) 2
(2) 3
(2) 3
(1) 2-1/2
3
250 PSIG STEAM

NO. OF
OUTLET
VALVES
SIZE (IN.)
REQ'D
1-1/2
1-1/4
(1) 1-1/4
(1) 1
1-1/4
(1) 1
(1) 1-1/4
1-1/2
(1) 1-1/2
(1) 1-1/4
1-1/4
(1) 2
(1) 1-1/2
1-1/2
(1) 1-1/2
(1) 1-1/4
(1) 2
(1) 1-1/2
1-1/2
(1) 2-1/2
(1) 2
2
2
1-1/2
200 PSIG STEAM

NO. OF
OUTLET
VALVES
SIZE (IN.)
REQ'D
(1) 1-1/2
(1) 1-1/4
(1) 1-1/2
(1) 1-1/4
(1) 2-1/2
(1) 2
(1) 2-1/2
(1) 2
2-1/2
(3) 3
(2) 2-1/2
3
2
2-1/2
2
(1) 2-1/2
(1) 2
(3) 3
(2) 2-1/2
700, 800
5
3
2
2-1/2
2
(2) 2-1/2
(1) 2
600
(1) 1-1/2
(1) 2
(1) 1-1/2
(1) 2
2
(1) 2
(1) 2-1/2
2-1/2
A3-19
09-09
Section A3
Table A3-13. Model 4WG Hot Water Relief Valve Outlet Size
NO. OF
OUTLET
BOILER HP
VALVES
REQ'D
SIZE (IN.)
125 PSIG HW
NO. OF
OUTLET
VALVES
REQ'D
SIZE (IN.)
150 PSIG HTHW

NO. OF
OUTLET
VALVES
REQ'D
SIZE (IN.)
100
2-1/2
1-1/4
125
2-1/2
1-1/4
150
2-1/2
200
250
(1) 2
(1) 2-1/2
300
2-1/2
2-1/2
(1) 2-1/2
(1) 1-1/4
(1) 2
(1) 2-1/2
2-1/2
2
(1) 1-1/2
(1) 2
(1) 1-1/2
(1) 2
(2) 2-1/2
(1) 2-1/2
1
2-1/2
2
(1) 1
(1) 3
(1) 2
(1) 2-1/2
400
3
1
2-1/2
2
(2) 2-1/2
(1) 3
(1) 1
(1) 1
500
4
2
2
3
(3) 2-1/2
(1) 2-1/2
(3) 2-1/2
(1) 1-1/4
(2) 3
600
4
2
3
(1) 2
(1) 2-1/2
(1) 2-1/2
(1) 1
(1) 2-1/2
700, 800
5
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
350
Table A3-14. 4WG Recommended Steam Nozzle Size

OPERATING PRESSURE
BOILER HP
PSIG
100
125
150
200
250
300
350
400
500
600
700
15
8
8
8
10
10
12
12
12
12
12
12
30
6
6
6
8
8
8
10
10
10
12
12
40
6
6
6
6
8
8
8
10
10
10
12
50
4
6
6
6
6
8
8
8
10
10
10
75
4
4
4
6
6
6
8
8
8
8
10
100
4
4
4
6
6
6
6
6
8
8
8
125
4
4
4
4
6
6
6
6
8
8
8
150
2.5
3
3
4
4
6
6
6
6
6
8
200
2.5
2.5
3
4
4
4
4
6
6
6
6
250
2
2.5
3
3
4
4
4
4
6
6
6
NOTES:
3. All standard steam nozzle sizes for 150 psig design pressure or greater are the same as 125 psig operating
pressure on the above table. To increase or decrease the standard size, request the change with your local
A3-20
09-09
09-09
800
12
12
12
12
10
10
8
8
6
6
Section A3

Table A3-15. 4WG Recommended Non-Return Valve Size
BOILER HP
100
125
150
200
250
300
350
400
500
600
700
800
BOILER CAPACITY
(LBS/HR)
3450
4313
5175
6900
8625
10350
12025
13800
17210
20700
24150
27600
50
2-1/2
3
3
3*
4
4
4
5
6
6
6
6
75
2-1/2
2-1/2
3
3
3*
4
4
4
5
6
6
6
OPERATING PRESSURE (PSIG)

100
125
150
175
NA
NA
NA
NA
2-1/2
2-1/2
NA
NA
2-1/2
2-1/2
2-1/2
2-1/2
3
3
3
2-1/2
3
3
3
3
4
3*
3
3
4
4
4
3*
4
4
4
4
5
4
4
4
5
5
5
4
6
5
5
5
6
6
6
5
200
NA
NA
NA
2-1/2
3
3
3
4
4
4
5
5
250
NA
NA
NA
2-1/2
3
3
3
3*
4
4
4
5

Standard Non-Return valve selections limited to a maximum 2 to 1 turndown (50% of full load); selections based on typical nonreturn valve sizing recommendations. For final valve selection contact your C-B authorized representative. For high turndown applications see Boiler Book Section I3, Table I3-3.
* Indicates pressure drop of less than 7.5 psig. All other selections are less than 6 psig pressure drop.
Table A3-16. Altitude Correction for Gas

ALTITUDE CORRECTION ALTITUDE CORRECTION
(FT)
FACTOR
(FT)
FACTOR
1000
1.04
6000
1.25
2000
1.07
7000
1.3
3000
1.11
8000
1.35
4000
1.16
9000
1.4
5000
1.21
oz/sq-in x 1.732 = inches WC.
Inches WC x 0.0361 = psig.
oz/sq-in x 0.0625 = psig.
psig x 27.71 = Inches WC.
psig x 16.0 = oz/sq-in.
A3-21
09-09
09-09
Section A3
Table A3-17. Model 4WG, Standard and Low NOx (30 ppm), Minimum Required Gas Pressure at Entrance to
Standard, FM and IRI Gas Trains (Upstream of Gas Pressure Regulator)
BOILER
HP
100
125
150
200
250
300
350
400
500
600
700
800
STD PIPE
SIZE
(Inches)
2
2
2
2.5
2.5
2.5
3
1.5-2
2-2.5
2.5
3
1.5-2.5
2-2.5
2.5
3
2-1.5-2.5
2-2.5
2.5
2.5-3
3
2-3
2.5-3
3
4
2-3
2.5-3
3
4
PRESSURE REQUIRED-STD
("WC)
GPR*
Minimum
Maximum
RV91
9
27.7
RV91
16.6
27.7
RV91
23.2
27.7
210G
20.7
277
210G
29.9
277
210G
40.8
277
210G
42.7
277
S
130
208
S
89
130
S
64
89
S
39
64
S
183
277
S
130
183
S
89
130
S
50
89
S
233
277
S
177
233
S
119
177
S
100
119
S
61
100
S
222
277
S
133
222
S
83
133
S
55
83
S
255
277
S
152
255
S
94
152
S
53
94
PRESSURE REQUIRED-30 PPM

("WC)
GPR*
Minimum Maximum
RV91
12.3
27.7
RV91
21.6
27.7
RV91
21.9
27.7
210G
28.5
277
210G
29
277
210G
39.5
277
210G
40.7
277
S
130
208
S
89
130
S
64
89
S
39
64
S
175
277
S
125
175
S
83
125
S
44
83
S
241
277
S
186
241
S
127
186
S
108
127
S
69
108
S
213
277
S
125
213
S
75
125
S
44
75
S
260
277
S
155
260
S
94
155
S
55
94
NOTE: Where multiple gas train sizes are shown, the shaded row indicates standard size. For altitudes above 700 feet,
contact your local Cleaver-Brooks authorized representative.
* GPR Gas Pressure Regulator
S-Siemens regulating actuator.
A3-22
09-09
09-09
Section A3
Figure A3-8. Typical Fuel Oil Supply Arrangement
A3-23
09-09
Section A3
FRONT
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
1. Shortest boiler room length (Dwg A) is obtained by allowing for possible future tube replacement (from front or rear of boiler)
through a window or doorway. Allowance is only made for minimum door swing at each end of the boiler. This arrangement
provides sufficient aisle space at the front of the boiler but a tight space condition at the rear.
2. Next shortest boiler room length (Dwg B) is obtained by allowing for possible future tube replacement from the front of the
boiler. Allowance is only made for minimum door swing at the rear.
Figure A3-9. Boiler Room Length (Typical Layouts) - Model 4WG

BOILER HP
100-125 150-200 250-300 350-400 500-600 700-800
DIM. "A"
87
91
96
100
105
110
DIM. "B"
120
127
144
151
174
184
NOTES:
1. Recommended Minimum Distance Between Boiler and Wall. Dimension "A" allows for a
"clear" 42" aisle between the water column on the boiler and the wall. If space
permits, this aisle should be widened.
Dimension "B" between boilers allows for a "clear" aisle of:
42" - 100-200 HP
A
B
48" - 250-400 HP
60" - 500-800 HP
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
Figure A3-10. Boiler Room Width (Typical Layouts) - Model 4WG

A3-24
09-09
Section A3
Criterion Model 4WG
SAMPLE SPECIFICATIONS Model 4WG STEAM BOILERS

PART 1
GENERAL
STEAM BOILERS
Cleaver Brooks Criterion Line
1.01
SCOPE
A. The work to be performed consists of providing all labor, equipment, materials, etc. to furnish and
B. Related Sections include the following:
1. Division 15 Section "Chemical Water Treatment" for feedwater treatment and connections.
2. Division 15 Section "Breechings, Chimneys, and Stacks" for connections to breechings,
chimneys, and stacks.
3. Division 15 Sections for control wiring for automatic temperature control.
1.02
REFERENCES
D. Source Quality Control Tests and Inspection Reports: Indicate and interpret test results for compliance
with performance requirements before shipping.
E. Field Test Reports: Indicate and interpret test results for compliance with performance requirements.
F. Maintenance Data: Include in the maintenance manuals specified in Division 1. Include parts list,
maintenance guide, and wiring diagrams for each boiler.
1.
ASME Section (I or IV) (Power boilers or Heating Boilers)
2. ANSI Z21.13 (Gas Fired Low Pressure Boilers)
3. NFPA 54 (ANSI Z221.3) National Fuel Gas Code
4. FACTORY MUTUAL
5. ASME CSD-1 (Controls and Safety Devices)
6. IRI (Industrial Risks Insurance)
7. UBC (Uniform Building Code)
8. UMC (Uniform Mechanical Code)
9. NEC (National Electrical Code)
10. UL (Underwriters Laboratories)
11. NFPA 85
1.03
QUALITY ASSURANCE
A. The equipment shall, as a minimum, be in strict compliance with the requirements of this specification
and shall be the manufacturer's standard commercial product unless specified otherwise. Additional
equipment features, details, accessories, appurtenances, etc. which are not specifically identified but
which are a part of the manufacturer's standard commercial product, shall be included in the equipment
being furnished.
A3-25
09-09
Criterion Model 4WG

B.
C.
D.
E.
Section A3
The equipment shall be of the type, design, and size that the manufacturer currently offered for sale
and appears in the manufacturer's current catalogue. The equipment shall be new and fabricated from
new materials and shall be free from defects in materials and workmanship
The equipment must fit within the allocated space, leaving ample allowance for maintenance and
cleaning, and must leave suitable space for easy removal of all equipment appurtenances. Tube pull
clearance space from either the front or rear of boiler must be maintained.
All units of the same classification shall be identical to the extent necessary to insure
In order to provide unit responsibility for the specified capacities, efficiencies, and performance, the
boiler manufacturer shall certify in writing that the equipment being submitted shall perform as
specified. The boiler manufacturer shall be responsible for guarantying that the boiler provides the
performance as specified herein.
1.04
SUBMITTALS
A. The contractor shall submit, in a timely manner, all submittals for approval by the engineer. Under no
circumstances shall the contractor install any materials until the engineer has made final approval on
the submittals.
modification, or substitution to this specification for evaluation no later than ten (10) days prior to the
bid date. A request for any substitution shall be accompanied by technical data, drawings, product
samples, and complete data substantiating compliance of proposed substitution with these
specifications. No materials shall be deemed acceptable if not in strict and full compliance with these
specifications. All bidders must bid solely on the specified materials unless acceptance by the engineer
of a deviation, omission, modification, or substitution is granted in writing to all bidders prior to the
bid date.
D. Shop Drawings - Shop drawings shall be submitted to the engineer for approval and shall consist of:
3. Schematic wiring diagram of boiler control system of the ladder-type showing all components,
all interlocks, etc. Schematic wiring diagram shall clearly identify factory wiring and field
wiring.
E. Installation Instructions: Manufacturer's printed instructions for installation shall be submitted to the
engineer for approval.
F. Manufacturer's Warranties: Manufacturer's printed warranties, as specified hereinafter, shall be
G. Manufacturer's Field Service: Manufacturer's printed field service procedures and reports, as specified
hereinafter, shall be submitted prior to final acceptance by the engineer. Report forms shall contain all
information as required to do start-up and testing as specified in the products section.
1.05
CERTIFICATIONS
A3-26
09-09
Section A3
Criterion Model 4WG

2.
B.
C.
D.
E.
The boiler, burner and other associated mechanical and electrical equipment have all been
5. The equipment furnished has been installed in accordance with the manufacturer's installation
instructions.
Boiler Inspectors' Certification: All boiler inspections during hydrostatic testing shall be performed by
an authorized boiler inspector who is certified by the National Board of Boiler and Pressure Vessel
Inspectors and shall be submitted in writing prior to final acceptance by the engineer.
Test Reports: Factory and field test reports as described above and as specified hereinafter, shall be
Operation and Maintenance Manuals: Manufacturer's printed operation and maintenance manuals shall
be submitted prior to final acceptance by the engineer. Operation and maintenance manuals shall
contain shop drawings, product data, operating instructions, cleaning procedures, replacement parts
list, maintenance and repair data, complete parts list, etc.
1.06

contractor shall be responsible for unloading and rigging of the equipment. The contractor shall be
responsible for protecting the equipment from the weather, humidity and temperature conditions, dirt,
dust, other contaminants, as well as job site conditions during construction.
B. Equipment shall be unloaded, handled, and stored in accordance with the manufacturer's handling and
storage instructions.
C. The work to be performed consists of providing all labor, equipment, materials, etc. to furnish and
install new factory assembled, low pressure hot water boilers as described in the specifications herein.
PART 2
PRODUCTS
2.01
MANUFACTURERS
A. Contractor shall furnish and install Cleaver Brooks Model 4WG natural gas (combination Gas/Oil
B. Alternate manufacturers complying with plans and specifications must be submitted and approved by
the consulting engineer within 10 days prior to bid date.
2.02
GENERAL DESCRIPTION
Factory packaged unit shall include boiler, burner, heavy duty skids, painted steel jacket with two inches of fiberglass
insulation, controls and accessories all piped and wired for single point field connections. Units shall carry packaged
label of Underwriters Laboratory (UL) and be in accordance with ASME/CSD-1, all codes required by the local
governing authorities and as indicated on the design performance data sheet. A certified factory fire-test shall be
provided on all fuels with data sheets furnished to Engineer and Owner. ASME certified, labeled, stamped and
A3-27
09-09
Criterion Model 4WG
Section A3
designed for PSIG steam in accordance with Section (I or IV) of ASME Code. Unit shall be designed to Seismic
Zone _ requirements and be provided with tie down clips and calculations showing bolt diameter requirements.
Manufacturer's Representative to provide services for field testing and adjusting of boiler and controls to meet design
requirements.
2.03

Manufacturer:
CLEAVER-BROOKS
Model:
Criterion Line
Horsepower:
________HP
Output:
________#/hr (from and at 212F)
Gas Input:
________MB
Oil Input:
________GPH
Design Pressure:
________PSIG
Operating Pressure
________PSIG
________Sq. Inches
________Cu. Ft.
________BTU/Cu. Ft.

No. 2 Oil:
Natural Gas (%):
No. 2 Oil (%):


Gas (Natural):
Oil (No. 2):

Gas (Natural):
Oil (No. 2):

Electrical:
Fan Motor:
Oil Pump Motor:
____ V / ____ H / ____ P

____HP
____HP
____HP
____dBA
____PSIG
A3-28
09-09
Section A3
Criterion Model 4WG

Weight
Dry:
Flooded:
____
____
Seismic Zone:
____
Altitude:
____
Code Requirements:

CSD-1 NFPA 8501
State Of _______
Factory Mutual (FM)
ASL
A.Noise Sound Levels: Based on ABMA test code for packaged boilers measured 41/2 feet vertically above the
bottom of the base rail and 3'0" horizontally in front of the end of the blower motor or front surface of control
cabinet. Sound levels dBA on the scale in reference to 0.0002 microbars.
High Fire#2
#2 oil
____ dBA
Low Fire
#2 oil
____ dBA
High Fire
Nat Gas
____ dBA
Low Fire
Nat Gas
____ dBA
2.04
BOILER DESIGN
A. Four pass steel scotch marine firetube boiler for positive pressurized firing with forced draft burner.
Wet-Back design with a minimum five (5) square feet of heating surface per boiler horsepower. Front
and rear doors shall be davited and sealed with tad-pole gaskets using heavy duty cap screws threaded
into replaceable brass nuts. When opened, doors shall expose all tubes, tubesheets and furnace for ease
of inspection and maintenance. Lifting loops shall be provided. The rear door shall be insulated with a
blanket material and a steel covering to give the surface a hard durable finish.The boiler tubes shall not
include turbulators, swirlers or other add-on appurtenances. The boiler shall be furnished with a
manhole and handholes to facilitate boiler inspection and cleaning.
B. The boiler pressure vessel shall be completely insulated with a minimum of 2" of insulation and shall
be encased in an 18 gauge metal cabinet with primer and finish coat of paint. The entire boiler based
frame and other components shall be factory painted before shipment using a hard finish enamel
coating.
2.05
BURNER DESIGN
A. GENERAL: Forced draft burner of the gun design with hinged access for inspection and service.
Reversed curve fabricated aluminum blower fan; motor(s); single point positioning system consisting
of rotary air damper located on the combustion air intake, straight line linkage and characterized cams;
air flow switch; fuel trains and control panels. To conform to UL and other insurance requirements as
indicated.
A3-29
09-09
Criterion Model 4WG

B.
C.
D.
E.
F.
G.
2.06
Section A3
GAS BURNER: Shall be of the high radiant multi-port type for natural gas. Minimum pilot safety
burner shall consist of gas-electric spark ignition with 100% safety shut-off pilot, solenoid gas valve,
pressure regulator and shut-off cock. Minimum main gas train shall include manual shut-off valve,
pressure regulating valve, dual safety gas valves, manual test valve high-low pressure switches,
manifold pressure gauge and butterfly gas valve with (14) point characterized cam assembly. Gas train
shall be factory packaged to meet insurance requirements as indicated. Gas turn down shall be
minimum 8:1 up to 800 HP.
OIL BURNER Oil burner shall be of the low pressure air atomizing type for No. 2 oil. Minimum pilot
safety burner shall consist of gas-electric spark ignition with 100% safety shut-off pilot, solenoid gas
valve, pressure regulator and shut-off cock. Oil train shall consist of gauges, air purge valve; (14) point
characterized cam assembly; dual oil solenoids; temperature switch, air compressor assembly and oil
pump assembly. Oil train shall be factory packaged to meet insurance requirements as indicated. Oil
turn down shall be minimum 6:1 for #2 Oil and 4:1 for Heavy Oil.
with manual-auto switch on boiler control panel in addition to automatic fuel-air controller. Linkage
system shall be single point positioning with rotary air damper, linkage and (14) point characterized
cam assembly for all fuels. Provide automatic operating control and manual reset high limit.
FORCED DRAFT BLOWER: Backward curved aluminum radial impeller shall be directly connected
to a flanged type ODP motor. The combustion air damper shall be an integral rotating damper and shall
be automatically adjusted for proper air quantity by a mod motor to maintain proper fuel-air ratios.
EMISSION CONTROL: Boiler NOx shall be furnished with guaranteed internal induced NOx control
for 60 PPM (30, 15, <9 PPM NOx systems are optional) corrected to3% 02 over the entire turndown
range. Boiler capacity, turndown, flame stability and efficiency shall not be affected by the internal
NOx control. Low NOx system shall be part of the Boiler/Burner UL package label and manufacture
shall have Twelve (12) years of emission control experience in the state of_____.
BOILER TRIM
3. Auxiliary Low Water Cutoff, (optional)
4. Primary low water cut-off.
8.
Feedwater regulating valve with 3 valve bypass
9.
Low fire hold controller (optional).
12. Feedwater Globe Valve, Size______ ", Class 240# m.
13. 1 Feedwater Check Valve, Size______ ", Class 240# n.
16. 1 Stop Check Valve (Non-Return Valve), Size______ ", Flanged, Cast Iron, Class 250", Straight
Pattern, with Free Blow Drain Valve
A3-30
09-09
Section A3
Criterion Model 4WG

17.
18.
19.
20.
21.
B.
2.07
Factory mounted, installed, tested, and certified piping (by A, S, or PP ASME stamp holder) and
valves per ASME Code, including:
Water Column piping
JHB Modulating Feedwater Control Valve, including 3-Valve Bypass
Oil Pump, Mounted and Wired
Air Atomizing Compressor, Mounted and Wired
Platforms and ladder to access steam header and safety relief valves. Built to OSHA
requirements.
WATER COLUMN/LOW WATER CUTOFF AND WATER LEVEL CONTROL SYSTEM:

McDonnell & Miller 157.
BOILER CONTROLS
enclosure(s) with key lock; fusing, magnetic starters; step-down control transformer; flame safeguard
and burner management system as indicated; annunciator lights for load demand, fuel on, low water
and flame failure; selector switches, required by dry contacts, relays and terminal strips. Oil, heat and
moisture resistant wire with circuit number corresponding to electrical wiring diagrams. In accordance
with UL and National Electric Code.
B. (OPTION 1) BURNER MANAGEMENT SYSTEM (CB 120; standard): Boiler mounted in control
control and supervise burner light off sequence, and initiate an orderly safety procedure in the event of
interlock or flame failure. Dynamic self checking. System to provide pre-post purge status, fault
history, and diagnostic information by means of a two-line alpha-numeric display (optional) with
alarm/status LEDs.
C. (OPTION 2) CB-HAWK ICS Boiler Control System - Integrated Boiler Control and Management
System combining a Digital Burner Management System for flame safety, and a Programmable Logic
Controller for boiler modulation and operator interface functions. The factory pre-configured Boiler
Control System shall integrate the Burner Management functions and the PLC based modulation and
operator interface functions. The logic of the Burner Management System and the modulating controls
will not be run in the same processor or be powered by the same DC supply. The PLC and Operator
Interface Hardware shall be as manufactured by Allen Bradley. Major system components shall
include:
1.
2.
Touch Screen HMI
3.
4.
5.
D. Major functions provided by the Boiler Control System shall be:
1. Automatic sequencing of the boiler through standby, pre-purge, pilot flame establishing period,
main flame establishing period, run, flame proving and lockout and post-purge
2. Full modulating control of fuel and air
A3-31
09-09
Criterion Model 4WG
Section A3
3.
E.
a. Modulating control (algorithm shall be Proportional-lntegral-Derivative (PID) type)
4. Touch Screen graphical operator interface and monitoring
a. Manual control of the boiler firing rate using control screens on the HMI to increment or
decrement the firing rate
d. On screen history of alarms and faults
f.
5. Stack Flue Gas, Combustion Air and Shell (water) temperature indication
1. Examine all load terminals to assure it is capable of recognizing the true status of the external
controls, limits and interlocks. If any input fails this test, the Burner Management System shall
lockout on safety shutdown.
2. Closed-loop logic test of critical loads (ignition, pilot and main fuel valves) and must be able to
lockout on safety.
3. Pre-ignition interlocks (fuel valve proof of closure, etc.) and flame signal checked during
4. Dynamic checking of the flame signal amplifier.
5. Safe start check and expand check to include monitoring flame signal during standby.
6. High and Low fire switches checked for proper sequencing.
7. The Boiler Control System shall provide the ability to communicate with external digital via
Ethernet as a standard. It shall be possible to communicate with any OPC compliant Internet
communications shall be supported, with the Boiler Control System supplied with its own IP
address.
2.08
SHOP TEST
A. Shop test: The complete packaged boiler shall receive factory tests to check construction and function
of all controls. All shop tests may be witnessed by the purchaser at his own c upon sufficient notice to
the company.
2.9
2.10
2.11
2.12
A3-32
09-09
Section A3
Criterion Model 4WG
2.13
ACCESSORIES - 02 TRIM SYSTEM AND/OR
2.14
2.15
MANUFACTURES FIELD SERVICES

A. General: The boiler and accessories supplier shall be responsible for performance of insp up and
testing of the package boiler and accessory equipment and materials furnished under Section. A
detailed written record of the start up performance, including burner setting data entire load range shall
be furnished to the test engineer before test personnel leave the site equipment and test apparatus shall
be furnished by the supplier. All equipment defects discovered by the tests shall be rectified. The
minimum time for two (2) boilers is five (5) days.
B. Equipment inspection: Boiler representative to provide ______hours of job site assistance to i boilers
and other equipment upon arrival, verifying completeness of equipment supplied ar damages.
Responsibility of making freight claims to be performed by contractor or owner personnel.
C. Pre start-up walk through: Boiler representative shall spend _____ hours at job site reviewing with
mechanical contractor to be conducted approximately 1 week prior to startup.
1. Demonstrate that boiler, burner, controls and accessories comply with requirement Section as
proposed by the boiler and accessories supplier. Pre-test all items prior to scheduling the final
testing that will be witnessed by the test engineer.
2. Readings at different firing rates (25, 50, 75 and 100%) of load for the modulating burner shall be
taken with a written report of the tests submitted to the test engineer. The reports shall include
readings for each firing rate tested and include stack temperatures, O2, CO, Nox and overall
boiler efficiency.
3. Auxiliary Equipment and Accessories: Observe and check all valves, draft fans, electric motors
and other accessories and appurtenant equipment during the operational and capacity tests for
leakage, malfunctioning, defects, and non compliance with referenced standards or overloading
as applicable.
f.
Check all safeties, including: Flame safeguard, LWCO, ALWCO, Air flow, Fuel pressures,
High limits
i.
j.
Set up and verify Emissions Compliance
5. Training to include all safety procedures, maintenance procedures, control operations, and
diagnostic procedures. Training to be provided in a single _ hour continuous session to
6. Special tool / safety equipment:
a. Boiler/burner supplier to include in their proposal safety equipment required to perform
annual inspections and maintenance per OSHA requirements, Section 29CFR,1910.146,
A3-33
09-09
Criterion Model 4WG
b.
Section A3
date 4115193, Paragraphs 5.6.4.2 through 5.6.6.6 confined space requirements on rear
furnace and flue gas turnaround area. Items to include respirator, tag out devices,
atmospheric tester, acid suit, harness, wrist straps, life wire, and safety belt
Special Safety Training on safety procedures by a qualified trainer to be provided per
OSHA Section 1910.146, Paragraph 5.6.5.2, to all owners and employees who are operating
specified equipment. The cost of training to be included in boiler supplier's proposal
2.16

A. Provide two (2) Operating and Maintenance manuals including cut-away views of boiler and burner,
schematics including fuel trains, general instructions for maintenance and inspections, complete spare
parts lists and trouble shooting procedures. Operating and maintenance manuals shall be provided
including cut-away views of boiler and burner schematics including fuel trains, general instructions for
maintenance and inspections, complete spare parts lists and trouble shooting procedures.
2.17
WARRANTY DATA
A. The entire boiler/burner package shall be guaranteed and warranted by the boiler manufacturer.
PART 3
EXECUTION
3.01
GENERAL
A. Installation shall be provided by the contractor in accordance with the requirements of the codes
3.02
INSTALLATION
A. Install equipment in strict compliance with manufacturer's installation instructions.ww
B. Install equipment in strict compliance with state and local codes and applicable NFPA standards.
C. Maintain manufacturer's recommended clearances around sides and over top of equipment.
D. Install components that were removed from equipment for shipping purposes.
E. Install components that were furnished loose with equipment for field installation.
F. Provide all interconnecting electrical control and power wiring.
3.03
FIELD TESTING
controllers, gauges, thermometers, pilot lights, switches, etc. Any malfunctioning component shall be
replaced.
B. All adjustments to boiler, burner, and boiler control system shall be performed by the manufacturer's
representative.
A3-34
09-09
Section A3
Criterion Model 4WG
3.04
The manufacturer's representative shall provide start-up and instruction of each new boiler, including burner and
boiler control system as specified herein. Start-up and instruction shall cover all components assembled and
furnished by the manufacturer whether or not of his own manufacture.
A3-35
09-09
Criterion Model 4WG
Section A3
A3-36
09-09
Section A3
Criterion Model 4WG
SAMPLE SPECIFICATIONS Model 4WG HOT WATER BOILERS

PART 1
GENERAL
HOT WATER
Cleaver Brooks Criterion Line
1.01
SCOPE
A. The work to be performed consists of providing all labor, equipment, materials, etc. to furnish and
1. Division 15 Section "Chemical Water Treatment" for feedwater treatment and connections.
2. Division 15 Section "Breechings, Chimneys, and Stacks" for connections to breechings,
chimneys, and stacks.
3. Division 15 Sections for control wiring for automatic temperature control.
1.02
REFERENCES
D. Source Quality Control Tests and Inspection Reports: Indicate and interpret test results for compliance
with performance requirements before shipping.
E. Field Test Reports: Indicate and interpret test results for compliance with performance requirements.
F. Maintenance Data: Include in the maintenance manuals specified in Division 1. Include parts list,
maintenance guide, and wiring diagrams for each boiler.
1.
ASME Section (I or IV) (Power boilers or Heating Boilers)
2. ANSI Z21.13 (Gas Fired Low Pressure Boilers)
3. NFPA 54 (ANSI Z221.3) National Fuel Gas Code
4. FACTORY MUTUAL
5. ASME CSD-1 (Controls and Safety Devices)
6. IRI (Industrial Risks Insurance)
7. UBC (Uniform Building Code)
8. UMC (Uniform Mechanical Code)
9. NEC (National Electrical Code)
10. UL (Underwriters Laboratories)
11. NFPA 85
1.03
QUALITY ASSURANCE
A. The equipment shall, as a minimum, be in strict compliance with the requirements of this specification
and shall be the manufacturer's standard commercial product unless specified otherwise. Additional
equipment features, details, accessories, appurtenances, etc. which are not specifically identified but
which are a part of the manufacturer's standard commercial product, shall be included in the equipment
being furnished.
A3-37
09-09
Criterion Model 4WG

B.
C.
D.
E.
Section A3
The equipment shall be of the type, design, and size that the manufacturer currently offered for sale
and appears in the manufacturer's current catalogue. The equipment shall be new and fabricated from
new materials and shall be free from defects in materials and workmanship
The equipment must fit within the allocated space, leaving ample allowance for maintenance and
cleaning, and must leave suitable space for easy removal of all equipment appurtenances. Tube pull
clearance space from either the front or rear of boiler must be maintained.
All units of the same classification shall be identical to the extent necessary to insure
In order to provide unit responsibility for the specified capacities, efficiencies, and performance, the
boiler manufacturer shall certify in writing that the equipment being submitted shall perform as
specified. The boiler manufacturer shall be responsible for guarantying that the boiler provides the
performance as specified herein.
1.04
SUBMITTALS
A. The contractor shall submit, in a timely manner, all submittals for approval by the engineer. Under no
circumstances shall the contractor install any materials until the engineer has made final approval on
the submittals.
modification, or substitution to this specification for evaluation no later than ten (10) days prior to the
bid date. A request for any substitution shall be accompanied by technical data, drawings, product
samples, and complete data substantiating compliance of proposed substitution with these
specifications. No materials shall be deemed acceptable if not in strict and full compliance with these
specifications. All bidders must bid solely on the specified materials unless acceptance by the engineer
of a deviation, omission, modification, or substitution is granted in writing to all bidders prior to the
bid date.
D. Shop Drawings - Shop drawings shall be submitted to the engineer for approval and shall consist of:
3. Schematic wiring diagram of boiler control system of the ladder-type showing all components,
all interlocks, etc. Schematic wiring diagram shall clearly identify factory wiring and field
wiring.
E. Installation Instructions: Manufacturer's printed instructions for installation shall be submitted to the
engineer for approval.
F. Manufacturer's Warranties: Manufacturer's printed warranties, as specified hereinafter, shall be
G. Manufacturer's Field Service: Manufacturer's printed field service procedures and reports, as specified
hereinafter, shall be submitted prior to final acceptance by the engineer. Report forms shall contain all
information as required to do start-up and testing as specified in the products section.
1.05
CERTIFICATIONS
A3-38
09-09
Section A3
Criterion Model 4WG

2.
B.
C.
D.
E.
The boiler, burner and other associated mechanical and electrical equipment have all been
5. The equipment furnished has been installed in accordance with the manufacturer's installation
instructions.
Boiler Inspectors' Certification: All boiler inspections during hydrostatic testing shall be performed by
an authorized boiler inspector who is certified by the National Board of Boiler and Pressure Vessel
Inspectors and shall be submitted in writing prior to final acceptance by the engineer.
Test Reports: Factory and field test reports as described above and as specified hereinafter, shall be
Operation and Maintenance Manuals: Manufacturer's printed operation and maintenance manuals shall
be submitted prior to final acceptance by the engineer. Operation and maintenance manuals shall
contain shop drawings, product data, operating instructions, cleaning procedures, replacement parts
list, maintenance and repair data, complete parts list, etc.
1.06

contractor shall be responsible for unloading and rigging of the equipment. The contractor shall be
responsible for protecting the equipment from the weather, humidity and temperature conditions, dirt,
dust, other contaminants, as well as job site conditions during construction.
B. Equipment shall be unloaded, handled, and stored in accordance with the manufacturer's handling and
storage instructions.
C. The work to be performed consists of providing all labor, equipment, materials, etc. to furnish and
install new factory assembled, low pressure hot water boilers as described in the specifications herein.
PART 2
PRODUCTS
2.01
MANUFACTURERS
A. Contractor shall furnish and install Cleaver Brooks Model 4WG natural gas (combination Gas/Oil
B. Alternate manufacturers complying with plans and specifications must be submitted and approved by
the consulting engineer within 10 days prior to bid date.
2.02
GENERAL DESCRIPTION
Factory packaged unit shall include boiler, burner, heavy duty skids, painted steel jacket with two inches of fiberglass
insulation, controls and accessories all piped and wired for single point field connections. Units shall carry packaged
label of Underwriters Laboratory (UL) and be in accordance with ASME/CSD-1, all codes required by the local
governing authorities and as indicated on the design performance data sheet. A certified factory fire-test shall be
provided on all fuels with data sheets furnished to Engineer and Owner. ASME certified, labeled, stamped and
A3-39
09-09
Criterion Model 4WG
Section A3
designed for PSIG steam in accordance with Section (I or IV) of ASME Code. Unit shall be designed to Seismic
Zone _ requirements and be provided with tie down clips and calculations showing bolt diameter requirements.
Manufacturer's Representative to provide services for field testing and adjusting of boiler and controls to meet design
requirements.
2.03

Manufacturer:
CLEAVER-BROOKS
Model:
Criterion Line
Horsepower:
________HP
Output:
________#/hr (from and at 212F
Gas Input:
________MB
Oil Input:
________GPH
Design Pressure:
________PSIG
Operating Pressure
________PSIG
________Sq. Inches
________Cu. Ft.
________BTU/Cu. Ft.

No. 2 Oil:
Natural Gas (%):
No. 2 Oil (%):


Gas (Natural):
Oil (No. 2):

Gas (Natural):
Oil (No. 2):

Electrical:
Fan Motor: Air Compressor Motor:
Oil Pump Motor:
____ V / ____ H / ____ P

____HP
____HP
____dBA
____PSIG
Weight
Dry:
Flooded:
____
____
A3-40
09-09
Section A3
Criterion Model 4WG

Seismic Zone:
____
Altitude:
____
Code Requirements:

CSD-1 NFPA 8501
State Of _______
Factory Mutual (FM)
ASL
A.Noise Sound Levels: Based on ABMA test code for packaged boilers measured 41/2 feet vertically above the
bottom of the base rail and 3'0" horizontally in front of the end of the blower motor or front surface of control
cabinet. Sound levels dBA on the scale in reference to 0.0002 microbars.
High Fire#2
#2 oil
____ dBA
Low Fire
#2 oil
____ dBA
High Fire
Nat Gas
____ dBA
Low Fire
Nat Gas
____ dBA
2.04
BOILER DESIGN
A. Four pass steel scotch marine firetube boiler for positive pressurized firing with forced draft burner.
Wet back design with a minimum five (5) square feet of heating surface per boiler horsepower. Front
and rear doors shall be davited and sealed with tad-pole gaskets using heavy duty cap screws threaded
into replaceable brass nuts. When opened, doors shall expose all tubes, tubesheets and furnace for ease
of inspection and maintenance. Lifting loops shall be provided. The rear door shall be insulated with a
blanket material and a steel covering to give the surface a hard durable finish.The boiler tubes shall not
include turbulators, swirlers or other add-on appurtenances. The boiler shall be furnished with a
manhole and handholes to facilitate boiler inspection and cleaning.
B. The boiler pressure vessel shall be completely insulated with a minimum of 2" of insulation and shall
be encased in an 18 gauge metal cabinet with primer and finish coat of paint. The entire boiler based
frame and other components shall be factory painted before shipment using a hard finish enamel
coating.
2.05
BURNER DESIGN
A. GENERAL: Forced draft burner of the gun design with hinged access for inspection and service.
Reversed curve fabricated aluminum blower fan; motor(s); single point positioning system consisting
of rotary air damper located on the combustion air intake, straight line linkage and characterized cams;
air flow switch; fuel trains and control panels. To conform to UL and other insurance requirements as
indicated.
A3-41
09-09
Criterion Model 4WG

B.
C.
D.
E.
F.
G.
2.06
Section A3
GAS BURNER: Shall be of the high radiant multi-port type for natural gas. Minimum pilot safety
burner shall consist of gas-electric spark ignition with 100% safety shut-off pilot, solenoid gas valve,
pressure regulator and shut-off cock. Minimum main gas train shall include manual shut-off valve,
pressure regulating valve, dual safety gas valves, manual test valve high-low pressure switches,
manifold pressure gauge and butterfly gas valve with (14) point characterized cam assembly. Gas train
shall be factory packaged to meet insurance requirements as indicated. Gas turn down shall be
minimum 8:1 up to 800 HP.
OIL BURNER Oil burner shall be of the low pressure air atomizing type for No. 2 oil. Minimum pilot
safety burner shall consist of gas-electric spark ignition with 100% safety shut-off pilot, solenoid gas
valve, pressure regulator and shut-off cock. Oil train shall consist of gauges, air purge valve; (14) point
characterized cam assembly; dual oil solenoids; temperature switch, air compressor assembly and oil
pump assembly. Oil train shall be factory packaged to meet insurance requirements as indicated. Oil
turn down shall be minimum 6:1 for #2 Oil and 4:1 for Heavy Oil.
with manual-auto switch on boiler control panel in addition to automatic fuel-air controller. Linkage
system shall be Cleaver-Brooks single point positioning with rotary air damper, linkage and (14) point
characterized cam assembly for all fuels. Provide automatic operating control and manual reset high
limit.
FORCED DRAFT BLOWER: The Backward curved aluminum radial impeller shall be directly
connected to a flanged type ODP motor. This rigid mounting shall eliminate vibration and reduce noise
level. The balanced blower wheel shall be aluminum with radial blades. The combustion air damper
shall be an integral rotating damper and shall be automatically adjusted for proper air quantity by a
mod motor to maintain proper fuel-air ratios.
EMISSION CONTROL: Boiler NOx shall be furnished with guaranteed internal induced NOx control
for 60 PPM (30, 25, 20 PPM NOx systems are optional) corrected to3% 02 over the entire turndown
range. Boiler capacity, turndown, flame stability and efficiency shall not be affected by the internal
NOx control. Low NOx system shall be part of the Boiler/Burner UL package label and manufacture
shall have Twelve (12) years of emission control experience in the state of_____.
BOILER TRIM
1. ______" diameter temperature gauge.
4. Low water cutoff McD-M No. PS-750 MT-120
8.
Feedwater regulating valve with 3 valve bypass
9.
Low fire hold controller (optional).
12. Feedwater Globe Valve, Size______ ", Class 240# m.
13. 1 Feedwater Check Valve, Size______ ", Class 240# n.
A3-42
09-09
Section A3
Criterion Model 4WG

16. 1 Stop Check Valve (Non-Return Valve), Size______ ", Flanged, Cast Iron, Class 250", Straight
Pattern, with Free Blow Drain Valve
17. Factory mounted, installed, tested, and certified piping (by A, S, or PP ASME stamp holder) and
valves per ASME Code, including:
Water Column piping
18. JHB Modulating Feedwater Control Valve, including 3-Valve Bypass
19. Oil Pump, Mounted and Wired
20. Air Atomizing Compressor, Mounted and Wired
21. Platforms and ladder to access safety relief valves. Built to OSHA requirements.
2.07
BOILER CONTROLS
enclosure(s) with key lock; fusing, magnetic starters; step-down control transformer; flame safeguard
and burner management system as indicated; annunciator lights for load demand, fuel on, low water
and flame failure; selector switches, required by dry contacts, relays and terminal strips. Oil, heat and
moisture resistant wire with circuit number corresponding to electrical wiring diagrams. In accordance
with UL and National Electric Code.
B. (OPTION 1) BURNER MANAGEMENT SYSTEM (CB 780-Standard): Boiler mounted in control
control and supervise burner light off sequence, and initiate an orderly safety procedure in the event of
interlock or flame failure. Dynamic self checking. System to provide pre-post purge status, fault
history, and diagnostic information by means of a two-line alpha-numeric display with alarm/status
LEDS.
C. (OPTION 2) CB-HAWK ICS Boiler Control System (Optional upgrade): Burner Management System
(CB HAWK ICS - optional upgrade): Integrated Boiler Control and Management System:
Management System for flame safety, and a Programmable Logic Controller for boiler modulation and
operator interface functions.
The factory pre-configured Boiler Control System shall integrate the Burner Management functions
and the PLC based modulation and operator interface functions. The logic of the Burner Management
System and the modulating controls will not be run in the same processor or powered by the same DC
supply. The PLC and Operator Interface Hardware shall be as manufactured by Allen Bradley.
D.

1. Programmable Logic Controller
2.
Touch Screen HMI
3.
4.
5.
1. Automatic sequencing of the boiler through standby, pre-purge, pilot flame establishing period,
main flame establishing period, run, flame proving and lockout and post-purge
2. Full modulating control of fuel and air
A3-43
09-09
Criterion Model 4WG
Section A3
3.
E.
a. Modulating control (algorithm shall be Proportional-lntegral-Derivative (PID) type)
4. Touch Screen graphical operator interface and monitoring
a. Manual control of the boiler firing rate using control screens on the HMI to increment or
decrement the firing rate
d. o On screen history of alarms and faults
f.
5. Stack Flue Gas, Combustion Air and Shell (water) temperature indication
1. Examine all load terminals to assure it is capable of recognizing the true status of the external
controls, limits and interlocks. If any input fails this test, the Burner Management System shall
lockout on safety shutdown.
2. Closed-loop logic test of critical loads (ignition, pilot and main fuel valves) and must be able to
lockout on safety.
3. Pre-ignition interlocks (fuel valve proof of closure, etc.) and flame signal checked during
4. Dynamic checking of the flame signal amplifier.
5. Safe start check and expand check to include monitoring flame signal during standby.
6. High and Low fire switches checked for proper sequencing.
7. The Boiler Control System shall provide the ability to communicate with external digital via
Ethernet as a standard. It shall be possible to communicate with any OPC compliant Internet
communications shall be supported, with the Boiler Control System supplied with its own IP
address.
2.08
SHOP TEST
A. Shop test: The complete packaged boiler shall receive factory tests to check construction and function
of all controls. All shop tests may be witnessed by the purchaser at his own c upon sufficient notice to
the company.
2.9
2.10
2.11
2.12
A3-44
09-09
Section A3
Criterion Model 4WG
2.13
ACCESSORIES - 02 TRIM SYSTEM AND/OR
2.14
2.15
MANUFACTURES FIELD SERVICES

A. General: The boiler and accessories supplier shall be responsible for performance of insp up and
testing of the package boiler and accessory equipment and materials furnished un~ Section. A detailed
written record of the start up performance, including burner setting dat entire load range shall be
furnished to the test engineer before test personnel leave the sit equipment and test apparatus shall be
furnished by the supplier. All equipment defects discovered by the tests shall be rectified. The
minimum time for two (2) boilers is five (5) days.
B. Equipment inspection: Boiler representative to provide ______hours of job site assistance to i boilers
and other equipment upon arrival, verifying completeness of equipment supplied ar damages.
Responsibility of making freight claims to be performed by contractor or owner personnel.
C. Pre start-up walk through: Boiler representative shall spend _____ hours at job site reviewing with
mechanical contractor to be conducted approximately 1 week prior to startup.
1. Demonstrate that boiler, burner, controls and accessories comply with requirement Section as
proposed by the boiler and accessories supplier. Pre-test all items prior to scheduling the final
testing that will be witnessed by the test engineer.
2. Readings at different firing rates (25, 50, 75 and 100%) of load for the modulating burner shall be
taken with a written report of the tests submitted to the test engineer. The reports shall include
readings for each firing rate tested and include stack temperatures, O2, CO, Nox and overall
boiler efficiency.
3. Auxiliary Equipment and Accessories: Observe and check all valves, draft fans, electric motors
and other accessories and appurtenant equipment during the operational and capacity tests for
leakage, malfunctioning, defects, and non compliance with referenced standards or overloading
as applicable.
f.
Check all safeties, including: Flame safeguard, LWCO, ALWCO, Air flow, Fuel pressures,
High limits
i.
j.
Set up and verify Emissions Compliance
5. Training to include all safety procedures, maintenance procedures, control operations, and
diagnostic procedures. Training to be provided in a single _ hour continuous session to
6. Special tool / safety equipment:
a. Boiler/burner supplier to include in their proposal safety equipment required to perform
annual inspections and maintenance per OSHA requirements, Section 29CFR,1910.146,
A3-45
09-09
Criterion Model 4WG
b.
Section A3
date 4115193, Paragraphs 5.6.4.2 through 5.6.6.6 confined space requirements on rear
furnace and flue gas turnaround area. Items to include respirator, tag out devices,
atmospheric tester, acid suit, harness, wrist straps, life wire, and safety belt
Special Safety Training on safety procedures by a qualified trainer to be provided per
OSHA Section 1910.146, Paragraph 5.6.5.2, to all owners and employees who are operating
specified equipment. The cost of training to be included in boiler supplier's proposal
2.16

A. Provide two (2) Operating and Maintenance manuals including cut-away views of boiler and burner,
schematics including fuel trains, general instructions for maintenance and inspections, complete spare
parts lists and trouble shooting procedures. Operating and maintenance manuals shall be provided
including cut-away views of boiler and burner schematics including fuel trains, general instructions for
maintenance and inspections, complete spare parts lists and trouble shooting procedures.
2.17
WARRANTY DATA
A. The entire boiler/burner package shall be guaranteed and warranted by the boiler manufacturer.
PART 3
EXECUTION
3.01
GENERAL
A. Installation shall be provided by the contractor in accordance with the requirements of the codes
3.02
INSTALLATION
A.
B.
C.
D.
E.
F.
G.
H.
3.03
Install equipment in strict compliance with manufacturer's installation instructions.ww

Install equipment in strict compliance with state and local codes and applicable NFPA standards.
Maintain manufacturer's recommended clearances around sides and over top of equipment.
Install components that were removed from equipment for shipping purposes.
Install components that were furnished loose with equipment for field installation.
Provide all fuel gas vent and service piping.
Provide all piping for boiler pipe connections.
FIELD TESTING
controllers, gauges, thermometers, pilot lights, switches, etc. Any malfunctioning component shall be
replaced.
A3-46
09-09
Section A3
B.
Criterion Model 4WG

All adjustments to boiler, burner, and boiler control system shall be performed by the manufacturer's
representative.
3.04
The manufacturer's representative shall provide start-up and instruction of each new boiler, including burner and
boiler control system as specified herein. Start-up and instruction shall cover all components assembled and
furnished by the manufacturer whether or not of his own manufacture.
A3-47
09-09
Criterion Model 4WG
Section A3
A3-48
09-09
Section A4
Criterion Series Model ICB 100-800 HP
Table of Contents
Four-Pass Intercooled Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-3
Three-Pass Intercooled Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-3
Intercooled Rear Turnaround . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-3
Front and Rear Doors: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-3
Natural Gas, No. 2 Oil, or Combination Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-3
Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-19
Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-19
Fuel Connections Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-19
Fuel Connections Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-19
Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-20
Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-20
Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-21
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-29
A4-1
09-09
Section A4
ILLUSTRATIONS
Figure A4-1. Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional) . . . . . . . . . . . . . A4-9
Figure A4-2. Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional) . . . . . . . . . . A4-11
Figure A4-3. Model ICB-LE Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional) . . . . . . . . . . . A4-13
Figure A4-4. Model ICB-LE Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional) . . . . . . . . A4-15
Figure A4-5. Space Required to Open Rear Head on Model ICB Boilers . . . . . . . . . . . . . . . . . . . . A4-17
Figure A4-6. Model ICB Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-17
Figure A4-7. Model ICB Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-18
Figure A4-8. Typical Fuel Oil Supply Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-27
Figure A4-9. Boiler Room Length (Typical Layouts) Model ICB . . . . . . . . . . . . . . . . . . . . . . . . A4-28
Figure A4-10. Boiler Room Width (Typical Layout) Model ICB . . . . . . . . . . . . . . . . . . . . . . . . A4-28
TABLES
Table A4-1. Model ICB Steam Boiler Ratings, 4-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-5

Table A4-2. Model ICB Steam Boiler Ratings, 3-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-5
Table A4-3. Model ICB Hot Water Boiler Ratings, 4-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-6
Table A4-4. Model ICB Hot Water Boiler Ratings, 3-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-6
Table A4-5. Model ICB-LE Steam Boiler Ratings, 4 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-7
Table A4-6. Model ICB-LE Steam Boiler Ratings, 3 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-7
Table A4-7. Model ICB-LE Hot Water Ratings, 4 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-8
Table A4-8. Model ICB-LE Hot Water Ratings, 3 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-8
Table A4-9. Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass . . . . . . . . . . . . . . . . . . . . . A4-10
Table A4-10. Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass . . . . . . . . . . . . . . . . . A4-12
Table A4-11. Model ICB-LE Steam Boiler Dimensions, 4-Pass and 3-Pass . . . . . . . . . . . . . . . . . . A4-14
Table A4-12. Model ICB-LE Hot Water Boiler Dimensions, 4-Pass and 3-Pass . . . . . . . . . . . . . . . A4-16
Table A4-13. Model ICB Steam Volume and Disengaging Areas . . . . . . . . . . . . . . . . . . . . . . . . . A4-21
Table A4-14. Model ICB Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . A4-22
Table A4-15. Model ICB Hot Water Boiler Relief Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . A4-22
Table A4-16. Model ICB Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-23
Table A4-17. Model ICB Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . A4-23
Table A4-18. Model ICB Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-24
Table A4-19. Altitude Correction for Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-24
Table A4-20. Sound Levels in dBA for 4-Pass ICB Boilers at High Fire . . . . . . . . . . . . . . . . . . . . A4-24
Table A4-21. Model ICB, Standard, Min. Req. Gas Pressure Standard, FM & IRI Gas Trains . . . . . A4-25
Table A4-22. Model ICB, Low NOx, Min. Req. Gas Pressure Standard, FM & IRI Gas Trains . . . . . . A4-26
The following information applies to the Cleaver-Brooks Model ICB Boiler.
A4-2
09-09
Section A4

The Cleaver-Brooks Model ICB Boiler line provides a quality product utilizing a
baseline boiler/burner design. Additionally, the boiler/burner package is UL
compliant. The following features apply:
Four-Pass
Intercooled Design:
Four-pass design provides high flue gas velocities and low stack temperatures to
maximize efficiency.
Three-Pass
Intercooled Design
(optional):
Versatile design offered with choice of three or four-pass construction to meet

application needs.
Intercooled Rear
Turnaround:
Rear furnace turnaround area is fluid cooled and has a davited access opening
for full accessibility to 2nd pass tubes and furnace. It eliminates confined space
issues and provides for ease of maintenance. All tubes can be removed from
either the front or rear of the boiler.
Front and Rear

Doors:
Davit, front and rear doors, all sizes.
Provides access to front and rear tube sheet.

adjustment.
Ultra low NOx emissions (<9ppm), consult factory.
Natural Gas, No. 2

Oil, or Combination
Burners Available:
PRODUCT OFFERING
Cleaver-Brooks Model ICB Boilers are available in low pressure steam, high pressure
steam, and hot water designs. Burners are available to fire natural gas, No. 2 oil, or
a combination of oil and gas. Standard product offering is:
100 800 hp.
15 300 psig steam.
Available options include the following (contact your local Cleaver-Brooks

Authorized Representative for option details).
Boiler Options:
Three-pass design.
Drain valves.
Additional screwed or flanged tappings.
Blowdown valves.
Non-return valves.
Blend pump.
Surge load baffles.
Seismic design.
A4-3
09-09
Section A4
Lead/lag system.
High altitude design.
Elapsed time meter.
NEMA enclosures.
Circuit breakers.
Day/night controls.
Stack thermometer.
Fuel Options
Air atomizing oil burner, 200 800 hp.
Pressure atomizing oil burner, 100 150 hp.
Gas strainer.
Gas pressure gauge.

Dimensions and ratings for the Model ICB Boilers are shown in the following tables
and illustrations. The information is subject to change without notice.
Table A4-1 Model ICB Steam Boiler Ratings, 4-Pass
Table A4-2 Model ICB Steam Boiler Ratings, 3-Pass (Optional)
Table A4-3 Model ICB Hot Water Boiler Ratings, 4-Pass
Table A4-4 Model ICB Hot Water Boiler Ratings, 3-Pass (Optional)
Figure A4-1 Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional)
Table A4-9 Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional)
Figure A4-6 Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass
(Optional)
Table A4-10 Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass
(Optional)
Figure A4-5 Space Required to Open Rear Head on Model ICB Boilers
Figure A4-6 Model ICB Boilers Lifting Lug Location
Figure A4-7 Model ICB Boiler Mounting Piers
A4-4
09-09
Section A4

Table A4-1. Model ICB Steam Boiler Ratings, 4-Pass
BOILER H.P.
BURNER MODEL Model ICB
100
125
150
200
250
300
350
400
500
600
700
800
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

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
7-1/2
7-1/2
7-1/2
15
20
25
30
40
60
60
Separate Compressor Motor hp (Oil only)
**
**
**
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
15
Oil Metering Pump Motor hp (Oil only)
1/2
3/4
3/4
3/4
3/4
1/2
1/2
3/4
3/4
3/4
3/4
3/4
353
438
555
729
885
1055
1384
1522
1734
2094
3244
3641
Circulating Oil Pump Motor hp (Oil only)

BOILER DATA
Heating Surface sq.-ft. (Fireside)
* = Integral oil pump

** = No air compressor required (pressure atomized system)
NOTE: All fractional hp motors will be single phase voltage except oil metering pump motor (3-phase); integral motors will be 3-phase voltage.
Table A4-2. Model ICB Steam Boiler Ratings, 3-Pass

BOILER H.P.
100
125
150
200
250
300
350
400
500
600
700
800
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
3348
4184
5021
6695
8369
10043
11716
13390
16738
20085
23433
26780

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
7-1/2
7-1/2
10
10
20
25
30
40
60
**
**
**
7-1/2
7-1/2
7-1/2
1/2
3/4
3/4
3/4
3/4
1/2
1/2
3/4
3/4
3/4
3/4
3/4
353
438
555
729
885
1055
1384
1522
1734
2094
3244
3641

BOILER DATA

A4-5
09-09
Section A4
Table A4-3. Model ICB Hot Water Boiler Ratings, 4-Pass

BOILER H.P.
100
125
150
200
250
300
350
400
500
600
700
800
FP-3
FP-3
FP-3
FP-4
FP-4
D145P
D175P
D210P
D252P
D300P
D336P
D378P
3348
4184
5021
6695
8369
10043
11716
13390
16738
20085
23433
26780


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
7-1/2
7-1/2
7-1/2
15
20
25
30
40
60
60
**
**
**
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
15
1/2
3/4
3/4
3/4
3/4
1/2
1/2
3/4
3/4
3/4
3/4
3/4
353
438
555
729
885
1055
1384
1522
1734
2094
3244
3641

BOILER DATA

Table A4-4. Model ICB Hot Water Boiler Ratings, 3-Pass

BOILER H.P.
100
125
150
200
250
300
350
400
500
600
700
800
FP-3
FP-3
FP-3
FP-4
FP-4
FP-4
FP-4
D175P
D210P
D252P
D300P
D336P
3348
4184
5021
6695
8369
10043
11716
13390
16738
20085
23433
26780


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
7-1/2
7-1/2
10
10
20
25
30
40
60
**
**
**
7-1/2
7-1/2
7-1/2
1/2
3/4
3/4
3/4
3/4
1/2
1/2
3/4
3/4
3/4
3/4
3/4
353
438
555
729
885
1055
1384
1522
1734
2094
3244
3641

BOILER DATA

A4-6
09-09
Section A4
Table A4-5. Model ICB-LE Steam Boiler Ratings, 4 Pass

BOILER H.P.
100
BURNER MODEL
LND54P

0
from and at 212 F)

125
150
200
250
300
350
400
500
600
700
800
LND84P LND105P LND125P LND145P LND175P LND210P LND252P LND300P LND315P LND378P LND420P
3450
4313
5175
6900
8625
10350
12075
13800
17250
20700
24150
27600
3348
4184
5021
6695
8369
10043
11716
13390
16738
20085
23433
26780
29.2
4082
40.8

Gas CFH (1000 Btu)
Gas (Therm/hr)
36.4
5103
51.0
43.7
6124
61.2
58.3
8165
81.7
72.9
10206
102.1
87.5
12247
122.5
102.1
14280
142.8
116.6
16329
163.3
145.8
20415
204.2
175.0
24494
245.0
204.1
28576
285.8
233.3
32659
326.6

Blower Motor hp
Separate Compressor Motor hp
(Oil only)
Integral Oil/Air Motor hp
(Oil only)
(Oil only)
(Oil only)
7 1/2
10
15
15
20
25
30
40
60
60
60
7 1/2
7 1/2
7 1/2
15
15
1/2
3/4
3/4
3/4
3/4
1/2
1/2
1/2
1/2
1/2
3/4
3/4
3/4
3/4
3/4
353
438
555
729
885
1055
1384
1522
1734
2094
3244
3641
600
700
800
BOILER DATA
Table A4-6. Model ICB-LE Steam Boiler Ratings, 3 Pass

BOILER H.P.
100
125
BURNER MODEL
LND54P
LND63P

0
from and at 212 F)

150
200
250
300
350
400
500
LND84P LND105P LND145S LND145P LND175P LND210P LND252P LND300P LND315P LND378P
3450
4313
5175
6900
8625
10350
12075
13800
17250
20700
24150
27600
3348
4184
5021
6695
8369
10043
11716
13390
16738
20085
23433
26780

Gas CFH (1000 Btu)
Gas (Therm/hr)
29.9
4184
41.8
37.5
5230
52.3
45.0
6280
62.8
60.0
8370
83.7
74.5
10460
104.6
89.5
12555
125.5
104.5
14650
146.5
119.5
16750
167.5
149.5
20925
209.3
179.5
25100
251.0
209
29300
293.0
239
33500
335.0

Blower Motor hp
Separate Compressor Motor hp
(Oil only)
(Oil only)
(Oil only)
(Oil only)
7 1/2
10
15
15
20
25
30
40
60
60
7 1/2
7 1/2
7 1/2
15
1/2
3/4
3/4
3/4
3/4
1/2
1/2
1/2
1/2
1/2
3/4
3/4
3/4
3/4
3/4
353
438
555
729
885
1055
1384
1522
1734
2094
3244
3641
BOILER DATA
A4-7
09-09
Section A4
Table A4-7. Model ICB-LE Hot Water Ratings, 4 Pass

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
3348
4184
5021
6695
8369
10043
11716
13390
16738
20085
23433
26780
Light Oil gph (140,000 Btu/g 29.2
36.4
43.7
58.3
72.9
87.5
102.1
116.6
145.8
175.0
204.1
233.3
Gas CFH (1000 Btu)
4082
5103
6124
8165
10206
12247
14280
16329
20415
24494
28576
32659
Gas (Therm/hr)
40.8
51.0
61.2
81.7
102.1
122.5
142.8
163.3
204.2
245.0
285.8
326.6
Blower Motor hp
5
7 1/2
10
15
15
20
25
30
40
60
60
60
Separate Compressor
5
5
7 1/2
7 1/2
7 1/2
15
15
Motor hp (Oil only)
1
1
1
1
2
(Oil only)
Oil Metering Pump Motor
1/2
3/4
3/4
3/4
3/4
1
1
hp (Oil only)
1/2
1/2
1/2
1/2
1/2
3/4
3/4
3/4
3/4
3/4
1
1
hp (Oil only)
BOILER DATA
Heating Surface sq-ft. (Fires 353
438
555
729
885
1055
1384
1522
1734
2094
3244
3641
Table A4-8. Model ICB-LE Hot Water Ratings, 3 Pass

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
3348
4184
5021
6695
8369
10043
11716
13390
16738
20085
23433
26780
Light Oil gph (140,000 Btu/g 29.9
37.5
45.0
60.0
74.5
89.5
104.5
119.5
149.5
179.5
209
239
Gas CFH (1000 Btu)
4184
5230
6280
8370
10460
12555
14650
16750
20925
25100
29300
33500
Gas (Therm/hr)
41.8
52.3
62.8
83.7
104.6
125.5
146.5
167.5
209.3
251.0
293.0
335.0
Blower Motor hp
5
5
7 1/2
10
15
15
20
25
30
40
60
60
Separate Compressor
5
5
7 1/2
7 1/2
7 1/2
15
Motor hp (Oil only)
1
1
1
1
2
2
(Oil only)
Oil Metering Pump Motor
1/2
3/4
3/4
3/4
3/4
1
hp (Oil only)
1/2
1/2
1/2
1/2
1/2
3/4
3/4
3/4
3/4
3/4
1
1
hp (Oil only)
BOILER DATA
Heating Surface sq-ft. (Fire
353
438
555
729
885
1055
1384
1522
1734
2094
3244
3641
A4-8
09-09
Section A4

4-PASS ICB STANDARD STEAM BOILERS
3-PASS ICB STANDARD STEAM BOILERS
Figure A4-1. Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional)
A4-9
09-09
Section A4
Table A4-9. 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)
171"
197"
195"
243-1/2" 208-1/2" 234-1/2" 237-1/2"
263"
Overall (4-Pass)
171"
197"
195"
243-1/2" 208-1/2"
268"
Shell
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
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
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
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"
241"
247"
255"
290-1/2" 281-1/2" 306-1/2"
257-1/2" 290-1/2" 284-1/2"
312"
WIDTHS
Overall
80"
80"
85"
85"
97"
97"
103"
103"
117"
117"
131"
131"
I.D. Boiler
55"
55"
60"
60"
72"
72"
78"
78"
92"
92"
106"
106"
42-1/2"
42-1/2"
45"
45"
51"
51"
54"
54"
61"
61"
68"
68"
Center to Lagging
30-1/2"
30-1/2"
33"
33"
39"
39"
42"
42"
49"
49"
56"
56"
LL
37-1/2"
37-1/2"
40"
40"
46"
46"
49"
49"
56"
56"
63"
63"
Base Outside
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
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"
44-1/2"
44-1/2"
46"
46"
54"
54"
56"
56"
65-1/2"
65-1/2"
71"
71"
Base to Vent Outlet
80-3/4"
80-3/4"
85"
85"
101"
101"
106"
106"
122-1/2" 122-1/2" 135-5/8" 135-5/8"
106"
106"
122-1/2" 122-1/2" 135-5/8" 135-5/8"
HEIGHTS
Base to Rear Door Davit
OA
82-1/4"
82-1/4"
86-1/2"
86-1/2"
101"
101"
78-3/8"
78-3/8"
82-3/8"
82-3/8"
96-1/4"
96-1/4"
118"
118"
Base Frame
12"
12"
12"
12"
10"
10"
10"
10"
12"
12"
12"
12"
Base to Bottom Boiler
16"
16"
16"
16"
17"
17"
17"
17"
19"
19"
17-1/2"
17-1/2"
101-1/2" 101-1/2"
130-5/8" 130-5/8"
CONNECTIONS
Chemical Feed
1"
1"
1"
1"
1"
1"
1"
1"
1"
1"
1"
1"
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.
8"
8"
8"
10"
10"
12"
12"
12"
12"
12"
12"
12"
4"
4"
4"
4"
6"
6"
6"
6"
8"
8"
8"
8"
Drain Front & Rear (15 psig)
1-1/2"
1-1/2"
1-1/2"
2"
2"
2"
2"
2"
2"
2"
2"
2"
Blowdown-Front & Rear(150 psig)
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)
1"
1"
1"
1"
1"
1"
1"
1"
1"
1"
1"
1"
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
389"
326"
378"
385"
Rear of Boiler (3-Pass)
RR
303-1/2" 355-1/2" 351-1/2"
257"
309"
307"
441"
371"
423"
427"
417"
RR
303-1/2" 355-1/2" 351-1/2"
441"
371"
Thru Window or Door (3-Pass)
RD
237"
263"
263"
311-1/2" 283-1/2" 309-1/2" 315-1/2"
341"
RD
237"
263"
263"
311-1/2" 283-1/2"
395"
468-1/2" 441-1/2"
429-1/2" 436-1/2" 473-1/2"
316"
325"
346"
444"
340"
461"
450"
510"
492"
494"
539"
510"
495"
544-1/2"
375-1/2" 373-1/2" 398-1/2"
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
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
30,026
45,226
10,877
12,220
13,112
15,637
17,613
20,404
25,344
27,175
31,990
36,780
45,724
50,244
NOTE: Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for actual option requirements.
A4-10
09-09
Section A4

4-PASS ICB STANDARD HOT WATER BOILERS
3-PASS ICB STANDARD HOT WATER BOILERS
Figure A4-2. Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional)
A4-11
09-09
Section A4
Table A4-10. 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
Overall (3-Pass)
171"
197"
195"
243-1/2" 208-1/2" 234-1/2" 237-1/2"
263"
Overall (4-Pass)
171"
197"
195"
243-1/2" 208-1/2"
268"
Shell
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
124-3/8" 150-3/8" 148-3/8" 189-3/8" 157-3/8" 183-3/8" 184-3/8" 200-3/8" 187-1/4" 220-1/4" 211-3/8" 233-3/8"
9-1/2"
9-1/2"
9-1/2"
Flange to Return
82"
98"
95-5/8"
Flange to Outlet
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"
Overall
65"
65"
70"
70"
82"
82"
88"
88"
102"
102"
116"
116"
I.D. Boiler
55"
55"
60"
60"
72"
72"
78"
78"
92"
92"
106"
106"
LENGTHS
9-1/2"
9-1/2"
241"
9-1/2"
247"
9-1/2"
9-1/2"
255"
290-1/2" 281-1/2" 306-1/2"
257-1/2" 290-1/2" 284-1/2"
14-1/2"
14-1/2"
14-1/2"
312"
14-1/2"
136-5/8" 101-5/8" 115-5/8" 117-5/8" 132-5/8" 125-1/2" 143-1/2" 139-1/2" 161-1/2"

175"
171"
193"
WIDTHS
34-1/2"
34-1/2"
37
37"
43"
43"
46"
46"
53"
53"
60"
60"
Base Outside
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
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"
65-1/2"
71"
71"
HEIGHTS
44-1/2"
44-1/2"
46"
46"
54"
54"
56"
56"
65-1/2"
Base to Vent Outlet
80-3/4"
80-3/4"
85"
85"
101"
101"
106"
106"
122-1/2" 122-1/2" 135-5/8" 135-5/8"
106"
106"
122-1/2" 122-1/2" 135-5/8" 135-5/8"
OA
82-1/4"
82-1/4"
86-1/2"
86-1/2"
101"
101"
Base to Return/Outlet
78-3/8"
78-3/8"
82-3/8"
82-3/8"
96-1/4"
96-1/4"
118"
118"
Base Frame
12"
12"
12"
12"
10"
10"
10"
10"
12"
12"
12"
12"
16"
16"
16"
16"
17"
17"
17"
17"
19"
19"
17-1/2"
17-1/2"
Waterfill (Both Sides)
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
4"
6"
6"
6"
8"
8"
8"
10"
10"
12"
12"
12"
Water Outlet
4"
6"
6"
6"
8"
8"
8"
10"
10"
12"
12"
12"
Drain Front & Rear
1-1/2"
1-1/2"
1-1/2"
2"
2"
2"
2"
2"
2"
2"
2"
2"
Air Vent
1-1/4"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
2"
2"
2"
2"
BB
16"
16"
16"
16"
20"
20"
20"
20"
24"
24"
24"
24"
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"
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"
101-1/2" 101-1/2"
130-5/8" 130-5/8"
CONNECTIONS
MINIMUM CLEARANCES
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
RR
303-1/2" 355-1/2" 351-1/2"
257"
309"
307"
389"
326"
378"
385"
441"
371"
423"
427"
441"
371"
417"
RR
303-1/2" 355-1/2" 351-1/2"
RD
237"
263"
263"
311-1/2" 283-1/2" 309-1/2" 315-1/2"
341"
RD
237"
263"
263"
311-1/2" 283-1/2"
395"
468-1/2" 441-1/2"
429-1/2" 436-1/2" 473-1/2"
316"
325"
346"
444"
340"
461"
450"
494"
510"
492"
539"
510"
495"
544-1/2"
375-1/2" 373-1/2" 398-1/2"
342-1/2" 375-1/2" 376-1/2"
404"
WEIGHTS
5,848
7,397
8,378
11,180
11,940
14,380
16,190
17,884
22,572
27,431
32,991
37,120
10,123
11,303
11,931
14,106
16,958
19,051
22,344
23,918
28,934
33,189
41,179
45,226
10,238
11,418
13,153
15,679
18,609
21,270
24,522
26,631
32,175
36,972
47,122
51,782
A4-12
BBA4_02-08
09-09
Section A4
Figure A4-3. Model ICB-LE Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional)
A4-13
09-09
Section A4
Table A4-11. Model ICB-LE Steam Boiler Dimensions, 4-Pass and 3-Pass
BOILER H.P.
DIM
100
125
150
200
250
300
350
400
500
600
700
800
Overall (3-Pass)
173"
199"
199"
240"
215"
241"
247"
Overall (4-Pass)
173"
201"
199"
240"
215"
244"
252"
Shell
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
124-3/8" 150-3/8" 148-3/8" 189-3/8" 157-3/8" 183-3/8" 184-3/8" 200-3/8" 187-1/4" 220-1/4" 211-3/8" 233-3/8"
9-1/2"
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"
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"
Overall (3-Pass)
87"
87"
92"
92"
104"
106"
112"
112"
126"
128"
142"
142"
Overall (4-Pass)
82"
82"
87"
87"
100"
100"
109"
109"
122"
122"
133"
133"
I.D. Boiler
55"
55"
60"
60"
72"
72"
78"
78"
92"
92"
106"
106"
LENGTHS
268"
257-1/2" 290-1/2" 285-1/2"
270-1/2" 257-1/2" 293-1/2"
290"
312"
312"
WIDTHS
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"
37"
37"
37"
37"
47"
47"
53"
53"
59"
59"
59"
59"
FGR Duct Size (3-Pass)
6"
6"
6"
6"
6"
8"
8"
8"
8"
10"
10"
10"
6"
6"
6"
6"
8"
8"
8"
8"
10"
10"
10"
10"
Center to Lagging
30-1/2"
30-1/2"
33"
33"
39"
39"
42"
42"
49"
49"
56"
56"
LL
37-1/2"
37-1/2"
40"
40"
46"
46"
49"
49"
56"
56"
63"
63"
Base Outside
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
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"
65-1/2"
71"
71"
HEIGHTS
44-1/2"
44-1/2"
46"
46"
54"
54"
56"
56"
65-1/2"
Base to Vent Outlet
80-3/4"
80-3/4"
85"
85"
101"
101"
106"
106"
122-1/2" 122-1/2" 135-5/8" 135-5/8"
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 FGR Stack Extension

(3-Pass Only)
FF
94-3/4"
94-3/4"
99"
99"
118"
118"
123"
123"
142-1/2" 142-1/2" 155-5/8" 155-5/8"
78-3/8"
78-3/8"
82-3/8"
82-3/8"
96-1/4"
96-1/4"
118"
118"
Base Frame
12"
12"
12"
12"
10"
10"
10"
10"
12"
12"
12"
12"
16"
16"
16"
16"
17"
17"
17"
17"
19"
19"
17-1/2"
17-1/2"
101-1/2" 101-1/2"
130-5/8" 130-5/8"
CONNECTIONS
Chemical Feed
1"
1"
1"
1"
1"
1"
1"
1"
1"
1"
1"
1"
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"
8"
8"
8"
10"
10"
12"
12"
12"
12"
12"
12"
12"
4"
4"
4"
4"
6"
6"
6"
6"
8"
8"
8"
8"
Drain Front & Rear (15 psig)
1-1/2"
1-1/2"
1-1/2"
2"
2"
2"
2"
2"
2"
2"
2"
2"
Blowdown-Front & Rear(150 psig)
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)
1"
1"
1"
1"
1"
1"
1"
1"
1"
1"
1"
1"
BB
16"
16"
16"
16"
20"
20"
20"
20"
24"
24"
24"
24"
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"
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"
MINIMUM CLEARANCES
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
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"
257"
309"
307"
389"
326"
378"
385"
417"
RR 305-1/2" 359-1/2" 355-1/2" 437-1/2" 377-1/2" 432-1/2" 441-1/2"
476"
RD
239"
265"
267"
308"
290"
316"
325"
346"
RD
239"
267"
267"
308"
290"
319"
330"
395"
461"
450"
494"
444"
510"
496"
544-1/2"
444"
513"
500-1/2" 544-1/2"
342-1/2" 375-1/2" 376-1/2"
348-1/2" 342-1/2" 378-1/2"
404"
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
A4-14
09-09
Section A4
Figure A4-4. Model ICB-LE Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional)
A4-15
09-09
Section A4
Table A4-12. Model ICB-LE 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
Overall (3-Pass)
173"
199"
199"
240"
215"
241"
247"
Overall (4-Pass)
173"
201"
199"
240"
215"
244"
252"
Shell
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
124-3/8" 150-3/8" 148-3/8" 189-3/8" 157-3/8" 183-3/8" 184-3/8" 200-3/8" 187-1/4" 220-1/4" 211-3/8" 233-3/8"
9-1/2"
9-1/2"
9-1/2"
Flange to Return
82"
98"
95-5/8"
Flange to Outlet
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"
LENGTHS
9-1/2"
9-1/2"
9-1/2"
9-1/2"
268"
257-1/2" 290-1/2" 285-1/2"
270-1/2" 257-1/2" 293-1/2"
9-1/2"
14-1/2"
14-1/2"
290"
14-1/2"
312"
312"
14-1/2"
136-5/8" 101-5/8" 115-5/8" 117-5/8" 132-5/8" 125-1/2" 143-1/2" 139-1/2" 161-1/2"

175"
171"
193"
WIDTHS
Overall (3-Pass)
87"
87"
92"
92"
104"
106"
112"
112"
126"
128"
142"
142"
Overall (4-Pass)
81-1/2"
81-1/2"
84"
84"
100"
100"
109"
109"
122"
122"
129"
129"
106"
I.D. Boiler
55"
55"
60"
60"
72"
72"
78"
78"
92"
92"
106"
Center to Control Panel
44-1/2"
44-1/2"
47"
47"
53"
53"
56"
56"
63"
63"
70"
70"
42-1/2"
42-1/2"
45"
45"
51"
53"
56"
56"
63"
65"
72"
72"
37"
37"
37"
37"
47"
47"
53"
53"
59"
59"
59"
59"
6"
6"
6"
6"
6"
8"
8"
8"
8"
10"
10"
10"
6"
6"
6"
6"
8"
8"
8"
8"
10"
10"
10"
10"
Center to Lagging
30-1/2"
30-1/2"
33"
33"
39"
39"
42"
42"
49"
49"
56"
56"
Base Outside
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
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"
65-1/2"
71"
71"
HEIGHTS
44-1/2"
44-1/2"
46"
46"
54"
54"
56"
56"
65-1/2"
Base to Vent Outlet
80-3/4"
80-3/4"
85"
85"
101"
101"
106"
106"
122-1/2" 122-1/2" 135-5/8" 135-5/8"
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 FGR Stack Extension

(3-Pass Only)
FF
94-3/4"
94-3/4"
99"
99"
118"
118"
123"
123"
142-1/2" 142-1/2" 155-5/8" 155-5/8"
Base to Return/Outlet
78-3/8"
78-3/8"
82-3/8"
82-3/8"
96-1/4"
96-1/4"
118"
118"
Base Frame
12"
12"
12"
12"
10"
10"
10"
10"
12"
12"
12"
12"
16"
16"
16"
16"
17"
17"
17"
17"
19"
19"
17-1/2"
17-1/2"
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
4"
6"
6"
6"
8"
8"
8"
10"
10"
12"
12"
12"
Water Outlet
4"
6"
6"
6"
8"
8"
8"
10"
10"
12"
12"
12"
Drain Front & Rear
1-1/2"
1-1/2"
1-1/2"
2"
2"
2"
2"
2"
2"
2"
2"
2"
Air Vent
1-1/4"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
2"
2"
2"
2"
BB
16"
16"
16"
16"
20"
20"
20"
20"
24"
24"
24"
24"
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"
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"
101-1/2" 101-1/2"
130-5/8" 130-5/8"
CONNECTIONS
MINIMUM CLEARANCES
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
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"
257"
309"
307"
389"
326"
378"
385"
417"
RR 305-1/2" 359-1/2" 355-1/2" 437-1/2" 377-1/2" 432-1/2" 441-1/2"
476"
RD
239"
265"
267"
308"
290"
316"
325"
346"
RD
239"
267"
267"
308"
290"
319"
330"
395"
461"
450"
494"
444"
510"
496"
544-1/2"
444"
513"
500-1/2" 544-1/2"
342-1/2" 375-1/2" 376-1/2"
348-1/2" 342-1/2" 378-1/2"
404"
382"
404"
WEIGHTS
5,848
7,397
8,378
11,180
11,940
14,380
16,190
17,884
22,572
27,431
32,991
37,120
10,123
11,303
11,931
14,106
16,958
19,051
22,344
23,918
28,934
33,189
41,179
45,226
10,238
11,418
13,153
15,679
18,609
21,270
24,522
26,631
32,175
36,972
47,122
51,782
A4-16
BBA4_02-08
09-09
Section A4

BOILER HP
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 A4-5. Space Required to Open Rear Head on Model ICB Boilers

BOILER HP
100
75-1/4
21-3/8
81-1/4
10
125
75-1/4
21-3/8
107-1/4
10
150
79-1/2
25-3/8
96-1/2
10
200
79-1/2
25-3/8
137-1/2
10
250
94
32
96-1/4
10
300
94
32
122-1/4
10
350
99
32
123-1/4
10
400
99
32
139-1/4
10
500
115-1/2
34
125-3/4
11
600
115-1/2
34
158-3/4
11
700
128-1/4
34
151
11
800
128-1/4
34
173
11
Figure A4-6. Model ICB Boilers Lifting Lug Location

A4-17
09-09
Section A4
" E"

BOILER HP
100
127-1/2
34-1/2
52-1/2
39-1/2
17-1/2
125
153-1/2
34-1/2
52-1/2
39-1/2
17-1/2
150
151-1/2
39-1/2
57-1/2
44-1/2
17-1/2
200
192-1/2
39-1/2
57-1/2
44-1/2
17-1/2
250
160-1/2
45-1/2
63-1/2
50-1/2
17-1/2
300
186-1/2
45-1/2
63-1/2
50-1/2
17-1/2
350
187-1/2
51
69
56
17-1/2
400
203-1/2
51
69
56
17-1/2
500
12
190-1/2
49-1/2
73-1/2
6-1/2
55
20-1/2
600
12
223-1/2
49-1/2
73-1/2
6-1/2
55
20-1/2
700
12
214-1/2
56-1/4
80-1/4
6-1/2
61-3/4
20-1/2
800
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 provides increased inspection accessibility to the boiler and added height for washing down the area beneath the
boiler.
Figure A4-7. Model ICB Boiler Mounting Piers
PERFORMANCE DATA
Contact your local Cleaver-Brooks Authorized Representative for efficiencies or
additional information.
Cleaver-Brooks ICB boilers are available with the standard burner package, or
optional induced flue gas recirculation, refer to the Model ICB-LE for low NOx
information.
ENGINEERING DATA
The following engineering information is provided for Model ICB Boilers. Additional
detail is available from your local Cleaver-Brooks Authorized Representative.
Boiler Information
Table A4-13 shows steam volume and disengaging area for Model ICB Boilers.
A4-18
09-09
Section A4

Table A4-14 lists quantity and outlet size for safety valves supplied on Model ICB
Steam Boilers.
Table A4-15 lists quantity and outlet size for relief valves supplied on Model ICB Hot
Water Boilers.
Table A4-16 gives recommended steam nozzle sizes on Model ICB Boilers.
Table A4-17 shows recommended non-return valve sizes for Model ICB Boilers.
Blowdown Water
Requirements
Some local codes require blowdown tanks to be constructed in accordance with

recommendations of the National Board of Boiler and Pressure Vessel Inspectors.
The National Boards recommendations base the size of the blowdown tank on the
removal of at least 4 inches of water from the boiler.
Table A4-18 lists the approximate quantity of water represented by 4 inches of
water at normal operating level for Cleaver-Brooks Model ICB Boilers.
Burner/Control
Information
Maximum altitude for standard burners is 700 feet. Contact your local CleaverBrooks Authorized Representative for higher altitude availability. Note that altitude
correction and burner changes are required for higher altitudes which may alter
dimensions, motor hp and gas pressures.
Gas-Fired Burners
Table A4-19 lists minimum required gas pressure for altitude correction.
Table A4-21 shows minimum and maximum gas pressure requirements for
Standard, FM and IRI ICB Boiler gas trains upstream of the gas pressure regulator.
For oversized or undersized gas trains or altitude above 700 feet, contact your local
Cleaver-Brooks Authorized Representative.
Fuel Connections
Gas
The local gas company should be consulted for requirements and authorization for
installation and inspection of gas supply piping. Installation of gas supply piping and
venting must be in accordance with all applicable engineering guidelines and
regulatory codes. All connections made to the boiler should be arranged so that all
components remain accessible for inspection, cleaning and maintenance.
A drip leg should be installed in the supply piping before the connection to the gas
pressure regulator. The drip leg should be at least as large as the inlet fitting
supplied with the boiler. Consideration must be given to both volume and pressure
requirements when choosing gas supply piping size. Refer to the boiler dimension
diagram provided by Cleaver-Brooks for the particular installation. Connections to
the burner gas train should be made with a union, so that gas train components or
the burner may be easily disconnected for inspection or service. Upon completion of
the gas piping installation, the system should be checked for gas leakage and tight
shutoff of all valves.
Fuel Connections
Oil
Oil-fired burners are equipped with an oil pump, which draws fuel from a storage
tank and supplies pressurized oil to the burner nozzle(s). The burner supply oil
pump has a greater capacity than the burner requires for the maximum firing rate.
Fuel not delivered to the nozzle is returned to the storage tank. A two-pipe (supply
and return) oil system is recommended for all installations. Figure A4-8 shows a
typical fuel oil supply arrangement. Oil lines must be sized for the burner and burner
supply oil pump capacities.
The burner supply oil pump suction should not exceed 10" Hg. If a transfer pump is
A4-19
09-09
Section A4
used, it must have a pumping capacity at least equal to that of the burner pump(s).
Supply pressure to the burner pump should not exceed 3 psig.
A strainer must be installed in the supply piping upstream of the burner supply
pump in order to prevent entry of foreign material into the pump, fuel control valves,
or burner nozzle(s). The strainer must be sized for the burner supply pump capacity.
A strainer mesh of 150 microns (0.005") is recommended.
Install a check valve in the line to prevent draining of the oil suction line when the
burner is not in operation. Location of the check valve varies with the system, but
usually it is located as close as possible to the storage tank.
Installation of a vacuum gauge in the burner supply line between the burner oil
pump and the strainer is recommended. Regular observation and recording of the
gauge indication will assist in determining when the strainer needs servicing.
Upon completion of the oil piping installation, the system should be checked for oil
or air leakage and tight shutoff of all valves.
Boiler Room
Information
Stack Support
Capabilities
100 800 hp Model ICB Boilers can support up to 2000 lbs without additional
support.
100 800 hp Model ICB Boilers can be reinforced to support up to 3000 lbs.
Boiler Room
Combustion Air
A. Two (2) permanent air supply openings in the outer walls of the boiler room are
recommended. Locate one (1) at each end of the boiler room, preferably below a height
of 7 feet. This allows air to sweep the length of the boiler.
B. Air supply openings can be louvered for weather protection, but they should not be
covered with fine mesh wire, as this type of covering has poor air flow qualities and is
subject to clogging by dust or dirt.
C. A vent fan in the boiler room is not recommended, as it could create a slight vacuum
under certain conditions and cause variations in the quantity of combustion air. This
can result in unsatisfactory burner performance. Under no condition should the total
area of the air supply openings be less than one (1) square foot.
D. Size the openings by using the formula:
Area (sq.-ft.) = CFM/FPM

B. Ventilation Air = Maximum bhp x 2 cfm/bhp or a total of 10 cfm/bhp up to 1000
feet elevation. Add 3 percent more per 1000 feet of added elevation.
A. From floor to (7) foot height 250 fpm.
A4-20
09-09
Section A4

B. Above (7) foot height 500 fpm.
Area Required: Area = cfm/fpm = 3000/250 = 12 sq.-ft. total.
Area/Opening: 12/2 = 6 sq.-ft./opening (2 required).
Notice
Stack/Breeching
Size Criteria
Although constant pressure at the flue gas outlet of the Model ICB is not required, it
is necessary to size the stack/breeching to limit flue gas pressure variation. The
allowable pressure range is 0.25" W.C. to +0.25" W.C.
For additional information, please review Section I4, General Engineering Data
(Stacks) and Section F, Stacks. Stack and breeching sizes should always be provided
by a reputable stack supplier who will design the stack and breeching system based
on the above criteria. Your local Cleaver-Brooks Authorized Representative is capable
of assisting in your evaluation of the stack/breeching design.
Table A4-13. Model ICB Steam Volume and Disengaging Areas

STEAM VOLUME CU-FT.
STEAM RELIEVING
AREA SQ.-IN
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:
A4-21
09-09
Section A4
Table A4-14. Model ICB Steam Boiler Safety Valve Outlet Size
VALVE
SETTING
BOILER HP
100
125
150
15 PSIG STEAM
NO. OF
VALVES
OUTLET
REQD
SIZE (IN.)
1
2-1/2
1
2-1/2
1
3
200
250
300
350
(1) 2-1/2
(1) 2
(2) 2-1/2
150 PSIG STEAM

NO. OF
VALVES
OUTLET
REQD
SIZE (IN.)
1
1-1/2
1
2
2
(1) 1-1/2
(1) 1-1/4
2
1-1/2
2
2
3
(1) 2-1/2
(2) 3
400
(2) 3
500
600
(2)3
(1) 2-1/2
(3) 3
700
(4) 3
800
(3) 3
(2) 2-1/2
(1) 2
(1) 1-1/2
(1) 2
(1) 1-1/2
(1) 2-1/2
(1) 2
(1) 2-1/2
(1) 2
(1) 2-1/2
(1) 2
(2) 2-1/2
(2) 2-1/2
(1) 2
2-1/2
200 PSIG STEAM

NO. OF
VALVES
OUTLET
REQD
SIZE (IN.)
1
1-1/2
1
(1) 1-1/2
2
1-1/4
(1) 1
2
(1) 1-1/2
(1) 1-1/4
2
1-1/2
(1) 1-1/4
2
(2) 1-1/2
2
2
2
2
2
3
250 PSIG STEAM

NO. OF
VALVES
OUTLET
REQD
SIZE (IN.)
1
1-1/4
1
1 1/2
2
1
2
(1) 1-1/2
2
(1) 1-1/2
(1) 2-1/2
(1) 2
(1) 2-1/2
(1) 2
2-1/2
(2) 2
(1) 2-1/2
1-1/4
(1) 1-1/2
(1) 1-1/4
(1) 1-1/2
(1) 1-1/4
(1) 1-1/2
(1) 2
(2) 1-1/2
2
2
2
2
2
2
2
Table A4-15. Model ICB Hot Water Boiler Relief Valve Outlet Size
VALVE
SETTING
30 PSIG HW
125 PSIG HW
150 PSIG HW
OUTLET
SIZE (IN.)
2
2-1/2
NO. OF
VALVES
REQD
1
1
OUTLET
SIZE (IN.)
1
1-1/4
NO. OF
VALVES
REQD
1
2
2-1/2
1-1/4
200
250
300
350
400
2
3
1
1
2-1/2
2-1/2
2
2
500
2-1/2
600
(1) 2-1/2
(1) 1
(1) 1-1/4
(1) 2-1/2
(1) 2-1/2
(1) 2
2-1/2
(1) 1
(2) 2-1/2
(1) 2
(2) 2-1/2
2-1/2
700
(4) 2-1/2
800
(1) 1
(4)2-1/2
(1) 1
(1) 2-1/2
(1) 2-1/2
(1) 1-1/4
(1) 2-1/2
(1) 2
BOILER HP
100
125
NO. OF
VALVES
REQD
1
1
150
3
3
NOTE: Relief valve is Kunkle #537 for 30# & 125#(Section IV) boiler and is Kunkle #927 for 150# HTHW (Section I) boiler.
A4-22
BBA4_02-08
09-09
OUTLET
SIZE (IN.)
2
(1) 1-1/2
(1) 2
(1) 1-1/2
(1) 2
2
(1) 2
(1) 2-1/2
(1) 1-1/2
(1) 2
(2) 2-1/2
(1) 2-1/2
(1) 3
(1) 3
(1) 2-1/2
3
(2) 3
(1) 2-1/2
3
2
(1) 1-1/2
2
(1) 2-1/2
(1) 2
2-1/2
Section A4

Table A4-16. Model ICB Recommended Steam Nozzle Size
OPERATING
PRESSURE
PSIG
BOILER HP
100
125
150
200
250
300
350
400
500
600
700
800
15
10
10
12
12
12
12
12
12
12
30
10
10
10
12
12
12
40
10
10
10
12
12
50
10
10
10
12
75
10
10
100
10
125
150
2.5
200
2.5
2.5
250
2.5
NOTES:
3. All standard steam nozzle sizes for 150 psig design pressure or greater are the same as 125 psig
operating pressure on the above table. To increase or decrease the standard size, request the change with
Table A4-17. Model ICB Recommended Non-Return Valve Size

BOILER
BOILER CAPACITY
HP
(LBS/HR)
50
75
100
125
150
175
200
250
100
3450
2-1/2
2-1/2
NA
NA
NA
NA
NA
NA
125
4313
2-1/2
2-1/2
2-1/2
NA
NA
NA
NA
150
5175
2-1/2
2-1/2
2-1/2
2-1/2
NA
NA
200
6900
3*
2-1/2
2-1/2
2-1/2
250
8625
3*
300
10350
3*
350
12025
3*
400
13800
3*
500
17210
600
20700
700
24150
800
27600
NOTE:
Valve sizes (300# flanges) given in inches).
Standard non-return valve selections limited to a maximum 2 to 1 turndown (50% of full boiler output); selection based on typical
valve sizing recommendations. For final valve selection contact your authorized C-B representative. For high turndown applications see
Boiler Book Section I3, Table I3-3.
*Indicates pressure drop of less than 7.5 psig. All other selections are less than 6 psig pressure drop.
A4-23
09-09
BBA4_02-08
Section A4
Table A4-18. Model ICB Blowdown Tank Sizing Information

BOILER HP
WATER (GAL)
100
75
125
94
150
102
200
135
250
125
300
150
350
174
400
191
500
206
600
248
700
266
800
297
NOTE: Quantity of water removed from boiler by lowering normal water line 4"

ALTITUDE CORRECTION ALTITUDE CORRECTION
(FT.)
FACTOR
(FT.)
FACTOR
1000
2000
3000
4000
5000
1.04
1.07
1.11
1.16
1.21
6000
7000
8000
9000
1.25
1.3
1.35
1.4
NOTE: To obtain minimum required gas pressure at altitudes above 700 feet, multiply
the pressure by the listed factors:
Inches WC x 0.577 = oz/sq.-in.
oz/sq.-in x 1.732 = Inches WC.
Inches WC x 0.0361 = psig.
oz/sq.-in x 0.0625 = psig.
psig x 16.0 = oz/sq.-in.
Table A4-20. Sound Levels in dBA for 4-Pass ICB Boilers at High Fire
Sound Level dBA
BHP
ICB
100
125
150
200
250
300
350
400
500
600
700
800
80.0
84.5
84.5
84.5
84.5
91.0
94.0
91.5
93.5
93.5
93.7
93.7
A4-24
09-09
Section A4
Table A4-21. Model ICB, Standard Emissions, Minimum Required Gas Pressure at Entrance to Standard,
FM & IRI Gas Trains (Upstream of Gas Pressure Regulator)
BOILER
HP
100
125
150
200
250
300
350
400
500
600
700
800
PRESSURE REQUIRED,
3-PASS ("WC)
PRESSURE REQUIRED,
4-PASS ("WC)
STD PIPE
SIZE
(Inches)
GPR*
Minimum
Maximum
GPR*
Minimum
Maximum
2
2
2
2-1/2
2-1/2
2-1/2
3
1.5-2
2-2.5
2.5
3
1.5-2.5
2-2.5
2.5
3
2-1.5-2.5
2-2.5
2.5
2.5-3
3
2-3
2.5-3
3
4
2.5-3
3
4
RV91
RV91
RV91
RV111
210G
210G
210G
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
8.5
13.5
17
20
32.5
45
46
133
91
64
39
191
139
94
55
249
191
130
108
66
233
141
91
58
177
114
72
27.7
27.7
27.7
27.7
277
277
277
208
133
91
64
277
191
139
94
277
249
191
130
108
277
233
141
91
277
177
114
RV91
RV91
RV91
210G
210G
210G
210G
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
10.5
16
21
26
33
45.5
46.5
133
94
66
42
183
133
89
53
244
188
133
111
72
230
141
91
64
175
114
72
27.7
27.7
27.7
277
277
277
277
208
133
94
66
277
183
133
89
277
244
188
133
111
277
230
141
91
277
175
114
A4-25
BBA4_02-08
09-09
Section A4
Table A4-22. Model ICB, Low NOx, Minimum Required Gas Pressure at Entrance to Standard,
FM & IRI Gas Trains (Upstream of Gas Pressure Regulator)
PRESSURE REQUIRED,
3-PASS ("WC)
PRESSURE REQUIRED,
4-PASS ("WC)
BOILER
HP
STD PIPE
SIZE
(Inches)
GPR*
Minimum
Maximum
GPR*
Minimum
Maximum
100
RV91
13
27.7
RV91
15
27.7
125
RV91
19.5
27.7
RV91
17.5
27.7
150
RV91
20
27.7
RV91
21.5
27.7
200
2-1/2
210G
27
277
210G
32.5
277
250
2-1/2
210G
30
277
210G
35.5
277
300
2-1/2
210G
43
277
210G
47.5
277
350
210G
45
277
210G
49.5
277
1.5-2
133
208
133
208
91
133
91
133
2.5
66
91
66
91
39
66
42
66
1.5-2.5
188
277
186
277
2-2.5
136
188
136
186
2.5
91
136
94
136
53
91
55
94
2-1.5-2.5
252
277
247
277
2-2.5
194
252
191
247
2.5
130
194
133
191
2.5-3
108
130
111
133
69
108
75
111
2-3
235
277
230
277
2.5-3
144
235
141
230
91
144
91
141
61
91
61
91
2.5-3
175
277
175
277
111
175
114
175
69
111
114
400
500
600
700
800
A4-26
09-09
Section A4
A4-27
09-09
Section A4
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 A4-9. Boiler Room Length (Typical Layouts) Model ICB
BOILER HP
100 125
150 200
250 300
350 400
500 600
DIM. A
84-1/2
87
93
96
103
700 800
110
DIM. B
115-1/2
120
138
144
170
184
NOTES:
1. Recommended Minimum Distance Between Boiler and Wall.
Dimension "A allows for a clear 42" aisle between the water column on the boiler and
the wall. If space permits, this aisle should be widened.
42" 100-200 hp
48" 250-400 hp
60 500-800 hp
Figure A4-10. Boiler Room Width (Typical Layout) Model ICB
A4-28
09-09
Section A4
Model ICB
Sample Specifications
Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-28
General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-28
Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-30
Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-30
Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-35
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-36
Shop Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-36
Boiler Characteristics (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-37
General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-37
Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-38
Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-38
Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-42
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-42
Shop Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-42
Start-Up Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-42
A4-29
09-09
Section A4
SAMPLE SPECIFICATION
The following sample specification is provided by Cleaver-Brooks to assist you in meeting your customers
specific needs and application.
The Sample Specifications are typically utilized as the base template for the complete boiler specification.
Contact your local Cleaver-Brooks Authorized Representative for information on special insurance
requirements, special code requirements, optional equipment, or general assistance in completing the
specification.
PART 1 GENERAL
Model ICB Steam Boiler (100 800 hp, 15 300 psig)
1.1
BOILER CHARACTERISTICS (STEAM)

A. The Steam Boiler shall be Cleaver-Brooks Model ICB, Fuel Series ______ (100,
200, 700), _____ hp designed for _____ psig (15, 150, 200, 250, 300 psig
steam). The maximum operating pressure shall be _____ psig.
fired with CS 12-48 No. 2 oil and/or natural gas, _____ Btu/cu-ft. Electrical power
available will be _____ Volt _____ Phase _____ Cycle and 115/1/60 for the control
circuit.
PART 2 PRODUCTS
2.1

A. Number of Passes Select one of the following:
(Four-Pass) The boiler shall be a four-pass intercooled horizontal firetube updraft
boiler. It shall be mounted on a heavy steel frame with forced draft burner and
burner controls.
(Three-Pass) The boiler shall be a three-pass intercooled horizontal firetube
updraft boiler. It shall be mounted on a heavy steel frame with forced draft
burner and burner controls.
1.
B.
Approvals: The complete burner/boiler package shall be approved as a unit by

Underwriters Laboratories Inc. and bear the UL/cUL label.
connections.
3. Front and rear doors on the boiler shall be davited.
4. The rear door shall be insulated with a blanket material and a steel covering to
give the surface a hard durable finish.
appurtenances.
A4-30
09-09
Section A4
6.
The boiler shall be furnished with a manhole and handholes to facilitate boiler
inspection and cleaning.
7. Exhaust Vent Select one of the following:
a. (Four-Pass) The exhaust gas vent shall be located near the front of the
boiler on the top center line and shall be capable of supporting 2000 lbs.
b. (Three-Pass) The exhaust gas vent shall be located at the rear of the
boiler on the top center line and shall be capable of supporting 2000 lbs.
8. Observation ports for the inspection of flame conditions shall be provided at
each end of the boiler.
9. The boiler insulation shall consist of a 2 inch blanket under a sectional
preformed sheet metal lagging. This insulation must be readily removable and
capable of being reinstalled, if required.
10. The entire boiler based frame and other components shall be factory painted
before shipment using a hard finish enamel coating.
11. An inner rear turnaround access opening shall swing on a davit, to allow full
accessibility to the 2nd pass tubes and furnace.
12. Tubes shall be removable from either the front or rear of the boiler.
2.2
STEAM BOILER TRIM

A. 3.1 Water Column
water column to automatically actuate a motor driven feedwater pump
2. Low Water Cutoff
The low water cutoff shall be included as an integral part of the boiler
feedwater control wired into the burner control circuit to prevent burner
operation if the boiler water level falls below a safe level.
B. Auxiliary Low Water Cutoff
The auxiliary low water cutoff shall be included, piped to the vessel, and wired to
the burner control circuit. A manual reset device shall be used for this control.
C. Steam Pressure Gauge
D. Safety Relief Valves
shipped loose.
E. Steam Pressure Controls
water column.
2.3
BURNER AND CONTROLS

Burner operation shall be the full modulation principle. The burner shall always
return to low fire position for ignition.
A4-31
09-09
Section A4
B.
C.
Blower
1. All air for combustion shall be supplied by a forced draft blower mounted on
the burner, to eliminate vibration and reduce noise level.
2. Maximum sound level of the boiler/burner package shall not exceed _____ dBA
3. The impeller shall be fabricated aluminum with radial blade, carefully
balanced, and directly connected to the blower motor shaft.
4.3 Combustion Air Control Select one of the following:
(Four-Pass) Combustion air damper and fuel control valve (100 250 hp) or
cam operated fuel metering valve
(300 800 hp) shall be operated by a single damper control motor that
regulates the flame according to load demand. Potentiometer type position
controls shall be provided to regulate operation of the damper control motor.
(Three-Pass) Combustion air damper and fuel control valve (100 350 hp) or
cam operated fuel metering valve
(400 800 hp) shall be operated by a single damper control motor that
regulates the flame according to load demand. Potentiometer type position
controls shall be provided to regulate operation of the damper control motor.
D.

Fuel series 700 Gas fired (para 4.4.1).
Fuel series 100 Light oil (No. 2) fired (para 4.4.2).
Fuel series 200 Light oil or gas fired (para 4.4.3).
1.
FUEL SERIES 700 GAS FIRED

a. Burner Type The burner shall be mounted at the front of the boiler and
be of high radiant multi-port type for gas. The burner shall be approved
for operation on natural gas fuel.
b. Gas Pilot The gas pilot shall be a premix type with automatic electric
train shall include one (1) shut-off valve, solenoid valve, pressure
regulator, and one (1) plugged leakage test connection (Canada only).
c. Gas Burner Piping Select one of the following:
1) 100 hp. Gas burner piping on all units shall include two (2) manual
shut-off valves, gas pressure regulator, one (1) motorized gas valve
with proof of closure switch, two (2) plugged leakage test
connections, and high and low gas pressure switches. The gas
valves shall be wired to close automatically in the event of power
failure, flame failure, low water, or any abnormal shutdown
condition.
A4-32
09-09
Section A4
2)
2.
125 250 hp. Gas burner piping on all units shall include two (2)
manual shut-off valves, gas pressure regulator, two (2) motorized
gas valves, one (1) valve with proof of closure switch, two (2)
plugged leakage test connections, and high and low gas pressure
switches. The gas valves shall be wired to close automatically in the
event of power failure, flame failure, low water, or any abnormal
shutdown condition.
3) 300 350 hp. Gas burner piping on all units shall include two (2)
manual shut-off valves, gas pressure regulator, two (2) motorized
gas valves, one (1) valve with proof of closure switch, main gas vent
valve, two (2) plugged leakage test connections, and high and low
gas pressure switches. The gas valves shall be wired to close
automatically in the event of power failure, flame failure, low water,
or any abnormal shutdown condition.
d. 400 800 hp. Gas burner piping on all units shall include two (2)
manual shut-off valves, gas pressure regulator, two (2) motorized gas
valves, one (1) valve with proof of closure switch, main gas vent valve,
two (2) plugged leakage test connections, and high and low gas pressure
switches. The gas valves shall be wired to close automatically in the event
of power failure, flame failure, low water, or any abnormal shutdown
condition.
FUEL SERIES 100 LIGHT OIL FIRED
a. Burner Type The burner shall be mounted at the front of the boiler, and
shall be approved for operation with CS12-48, Commercial No. 2 oil.
c. Oil Pump An oil pump with a capacity of approximately twice the
maximum burning rate shall be included. Pump shall be motor driven and
shipped loose to be field installed near the oil storage tank. Oil pump
motor starter shall also be provided.
d. Oil Burner Piping
1) Four-Pass Select one of the following:
100 150 hp. Fuel oil piping on the unit shall include oil pressure
regulating device, oil metering controls, two (2) solenoid oil shut-off
valves, and pressure gauge all integrally mounted on the unit.
valves, atomizing air proving switch, low oil pressure switch, and
pressure gauge all integrally mounted on the unit.
300 800 hp. Fuel oil piping on the unit shall include oil metering
system, one (1) solenoid oil shut-off valve, one (1) motorized oil valve
with proof of closure switch, pressure relief valve, atomizing air
proving switch, and low oil pressure switch all integrally mounted on
the unit.
2)
Three-Pass Select one of the following:
A4-33
09-09
Section A4
valves, atomizing air proving switch, low oil pressure switch, and
400 800 hp. Fuel oil piping on the unit shall include oil metering
system, one (1) solenoid oil shut-off valve, one (1) motorized oil
valve with proof of closure switch, pressure relief valve, atomizing air
proving switch, and low oil pressure switch all integrally mounted on
the unit.
e.
Oil Atomization Type Select one of the following:

1) 100 150 hp. Burner shall include a complete mechanical oil
atomizing system and be of the pressure atomizing type.
2) 200 800 hp. Burner shall be a low pressure air atomizing type,
including a shipped loose air compressor assembly.
3. FUEL SERIES 200 LIGHT OIL OR GAS FIRED
a. Burner Type Select one of the following:
1) 100 150 hp. The burner, mounted at the front of the boiler, shall
be a combination pressure atomizing type for oil and high radiant
multi-port type for gas. The burner shall be approved for operation
with either CS12-48 Commercial No. 2 oil or natural gas.
2) 200 800 hp. The burner, mounted at the front of the boiler, shall
be a combination of low pressure air atomizing type for oil and high
radiant multi-port type for gas. The burner shall be approved for
operation with either CS12-48 Commercial No. 2 oil or natural gas.
b. Gas Pilot The gas pilot shall be premix type with automatic electric
shall include one (1) manual shut-off valve, solenoid valve, pressure
c. Oil Burner
1) Oil Pump An oil pump with a capacity of approximately twice the
maximum burning rate shall be included. Pump shall be motor
driven and shipped loose to be field installed near the oil storage
tank. Oil pump motor starter shall also be provided.
2) Oil Burner Piping
Four-Pass Select one of the following:
a. 100 150 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering
controls, two (2) solenoid oil shut-off valves, and pressure gauge all integrally mounted on the unit.
200 250 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering
controls, two (2) solenoid oil shut-off valves, atomizing air proving switch, low oil pressure switch
and pressure gauge all integrally mounted on the unit.
A4-34
09-09
Section A4
300 800 hp. Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shutoff 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. 100 150 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering
3)
a. 100 150 hp. Burner shall include a complete mechanical oil atomizing system and be of the
pressure atomizing type.
200 800 hp. Burner shall be a low pressure air atomizing type, including a shipped loose air
compressor assembly.
d.
Gas Burner Piping Select one of the following:
a. 100 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure
regulator, one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test
connections, and high and low gas pressure switches. The gas valves shall be wired to close
automatically in the event of power failure, flame failure, low water, or any abnormal shutdown
condition.
125 150 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas
pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch,
two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves
shall be wired to close automatically in the event of power failure, flame failure, low water, or any
abnormal shutdown condition.
pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch,
main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure
switches. The gas valves shall be wired to close automatically in the event of power failure, flame
failure, low water, or any abnormal shutdown condition.
pressure regulator, two (2) motorized gas valves and one (1) valve with proof of closure switch, main
gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches.
The gas valves shall be wired to close automatically in the event of power failure, flame failure, low
water or any abnormal shutdown condition.
E.
4.5 Control Panel and Flame Safeguard Controller

1. Control Panel
A factory prewired control panel shall be supplied with the boiler/burner
package. Panel may be mounted on the burner or boiler.
2. The panel will have a NEMA 1A rating and contain the flame safeguard
controller, burner motor starter, air compressor motor starter, oil metering
pump motor starter, control circuit transformer and fuses, selector switches,
indicating lights and terminal strips. Lights shall indicate load demand, flame
failure, low water, and fuel valve open.
3. The panel shall contain fuse protection for the burner motor, air compressor
motor, and oil metering pump.
A4-35
09-09
Section A4
4.
The flame safeguard controller shall be a CB110 flame monitor with EPD170
program module. Flame detector shall be ultra-violet type.
2.4
A. The boiler must be guaranteed to operate at a minimum fuel-to-steam efficiency of
____ percent at 100 percent of rating when burning natural gas and ________ fuelto-steam efficiency at 100% firing rate when burning oil (Contact your local CleaverBrooks Authorized Representative for efficiency details).
2.5
WARRANTY
A. All equipment is to be guaranteed against defects in materials and/or workmanship
for a period of 12 months from date of start-up or 18 months from date of
shipment, whichever comes first.
PART 3 EXECUTION
3.1
SHOP TESTS
B. Start-Up Service
1. After boiler installation is completed, the manufacturer shall provide the
services of a field representative for starting the unit and training the operator
at no additional costs.
a. A factory approved and authorized start-up report shall be submitted to
the customer/user at the time of start-up.
A4-36
09-09
Section A4
Model ICB Hot Water Boiler (100 800 hp, 30 psig, 125 psig)
PART 1 GENERAL
1.1
BOILER CHARACTERISTICS (HOT WATER)

A. The Hot Water Boiler shall be Cleaver-Brooks Model ICB, Fuel Series ______ (100,
200, 700), _____ hp designed for _____ psig (30, 125, or other psig hot water).
The maximum water temperature will be _____ degree F, and the maximum system
temperature drop will be _____ degree F.
circuit.
PART 2 PRODUCTS
2.1

A. Number of Passes Select one of the following:
(Four-Pass) The boiler shall be a four-pass intercooled horizontal firetube updraft boiler. It
shall be mounted on a heavy steel frame with forced draft burner and burner controls.
(Three-Pass) The boiler shall be a three-pass intercooled horizontal firetube updraft boiler. It
shall be mounted on a heavy steel frame with forced draft burner and burner controls.
1.
Approvals: The complete burner/boiler package shall be approved as a unit by

Underwriters Laboratories Inc. and bear the UL/cUL label.
connections.
line of the boiler. The boiler shall be designed to rapidly mix the return water
6. The rear door shall be insulated with a blanket material and a steel covering to
give the surface a hard durable finish.
appurtenances.
8. The boiler shall be furnished with a manhole and handholes to facilitate boiler
9. Exhaust Vent Select one of the following:
(Four-Pass) The exhaust gas vent shall be located near the front of the boiler on the top
center line and shall be capable of supporting 2000 lbs.
A4-37
09-09
Section A4
(Three-Pass) The exhaust gas vent shall be located at the rear of the boiler on the top center
line and shall be capable of supporting 2000 lbs.
before shipment using a hard finish enamel coating.
13. An inner rear turnaround access opening shall swing on a davit, to allow full
accessibility to the 2nd pass tubes and furnace.
14. Tubes shall be removable from either the front or rear of the boiler.
2.2

A. Hot Water Connections
The hot water outlet and return connections shall be located on the top center line
of the boiler. The internal design of these connections shall provide forced internal
circulation, mixing return water with the hot water within the boiler.
B. Dip Tube
The dip tube, an integral part of the hot water outlet, and an air vent tapping in the
boiler shell must be provided for removal of air.
C. Low Water Cutoff
A low water cutoff control shall be mounted on the top centerline of the boiler wired
into the burner control circuit to prevent burner operation if boiler water falls below
a safe level. A manual reset device shall be used on this control.
D. Pressure and Temperature Gauges
Pressure and temperature gauges shall be mounted on the boiler with temperature
sensing element located adjacent to the hot water outlet.
E. Relief Valves
Water relief valves of a type and size to comply with ASME Code requirements shall
be shipped loose.
F.
Temperature Controls
The temperature controls to regulate burner operation shall be mounted on the unit
with temperature sensing elements located adjacent to the hot water outlet.
2.3
BURNER AND CONTROLS

B. Blower
3. The impeller shall be fabricated aluminum with radial blade, carefully
C. Combustion Air Control Select one of the following:
A4-38
09-09
Section A4
(Four-Pass) Combustion air damper and fuel control valve (100 250 hp) or cam operated
fuel metering valve
(300 800 hp) shall be operated by a single damper control motor that regulates the flame
according to load demand. Potentiometer type position controls shall be provided to regulate
operation of the damper control motor.
(Three-Pass) Combustion air damper and fuel control valve (100 350 hp) or cam operated
fuel metering valve
(400 800 hp) shall be operated by a single damper control motor that regulates the flame
according to load demand. Potentiometer type position controls shall be provided to regulate
operation of the damper control motor.
D.

Fuel series 700 Gas fired (para 4.4.1).
Fuel series 100 Light oil (No. 2) fired (para 4.4.2).
Fuel series 200 Light oil or gas fired (para 4.4.3).
1.
FUEL SERIES 700 GAS FIRED

a. Burner Type The burner shall be mounted at the front of the boiler and
of high radiant multi-port type for gas. The burner shall be approved for
operation on natural gas fuel.
c. Gas Burner Piping Select one of the following:
100 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure
connections, and high and low gas pressure switches. The gas valves shall be wired to close
condition.
125 250 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure
regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, two (2) plugged
leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close
condition.
regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, main gas vent
valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves
regulator, two (2) motorized gas valves and one (1) valve with proof of closure switch, main gas vent
valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves
2.
FUEL SERIES 100 LIGHT OIL FIRED

a. Burner Type The burner shall be mounted at the front of the boiler, and
A4-39
09-09
Section A4
b.
c.
d.

Gas Pilot The gas pilot shall be premix type with automatic electric
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.
Oil Burner Piping
1) Four-Pass Select one of the following:
controls, two (2) solenoid oil shut-off valves, atomizing air proving switch, low oil pressure switch,
2)
controls, two (2) solenoid oil shut-off valves, atomizing air proving switch, low oil pressure switch,
e.
100 150 hp. Burner shall include a complete mechanical oil atomizing system and be of the
3.
FUEL SERIES 200 LIGHT OIL OR GAS FIRED

a. Burner Type Select one of the following:
100 150 hp. The burner, mounted at the front of the boiler, shall be a combination pressure
atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for
200 800 hp. The burner, mounted at the front of the boiler, shall be a combination of low pressure
air atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for
A4-40
09-09
Section A4
b.
c.
Gas Pilot The gas pilot shall be premix type with automatic electric
Oil Burner
1) Oil Pump An oil pump with a capacity of approximately twice the
maximum burning rate shall be included. Pump shall be motor
driven and shipped loose to be field installed near the oil storage
tank. Oil pump motor starter shall also be provided.
2) Oil Burner Piping
a.Four-Pass Select one of the following:
b.Three-Pass Select one of the following:
c.Oil Atomization Type Select one of the following:
100 150 hp. Burner shall include a complete mechanical oil atomizing system and be of the
3)
Gas Burner Piping Select one of the following:

a.100 hp. Gas burner piping on all units shall include two (2) manual 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 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
A4-41
09-09
Section A4
gas valve with proof of closure switch, main gas vent valve, two (2) plugged
leakage test connections, and high and low gas pressure switches. The gas
valves shall be wired to close automatically in the event of power failure,
flame failure, low water, or any abnormal shutdown condition.
d.400 800 hp. Gas burner piping on all units shall include two (2) manual
shut-off valves, gas pressure regulator, two (2) motorized gas valves and one
(1) valve with proof of closure switch, main gas vent valve, two (2) plugged
leakage test connections, and high and low gas pressure switches. The gas
valves shall be wired to close automatically in the event of power failure,
flame failure, low water or any abnormal shutdown condition.
E.
2.4
Control Panel and Flame Safeguard Controller

1. Control Panel
A factory prewired control panel shall be supplied with the boiler/burner
package. Panel may be mounted on the burner or boiler.
2. The panel will have a NEMA 1A rating and contain the flame safeguard
controller, burner motor starter, air compressor starter, oil metering pump
motor starter, control circuit transformer and fuses, selector switches,
indicating lights and terminal strips. Lights shall indicate load demand, flame
3. The panel shall contain fuse protection for the burner motor, air compressor
motor, and the oil metering pump.
4. The flame safeguard controller shall be a CB110 flame monitor with EPD170
A. The boiler must be guaranteed to operate at a minimum fuel-to-water efficiency of
____ percent at 100 percent of
rating when burning natural gas and ________ fuel-to-steam efficiency at 100%
firing rate when burning oil (Contact your local Cleaver-Brooks Authorized
Representative for efficiency details).
PART 3 EXECUTION
3.1
WARRANTY
for a period of 12 months from date of
3.2
SHOP TESTS
3.3
START-UP SERVICE
A. After boiler installation is completed, the manufacturer shall provide the services of
a field representative for starting the unit and training the operator at no additional
costs.
1. A factory approved and authorized start-up report shall be submitted to the
A4-42
09-09
Section A5
Model CBL 900-1800 HP
TABLE OF CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Three Pass or Four Pass Design: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front and Rear Doors: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Natural Gas, No. 2 Oil, No. 6 Oil, or Combination Burners Available: . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Connections - Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Connections - Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A5-3
A5-3
A5-3
A5-3
A5-3
A5-4
A5-9
A5-9
A5-10
A5-10
A5-10
A5-10
A5-11
A5-11
A5-11
A5-12
A5-12
A5-12
A5-12
A5-21
A5-1
09-09
Section A5
ILLUSTRATIONS
Figure A5-1. CBL Steam Boiler Dimensions, 4 Pass (Page 1 of 2) (4 pass) . . . . . . . . . . . . . . . . . . . . . . . . .A5-7
Figure A5-2. Space Required to Open Rear Doors on CBL Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-9
Figure A5-3. CBL Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-9
Figure A5-4. CBL Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-10
Figure A5-5. No. 2 Oil Piping, Single Boiler Installation, Oil Pump Integral With Boiler . . . . . . . . . . . . . .A5-19
Figure A5-6. No. 6 Oil Piping, Single Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . . . . . . . . . . .A5-19
Figure A5-7. Boiler Room Length (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-19
Figure A5-8. Boiler Room Width (Typical Layouts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-20
TABLES
Table A5-1. CBL Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-5
Table A5-2. CBL Input Ratings (3-Pass Boilers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-5
Table A5-3. CBL Input Ratings (4-Pass Boilers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-6
Table A5-4. Predicted Fuel-to-Steam Efficiencies (%) CBL Boilers- 125 psig,
Natural Gas, 5sq. ft./BHP, 4 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-14
No. 2 Oil, 5sq. ft./BHP, 4 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-14
No. 6 Oil, 5sq. ft./BHP, 4 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-14
Natural Gas, 4 sq. ft./BHP, 3 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-15
No. 2 Oil, 4 sq. ft./BHP, 3 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-15
No. 6 Oil, 4 sq. ft./BHP, 3 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-15
Table A5-10. CBL Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-16
Table A5-11. CBL Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-16
Table A5-12. CBL Steam Volume and Disengaging Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-17
Table A5-13. CBL Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-17
Table A5-14. CBL Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-17
Table A5-15. CBL gas train connection size and gas pressure requirements . . . . . . . . . . . . . . . . . . . . . . . . .A5-18
Table A5-16. Altitude Correction for Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-18
The following information applies to the Cleaver-Brooks CBL Boiler.
A5-2
09-09
Section A5

The CBL 900-1800 HP Firetube boiler is designed, manufactured, and packaged by
Cleaver-Brooks. All units are factory fire tested and shipped as a package, ready for
quick connection to utilities. In addition to the features provided on all Cleaver-Brooks
Firetube boilers, the following features apply to the CBL.
Three Pass or Four Pass Design:
The packaged boiler offers high efficiency, flexibility, reliability, safety and ease of
operation.
Front and Rear Doors:
Davited, front and rear doors, all sizes.
Provides access to front tube sheet and furnace.
Natural Gas, No. 2 Oil, No. 6 Oil, or Combination Burners Available:

adjustment.
PRODUCT OFFERING
Cleaver-Brooks CBL Boilers are available in low pressure and high pressure steam and
hot water designs. Burners are available to fire natural gas, No. 2 oil, No. 6 oil, or a
combination of oil and gas. Standard product offering is:
900 - 1800 hp.
Three pass wetback design or four pass wetback design.
4 or 5 square foot of heating surface per boiler horsepower
15- 250 psig steam in most sizes.
30 & 125 psig hot water in most sizes.
Available options include the following (contact your local Cleaver-Brooks authorized
representative for option details).
Boiler Options:
Blowdown valves.
Non-return valves.
Surge load baffles.
Seismic design.
Lead/lag system.
A5-3
09-09
Section A5
Special insurance and code requirements (e.g., IRI, FM, NFPA8501).
Main disconnect.
Elapsed time meter.
NEMA enclosures.
Circuit breakers.
Day/night controls.
Low NOx Equipment.
HAWK ICS
Fuel Options:
Gas strainer.
Gas pressure gauge.
Optional Oil Pumps.

Dimensions and ratings for the CBL Boilers are shown in the following tables and
illustrations. The information is subject to change without notice.
Table A5-1. CBL Steam Boiler Ratings
Table A5-2. Heating Surface
Figure A5-1. CBL Steam Boiler Dimensions
Figure A5-2. CBL Boiler Space Requirements to Open Rear Door
Figure A5-3. Lifting Lug Location, CBL Boilers
Figure A5-4. CBL Boiler Mounting Piers
A5-4
09-09
Section A5

Table A5-1. CBL Steam Boiler Ratings
BOILER HP
800
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
RATINGS - SEA LEVEL TO 1000 FT B

from and at 212 F)
27600 31050 34500 37950 41400 44850 48300 51750 55200 58650 62100
26780 30125 33475 36820 40170 43515 46865 50210 53550 56905 60255
75
100
100
100
Oil Pump Motor hp (#2 oil)
1-1/2
1-1/2
1-1/2
1-1/2
Oil Pump Motor hp (#6 oil)
1-1/2
Air Comp. Motor, hp (#2 oil)
7-1/2
15
15
15
15
15
15
15
Oil heater Kw (#6 oil)
10
10
10
15
15
15
15
15
ac
75
tF
60
ta
c
60
on
60
Blower Motor, hp A(Gas and

Oil)
to
ry
POWER REQUIREMENTS SEA LEVEL TO 1000 FT ( 60 HZ)
NOTE:
A. Blower motor HP may increase if a low NOx option is added
B. Ratings based on nominal 80% efficiency.
C. Ratings based on 60 hertz, please verify 50 hertz ratings with factory.
Table A5-2. CBL Input Ratings (3-Pass Boilers)

Boiler Square Foot Heating Surface
4000
4500
5000
5500
6000
6500
7000
7500
Approximate Fuel Consumption D

Horsepower
(5 sq.ft./bhp)
800
900
1000
1100
1200
1300
1400
1500
Natural Gas A (cfh)
33475
37660
41845
46025
50215
54395
58585
62765
No. 2 Oil B (gph)
239.3
269.0
299.0
329.0
359.0
388.5
418.0
447.5
No. 6 Oil C (gph)
223.4
251.1
279.0
307.0
335.0
363.0
390.0
417.0
Horsepower
(4 sq.ft./bhp)
1000
1100
1200
1300
1500
1600
1700
1800
Natural Gas A (cfh)
41845
46025
50215
54395
62765
66950
71133
75318
No. 2 Oil B (gph)
299.0
329.0
359.0
388.5
447.5
477.3
507.2
537
No. 6 Oil C(gph)
279.0
307.0
335.0
363.0
417.0
444.8
472.6
500.4
Note:
A. Natural gas based on heating value of 1000 BTU/cu.ft
B. No. 2 oil based on heating value of 140,000 BTU/gal.
C. No. 6 oil based on heating value of 150,000 BTU/gal.
D. Ratings based on nominal 80% efficiency.
A5-5
09-09
Section A5
Table A5-3. CBL Input Ratings (4-Pass Boilers)
Boiler Square Foot Heating Surface
4000
4500
5000
5500
6000
6500
7000
7500
Approximate Fuel Consumption D

Horsepower
(5 sq.ft./bhp)
800
900
1000
1100
1200
1300
1400
1500
Natural Gas A (cfh)
32659
36741
40824
44906
48989
53071
57153
61236
No. 2 Oil B (gph)
233.3
262.4
291.6
320.8
349.9
379.1
408.2
437.4
No. 6 Oil C (gph)
217.7
244.9
272.2
299.4
326.6
353.8
381.0
408.2
Horsepower
(4 sq.ft./bhp)
1000
1100
1200
1300
1500
1600
1700
1800
Natural Gas A (cfh)
40824
44906
48989
53071
57153
65317
69399
73481
No. 2 Oil B (gph)
291.6
320.8
349.9
379.1
437.4
466.6
495.7
524.9
No. 6 Oil C(gph)
272.2
299.4
326.6
353.8
408.2
435.4
462.6
489.9
Note:
A. Natural gas based on heating value of 1000 BTU/cu.ft
B. No. 2 oil based on heating value of 140,000 BTU/gal.
C. No. 6 oil based on heating value of 150,000 BTU/gal.
D. Ratings based on nominal 82% efficiency.
A5-6
09-09
Section A5
BB
J
RF/RD
B
Y
GG
L
K
CC
F
G
O
D
Q
N
M
W
A
BOILER SQUARE FOOT

HEATING SURFACE
4000
4500
5000
5500
6000
6500
7000
7500
Boiler Horsepower@ 5 ft2/bhp
800
900
1000
1100
1200
1300
1400
1500
ft2/bhp
1000
1100
1200
1300
1500
1600
1700
1800
Boiler Horsepower @ 4
DIM
LENGTHS
Overall
*B
367
394
386
411
434
387
406
425
Shell
293
323
288
312
335
304
323
342
Base Frame *
285
317
282
304
327
296
315
334
26
26
26
26
26
26
26
26
148
148
148
148
148
148
148
148
WIDTHS
Overall With Trim
144
144
156
156
156
168
168
168
I. D. Boiler
114
114
126
126
126
138
138
138
72
72
78
78
78
84
84
84
Center to Lagging
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
96
96
96
96
96
96
96
96
Base Inside
80
80
80
80
80
80
80
80
* Approximate - varies with burner selection

Boiler Horsepower@ 5
ft2/bhp
800
900
1000
1100
1200
1300
1400
1500
Boiler Horsepower @ 4
ft2/bhp
1000
1100
1200
1300
1500
1600
1700
1800
Figure A5-1. CBL Steam Boiler Dimensions, 4 Pass (Page 1 of 2)
A5-7
09-09

BOILER SQUARE FOOT
HEATING SURFACE
Section A5
DIM
4000
4500
5000
5500
6000
6500
7000
7500
HEIGHTS
Base to piping
connections
149
149
161
161
161
77-1/2
77-1/2
83-3/4
83-3/4
83-3/4
Base to Vent Outlet
141
141
153-1/2 153-1/2 153-1/2 162-1/8 162-1/8 162-1/8
141
141
153-1/2 153-1/2 153-1/2 162-1/8 162-1/8 162-1/8
Base Frame
12
12
12
12
12
12
12
12
20
20
20
20
20
17
17
17
168-1/8 168-1/8 168-1/8

86-1/2
86-1/2
86-1/2
CONNECTIONS
Chemical Feed
3/4
3/4
3/4
3/4
3/4
3/4
3/4
3/4
10
10
10
12
12
12
12
12
Blowdown - Front & Rear
Surface Blowoff
BB
32
32
36
36
36
42
42
42
CC
17-1/2
17-1/2
19-1/2
19-1/2
19-1/2
24
24
24
Steam
NozzleA
(150 psig)
MISCELLANEOUS
Rear Door Swing
AA
GG
246
276
217
241
264
233
252
271
Min. Boiler Room Length For

Tube Removal Front
RF
537
597
538
586
632
665
703
741
Min. Boiler Room Length For

Tube Removal Thru Door
RD
484
514
489
513
536
528
547
566
Normal Water Weight (Lbs)
43800
49400
49300
54000
60000
61000
66000
71000
Flooded Water Weight (Lbs)
54500
61300
65300
71900
78300
83000
89000
96000
Approx. Wt. 15/30 psig (Lbs.)
58000
63000
73100
77200
82200
87000
91700
96600
Approx. Wt. 150 psig (Lbs.)
65000
71000
79600
85300
90900
97300
102600 108200
73500
82200
88600
95000
101500 107800 115500 121000
81300
89000
97200
104000 110000 118000 124000 132000
NOTES:
Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for actual option
requirements.
A. 300 psig Flange. See recommended steam nozzle size chart for operating pressure greater than 125 psig.
B. Add 11 1/2 inches to dimension B for a three pass boiler.
C. Reference Figure A11-2.
D. Overall height is 171 inches after trim is mounted on the boiler in the field.
Figure A5-1. CBL Steam Boiler Dimensions, 4 Pass (Page 2 of 2)
A5-8
09-09
Section A5
3-PASS BOILER SHOWN.

4 PASS VENT STUB ON
OPPOSITE END.
"D"
"B"
"A"
BOILER
DIMENSION (INCHES)
ID
114"
60
72
39
82
22
"E"
"C"
REAR DOOR
126"
66
78
52
93
33
138"
72
84
66
105
45
MAXIMUM REAR
MINIMUM SIDE
MINIMUM REAR
MAXIUM SIDE
Figure A5-2. Space Required to Open Rear Doors on CBL Boilers
BOILER SQUARE
FOOT OF HEATING
SURFACE
4000
4500
5000
5500
6000
6500
7000
7500
BHP
4 sq.ft.
5 sq.ft.
1000
1100
1200
1300
1500
1600
1700
1800
800
900
1000
1100
1200
1300
1400
1500
138
138
150
150
150
162
162
162
47
47
47
47
47
47
47
47
205
238
200
222
247
216
235
254
12
12
12
12
12
12
12
12
3
3
3
3
3
3
3
3
Figure A5-3. CBL Boilers Lifting Lug Location
A5-9
09-09
Section A5
H
E
BOILER SQUARE
BHP
FOOT OF HEATING
4 sq-ft
5 sq-ft
SURFACE
4000
1000
800
4500
1100
900
5000
1200
1000
5500
1300
1100
6000
1500
1200
6500
1600
1300
7000
1700
1400
7500
1800
1500
NOTE: All numbers in table are in inches.
6
6
6
6
6
6
6
6
12
12
12
12
12
12
12
12
*
*
*
*
*
*
*
*
76
76
76
76
76
76
76
76
100
100
100
100
100
100
100
100
8
8
8
8
8
8
8
8
80
80
80
80
80
80
80
80
12
12
15
15
15
15
15
15
6-inch high mounting piers recommended for beneath the boiler frame. The use of these piers provides increased
inspection accessibility to the piping beneath the boiler and added height for washing down the area beneath the
boiler.
The (*) varies with horsepower rating and burner selection, see Dimension Diagram for job-specific mounting pier
length.
Figure A5-4. CBL Boiler Mounting Piers
PERFORMANCE DATA
Efficiency
Tables A5-4, A5-5, A5-6, A5-7, A5-8, and A5-9 show predicted fuel-to-steam
efficiencies (including radiation and convection losses) for Cleaver-Brooks CBL
Firetube boilers. For specific efficiencies on firetube boiler offerings not listed here,
Cleaver-Brooks offers an industry leading fuel-to-steam boiler efficiency guarantee for
CBL Firetube Boilers. The guarantee is based on the fuel-to-steam efficiencies shown in
the efficiency tables and the following conditions. The efficiency percent number is only
meaningful if the specific conditions of the efficiency calculations are clearly stated in
the specification (see Cleaver-Brooks publication CB-7767 for a detailed description of
efficiency calculations).
achieve fuel-to-steam efficiency (as shown in the tables listed above) at 100% firing rate
A5-10
09-09
Section A5

(add efficiency guarantees at 25%, 50%, and 75% of rating, if required). If the boiler(s)
manufacturer will rebate, to the ultimate boiler owner, five thousand dollars ($5,000) for
1.
Natural Gas
Carbon,% (wt) = 69.98

Sulfur,% (wt) = 0.0
No. 2 Oil

Sulfur,% (wt) = 0.2
No. 6 Oil

2.
Efficiencies are based on ambient air temperature of 80 F, relative humidity of 30%, and 15%
excess air in the exhaust flue gas.
3.
Efficiencies are based on the following radiation and convection losses. Firing rate of 25% 1.2%, 50% - 0.6%, 75% - 0.4%, and 100% - 0.3%.
ENGINEERING DATA
The following engineering information is provided for CBL Boilers. Additional detail is
available from your local Cleaver-Brooks authorized representative.
Boiler Information
Table A5-12 shows steam volume and disengaging area for CBL boilers.
Table A5-10 lists quantity and outlet size for safety valves supplied on CBL boilers.
Table A5-11 gives recommended steam nozzle sizes on CBL Boilers.
Table A5-13 shows recommended non-return valve sizes for CBL Boilers.
Blowdown Water Requirements
Table A5-14 lists the approximate quantity of water represented by 4 inches of water at
normal operating level for Cleaver-Brooks CBL Boilers.
Burner/Control
Information
Note that altitude correction and burner changes are required for higher altitudes which
A5-11
09-09
Section A5
may alter dimensions, motor hp and gas pressures. Also 50 Hz applications and low NOx
options should be reviewed by the Cleaver-Brooks authorized representative.
Gas-Fired Burners
Table A5-15 gives gas train connection sizes and gas pressure requirements.
Table A5-16 shows correction factors for gas pressure at elevations over 1000 ft. above
sea level.
For oversized or undersized gas trains or altitude above 1,000 feet, contact your local
venting must be in accordance with all applicable engineering guidelines and regulatory
codes. All connections made to the boiler should be arranged so that all components
remain accessible for inspection, cleaning and maintenance.
pressure regulator. The drip leg should be at least as large as the inlet fitting supplied
with the boiler. Consideration must be given to both volume and pressure requirements
when choosing gas supply piping size. Refer to the boiler dimension diagram provided
by Cleaver-Brooks for the particular installation. Connections to the burner gas train
should be made with a union, so that gas train components or the burner may be easily
disconnected for inspection or service. Upon completion of the gas piping installation,
the system should be checked for gas leakage and tight shutoff of all valves.
Oil-fired burners are equipped with an oil pump, which draws fuel from a storage tank
and supplies pressurized oil to the burner nozzle(s). The burner supply oil pump has a
greater capacity than the burner requires for the maximum firing rate. Fuel not delivered
to the nozzle is returned to the storage tank. A two-pipe (supply and return) oil system is
recommended for all installations. Figure A5-5 shows a typical fuel oil supply
arrangement. Oil lines must be sized for the burner and burner supply oil pump
capacities.
The burner supply oil pump suction should not exceed 10" Hg. If a transfer pump is used,
it must have a pumping capacity at least equal to that of the burner pump(s). Supply
pressure to the burner pump should not exceed 3 psig.
A strainer must be installed in the supply piping upstream of the burner supply pump in
order to prevent entry of foreign material into the pump, fuel control valves, or burner
nozzle(s). The strainer must be sized for the burner supply pump capacity. A strainer
mesh of 150 microns (0.005") is recommended.
Install a check valve in the line to prevent draining of the oil suction line when the burner
is not in operation. Location of the check valve varies with the system, but usually it is
located as close as possible to the storage tank.
Installation of a vacuum gauge in the burner supply line between the burner oil pump and
the strainer is recommended. Regular observation and recording of the gauge indication
will assist in determining when the strainer needs servicing.
Upon completion of the oil piping installation, the system should be checked for oil or air
leakage and tight shutoff of all valves.
A5-12
09-09
Section A5
Boiler Room
Information
Stack Support
Capabilities
CBL Boilers can support up to 2000 lbs. without additional support.
Boiler Room
Combustion Air

CBL Boilers can be reinforced to support up to 3000 lbs.
1.
Size (area) and location of air supply openings in boiler room.

recommended. Locate one (1) at each end of the boiler room, preferably below a height of
7 feet. This allows air to sweep the length of the boiler.
B. Air supply openings can be louvered for weather protection, but they should not be covered
with fine mesh wire, as this type of covering has poor air flow qualities and is subject to
clogging by dust or dirt.
C. A vent fan in the boiler room is not recommended, as it could create a slight vacuum under
certain conditions and cause variations in the quantity of combustion air. This can result in
unsatisfactory burner performance.
D. Under no condition should the total area of the air supply openings be less than one (1)
square foot.

2.
Amount of air required (cfm).

B. Ventilation Air = Maximum bhp x 2 cfm/bhp or a total of 10 cfm/bhp - up to 1000 feet
elevation. Add 3 percent more per 1000 feet of added elevation.
3.
Acceptable air velocity in Boiler Room (fpm).

Area Required: Area = cfm/fpm = 10000/250 = 40 Sq-ft total.
Notice
Stack/Breeching
Size Criteria
The design of the stack and breeching must provide the required draft at each boiler flue
gas outlet. Proper draft is critical to burner performance.
Although constant pressure at the flue gas outlet of the CBL is not required, it is
necessary to size the stack/breeching to limit flue gas pressure variation. The allowable
pressure range is 0.50 W.C. to +0.50 W.C. The maximum pressure variation at any
firing rate for the boiler is 0.50" W.C.
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.
A5-13
09-09
Section A5
For additional information, please review Section I4, General Engineering Data (Stacks)
and Section F, Stacks. Stack and breeching sizes should always be provided by a
reputable stack supplier who will design the stack and breeching system based on the
above criteria. Your local Cleaver-Brooks authorized representative is capable of
assisting in your evaluation of the stack/breeching design.
Table A5-4. Predicted Fuel-to-Steam Efficiencies (%) CBL

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

Boilers- 125 psig, No. 2 Oil, 5sq. ft./BHP, 4 Pass
25
50
75
100
800
82.0
82.3
82.7
82.5
900
82.3
82.0
82.5
82.5
BOILER
HP
1000
82.0
82.6
82.7
82.6
1100
82.3
82.7
82.7
82.7
1200
82.2
83.0
83.2
83.2
1300
82.5
82.8
83.0
1400
82.3
82.3
1500
82.0
83.0
FIRING RATE (%)

25
50
75
100
800
85.2
85.9
85.9
86.0
900
85.3
85.8
86.0
86.0
1000
85.8
86.0
86.0
86.2
83.0
1100
85.5
85.6
85.6
86.0
82.8
82.8
1200
85.8
86.0
86.3
86.5
83.0
83.0
1300
85.3
86.0
86.4
86.6
1400
85.9
86.0
86.4
86.5
1500
86.0
86.6
86.5
86.6

Boilers- 125 psig, No. 6 Oil, 5sq. ft./BHP, 4 Pass
BOILER
HP
A5-14
09-09
FIRING RATE (%)

25
50
75
100
800
86.5
86.0
86.5
86.8
900
86.6
86.5
86.5
86.9
1000
86.5
86.6
86.5
86.8
1100
86.5
86.7
86.6
86.9
1200
86.5
87.0
87.0
87.0
1300
86.3
86.6
87.0
87.0
1400
86.0
86.5
86.8
86.7
1500
86.0
86.5
86.8
86.6
Section A5

Boilers- 125 psig, Natural Gas, 4 sq. ft./BHP, 3 Pass
BOILER
HP
FIRING RATE (%)

25
50
75
100
1000
81.4
81.5
81.5
81.5
1100
81.3
81.6
82.0
82.0
1200
81.2
81.4
82.0
82.0
1300
81.0
81.3
81.6
82.0
1400
81.0
81.3
81.4
81.8
1500
81.0
81.4
81.4
81.9
Table A5-8. Predicted Fuel-to-Steam Efficiencies (%) CBL Boilers125 psig, No. 2 Oil, 4 sq. ft./BHP, 3 Pass
BOILER
HP
FIRING RATE (%)

25
50
75
100
1000
84.8
85.0
85.0
85.0
1100
84.7
85.0
85.0
85.0
1200
85.0
85.2
85.4
85.2
1300
85.0
85.0
84.8
85.5
1400
85.0
85.6
84.8
85.5
1500
85.0
85.5
84.9
85.6
Table A5-9. Predicted Fuel-to-Steam Efficiencies (%) CBL Boilers125 psig, No. 6 Oil, 4 sq. ft./BHP, 3 Pass
BOILER
HP
FIRING RATE (%)

25
50
75
100
1000
86.2
86.2
85.8
85.6
1100
86.3
86.4
86.1
85.9
1200
86.2
86.2
85.8
86.0
1300
86.0
86.4
86.1
85.8
1400
86.0
86.4
86.0
85.8
1500
86.0
86.3
86.2
85.9
A5-15
09-09
Section A5
Table A5-10. CBL Steam Boiler Safety Valve Outlet Size

VALVE
SETTING
BOILER
HP
15 PSIG STEAM
150 PSIG STEAM
200 PSIG STEAM
250 PSIG STEAM
NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET

VALVES
SIZE
VALVES
SIZE
VALVES
SIZE
VALVES
SIZE
REQ'D
(FPT)
REQ'D
(FPT)
REQ'D
(FPT)
REQ'D
(FPT)
800
1-3
1-4
1 - 2 1/2
1-3
2 1/2
900
1-3
1-4
1 - 2 1/2
1-3
1000
2-8
1-6
1 - 2 1/2
1-3
1100
2-8
1-6
1-3
1-4
1200
1-3
1-4
1300
2-3
1-4
1 - 2 1/2
2-3
1400
1-3
2-4
1500
1-3
2-4
NOTES:
Table A11-8 only applies to 5 Sq Ft/BHP units.
Valve manufacture is Kunkle.
Valve requirements can vary with special pressure settings.
Table A5-11. CBL Recommended Steam Nozzle Size

BOILER HP
OPERATING PRESSURE PSIG
800
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
12
18
18
20
20
24
24
24
24
24
24
24
30
14
16
16
16
18
18
18
20
20
20
20
50
12
12
12
14
16
16
16
16
16
16
16
75
10
10
12
12
12
12
12
14
14
14
14
100
10
10
10
10
12
12
12
12
12
12
14
125
10
10
10
10
10
12
12
12
12
12
150
10
10
10
10
10
10
10
12
200
10
10
10
10
10
10
10
225
10
10
10
10
10
10
NOTES:
Steam nozzle sizes given in inches.
All standard steam nozzle sizes for the 150 psig design pressure or greater are the same as 125 psig operating pressure
on the above table. To increase or decrease the standard size, request the change with your local Cleaver-Brooks authorized representative.
A5-16
09-09
Section A5

Table A5-12. CBL Steam Volume and Disengaging Areas
BHP
BOILER SQUARE FOOT

OF HEATING SURFACE
STEAM VOLUME (CU-FT)
STEAM RELIEVING AREA (SQ-
4 SQ.FT.
5 SQ.FT.
HIGH PRESSURE (A)
HIGH PRESSURE (A)
4000
1000
800
155
20566
4500
1100
900
174
23105
5000
1200
1000
250
24141
5500
1300
1100
273
26372
6000
1500
1200
300
28908
6500
1600
1300
352
28918
7000
1700
1400
379
31079
7500
1800
1500
405
33242
NOTES:
Based on normal water level.
Values are based on standard controls. Optional controls may result in different values.
Table A5-13. CBL Recommended Non-Return Valve Size

BOILER
HP
CAPACITY
LBS.PER HR.
OPERATING PRESSURE
50
75
100
125
150
175
200
225
900
31050
1000
34500
6*
1100
37950
1200
41400
1300
44850
1400
48300
1500
51750
1600
55200
10
10
1700
58650
10
10
1800
62100
10
10
10
NOTE:
Standard non-return valve selections limited to a maximum 2 to 1 turndown (50% of full boiler output); selection based on typical valve sizing recommendations. For
final valve selection contact your authorized C-B representative. For high turndown applications see Boiler Book Section I3, Table I3-3.
Table A5-14. CBL Blowdown Tank Sizing Information

BHP
BOILER SQUARE FOOT OF HEATING

SURFACE
4 SQ.FT.
5 SQ.FT.
4000
1000
800
356
4500
1100
900
400
5000
1200
1000
418
5500
1300
1100
460
6000
1500
1200
500
6500
1600
1300
500
7000
1700
1400
538
7500
1800
1500
575
WATER (GAL)
NOTE: Quantity of water removed from boiler by lowering normal water line 4".
Optional level controls can alter water quantities.
A5-17
09-09
09-09
Section A5
Table A5-15. CBL gas train connection size and gas pressure requirements
2
4 ft /bhp
3 pass
Boiler HP
std
Gas train
connection
2.5
3
3
3
3
4
1000
1100
1200
1300
1400
1500
Pressure
required
8.2
5.4
6.3
7.2
8.4
5.4
4 pass
30 ppm
Gas train
Pressure
connection
required
2.5
8.3
3
5.4
3
6.3
3
7.3
3
8.5
4
5.5
std
Gas train
connection
2.5
3
3
3
3
4
Pressure
required
8.1
5.4
6.3
7.2
8.3
5.6
30 ppm
Gas train
Pressure
connection
required
2.5
8.2
3
5.6
3
6.4
3
7.3
3
8.5
4
5.8
4.5 ft /bhp
3 pass
Boiler HP
std
Gas train
connection
2.5
2.5
3
3
3
3
4
900
1000
1100
1200
1300
1400
1500
Pressure
required
7.4
8.2
5.3
6.3
7.2
8.4
5.4
4 pass
30 ppm
Gas train
Pressure
connection
required
2.5
7.4
2.5
8.3
3
5.4
3
6.3
3
7.3
3
8.4
4
5.5
std
Gas train
connection
2.5
2.5
3
3
3
3
4
Pressure
required
7.3
8.1
5.3
6.2
7.2
8.2
5.4
30 ppm
Gas train
Pressure
connection
required
2.5
7.4
2.5
8.2
3
5.4
3
6.4
3
7.3
3
8.3
4
5.6
5 ft /bhp
3 pass
Boiler HP
800
900
1000
1100
1200
1300
1400
1500
std
Gas train
connection
2.5
2.5
2.5
3
3
3
3
4
Notes:
Pressure
required
6.0
7.4
8.2
5.3
6.3
7.2
8.4
5.4
4 pass
30 ppm
Gas train
Pressure
connection
required
2.5
6.1
2.5
7.4
2.5
8.2
3
5.4
3
6.3
3
7.2
3
8.4
4
5.5
std
Gas train
connection
2.5
2.5
2.5
3
3
3
3
4
Pressure
required
5.9
7.3
7.9
5.3
6.2
7.1
8.2
5.4
30 ppm
Gas train
Pressure
connection
required
2.5
6.0
2.5
7.4
2.5
8.0
3
5.4
3
6.3
3
7.2
3
8.3
4
5.6
3 pass boilers are based on 80% efficiency

4 pass boilers are based on 82% efficiency
Pressure shown is minimum required and is listed as psi
Incoming pressure is not to exceed 10 psi
Ultra Low Nox (9 and 15ppm) are handled on a case by case basis

ALTITUDE (FT)
CORRECTION FAC-
ALTITUDE (FT)
CORRECTION FACTOR
1000
1.04
6000
1.25
2000
1.07
7000
1.30
3000
1.11
8000
1.35
4000
1.16
9000
1.40
5000
1.21
To obtain minimum required gas pressure at altitudes above 700 feet, multiply the pressure by the listed factors:
inches WC x 0.577 = oz/sq-in.
inches WC x 0.0361= psig.
A5-18
09-09
Section A5

Installation, Oil Pump Integral With Boiler

BOILER SQUARE
FOOT OF HEATING
SURFACE
4000
4 sq.ft.
5 sq.ft.
1000
4500
BHP
800
610
484
1100
900
670
514
5000
1200
1000
606
489
5500
1300
1100
654
513
6000
1500
1200
700
536
6500
1600
1300
642
515
7000
1700
1400
680
534
7500
1800
1500
718
553
NOTE: A = Minimum length based on removing tubes in the boiler room.

B = Minimum length based on removing tubes through a wall opening.
Figure A5-7. Boiler Room Length (Typical Layout)

A5-19
09-09
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.
Section A5
2. Next shortest boiler room length (Dwg B) is obtained by allowing for possible future tube
replacement from the front of the boiler. Allowance is only made for minimum door swing at
the rear.
If space permits, approximately 1.5 additional feet should be allowed at the rear for additional
aisle and working space.
Boiler Square Foot of Heating

Surface
40004500
50006000
65007500
Dimension A (inches)
117
123
129
Dimension B (inches)
198
210
222
For reference to Boiler Horsepower per square foot see A11-7
Figure A5-8. Boiler Room Width (Typical

Layouts)
A5-20
09-09
Section A5
Model CBL
Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-22

General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-22
Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-23
Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-24
Fuel Specification and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-24
Boiler Flame Safeguard Controller and Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-28
Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-29
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-29
Shop Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-29
SAMPLE SPECIFICATIONS
The following sample specifications are provided by Cleaver-Brooks to assist you in meeting your customers specific needs and
application.
The detailed burner and control specifications, and detailed control specifications for CB100E Flame Safeguard control are
provided. See Section D, Controls, for additional information on control options.
The Sample Specifications are typically utilized as the base template for the complete boiler specification. Contact your local
Cleaver-Brooks authorized representative for information on special insurance requirements, special code requirements, optional
equipment, or general assistance in completing the specification.
A5-21
09-09
Sample Specifications Model CBL
Section A5
PART 1 GENERAL
CBL Steam Boiler (900-1800 hp, Steam 15-250 psig)
1.1

A. The Steam Boiler shall be Cleaver-Brooks Fuel Series ______ (100, 200, 400, 600, 700), ______ hp
designed for ______ psig (15, 150, 200, or 250 psig steam). The maximum operating pressure shall be
_____ psig and the minimum operating pressure shall be ______ psig.
B. The boiler shall have a maximum output of ______ Btu/hr, or ______ horsepower when fired with
CS12-48 ______ oil and/or natural gas, ______ Btu/cu-ft. Electrical power available shall be ______
Volt ______ Phase ______ Cycle.
PART 2 PRODUCTS
2.1

A. The boiler shall be a three pass or four pass horizontal firetube updraft boiler with ________ square
feet of heating surface per rated boiler horsepower. It shall be mounted on a heavy steel frame with
integral forced draft burner and burner controls.
1. The boiler shall be completely preassembled and fire tested at the factory. The unit shall be ready
for immediate mounting on floor or simple foundation and ready for attachment of water, fuel,
electrical, vent, and blowdown connections.
2. The boiler shall be built to comply with the following insurance and codes ______________
(Factory Mutual, Industrial Risk Insurance, ASME, NFPA 8501).
B. Boiler Shell (Steam)
1. The boiler shell must be constructed in accordance with ASME Boiler Code and must receive
authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished
to the purchaser.
2. The boiler shall be furnished with a manhole and handholes to facilitate boiler inspection and
cleaning. Two lifting lugs must be located on top of the boiler.
3. The front door shall be davited and the rear door shall be davited. Doors are to be sealed with
fiberglass tadpole gaskets and fastened tightly using heavy capscrews that thread into replaceable
brass nuts.
4. The boiler tubes shall not include turbulators, swirlers, or other add-on appurtenances.
5. The rear door shall be insulated with a blanket material with a steel covering to give the surface a
hard durable finish.
6. The exhaust gas vent shall be located at the front or rear of the boiler and be capable of
supporting 2000 lbs. The boiler vent shall contain a stack thermometer.
7. Observation ports for the inspection flame conditions shall be provided at each end of the boiler.
8. The boiler insulation shall consist of 2 inch blanket under a sectional pre-formed sheet metal
lagging. The insulation must be readily removable and capable of being reinstalled, if required.
9. The entire boiler base frame and other components shall be factory-painted before shipment,
using a hard-finish enamel coating.
10. The boiler shall contain a chemical feed connection.
2.2
STEAM BOILER TRIM

A. Water Column
A water column shall be located on the right-hand side of the boiler complete with gauge glass set, and
A5-22
09-09
Section A5
B.
C.
D.
E.
Sample Specificawater column blowdown valves.

1. Modulating feedwater Control
The boiler modulating feedwater control and valve shall be included to automatically maintain
the boiler water level within normal limits.
2. Low Water Cutoff
The low water cutoff shall be included as an integral part of the boiler feedwater control and
wired into the burner control circuit to prevent burner operation if the boiler water level falls
below a safe level.
Auxiliary Low Water Cut-off
Auxiliary low water cut-off shall be included, piped to the vessel, and wired to the burner control
circuit. A manual reset device shall be used on this control.
The steam pressure gauge shall be located at the front of the boiler and include cock and test
connection.
Safety Valves
Safety valves of a type and size to comply with ASME Code requirements shall be shipped loose.
Steam Pressure Controls
The steam pressure control to regulate burner operation shall be mounted near the water column.
Controls shall be a high limit (manual reset), operating limit (auto reset), and firing rate control.
2.3
BURNER AND CONTROLS

1. Burner operation shall be full modulation principle. The burner shall always return to low fire
2. A low fire hold temperature control is mounted and wired on the boiler.
B. Blower
1. Air for combustion shall be supplied by a forced draft blower mounted on the burner, to eliminate
vibration and reduce noise level.
2. Maximum sound level of the boiler/burner package shall not exceed _____ dbA (when measured
in accordance with ABMA Sound Test Standards).
3. The impeller shall be fabricated aluminum with radial blade, carefully balanced, and 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.
2.4
FUEL SPECIFICATION AND PIPING

Fuel series 700 - Gas-fired.
Fuel series 100 - Light oil (No. 2) fired .
Fuel series 200 - Light oil or gas-fired.
Fuel series 600 - No. 6 oil-fired.
Fuel series 400 - No. 6 oil or gas-fired.
A.
Fuel Series 700 - Gas-Fired

1. Burner Type - The burner shall be mounted at the front of the boiler and of high radiant multi-
A5-23
09-09
B.
C.
Section A5
port type gas entry. The burner shall be approved for operation on natural gas fuel.
2. Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic
detector shall monitor the pilot so that the primary gas valve cannot open until pilot flame has
been established. The pilot train shall include one manual shut-off valve, solenoid valve, pressure
regulator and one (1) plugged leakage test connection (Canada only).
3. Gas Burner Piping - Gas burner piping on all units shall include a gas pressure regulator, a
primary gas shutoff valve, motor operated with proof of closure switch and plugged leakage test
connection. The main gas valves shall be wired to close automatically in the event of power
failure, flame failure, low water or any safety shutdown condition. A lubricating plug cock shall
be provided as a means for a tightness check of the primary shutoff valve. An additional plug
cock shall be furnished at entrance to gas train. High and low gas pressure switches shall be
provided. A second motorized safety shutoff valve, plus an additional plugged leakage test
connection shall be provided. A vent valve shall be located between the safety shutoff valves.
4. Burner Turndown: Turndown range shall be 8:1 when firing natural gas on standard burners with
uncontrolled emissions (100 ppm NOx). Consult Cleaver-Brooks representative regarding
turndown capability for low NOx burners 30 ppm and less.
Fuel Series 100 - Light Oil-Fired
1. Burner Type - The burner shall be mounted at the front of the boiler, and shall be a low pressure
air atomizing type approved for operation with CS12-48, Commercial No. 2 oil.
detector shall monitor the pilot so that the primary oil valve cannot open until pilot flame has
regulator and one (1) plugged leakage test connection (Canada only).
3. Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall
be included. The motor-driven pump set, shipped loose, to be installed in a location favorable to
the oil storage tank, shall be provided.
4. Oil Burner Piping
a. Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering
controls, low oil pressure switch, two (2) motorized oil valves and pressure gauges, all
integrally mounted on the unit.
5. Low Pressure Air Atomizing: Separate air compressor module, shipped loose with burner
mounted low atomizing air pressure switch.
6. Turndown range shall be 6:1 when firing No. 2 oil on standard burners with uncontrolled
emissions. Consult Cleaver-Brooks representative regarding turndown capability for low NOx
burners.
Fuel Series 200 - Light Oil or Gas-Fired
1. Burner Type - The burner shall be mounted at the front of the boiler and shall be a combination of
the low pressure air atomizing type for oil and multi-port type for gas. The burner shall be
approved for operation with either CS12-48 Commercial No. 2 Oil or natural gas.
2. Gas Pilot - The gas pilot shall be premix type with automatic electric ignition. An electronic
detector shall monitor the pilot so that the primary fuel valve cannot open until flame has been
established. The pilot train shall include one manual shut-off valve, solenoid valve, pressure
regulator and pressure gauge and one (1) plugged leakage test connection (Canada only).
3. Oil Burner
a. Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate
shall be included. The motor-driven pump set, shipped loose, shall be provided, to be
installed in a location favorable to the oil storage tank.
A5-24
09-09
Section A5
Sample Specificab.
Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices,
oil metering controls, low oil pressure switch, two (2) motorized oil valves, and pressure
gauges all integrally mounted on the unit.
c. Low pressure Air Atomizing - Separate air compressor module, shipped loose with
burner-mounted low-atomizing air pressure switch.
d. Burner Turndown - Turndown range shall be 6:1 when firing No. 2 oil on standard burners
with uncontrolled emissions. Consult Cleaver-Brooks representative regarding turndown
capability for low NOx burners.
4. Gas Burner
a. Gas Burner Piping - Gas burner piping on all units shall include a gas pressure regulator,
and a primary gas shutoff valve, motor-operated with proof-of-closure switch and plugged
leakage test connection. The main gas valves shall be wired to close automatically in the
event of power failure, flame failure, low water or any safety shutdown condition. A
lubricating plug cock shall be provided as a means for a tightness check of the primary
shutoff valve. An additional plug cock shall be furnished at entrance to gas train. High and
low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus
and additional plugged leakage test connection shall be provided. A vent valve shall be
located between the safety shutoff valves.
b. Burner Turndown - Turndown range shall be 8:1 when firing natural gas on standard
burners with uncontrolled emissions (100 ppm NOx). Consult Cleaver-Brooks
representative regarding turndown capability for low NOx burners 30 ppm and less.
D. Fuel Series 600 - No. 6 Oil-Fired
1. Burner Type - The burner shall be mounted at the front of the boiler and low pressure air
atomizing type approved for operation with CS12-48, Commercial No. 6 Oil.
detector shall monitor the pilot so that the primary oil valve cannot open until pilot flame has
regulator and pressure gauge and one (1) plugged leakage test (Canada only).
3. Oil Pump - An oil pump set with a capacity of approximately twice the maximum burning rate
shall be included.
The motor driven pump set, shipped loose, to be installed in a location favorable to the oil storage tank shall be
provided.
4.
E.
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
5. Low Pressure Air-Atomizing - Separate air compressor module, shipped loose with the burnermounted low-atomizing air pressure switch.
6. Oil Preheat
The oil shall be preheated by a steam heater and electric heater, each with thermostatic control.
Both heaters shall be installed in a single compact shell; mounted, piped, and wired. The
thermostatic controls shall be set to cut-out the electric heater when steam is available.
7. Burner Turndown - Turndown range will be 4:1 when firing No. 6 oil on standard burners with
uncontrolled emissions. Consult Cleaver-Brooks representative regarding turndown capability
for low NOx burners.
Fuel Series 400 - No. 6 Oil or Gas-Fired
1. Burner Type - The burner shall be mounted at the front the boiler and shall be a combination of
the low pressure atomizing type for oil and multi-port type for gas. The burner shall be approved
for operation with either CS12-48 Commercial No. 6 oil or natural gas.
A5-25
09-09

2.
3.
2.5
Section A5
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 fuel valve cannot open until pilot flame has
regulator and pressure gauge, and one (1) plugged leakage test connection. (Canada only.)
Oil Burner
a. Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate
shall be included. The motor driven pump set, shipped loose, shall be provided to be
installed in a location favorable to the oil storage tank.
b. Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices,
oil metering controls, low oil pressure switch, two (2) motorized oil valves, and pressure
gauges all integrally mounted on the unit.
c. Low Pressure Air-Atomizing: Separate air compressor module shipped loose with burner
mounted low atomizing air pressure switch.
d. Oil Preheat - The oil shall be preheated by a steam heater and electric heater, each with
thermostatic control. Both heaters shall be installed in a single compact shell mounted,
piped, and wired. The thermostatic controls shall be sent to cut-out the electric heater when
steam is available.
e. Burner Turndown - Turndown range will be 4:1 when firing No. 6 oil on standard burners
with uncontrolled emissions. Consult Cleaver-Brooks representative regarding turndown
capability for low NOx burners.
f.
Gas Burner
1) Gas Burner Piping - Gas burner piping on all units shall include a gas pressure
regulator, and a primary gas shutoff valve, motor-operated with proof-of-closure
switch and plugged leakage test connection. The main gas valves shall be wired to
close automatically in the event of power failure, flame failure, low water or any
safety shutdown condition. A lubricating plug cock shall be provided as means for a
tightness check of the primary shutoff valve. An additional plug cock shall be
furnished at entrance to gas train. High and low gas pressure switches shall be
provided. A second motorized safety shutoff valve, plus an additional plugged leakage
test connection shall be provided. A vent valve shall be located between the safety
shutoff valves.
2) Burner Turndown - Turndown range shall be 6:1 when firing natural gas on standard
burners with uncontrolled emissions (100 ppm NOx). Consult Cleaver-Brooks
representative regarding turndown capability for low NOx burners 30 ppm and less.
BOILER FLAME SAFEGUARD CONTROLLER AND CONTROL PANEL

A. CB100E Flame Safeguard
1. Each boiler shall be factory-equipped with flame safeguard controller providing technology and
functions equal to the Cleaver-Brooks Model CB100E.
Flame safeguard shall be a Cleaver-Brooks Model CB 100E microprocessor-based control to
monitor all critical boiler and burner interlocks, control and supervise burner light-off sequence,
and initiate an orderly safety procedure in the event of interlock or flame failure. The system
shall provide status, fault history, and diagnostic information by means of a BACKLIT LCD
display. The system shall be approved by UL, FM, and CSA, and shall be acceptable by IRI.
B. Control Panel
A factory prewired control panel shall be supplied with the boiler/burner package. Panel may be
mounted on the burner or boiler.
1. The panel will have a NEMA 1A rating and contain the flame safeguard controller, burner motor
starter, air compressor motor starter, oil-metering pump motor starter, control circuit transformer
and fuses, selector switches, indicating lights and terminal strips. Lights shall indicate load
A5-26
09-09
Section A5
Sample Specifica-
2.
2.6
demand, flame failure, low water, and fuel valve open.

The panel shall contain over-current protection for the burner motor, air compressor motor, and
oil metering pump.
A. The boiler must be guaranteed to operate at a minimum fuel-to-steam efficiency of ____ percent at 100
percent of
rating when burning natural gas and ________ fuel-to-steam efficiency at 100% firing rate when
burning oil (Contact your local Cleaver-Brooks authorized representative for efficiency details).
PART 3 EXECUTION
3.1
WARRANTY
1. All equipment is to be guaranteed against defects in materials and/or workmanship for a period of
12 months from date of start-up, or 18 months from date of shipment; whichever comes first.
3.2
SHOP TESTS
A. The packaged boiler must receive factory tests to check the construction, controls, and operation of the
unit. All tests may be witnessed by the purchaser, if desired.
B. Start-up Service
1. After boiler installation is completed, the manufacturer shall provide the services of a field
a. A factory-approved and authorized start-up report shall be submitted to the customer/user at
the time of start-up.
A5-27
09-09
Section A5
Notes:
A5-28
09-09
Section A6
MODEL CB BOILERS 15-100 HP
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-4

PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-5
Burner/Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-5
Fuel Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-6
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-6
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-15
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-15
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-16
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-18
Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-18
Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-18
Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-18
Test Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-22
Sound Level Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-22
Sound Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-22
Typical Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-22
Octave Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-22
Gas-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-22
Oil-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-22
No. 6 Oil Piping, Storage Tank Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-23
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-31
Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-31
Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-31
Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-31
Sample Specifications - Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-35
Sample Specifications - Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-47
A6-1
09-09
Firetube Boilers
ILLUSTRATIONS
Figure A6-1 Model CB Steam Dimensions and Weights (15 and 150 psig -15 to 100 hp) . . . . . . . . . .A6-9
Figure A6-2 Model CB Hot Water Boiler Dimensions (30 psig and 125 psig - 15 to 100 hp) . . . . . .A6-11
Figure A6-3 Space required to open rear head on model cb boilers with davits . . . . . . . . . . . . . . . . .A6-13
Figure A6-4 Model CB Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-13
Figure A6-5 Lifting Lug Locations, Model CB Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-14
Figure A6-6 Predicted Stack Temperature Increase for Pressure Greater Than 125 psig . . . . . . . . . .A6-17
Figure A6-7 Standard Gas Train Connection Size and Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-24
Figure A6-8 Typical Gas Piping Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-25
Figure A6-9 Model CB Gas Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-26
Figure A6-10 No. 2 Oil Connection Size, Location and Recommended Line Sizes . . . . . . . . . . . . . .A6-27
Figure A6-11 No. 6 Oil Connection Size, Location and Recommended Line Sizes. . . . . . . . . . . . . . .A6-27
Figure A6-12 No. 2 Oil Piping, Single Boiler Installation, Remote Oil Pump . . . . . . . . . . . . . . . . . .A6-28
Figure A6-13 No. 2 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . . . .A6-28
Figure A6-14 No. 2 Oil Piping, Multiple Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-29
Figure A6-15 No. 2 Oil Piping (elevated locations using an oil transfer pump and tank) . . . . . . . . . .A6-30
Figure A6-16 Typical Fuel Storage Tank Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-30
Figure A6-17 Boiler Room Length (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-33
Figure A6-18 Boiler Room Width (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-33
Figure A6-19 Breeching Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-34
TABLES
Table A6-1 Model CB Steam Boiler Ratings (15 - 100 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-7
Table A6-2 Model CB Hot Water Boiler Ratings (15 - 100 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-7
Table A6-3 Steam Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-8
Table A6-4 HOT Water Boiler Relief Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-8
Table A6-5 Predicted Fuel-to-Steam Efficiencies - 10 psig, Natural Gas . . . . . . . . . . . . . . . . . . . . . .A6-16
Table A6-6 Predicted Fuel-to-Steam Efficiencies - 125 psig, Natural Gas . . . . . . . . . . . . . . . . . . . . .A6-16
Table A6-7 Predicted Fuel-to-Steam Efficiencies - 10 psig, No. 6 Oil . . . . . . . . . . . . . . . . . . . . . . . .A6-17
Table A6-8 Predicted Fuel-to-Steam Efficiencies - 125 psig, No 6 Oil . . . . . . . . . . . . . . . . . . . . . . . .A6-17
Table A6-9 Predicted Fuel-to-Steam Efficiencies - 10 psig, No. 2 Oil . . . . . . . . . . . . . . . . . . . . . . . .A6-17
Table A6-10 Predicted Fuel-to-Steam Efficiencies - 125 psig, No 2 Oi . . . . . . . . . . . . . . . . . . . . . . .A6-17
Table A6-11 Model CB Boiler Emission Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-18
Table A6-12 Heating Surface, Model CB Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-18
Table A6-13 Steam Volume and Disengaging Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-19
Table A6-14 Water circulation rate and temperature drop for hot water boiler . . . . . . . . . . . . . . . . . .A6-19
Table A6-15 Recommended Steam Nozzle Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-20
Table A6-16 Model CB Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-20
Table A6-17 Sound Pressure Level Summary (50-100 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-20
Table A6-18 Model CB Boiler Sound Pressure Level Details (40 hp) . . . . . . . . . . . . . . . . . . . . . . . .A6-21
Table A6-19 Model CB Boiler Sound Pressure Level Details (50 - 100 hp) . . . . . . . . . . . . . . . . . . . .A6-21
Table A6-20 Minimum required gas pressure at entrance to gas train . . . . . . . . . . . . . . . . . . . . . . . . .A6-23
Table A6-21 Minimum Required Gas Pressure Altitude Conversion . . . . . . . . . . . . . . . . . . . . . . . . .A6-23
Table A6-22 Maximum Gas Consumption (CFH) for Natural Gas and Propane Vapor . . . . . . . . . . .A6-24
Table A6-23 Gas Pilot Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-24
A6-2
09-09
Firetube Boilers
A6-3
09-09
Section A6

In addition to the features provided on all Cleaver-Brooks Firetube Boilers, the following
features apply specifically to Model CB Firetube Boilers. The CB four-pass dryback
boiler is the premium firetube boiler design available.
Four-Pass Dryback Design:
Four-pass design provides high flue gas velocities and low stack temperature for
guaranteed maximum efficiency.
Dryback design provides full access to boiler tubes, tube sheet, and furnace for ease
of maintenance.
Dryback design includes single rear tube sheet construction, providing reduced tube
sheet stresses.
Five Square Feet of Heating Surface per Boiler hp:
Maximum heat transfer with minimum thermal stresses provide guaranteed
efficiency and long boiler life.
Highest guaranteed fuel-to-steam efficiencies.
Low Furnace Location
Furnace located well below water level with generous clearance from bottom of
boiler, allowing proper circulation.
Low furnace provides additional safety margin between furnace and water level.
Reduces water carryover, producing drier steam.
Hinged or Davited Front and Rear Doors:
Provides full access to front and rear tube sheet and furnace.
Reduces maintenance costs.
High Turndown Burner:
4:1 turndown (gas and oil) is standard.
Advanced burner design provides maximum combustion efficiencies and high
turndown.
Reduced boiler cycling and maintenance.
Boiler stays on line during low load conditions for optimum efficiency and
performance.
Gas, No. 2 Oil, No. 6 Oil, and Combination Gas and Oil Burners Available:
High radiant multi-port gas burner designed for high gas velocities and complete
fuel/air mixing, providing maximum combustion efficiencies.
Air atomizing oil burner available for proper oil atomization, maximum combustion
efficiency, and low maintenance requirements.
Air atomizing compressor provided with the boiler package for clean oil burning and
ease of maintenance.
Combination gas/oil burners provide quick fuel changeover without re-adjustment of
the burner.
Fuel oil controller eliminates the need for over 40 connections, combining gauges,
valves, and regulators into a single casting.
Retractable oil nozzle provides easy access and cleaning and eliminates coking of oil
and nozzle tip when firing gas.
A6-4
09-09
Section A6
PRODUCT OFFERING
Model CB Firetube Boilers are available in low pressure steam, high pressure steam, and
hot water designs. Burners are available to fire natural gas, light oil, heavy oil, or a
combination of oil and gas. Optional alternate fuel burners are also available.
Model CB Boilers include:
150 psig - 350 psig high pressure steam.
30 psig or 125 psig hot water.
The Model CB Boiler is the premium firetube product offering providing maximum
boiler efficiency, the widest range of size and pressures, and premium control packages.
Available options: For option details, contact your Cleaver-Brooks authorized
representative. Options include the following:
Boiler Options
Burner/Control
Options
Auxiliary low water cut-off (standard on steam boilers).
Drain valves.
Special design pressures.
Surge load baffles.
Seismic design.
Internal hot water coils.
Blowdown valves.
Non-return valves.
Special doors, davited, hinged, left swing.
Special base rails.
Combustion relief door.
Weather-proofing.
Blend pump.
Special modulation controls.
Optional flame safeguard controller.
Lead/lag system.
High altitude design, up to 12,000 ft.
Special insurance and code requirements (e.g. FM, ASME CSD-1).
A6-5
09-09
Section A6
Fuel Options
Remote contacts.
Special purpose indicator lights.
Main disconnect.
Elapsed time meter.
NEMA enclosures.
Low fire hold controls.
Circuit breaker.
Day/night controls.
Automatic fuel changeover.
Special gas pressure regulator.
Gas strainer.
Special fuel shut-off valves.
Special pilot.
Alternate fuel firing (propane, digester gas, etc.).
Special oil pumps.
Dimensions and ratings for the Model CB boilers are shown in the following
tables and illustrations:
Table A6-1. Model CB Steam Boiler Ratings (15 thru 100 hp)
Table A6-2. Model CB Hot Water Boiler Ratings (15 thru 100 hp)
Table A6-3. Safety Valve Openings
Table A6-4. Relief Valve Openings
Figure A6-1. Model CB Steam Boiler Dimensions (15 and 150 lb design
pressure) (15 thru 100 hp)
Figure A6-2 Model CB Hot Water Boiler Dimensions (15 and 150 lb design
pressure) (15 thru 100 hp)
Figure A6-3. Space Required to Open Rear Head on Model CB Boilers

Equipped with Davits
Figure A6-4. Model CB Boiler Mounting PiersL
Figure A6-5. Lifting Lug Locations, Model CB Boilers
A6-6
09-09
Section A6
Table A6-1. Model CB Steam Boiler Ratings (15 - 100 hp)
BOILER HP
15C
20C
30C
40C
50
60
70
80
100
1035
1004
1380
1339
1725
1674
2070
2009
2415
2343
2760
2678
3450
3348
RATINGS - SEA LEVEL TO 3000 FT

Rated Cap. (lbs steam/hr @212F)
518
502
690
670

Light Oil (gph)A
Heavy Oil (gph)
Gas (cfh) 1000 Btu-Nat

Gas (Therm/hr)
4.5
6.0
9.0
12.0
15.0
18.0
21.0
24.0
30.0
14.0
16.5
19.5
22.5
28.0
625
6.3
835
8.4
1255
12.6
1675
16.8
2095
21.0
2510
25.1
2930
29.3
3350
33.5
4185
41.9

Blower Motor hp (except gas)
1-1/2
2D
Gas Models (only)
1-1/2
Belt-Driven From Blower
Oil Heater kW No. 6 Oil

(Oil firing Only)
Air Compressor Belt-Driven

from Blower Motor
1/3
1/3
1/3
1/3
1/3
1/3
1/3
1/3
1/3
1/3
NOTES:
1. For altitudes above 3000 ft, contact your local Cleaver-Brooks authorized representative for verification of blower motor hp.
B. Based on 150,000 Btu/gal.
C. No. 6 Oil not available in 15-40 hp range.
D. 3 hp above 2000 ft.
Table A6-2. Model CB Hot Water Boiler Ratings (15 - 100 hp)
BOILER HP
15c
20c
30c
40c
50
60
70
80
100A
100
125A
1674
2009
2343
2678
3348
3348
4184

Rated Cap Btu Output (1000 Btu/hr)
502
670
1004
1339
APPROXIMATE FUEL CONSUMPTION AT RATED CAPCITY

Light Oil (gph)A
4.5
6.0
9.0
12.0
15.0
18.0
21.0
24.0
30.0
30.0
37.5
Heavy Oil (gph)B
14.0
16.5
19.5
22.5
28.0
28.0
35.0
Gas (cfh)
MBtu- nat
Gas (Therm/hr)
625
6.3
835
8.4
1255
12.6
1675
16.8
2095
21.0
2510
25.1
2930
29.3
3350
33.5
4185
41.9
4185
41.9
5230
52.3

Blower Motor hp (except gas)
1-1/2
2D
Gas Models (only)
1-1/2
2D
Belt-Driven From Blower
1/3
1/3
1/3
1/3
1/3
1/3
1/2
1/3
1/3
1/3
1/3
1/3
1/3
1/2
Oil Heater kW No. 6 Oil

(Oil firing Only)
Air Compressor Belt-Driven

from Blower Motor
NOTES:
1. For altitudes above 3000 ft, contact your local Cleaver-Brooks authorized representative for verification of blower motor hp.
B. Based on 150,000 Btu/gal.
C. No. 6 Oil not available in 15-40 hp range.
D. 3 hp above 2000 ft.
A6-7
09-09
Section A6

VALVE
15 PSIG STEAM
SETTING
100 PSIG STEAM
125 PSIG STEAM
150 PSIG STEAM
200 PSIG STEAM
250 PSIG STEAM
BOILER
HP
NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET
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.)
15
1-1/2
3/4
3/4
3/4
3/4
20
1-1/2
3/4
3/4
3/4
25
3/4
3/4
30
1-1/4
3/4
3/4
40
2-1/2
1-1/4
1-1/4
50
2-1/2
1-1/2
1-1/2
1-1/4
60
1-1/2
1-1/2
1-1/4
1-1/4
70
1-1/2
1-1/2
1-1/4
1-1/4
80
2-1/2
1-1/2
1-1/2
1-1/4
1-1/4
100
2-1/2
1-1/2
1-1/2
1-1/4

VALVE
SETTING
30 PSIG HW
60 PSIG HW
100 PSIG HW
125 PSIG HW
BOILER
HP
NO.
OF OUTLET
VALVES SIZE
REQ'D
(IN.)
NO.
OF OUTLET
VALVES SIZE
REQ'D
(IN.)
NO.
OF OUTLET
VALVES SIZE
REQ'D
(IN.)
NO.
OF OUTLET
VALVES SIZE
REQ'D
(IN.)
15
20
25
1-1/4
30
1-1/4
40
1-1/4
50 & 50A
1-1/4
60
1-1/4
70
1-1/4
80
1-1/4
1-1/4
100
2-1/2
1-1/4
1-1/4
100A
2-1/2
1-1/4
1-1/4
NOTES:
1.Hot water relief valves are Kunkle #537.
2. BHP followed by A designates hot water boilers furnished in a smaller vessel size with additional tubes in the upper
portion of the vessel.
A6-8
09-09
Section A6
BOILER HP
DIM 15
20
30
40
50
60
70
80
100
Overall
96-5/8
96-5/8
114-5/8
140-5/8
129
129
168
168
187
Shell
62-5/8
62-5/8
80-5/8
106-5/8
92
92
131
131
150
Base Frame
59
59
77
103
91
91
130
130
148
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
15-1/2
15-1/2
15-1/2
15-1/2
18-1/2
18-1/2
18-1/2
18-1/2
18-1/2
Front Ring Flange to

Nozzle - 15 psig
36
36
45
57
46
46
65-1/2
65-1/2
75
Front Ring Flange to Nozzle - 150 psig
36
36
45
57
46
46
72-1/2
72-1/2
82
Ring Flange to Base
1-13/16
1-13/16
1-13/16
1-13/16
5/8
1/2
1/2
1/2
1/2
Overall
61
61
61
61
73
73
73
73
73
ID, Boiler
36
36
36
36
48
48
48
48
48
33
33
33
33
39
39
39
39
39
LENGTHS
WIDTHS
KK
22
22
22
22
29
29
29
29
29
Center to Lagging
20
20
20
20
27
27
27
27
27
LL
28
28
28
28
34
34
34
34
34
Base, Outside
28
28
28
28
37-5/8
37-3/8
37-3/8
37-3/8
37-3/8
Base, Inside
22
22
22
22
29-5/8
29-5/8
29-5/8
29-5/8
29-5/8
Figure A6-1. Model CB Steam Boiler Dimensions and Weights (15 and 150 psig Design Pressure 15 to 100 hp) Sheet 1 of 2
A6-9
09-09
Section A6
BOILER HP
DIM 15
20
30
40
50
60
70
80
100
PL
50-1/4
50-1/4
50-1/4
70-5/16
70-5/16
70-5/16
70-5/16
70-5/16
HEIGHTS
Base to Steam Outlet (15 psig only)
50-1/4
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
53-1/2
53-1/2
53-1/2
53-1/2
70
70
70
70
70
Base to Steam Outlet (150 psig only)
PH
50-1/4
50-1/4
50-1/4
50-1/4
66-31/2
66-1/2
66-1/2
66-1/2
70-5/16
Height of Base
12
12
12
12
12
12
12
12
12
16
16
16
16
16
BOILER CONNECTIONS
Chemical Feed
Feedwater, Right and Left
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
Low Pressure (15 psig only)

Steam Nozzle
U
W
4
1
4
1
4
1
6A
1-1/4
6A
1-1/4
6A
1-1/4
6A
1-1/2
6A
1-1/2
8A
1-1/2
High Pressure (150 psig only)

Surface Blowoff, Top CL
Steam Nozzle
Blowdown, Front and Rear
T
Y
W
1
1-1/2
1
1
1-1/2
1
1
2
1
1
2
1
1
3
1-1/4
1
3
1-1/4
1
3
1-1/4
1
3
1-1/4
1
4B
1-1/4
Diameter (flgd connection)
BB
10
10
12
12
12
Front Ring Flange to Vent CL
CC
DD
44
44
44
44
55
55
55
55
55
VENT STACK
MINIMUM CLEARANCES
Rear Door SwingC
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
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
RD
151
151
169
195
202
202
241
241
260
WEIGHT IN LBS
1340
1300
1710
2290
3130
2920
4620
4460
5088
Approx. Ship Wgt - 15 psig
3000
3100
3650
4350
6900
7000
8100
8200
9000
3100
3200
3800
4500
7000
7200
8800
9000
9500
3300
3400
4100
4700
7400
7600
9300
9500
10000
NOTES:
1. Air compressor belt driven from blower motor on sizes 15 thru 40
2. Air compressor module on sizes 50 thru 100 hp.
3. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints.
B. ANSI 300 psig flange.
C. 15 thru 100 hp standard hinged door.
Figure A6-1. Model CB Steam Boiler Dimensions and Weights (15 and 150 psig Design Pressure - 15 to 100 hp) Sheet
2 of 2
A6-10
09-09
Section A6
BOILER HP
DIM
15
20
30
40
50
60
70
80/ 100A 100/125A
Overall
97
97
114-5/8
140-5/8
129
129
168
168
187
Shell
62-5/8
62-5/8
80-5/8
106-5/8
92
92
131
131
150
Base Frame
59
59
77
103
91
91
130
130
148
Front Head Ext.
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.
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
43-5/8
43-5/8
62
81
69
69
108
108
127
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
1-13/16
1-13/16
1-13/16
1-13/16
5/8
5/8
5/8
5/8
LENGTHS
WIDTHS
Overall
48-3/4
48-3/4
48-3/4
48-3/4
63
63
63
63
63
ID, Boiler
36
36
36
36
48
48
48
48
48
28-3/4
28-3/4
28-3/4
28-3/4
36
36
36
36
36
KK
22
22
22
22
29
29
29
29
29
Center to Lagging
20
20
20
20
27
27
27
27
27
Base, Outside
28
28
28
28
37-5/8
37-5/8
37-5/8
37-5/8
37-5/8
Base, Inside
22
22
22
22
29-5/8
29-5/8
29-5/8
29-5/8
29-5/8
Figure A6-2. Model CB Hot Water Boiler Dimensions (30 psig and 125 psig Design Press. - 15 to 100 hp) Sheet
1 of 2
A6-11
09-09
Section A6
BOILER HP
DIM
15
20
30
40
50
60
70
80/ 100A 100/

125A
HEIGHTS
Overall
OO
66
66
66
66
72-5/8
72-5/8
72-5/8
72-5/8
72-5/8
Base to Vent Outlet
53-1/2
53-1/2
53-1/2
53-1/2
70
70
70
70
70
Base to Return and outlet
50
50
50
50
70-5/16
70-5/16
70-5/16
70-5/16
70-5/16
Davit (Front)
DF
Davit (Rear)
DR
Height of Base
12
12
12
12
12
Base to bottom of boiler
12
12
12
12
16
16
16
16
16
BOILER CONNECTION
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
Water Return - Threaded
2-1/2
2-1/2
Water Outlet - ThreadedA
2-1/2
2-1/2
Air Vent
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
BB
10
10
12
12
12
Front Ring Flange to vent CL
CC
VENT STACK
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
GG
46
46
64
90
74
74
113
113
132
309
347
MINIMUM BOLER ROOM LENGTH ALLOWING FOR DOOR SWING AND TUBE REMOVAL FROM:
Rear of Boiler
RR
163
163
199
251
231
231
309
Front of Boiler
RF
153
153
189
241
221
221
299
299
337
RD
151
151
169
195
202
202
241
241
260
1500
1460
1915
2585
3665
3500
5420
5250
5960

3000
3300
3100
3400
3650
3880
4350
4580
6800
7100
7000
7300
8000
8350
8100
8450
8800
9150
WEIGHT IN LBS
NOTES:
1. Accompanying dimensions and ratings while sufficiently accurate for layout purposes, must be confirmed for construction
by certified dimension prints.
2. Air compressor belt driven from blower motor on sizes 15 thru 40 hp.
3. Air compressor module on sizes 50 thru 100 hp.
4. 15 - 100 hp, hinged door standard.
5. Add 370lbs to the 80 hp ship weight for 100A and 485 lbs to the 100 hp ship weight for the 125A.
A. Dip Tube included.
Figure A6-2. Model CB Hot Water Boiler Dimensions (30 psig Design Pressure 15 to 100 hp) - Sheet 2 of 2
A6-12
09-09
Section A6
BOILER HP
DIMENSION (INCHES)
A
15 - 40, 50A
20
36
28
45
20
50 - 100, 100A, 125A
27
48
38
60
26
PLAN VIEW
NOTE:
1. Dimensions in inches.
2. 15 - 100 hp (100A & 125A)
boilers are standardly equipped with hinges. Davit available as an option.
Figure A6-3. Space Required to Open Rear Head on Model CB Boilers Equipped with Davits
BOILER HP
X1
X2
15-20
59
17
33
22
9-3/4
9-3/4
25-30
77
17
33
22
9-3/4
9-3/4
40-50A
103
17
33
22
9-3/4
9-3/4
50-60
91
26
42
29-5/8
8-1/4
8-1/4
70-80, 100A
130
26
42
29-5/8
8-1/4
8-1/4
100, 125A
148
26
42
29-5/8
8-1/4
8-1/4
NOTE:
2. 6-inch high mounting piers recommended for use beneath the boiler base frame. The use of these piers provides increased inspection accessibility
to the piping beneath the boiler and added height for washing down the area beneath the boiler.
Figure A6-4. Model CB Boiler Mounting Piers
A6-13
09-09
Section A6
FRONT
FLANGE
E DIA. HOLE
CL
VIEW A
D
D
NEAR
SIDE
FAR
SIDE
VIEW B
BOILER
HP
VIEW ALL DIMENSIONS IN INCHES

A
15
Steam
51-3/4
12
38-3/4
2-1/2
Hot Water
50-1/2
12
38-3/4
2-1/2
20
Steam
51-3/4
12
38-3/4
2-1/2
Hot Water
50-1/2
12
38-3/4
2-1/2
25
Steam
51-3/4
12
56-3/4
2-1/2
Hot Water
50-1/2
12
56-3/4
2-1/2
30
Steam
51-3/4
12
56-3/4
2-1/2
Hot Water
50-1/2
12
56-3/4
2-1/2
40
Steam
51-3/4
12
82-3/4
2-1/2
Hot Water
50-1/2
12
82-3/4
2-1/2
50A
Water
50-1/2
12
82-3/4
2-1/2
50
All
68
18
57
10
2-1/2
60
All
68
18
57
10
2-1/2
70
All
68
27
67
10
2-1/2
80
All
68
27
67
10
2-1/2
100
All
68
27
86
10
2-1/2
100A
Hot Water
68
27
67
10
2-1/2
NOTE:
1. A, B and C Dimensions may vary by 1/2 inch.
2. BHP followed by A designates hot water boilers furnished in a smaller vessel size with additional tubes in upper portion of vessel.
Figure A6-5. Lifting Lug Locations, Model CB Boilers
A6-14
09-09
Section A6
PERFORMANCE DATA
Efficiency
Tables A6-5 through A6-10 show predicted fuel-to-steam efficiencies (including

radiation and convection losses) for Cleaver-Brooks Model CB Firetube boilers. For
specific efficiencies on firetube boiler offerings not listed here, contact your local
Cleaver-Brooks offers an industry leading fuel-to-steam boiler efficiency guarantee for
Model CB Firetube Boilers. The guarantee is based on the fuel-to-steam efficiencies
shown in the efficiency tables and the following conditions. The efficiency percent
number is only meaningful if the specific conditions of the efficiency calculations are
clearly stated in the specification (see Cleaver-Brooks publication CB-7768 for a
detailed description of efficiency calculations).
achieve fuel-to-steam efficiency (as shown in the tables listed above) at 100% firing rate
(add efficiency guarantees at 25%, 50%, and 75% of rating, if required). If the boiler(s)
manufacturer will rebate, to the ultimate boiler owner, five thousand dollars ($5,000) for
Natural Gas
Carbon, % (wt) = 69.98
No. 2 Oil
Carbon, % (wt) = 85.8
No. 6 Oil
Carbon, % (wt) = 86.6
Sulfur, % (wt) = 2.09
2. Efficiencies are based on ambient air temperature of 80 F, relative humidity of 30%,

3. Efficiencies are based on manufacturers published radiation and convection losses.
When specifying the efficiencies in the tables, be sure to include the specific guarantee
conditions to maximize the effectiveness of your efficiency specification. If you have
any questions regarding the efficiency specifications, please contact your local CleaverBrooks authorized representative. For efficiencies and stack temperatures at operating
A6-15
09-09
Section A6
pressures not listed, follow these procedures:
When the operating steam pressure is between 10 psig and 125 psig, interpolate the
values from the efficiency tables.
Example:
Boiler: 100 hp.
Fuel: natural gas.
Find the fuel-to-steam efficiency at 100% firing rate. From Figure A6-6 for a 100 hp
boiler operating at 100% firing rate and an operating steam pressure of 125 psig, the
efficiency is 88.0%.
operating pressure. To estimate boiler efficiency, use this rule of thumb: For every 40 F
increase in stack temperature, efficiency decreases by 1%. Since the stack temperature
rise is 36 F, the decrease in the boiler efficiency at 200 psig operating pressure is
calculated as follows: 36/40 = .9%. Therefore, the boiler efficiency at 200 psig operating
pressure is 82.5 - .9 = 81.6%.
Emissions
The emission data included in this section consists of typical uncontrolled emission
levels for Cleaver-Brooks Model CB Firetube Boilers.
Notice
The data in Table A6-13 represents typical emission levels only. Guaranteed emission levels are available from your local Cleaver-Brooks authorized representative.
Table A6-5. Predicted Fuel-to-Steam Efficiencies (%),

Model CB Boilers - 10 psig, Natural Gas

Model CB Boilers - 125 psig, Natural Gas
BOILER
HP
FIRING RATE (%)

25
50
75
100
50
83.0
83.2
82.9
82.4
50
80.2
80.5
80.4
80.1
60
82.9
83.1
82.7
82.3
60
80.1
80.4
80.3
80.1
70
84.5
84.7
84.3
83.9
70
81.7
82.0
81.9
81.7
80
84.6
84.8
84.5
84.0
80
81.8
82.1
82.0
81.8
100
84.4
85.0
84.8
84.4
100
81.5
82.4
82.3
82.2
BOILER
HP
A6-16
09-09
FIRING RATE (%)

25
50
75
100
Section A6
Model CB Boilers - 10 psig, No. 6 Oil

Model CB Boilers - 125 psig, No 6 Oil
BOILER
HP
FIRING RATE (%)
FIRING RATE (%)
25
50
75
100
BOILER
HP
25
50
75
100
50
86.8
87.0
86.6
86.1
50
83.9
84.2
84.0
83.8
60
86.7
86.9
86.5
86.0
60
83.8
84.1
83.9
83.8
70
88.4
88.6
88.2
87.7
70
85.5
85.8
85.6
85.4
80
88.5
88.7
88.3
87.8
80
85.6
85.9
85.7
85.6
100
88.2
88.5
88.3
88.0
100
84.6
85.8
85.9
85.8

Model CB Boilers - 10 psig, No. 2 Oil
BOILER
HP
FIRING RATE (%)

25
50
75
100
50
86.5
86.7
86.3
60
86.3
86.6
86.2
70
87.9
88.2
80
88.1
88.3
100
87.8
88.4

Model CB Boilers - 125 psig, No 2 Oi
BOILER
HP
FIRING RATE (%)

25
50
75
100
85.8
50
83.6
84.0
83.8
83.5
85.7
60
83.5
83.8
83.7
83.5
87.8
87.3
70
85.1
85.4
85.3
85.1
87.9
87.4
80
85.2
85.6
85.4
85.3
88.1
87.7
100
84.8
85.7
85.6
85.5
A6-17
09-09
Section A6
Table A6-11. Model CB Boiler Emission Data
ESTIMATED LEVELS - UNCONTROLLED
POLLUTANT
NATURAL GAS
NO. 2 OILB
NO. 6 OILC
ppmA
200
90
95
Lb/MMBtu
0.15
0.07
0.075
ppmA
100
185
502
Lb/MMBtu
0.12
0.25
0.67
ppmA
278
278
Lb/MMbtu
0.001
0.52
0.52
ppmA
40
50
70
Lb/MMBtu
0.016
0.025
0.035
ppmA
Lb/MMBtu
0.01
0.025
0.160
CO
NOx
SOx
HC/VOCs
PM
NOTES:
Refer to Section E for detailed emission information.
A. ppm levels corrected to 3% O2, dry basis.
B. Based on fuel constituent levels of:
Fuel-bound nitrogen content = 0.015% by weight
Ash content = 0.01% by weight
C. Based on fuel constituent levels of:
Conradson carbon residue = 16% by weight
Table A6-12. Heating Surface, Model CB Boilers

BOILER
HP

FIRESIDE
WATERSIDE
15
75
85
20
100
109
25
125
144
30
150
162
40
200
219
50
250
266
60
300
323
70
350
388
80
400
441
100
500
544
ENGINEERING DATA
The following engineering information is provided for Model CB Firetube Boilers.
Additional detail is available from your local Cleaver-Brooks authorized representative.
Blowdown Water
Requirements

Sound Level
Table A6-17 summarizes predicted sound pressure levels for Model CB Boilers. Table
A6-18 and A6-19 give detailed octave band sound pressure levels for each boiler. These
values are based on standard motors. Optional motor types and altitude conditions can
increase sound levels.
Units
The units for the sound level tables are dBA (decibels, measured on the A-weighted
scale) in reference to 0.0002 microbars (20 micro-Newtons per square meter). They are
standardly referenced in specifying and reporting sound pressure levels on industrial
A6-18
09-09
Section A6
BOILER HP
STEAM VOLUME CU-FT
STEAM RELIEVING AREA, SQ-IN
HIGH PRESSUREA
LOW PRESSUREB
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
NOTE: Based on normal water level.

Table A6-14. Water Circulation Rate and Temperature Drop for Hot Water Boiler
SYSTEM TEMPERATURE DROP - DEGREES F
BOILER
OUTPUT
(1000)
BTU/HR
10
15
500
100
50
33
25
20
17
14
20
670
134
67
45
33
27
22
19
30
1005
200
100
67
50
40
33
40
1340
268
134
89
67
54
45
50
1675
335
168
112
84
67
60
2010
402
201
134
101
70
2345
470
235
157
118
80
2680
536
268
179
134
100 &
100A
3350
670
335
223
168
BOILER
HP
20
30
40
50
60
70
80
90
100
12
11
10
17
15
13
29
25
22
20
38
33
30
27
56
48
42
37
33
80
67
58
50
45
40
94
78
67
59
52
47
107
90
77
67
60
54
134
112
96
84
75
67
MAXIMUM CIRCULATING RATE - GPM
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.
A6-19
09-09
Section A6
Table A6-15. Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity)
BOILER HP
OPERATING
PRESSURE
PSIG
15
20
25
30
40
50
60
70
80
100
15
30
2.5
2.5
40
2.5
2.5
50
1.5
2.5
2.5
75
1.5
2.5
100
1.5
1.5
125
1.5
1.5
150
1.5
1.5
2.5
2.5
2.5
2.5
2.5
200
1.5
1.5
2.5
2.5
2.5
2.5
2.5
250
1.5
1.5
NOTES:
2. Recommended steam nozzle sizes based on 4000 to 5000 fpm steam velocity. Spool pieces
(300 lb flanges) are available in the following sizes (in inches): 3x2-1/2x30, 4x3x30, 6x4x36,
8x6x48, 10x8x48, and 12x8x48.
3. All standard steam nozzle sizes for 150 psig design pressure or greater are the same as 125 psig
operating pressure on the above table. To increase or decrease the standard size, request the
change with your local Cleaver-Brooks authorized representative.
Table A6-16. Model CB Blowdown Tank Sizing Information

BOILER HP
WATER (GAL.)
15-20
26
25-30
34
40
47
50-60
55
70-80
80
100
93
NOTE: Quantity of water removed from boiler by lowering normal water

line 4".
Table A6-17. Sound Pressure Level Summary (50-100 hp)

BOILER
HP
50
60
70
80
100
HFO, dBA
79
79
79
79
81
LFO, dBA
78
78
78
78
79
HFG, dBA
77
77
78
78
78
LFG, dBA
72
73
74
75
75
NOTES:
1. Boiler No. followed by an a designates hot water boilers furnished in a smaller vessel size
with additional tubes in the upper portion of the vessel.
2. Sound Pressure levels measured on boilers operating in various locations and expressed in
dBA are as follows:
NOTE:
ABBREVIATIONS:
HF = High Fire
LF = Low Fire
O = Oil
G = Gas
A6-20
09-09
Section A6
Table A6-18. Model CB Boiler Sound Pressure Level Details (40 hp)
FIRING
RATE
FUEL
SOUND
OCTAVE BAND SOUND PRESSURE LEVELS IN dB RE .0002 MICROBAR
LEVEL
31Hz
63Hz
125Hz
250Hz
500Hz
1kHz
2kHz
dBA
4kHz
8kHz
16kHz
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
40HP
NOTE:
ABBREVIATIONS:
HF = High Fire
LF = Low Fire
O = Oil
G = Gas
A. The data shown above was taken on the 40 hp. Since the highest Sound Level is below 80 dBA,
no additional 36" diameter Firetubes were tested. If Sound Level predictions are required for the
15 thru 30 hp, use the values shown for the 40 hp.
Table A6-19. Model CB Boiler Sound Pressure Level Details (50 - 100 hp)
FIRING
RATE
FUEL
SOUND
LEVEL
dBA
OCTAVE BAND SOUND PRESSURE LEVELS IN dB RE .0002 MICROBAR

31Hz
63Hz
125Hz
250Hz
LFG
72
71
65
71
71
500Hz
1kHz
2kHz
4kHz
8kHz
16kHz
68
63
60
53
46
50 HP
70
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
LFG
74
70
70
75
74
71
62
56
51
46
70 HP
73
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
LFG
75
69
69
75
76
71
65
63
59
50
100 & 100A HP

73
LFO
79
68
73
78
78
75
79
76
63
59
54
HFG
78
69
70
77
77
74
74
69
63
59
50
HFO
81
68
70
77
78
78
77
71
64
59
57
NOTES:
1. ABBREVIATIONS:
HF = High Fire
LF = Low Fire
O = Oil
G = Gas
2. Boiler HP followed by an A designates hot water boilers furnished in a smaller vessel size with additional tubes in the upper portion of the vessel.
A6-21
09-09
Section A6
equipment.
Test Method
The sound pressure levels in the above tables were obtained from tests in accordance
with the "ABMA Test Code for the Measurement of Sound from Packages Boilers." In
accordance with this code, the sound pressure levels reported were measured on the
cabinet.
Sound Level Meter
The sound level meter used complies with ANSI S1.4, Type 1 (Precision). The readings
are taken with the meter set for slow response.
Sound Pressure
On large size boilers, the need for auxiliary equipment, and the necessary
interconnecting piping, make it impractical (and sometimes impossible) to provide a
boiler testing environment that is suitable for obtaining the data needed to develop Sound
Pressure Power levels.
Typical Values
Sound pressure levels (dBA) for identical boilers will vary between boiler rooms. In
addition, variations will occur between different people using different sound meters on
the same boiler. And finally, no two boilers can be expected to give precisely the same
(dBA).
Octave Band
When predicting sound pressures in octave bands (e.g., dB at 125 Hz), even greater
variations between boilers, between sound meters, and between operators can be
expected. These larger variations in the low and high frequencies make octave band
levels a less reliable method of reporting than A-scale sound levels. (Since A-scale sound
levels are dominated by mid-frequency sounds, the A-scale sound levels between two
boilers can be in reasonable agreement even though the low and high frequencies of
octave band measurement do not closely correspond).
Gas-Fired Burners
Table A6-20 shows minimum gas pressure requirements for Model CB Boilers.
Table A6-22 shows maximum gas consumption for natural gas and propane vapor.
Figure A6-7 shows standard gas train sizes and locations for Model CB Firetube Boilers.
Figure A6-9 shows gas train components.
Oil-Fired Burners
Fuel oil consumption information is shown on the boiler rating sheets in the Dimensions
and Rating Section.
Figure A6-10 shows the oil connection sizes and locations for Model CB Boilers firing
No. 2 oil.
Figure A6-11 shows the oil connection sizes and locations for Model CB Boilers firing
No. 5 and No. 6 oil.
Figure A6-15 shows the detail of an oil transfer tank (day tank) typically utilized to
provide a storage reservoir between the oil system supply pump and the boiler oil pump.
No. 6 Oil Piping,

Storage Tank
Heating
If the oil viscosity exceeds 4,000 SSU at the pumping temperature, tank preheating is
required.
Based on the climate conditions for the job location, the minimum pumping temperature
A6-22
09-09
Section A6
can be predicted, and the viscosity for the particular oil at this pumping temperature can
be determined.
It is recommended to provide for tank and/or line heating on all No. 6 oil installations to
ensure against high viscosities at decreased pumping temperatures. The following are
two common methods:
1. Provide a tank suction heater and bundling the steam or water lines to the heater with
the oil lines.
2. Provide electric heating equipment on the oil lines and/or in the storage tank.
Notice
The temperature in the oil suction line should not exceed 130 F as higher temperatures could cause vapor binding of the oil pump and decreased oil flow.
See Figure A6-16 for an example of tank heating method.
Table A6-20. Minimum required gas pressure at entrance to gas train

Gas Supply Pressure Less Then 27" W.C.
Gas Supply Pressure Up To 10 Psi
Min. Supply Press
Min. Supply Press
Boiler Hp Train Size
Regulator Model*
"W.C.
Regulator Model*
"W.C.
15
1-1/4
Maxitrol 1-1/4", RV-61
4
Maxitrol 1", 210-D
4
20
1-1/4
7
Maxitrol 1", 210-D
7
30
1-1/2
6
Maxitrol 1-1/4", 210-D
7
40
1-1/2
9
10
50
2
Maxitrol 2", RV-91
6
6
60
2
Maxitrol 2", RV-91
7
8
70
2
Maxitrol 2", RV-91
10
11
80
2
Maxitrol 2", RV-91
12
13
100
2
Maxitrol 2", RV-91
12
14
*Maxitrol RV series is standard; 210 series is optional
ALTICORRECALTICORRECTUDE
TION FACTOR TUDE
TION FACTOR
(FT)
(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.
Psig x 27.71 = Inches WC.
Table A6-21. Minimum required gas

pressure altitude conversion
A6-23
09-09
Section A6
Table A6-22. Maximum Gas Consumption (CFH)
for Natural Gas and Propane Vapor
BOILER
HP

NATURAL GAS
1000 (Btu/cu-ft)
PROPANE GAS
2550 (Btu/cu-ft)
15
625
245
20
835
330
25
1045
410
30
1255
490
40
1675
655
50A
2095
820
50
2095
820
60
2510
985
70
2930
1150
80
3350
1315
100A
4185
1640
100
4185
1640
NOTES:
BHP followed by A designates hot water boilers furnished in a smaller
vessel size with additional tubes in upper portion of vessel.
Table A6-23. Gas Pilot Data

BHP
Connection
es) NPT
(inch- Min. Required Gas Max. Permissible Gas

Pressure (Up to 700) Pressure (psig)
Inches WC
50-100
1/2
BHP
Manufactured 500 Natural 1000 Btu/ Propane 2500 Btu/Cu

Btu/Cu. Ft
Cu. Ft
Ft
50-100
120
60
25
Approximate Gas Usage:

1. Multiply the CFH rate by 0.007 to obtain the number
of cu.ft of gas used in 25 sec. (Length of (1) light off).
2. Multiply the number of cu. ft/light (item 1) by the
estimated number of lights/hour or per day to obtain
the approximate usage in cu.ft/hour or cu.ft/day.
BOILER
HP
CONNECTION
SIZE
(IN.) (NPT)
LOCATION
DIMENSION
"A" (IN.)
15,20
1-1/4
65-1/2
30
1-1/2
68
40,50A
1-1/2
68
50
74
BOILER
FRONT
PLAN VIEW
MODEL CB
60, 70, 80
74
100A, 100
74
NOTE: BHP followed by A designates hot water boiler

furnished in a smaller vessel size with additional tubes in
upper portion of vessel.
Figure A6-7. Standard Gas Train Connection Size and Location
A6-24
09-09
Section A6
This figure illustrates the basic gas valve arrangement on Cleaver-Brooks Model CB Boiler and
shows the contractor's connection point. The valves and controls between the contractor connection point and the gas main in the street are representative of a typical installation. Actual requirements may vary depending on local codes or local gas company requirements which should be
investigated prior to preparation of specifications and prior to construction.
STREET GAS MAIN
MODEL
CB-LE
BOILERS
PLUG
COCK
MODEL
CB-LE
BOILERS
A
B
C
CONTRACTOR
CONNECTION
POINT
GAS TRAIN
ON BOILER

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:
The local gas utility will advise the pressure that is available at the outlet of their meter.
A6-25
09-09
Section A6
INS
UL
ITEM DESCRIPTION
5
BOILER HP 15-20 30-50
PILOT GAS LINE
FLOW
10
9
7
Gas
11
To
Burner
Supply
MAIN GAS LINE
FM
60100
1520
CSD-1
306015-20 30-50
100
100
Pilot Shut Off Cock
Gas Pilot Valve
Main Gas Valve with POC
10
Main Gas Regulator
11
Butterfly Valve
Figure A6-9. Model CB Gas Train Components
A6-26
09-09
x
x
Section A6
BOILER
HP
MODEL CB
SUPPLY DIM. A
AND
(IN.)
RETURN
CONN
SIZES
(IN.)
(NPT)

SIZES
(STANDARD PIPE)
(IN.)
STORAGE
TANK TO
BOILER
OR PUMP
CONNECT
PUMP TO RETURN
BOILER LINE TO
TANK
15, 20
3/4
8-1/4
3/4
NONE
3/4
30, 40
3/4
8-1/4
3/4
NONE
3/4
50, 60
3/4
11-1/2
3/4
3/4
70,80
3/4
11-1/2
3/4
3/4
100
3/4
11-1/2
CONTRACTOR
CONNECTIONS
BOILER
FRONT
BOILER BASE FRAME
A
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 A6-10. No. 2 Oil Connection Size, Location and Recommended Line Sizes
BOILER
FRONT
PLAN VIEW
BOILER
HP
50, 60, 70, 80, 100
SUPPLY
CONNECTION
RETURN
CONNECTION
RECOMMENDED OIL LINE

SIZES
(STANDARD PIPE)
(IN.)
SIZE
(IN.)
(NPT)
A (IN.)
SIZE
(IN.)
(NPT)
B (IN.)
STORAGE
PUMP TO RETURN
TANK
TO BOILER LINE TO
PUMP
TANK
1-1/4
27-3/4
3/4
19-3/4
1-1/4
1-1/4
NOTES:
1. All dimensions in inches.
2.For suction lines with a maximum of 10 feet of lift and a total of 100 equivalent feet of suction line.
3. This table is based on a single boiler installation.
Figure A6-11. No. 6 Oil Connection Size, Location and Recommended Line Sizes, Model CB Boiler
A6-27
09-09
Section A6
CHECK
VALVE
VACUUM
GAUGE
OIL PUMP
UNION
GATE VALVE
STRAINER
GATE VALVE
F.O.S.
RELIEF VALVE
F.O.R.
GATE VALVE
CHECK VALVE
BOILER
FRONT
BOILER
BASE FRAME
F.O.S.
F.O.R.
CONTRACTOR
CONNECTIONS
AT THIS POINT

VACUUM GAUGE
CHECK VALVE
GATE VALVE
STRAINER
GATE VALVE
F.O.S.
OIL
PUMP
NO. 2
F.O.R.
OIL PUMP NO. 1

UNION
GATE VALVE
RELIEF
VALVE
(100 PSIG)
GATE VALVE
CHECK VALVE

BOILER
FRONT
BOILER
BASE FRAME
F.O.S.
F.O.R.
CONTRACTOR
CONNECTIONS
AT THIS POINT
A6-28
09-09
Section A6
CHECK
VALVE
VACUUM GAUGE
STRAINER
GATE VALVE
F.O.S.
GATE
VALVE
F.O.R.
STANDBY
OIL PUMP
ADJUSTABLE
PRESSURE
RELIEF VALVE
(75 PSIG)
UNION
GATE VALVE
RELIEF
VALVE
(100 PSIG)
PRESSURE
GAUGE
GATE VALVE
CHECK VALVE
USE LAYOUT FOR: MODEL CB . . . . . . . 50 THRU 800 HP

BOILER
FRONT
BOILER
BASE FRAME
CONTACTOR
CONNECTIONS
AT THIS POINT
F.O.S.
F.O.R.
Figure A6-14. No. 2 Oil Piping, Multiple Boiler Installation
A6-29
09-09
Section A6
VENT
OIL TRANSFER TANK

AT LOCATION NEAR
BOILER
OIL LEVEL
TEST VALVE
OIL TRANSFER PUMP

NEAR STORAGE TANK
F.O.R.
GATE
CHECK
VALVE
VALVE STRAINER
F.O.S.
F.O.R.
F.O.S.
SUPPLY TO BOILER
TERMINAL BLOCK OR
TO BOILER OIL PUMP
RELIEF VALVE
(100 PSIG)
ITEM
SIZE
GATE
UNION VACUUM VALVE
GAUGE
DESCRIPTION

level switch
pump
connection
H
McD
3/16"
B
G A
2"
5"
3"
22"
60"
4" OR 6"
STD
BLACK
PIPE
33"
3"

D 3/16"
3/8" MTL

(For elevated boiler room locations using an oil
transfer pump and tank)

OIL RETURN
OIL SUCTION
STEAM OR HOT WATER
MANHOLE
OIL STORAGE
TANK

AND SUPPLY SYSTEMS.
A6-30
09-09
Section A6
Boiler Room
Information

Stack Support
Capabilities
Cleaver-Brooks Firetube Boilers 15 hp through 100 hp can support up to 1,000 lbs

without additional support. Firetube boilers 125 hp through 800 hp can support up to
2,000 lbs without additional support.
Firetube sizes 250 hp through 800 hp can be reinforced to support 3,000 lbs.
Stack/Breeching
Size Criteria
Although constant pressure at the flue gas outlet of the Model CB is not required, it is
necessary to size the stack/breeching to limit flue gas pressure variation. For boiler sizes
50 800 horsepower, the allowable pressure range is 0.5" W.C. to +0.5" W.C. The
maximum pressure variation at any firing rate for the boiler is 0.5" W.C. For boiler sizes
15 40 horsepower, the allowable pressure range is 0.25" W.C. to +0.25" W.C.
Boiler Room
Combustion Air
recommended. Locate one at each end of the boiler room, preferably below a height of 7
feet. This allows air to sweep the length of the boiler.
D. Under no condition should the total area of the air supply openings be less than (1) square
foot.
Area (sq-ft) = cfm/fpm

C. Total recommended air, 10 cfm/bhp - up to 1000 feet elevation. Add 3 percent more per
1000 feet of added elevation.
3. Acceptable air velocity in boiler room (fpm).

Example: Determine the area of the boiler room air supply openings for (1) 300 hp boiler
A6-31
09-09
Section A6
at 800 feet altitude. The air openings are to be 5 feet above floor level.
Area Required: Area = cfm = 3000/250 = 12 Sq-ft total.
Notice
A6-32
09-09
Section A6
FRONT
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
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.
BOILER HP
A
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
15-40
50-100
Dimension A
75"
81"
Dimension B
103"
115"
NOTES:
1. Recommended Minimum Distance Between Boiler and Wall. Dimension
"A" allows for a "clear" 42" aisle between the water column on the
boiler and the wall. If space permits, this aisle should be widened.
42" - 15-100 hp
TRENCH
A6-33
09-09
Section A6
TIGHT SEAL
CLEANOUT
STACK
MANUAL
DAMPER
LOCK (OPEN)
CLEANOUT
DRAIN
CONNECTION

MAXIMUM 10
CONE ANGLE
NOTE: These stack breeching arrangements for

multiple boilers are typical and not intended for your
specific design requirements. For additional
information, review Section F, Stacks.


local CLeaver-Brooks authorized representative is
capable of assisting in your evaluation of stack and
breeching design.
TIGHT SEAL
CLEANOUT
TIGHT SEAL
CLEANOUT
STACK
MANUAL
DAMPER
LOCK (OPEN)
STACK
MANUAL
DAMPER
LOCK (OPEN)
CLEANOUT
CLEANOUT
DRAIN
CONNECTION
DRAIN
CONNECTION
A6-34
09-09
Section A6
Model CB 15-100 HP
Steam Boiler Specifications
Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-36
General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-36
Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-37
Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-38
Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-44
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-45
Shop Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-45
Start-up Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-45
A6-35
09-09
Model CB 15-100 HP
Section A6
Model CB 15-100 HP
Model CB Steam Boiler (15-100 hp, Steam 15-350 psig)
The following sample specification is provided by Cleaver-Brooks to assist you in meeting your
customers specific needs and application.
A separate specification for steam boilers and hot water boilers is provided. Burner specifications and
detailed control specifications for CB 780 Flame Safeguard control and the CB-HAWK Flame
Safeguard control are included. See Section D, Controls, for additional information on control
options.
The Sample Specifications are typically utilized as the base template for the complete boiler
specification. Contact your local Cleaver-Brooks authorized representative for information on special
insurance requirements, special code requirements, optional equipment, or general assistance in
completing the specification.
1.01

A. The Steam Boiler shall be Cleaver-Brooks Model CB, Fuel Series ______ (100, 200,
400, 600, 700), _____ hp designed for _____ psig (15, 150, 200, or other psig
steam). The maximum operating pressure shall be _____ psig.
B. The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower
when fired with CS 12-48 _____ oil and/or natural gas, _____ Btu/cu-ft. Electrical
power available will be _____ Volt _____ Phase _____ Cycle.
1.02

feet of heating surface per rated boiler horsepower. It shall be mounted on a heavy
steel frame with integral forced draft burner and burner controls.
The complete package boiler shall be approved as a unit by Underwriters Laboratories and
shall bear the UL/ULC label, except in the case where 50 Hz has been selected.
1.
B.
The boiler shall be completely preassembled and fire tested at the factory. The
connections.
1. The boiler shell must be constructed in accordance with ASME Boiler Code
and must receive authorized boiler inspection prior to shipment. A copy of the
A6-36
09-09
Section A6
Model CB 15-100 HP
3.
Front and rear doors on the boiler shall be hinged or davited. Doors are to be
4. Rear refractory and insulation shall be contained in the formed door, which
must swing open for inspection of brick work.
appurtenances.
and cleaning when the doors are swung open. The boiler shall be furnished with
center line and shall be capable of supporting:
15-100 hp. 1000 lbs and shall contain a stack thermometer
C.
D.
E.
8. The boiler shell shall contain a chemical feed connection.

Observation ports for the inspection of flame conditions shall be provided at each
end of the boiler.
The entire boiler base frame and other components shall be factory painted before
1.03
Steam Boiler Trim

A. Water Column
A water column shall be located on the right hand side of the boiler complete with gauge glass set and
water column blowdown valves.
The boiler feedwater pump control shall be included as an integral part of the water column to
automatically actuate a motor driven feed water pump maintaining the boiler water level within
normal limits.
2. Low Water Cutoff
The low water cutoff shall be included as an integral part of the boiler feedwater control wired into
the burner control circuit to prevent burner operation if the boiler water level falls below a safe level.
Auxiliary low water cutoff manual reset shall be included, piped to the vessel, and wired to the burner
control circuit. A manual reset device shall be used on this control.
connection.
D. Safety Valves
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 (30100 hp).
A6-37
09-09
Model CB 15-100 HP
Section A6
1.04
Burner and Controls

1.
2.
15 and 20 hp. Burner operation shall be on-off principle.

30 and 40 hp. Burner operation shall be high-low-off principle. The burner
shall always return to low fire position for ignition.
3. 50 - 100 hp. Burner operation shall be full modulation principle. The burner
shall always return to low fire position for ignition.
B. Blower
front boiler door, above the burner, to eliminate vibration and reduce noise
level.
2. Maximum sound level of the boiler/burner package shall not exceed _____
dbA (when measured in accordance with ABMA Sound Test Standards).
A. 15 and 20 hp. Combustion air damper shall be manually set for proper air-fuel ratios.
B. 30 and 40 hp. Combustion air damper shall be linked to damper motor. Auxiliary switch on the
damper motor shall control high or low firing rate.
C. 50 - 100 hp. Combustion air damper and cam operated fuel metering valves shall be operated
by a single damper control motor that regulates the fire according to load demand. Potentiometer
type position controls shall be provided to regulate operation of the damper control motor.
D. Fuel Specification and Piping
Fuel series 600 - No. 6 oil fired (4.4.4).
Fuel series 400 - No. oil or gas fired (4.4.5).

1.

a. Burner Type - The burner shall be integral with the front head of the
boiler and of high radiant multi-port type for gas. The burner shall be
approved for operation on natural gas fuel.
A6-38
09-09
Section A6
Model CB 15-100 HP
c.
2.
3.
4.
5.
6.
Gas Burner Piping - Gas burner piping on all units shall include pressure
regulator, primary gas shutoff valve, motor operated with proof of closure
switch and plugged leakage test connection. The main gas valve(s) shall
be wired to close automatically in the event of power failure, flame
failure, low water or any safety shutdown condition. A lubricating plug
cock or butterfly shutoff valve shall be provided as a means for a tightness
check of the primary shut off valve. An additional plug cock on butterfly
valve shall be furnished at entrance to gas train. Select one of the
following:
1) 15-50 hp. Burners equipped as shown above.
1) 15 and 20 hp. Burner shall operate on the on/off principle.
2) 30 and 40 hp. Burner shall operate on the high-low-off principle
with a turndown of 3:1 when firing natural gas.
natural gas.
boiler, and shall be a low pressure air atomizing type approved for
operation with CS12-48, Commercial No. 2 oil.
Oil Pilot - The oil pilot shall be air atomizing type with automatic electric
ignition and include oil solenoid valve. An electronic detector shall monitor
the pilot so that the primary oil valve cannot open until flame has been
established.
Oil Pump - An oil pump with a capacity of approximately twice the maximum
burning rate shall be included. Select one of the following:
a. 15 hp through 40 hp. The oil pump shall be integral with the burner and
belt driven from the blower motor.
b. 50 hp through 100 hp. Separate motor driven pump set, shipped loose to
be installed in a location favorable to the oil storage tank, shall be
provided.
gauges and fuel strainer, all integrally mounted on the unit. Select one of the
following:
a. 50 hp through 100 hp. A fuel oil controller shall be provided to combine
all of the fuel oil controls into a single casting which is mounted on the
front door of the unit. A single tip retractable nozzle shall be used for the
low pressure air atomizing burner.
b. 70 hp through 100 hp. A low oil pressure switch shall be included in the
oil piping.
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.
A6-39
09-09
Model CB 15-100 HP
Section A6
7.
E.

a. 15 and 20 hp. Burner shall operate on the on/off principle.
b. 30 and 40 hp. Burner shall operate on the high-low-off principle with a
turndown of 3:1 when firing No. 2 oil.
c. 50 hp through 100 hp. Turndown range shall be 4:1 when firing No. 2 oil.
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.
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.
3. Oil Burner
a. Oil Pump - An oil pump with a capacity of approximately twice the
maximum burning rate shall be included. Select one of the following:
1) 15 hp through 40 hp. The oil pump shall be integral with the burner
and belt driven from the blower motor.
2) 50 hp through 100 hp. Separate motor driven pump set, shipped
loose, to be installed in a location favorable to the oil storage tank,
shall be provided.
4. Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure
following:
a. 50 hp through 100 hp. A fuel oil controller shall be provided to combine
all of the fuel oil controls into a single casting which is mounted on the
front door of the unit. A single tip retractable nozzle shall be used for the
low pressure air atomizing burner.
b. 70 hp through 100 hp. A low oil pressure switch shall be included in the
oil piping.
5. Low pressure air atomizing. Select one of the following:
level indicator, inlet air filter, air pressure gauge and low atomizing air
pressure switch.
6. Gas Burner
a. Gas Burner Piping - gas burner piping on all units shall include pressure
cock or butterfly shutoff valve shall be provided as a means for a tightness
A6-40
09-09
Section A6
Model CB 15-100 HP
check of the primary shut off valve. An additional plug cock or butterfly
following:
1) 15-50 hp. Burners equipped as shown above.
7. Burner Turndown
15 and 20 hp. Burner shall operate on the on/off principle.
30 and 40 hp. Burner shall operate on the high-low-off principle with a turndown of 3:1

A.
Fuel Series 600 - No. 6 Oil Fired

1. Burner Type - The burner shall be integral with the front head of the boiler and
low pressure air atomizing type approved for operation with CS12-48,
Commercial No. 6 Oil.
2. Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition.
An electronic detector shall monitor the 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.
3. Oil Pump - An oil pump set with a capacity of approximately twice the
maximum burning rate shall be included.
A separate motor driven pump set shall be included shipped loose for location favorable to the oil
storage tank.
4.
Oil Burner Piping - A fuel oil controller combining all of the fuel oil controls
into a single casing shall be provided. Oil pressure regulating devices, oil
metering controls, solenoid shutoff valves, high and low oil temperature
switches and necessary pressure and temperature gauges shall be included in
this packaged assembly mounted on the front door of the boiler. A fuel strainer
shall also be provided, mounted to the boiler. A single tip retractable nozzle
shall be used for the low pressure air atomizing burner. Flexible hoses shall be
provided to allow easy removal of the nozzle for inspection when it is placed in
the vice jaws located on the front door of the boiler.
The metering valve shall permit circulation of hot oil to the burner at all times. The burner drawer oil
piping and nozzle shall be purged of oil on each shutdown.
For 70 through 100 hp, a low oil pressure switch shall be included in the oil piping.
5.

a. 50 through 100 hp. Separate air compressor module mounted on boiler
6. Oil Preheat
The oil shall be preheated by a steam heater and electric heater, each with thermostatic control. Both
heaters shall be installed in a single compact shell mounted, piped, and wired on the boiler. The
thermostatic controls shall be set to cut-out the electric heater when steam is available. Select one of
the following:
a.
50 through 100 hp. Electric preheater size shall be 5 kW.
A6-41
09-09
Model CB 15-100 HP
Section A6
B.
Fuel Series 400 - No. 6 Oil or Gas Fired

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.
2. Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition.
An electronic detector shall monitor the pilot so that the primary oil valve
gauge.
3. Oil Burner
a. Oil Pump - An oil pump set with a capacity of approximately twice the
b. Oil Burner Piping - A fuel oil controller combining all of the fuel oil
controls into a single casing shall be provided. Oil pressure regulating
devices, oil metering controls, solenoid shutoff valves, high and low oil
temperature switches, and the necessary pressure and temperature gauges
shall be included in this packaged assembly mounted on the front door of
the boiler. A fuel strainer shall also be provided, mounted to the boiler. A
single tip retractable nozzle shall be used for the low pressure air
atomizing burner. Flexible hoses shall be provided to allow easy removal
of the nozzle for inspection when it is placed in the vice jaws located on
the front door of the boiler. The metering valve shall permit circulation of
hot oil to the burner at all times. The burner drawer oil piping and nozzle
shall be purged of oil at each shutdown.
1.

2. Oil Preheat
The oil shall be preheated by a steam heater and electric heater, each with thermostatic control. Both
heaters shall be installed in a single compact shell mounted, piped, and wired on the boiler. The
thermostatic controls shall be set to cut-out the electric heater when steam is available.
a.
3.
Gas Burner
a. Gas Burner Piping - Gas burner piping on all units shall include pressure
cock or butterfly shutoff valve shall be provided as means for a tightness
check of the primary shutoff valve. An additional plug cock or butterfly
following:
1) 50 hp. Burner equipped as shown above.
A6-42
09-09
Section A6
Model CB 15-100 HP
2)
60 through 100 hp. High and low gas pressure switches shall be
provided.
b. Burner Turndown - Turndown shall be 4:1.
C. Boiler Flame Safeguard Controller and Control Panel
flame safeguard controller providing technology and functions equal to
the Cleaver-Brooks Model CB780E.
Controller shall be computerized solid state having sequence and flame-on lights and alpha-numeric
first out fault indications of flame safeguard trip functions. It shall include dynamic self-check
logic. The controller shall have a fixed operating sequence incapable of being manually altered. The
sequence shall include start, pre-purge, pilot and main fuel ignition run and post-purge cycles.
Controller shall be the non-recycle type for maximum safety that shall shutdown the burner and
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 prepurge, during pilot ignition trial and run cycles for adjustments to firing rate motor, damper linkages
and pilot flame for minimum turndown tests.
b.
Control Panel - The control panel shall be mounted on the front door of
the boiler in a location convenient to the operator. The hinged metal
cabinet 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.
a. Lights
Red - low water.
2. Control Switches
Burner On-Off.
Manual-Automatic.

3.
4.
5.
All electrical equipment and wiring shall be in conformance with Underwriters
Boiler to be supplied with a control circuit transformer and fuse protection for
A6-43
09-09
Model CB 15-100 HP
Section A6
6.
Control Panel: The control panel shall be mounted on the front door of the
boiler in a location convenient to the operator. The hinged metal cabinet will
have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet
key type lock.
The panel shall contain the boiler flame safeguard controller, indicating lights and selector switches.
Panel shall have a removable sub-base for mounting the flame safeguard controller, and terminal
blocks. For combination gas-oil and heavy oil fired boilers the panel will contain the fuel selector
and/or oil heater selector switch.
7.
8.
9.
Oil, heat, and moisture resistant wire shall be used and identified with circuit
1.05
fuel-to-steam efficiency at 100% firing rate when burning natural gas and ________ fuel-to-steam
rating, if required). If the boiler(s) fail to achieve the corresponding guaranteed efficiency as
published, the boiler manufacturer will rebate, to the ultimate boiler owner, five thousand dollars
($5,000) for every full efficiency point (1.0%) that the actual efficiency is below the guaranteed level.
A.

1. Natural Gas
Carbon, % (wt) = 69.98

B.
No. 2 Oil
Carbon, % (wt) = 85.8

C.
No. 6 Oil
Carbon, % (wt) = 86.6

Sulfur, % (wt) = 2.09
D.
E.
F.

A6-44
09-09
Section A6
Model CB 15-100 HP
EXECUTION
1.06
Warranty
A. 6.1 All equipment is to be guaranteed against defects in materials and/or
workmanship for a period of 12 months from date of
start-up or 18 months from date of shipment, whichever comes first.
1.07
Shop Tests
1.08
Start-up Service
1.09
After boiler installation is completed, the manufacturer shall provide the services of a field
A. A factory approved and authorized start-up report shall be submitted to the customer/
user at the time of start-up.
A6-45
09-09
Model CB 15-100 HP
Section A6
Notes:
A6-46
09-09
Section A6
Model CB 15-100 HP
Sample Specifications, Hot Water Boiler
Boiler Characteristics (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-48
General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-48
Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-49
Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-49
Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-49
Combustion Air Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-49
Fuel Specification and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-50
Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-56
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-56
Shop Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-56
A6-47
09-09
Model CB 15-100 HP
Section A6
Model CB Hot Water Boiler (15-100 hp, 30 psig, 125 psig)

1.01

A. The Hot Water Boiler shall be Cleaver-Brooks Model CB, Fuel Series ______ (100,
200, 400, 600, 700), _____ hp designed for _____ psig (30, 125, or other psig hot
water). The maximum water temperature will be _____ degree F, and the maximum
system temperature drop will be _____ degree F.
available will be _____Volt _____ Phase _____ Cycle.
1.02

steel frame with integral forced draft burner and burner controls. The complete
package boiler shall be approved as a unit by Underwriters Laboratories and shall bear
the UL/ULC label.
connections.
line of the boiler. The boiler shall be designated to rapidly mix the return water
appurtenances.
and cleaning when the doors are swung open. The shell must be furnished with
9. The exhaust gas vent shall be located near the front of the boiler on the top center
line and shall be capable of supporting 1000 lbs and shall contain a stack
thermometer
C. Observation ports for the inspection of flame conditions shall be provided at each end
of the boiler.
A6-48
09-09
Section A6
Model CB 15-100 HP
D.
E.
1.03

A. Low Water Cutoff
A low water cutoff control (manual reset) shall be mounted on the top centerline of the boiler wired
into the burner control circuit to prevent burner operation if boiler water falls below a safe level.
Pressure and temperature gauges shall be mounted on the boiler with temperature sensing element
located adjacent to the hot water outlet.
C. Relief Valves
Water relief valves of a type and size to comply with ASME Code requirements shall be shipped loose.
Temperature controls to regulate burner operation shall be mounted on the unit with temperature
sensing elements located adjacent to the hot water outlet. Controls shall be high limit (manual reset),
operating limit (auto reset), and firing rate control (30-100 hp).
1.04
Burner and Controls

A.
B.
C.
1.05
15 and 20 hp. Burner operation shall be on-off principle.

30 and 40 hp. Burner operation shall be high-low-off principle. The burner shall
always return to low fire position for ignition.
50 - 100 hp. Burner operation shall be full modulation principle. The burner shall
always return to low fire position for ignition.
Blower
A. Air for combustion shall be supplied by a forced draft blower mounted in the front
boiler door, above the burner, to eliminate vibration and reduce noise level.
B. Maximum sound level of the boiler/burner package shall not exceed _____ dbA
C. The impeller shall be cast aluminum, radial blade, carefully balanced, and directly
1.06
A.
B.
C.
15 and 20 hp. Combustion air damper shall be manually set for proper air-fuel ratios.
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.
50 - 100 hp. Combustion air damper and cam operated fuel metering valves shall be
operated by a single damper control motor that regulates the fire according to load
demand. Potentiometer type position controls shall be provided to regulate operation
of the damper control motor (remove this sentence when a CB-HAWK Flame
Safeguard is used).
A6-49
09-09
Model CB 15-100 HP
Section A6
1.07
Fuel series 600 - No. 6 oil fired (4.4.4).
Fuel series 400 - No. oil or gas fired (4.4.5).

A.
B.

1. Burner Type - The burner shall be integral with the front head of
the boiler and of high radiant multi-port type for gas. The burner
shall be approved for operation on natural gas fuel.
2. Gas Pilot - The gas pilot shall be a premix type with automatic
electric ignition. An electronic detector shall monitor the pilot so
that the primary gas valve cannot open until pilot flame has been
established. The pilot train shall include two manual shut-off
valves, solenoid valve, pressure regulator and pressure gauge.
3. Gas Burner Piping - Gas burner piping on all units shall include
pressure regulator, primary gas shutoff valve, motor operated with
proof of closure switch and plugged leakage test connection. The
main gas valve(s) shall be wired to close automatically in the event
of power failure, flame failure, low water or any safety shutdown
condition. A lubricating plug cock or butterfly shutoff valve shall
be provided as a means for a tightness check of the primary shut
off valve. An additional plug cock on butterfly valve shall be
a. 15-50 hp. Burners equipped as shown above.
b. 60-100 hp. High and low gas pressure switches shall be
provided.
4. Burner Turndown - 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 natural gas.
c. 50-100 hp. Turndown range of burner shall be 4:1 when
firing natural gas.
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.
2. Oil Pilot - The oil pilot shall be air atomizing type with automatic
electric ignition and include oil solenoid valve. An electronic
detector shall monitor the pilot so that the primary oil valve cannot
open until flame has been established.
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.
A6-50
09-09
Section A6
Model CB 15-100 HP
b.
C.
50 hp through 100 hp. Separate motor driven pump set, shipped loose to be
installed in a location favorable to the oil storage tank, shall be provided.
4. Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure
following:
a. 50 hp through 100 hp. A fuel oil controller shall be provided to combine all
of the fuel oil controls into a single casting which is mounted on the front
door of the unit. A single tip retractable nozzle shall be used for the low
pressure air atomizing burner.
b. 70 hp through 100 hp. A low oil pressure switch shall be included in the oil
piping.
5. Low Pressure Air Atomizing - Select one of the following:
level indicator, inlet air filter, air pressure gauge, and low atomizing air
pressure switch.
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 100 hp. Turndown range shall be 4:1 when firing No. 2 oil.
CS12-48 Commercial No. 2 Oil or natural gas.
3. Oil Burner
1) 15 hp through 40 hp. The oil pump shall be integral with the burner
and belt driven from the blower motor.
2) 50 hp through 100 hp. Separate motor driven pump set, shipped loose,
to be installed in a location favorable to the oil storage tank, shall be
provided.
b. Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure
gauges and fuel strainer, all integrally mounted on the unit. Select one of
the following:
1) 50 hp through 100 hp. A fuel oil controller shall be provided to
combine all of the fuel oil controls into a single casting which is
mounted on the front door of the unit. A single tip retractable nozzle
A6-51
09-09
Model CB 15-100 HP
Section A6
shall be used for the low pressure air atomizing burner.

2) 70 hp through 100 hp. A low oil pressure switch shall be included in
the oil piping.
3) Low pressure air atomizing - Select one of the following:
15 hp through 40 hp. Belt driven air compressor, lubricating oil tank, oil level indicator, inlet
air filter, air pressure gauge and low atomizing air pressure switch.
50 hp through 100 hp. Separate air compressor module mounted on boiler base rail with low
atomizing air pressure switch.
4.
Gas Burner
a. Gas Burner Piping - gas burner piping on all units shall include pressure
switch and plugged leakage test connection. The main gas valve(s) shall be
wired to close automatically in the event of power failure, flame failure,
low water or any safety shutdown condition. A lubricating plug cock or
butterfly shutoff valve shall be provided as a means for a tightness check of
the primary shut off valve. An additional plug cock or butterfly valve shall
be furnished at entrance to gas train.
15-50 hp. Burners equipped as shown above.
60-100 hp. High and low gas pressure switches shall be provided.
5. Burner Turndown - Select one of the following:

15 and 20 hp. Burner shall operate on the on/off principle.
30 and 40 hp. Burner shall operate on the high-low-off principle with a turndown of 3:1

6.
Fuel Series 600 - No. 6 Oil Fired

and low pressure air atomizing type approved for operation with CS12-48,
Commercial No. 6 Oil.
oil valve cannot open until pilot flame has been established. The pilot train
and pressure gauge.
c. Oil Pump - An oil pump set with a capacity of approximately twice the
A separate motor driven pump set shall be included shipped loose for
location favorable to the oil storage tank.
d. Oil Burner Piping - A fuel oil controller combining all of the fuel oil
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.
A6-52
09-09
Section A6
Model CB 15-100 HP
The metering valve shall permit circulation of hot oil to the burner at all
times. The burner drawer oil piping and nozzle shall be purged of oil on
each shutdown.
e.
Low Pressure Air Atomizing

1) 50 through 100 hp. Separate air compressor module mounted on
f.
Oil Preheat
The oil shall be preheated by a safety type water-to-water-to-oil preheating system in conjunction with
an electric preheater, each with thermostatic control. Both heaters shall be mounted, piped, and wired
on the boiler.
1) 50 through 100 hp. Electric preheater size shall be 5 kW.
7. Fuel Series 400 - No. 6 Oil or Gas Fired
and shall be a combination of the low pressure atomizing type for oil and
high radiant multi-port type for gas. The burner shall be approved for
oil valve cannot open until pilot flame has been established. The pilot train
shall include two manual
shut-off valves, solenoid valve, pressure regulator and pressure gauge.
8. Oil Burner
a. Oil Pump - An oil pump set with a capacity of approximately twice the
b. Oil Burner Piping - A fuel oil controller combining all of the fuel oil
temperature switches, and the necessary pressure and temperature gauges
shall be included in this packaged assembly mounted on the front door of
the boiler. A fuel strainer shall also be provided, mounted to the boiler. A
single tip retractable nozzle shall be used for the low pressure air atomizing
burner. Flexible hoses shall be provided to allow easy removal of the
nozzle for inspection when it is placed in the vice jaws located on the front
door of the boiler. The metering valve shall permit circulation of hot oil to
the burner at all times. The burner drawer oil piping and nozzle shall be
purged of oil at each shutdown.
9.
Low Pressure Air Atomizing

10. Oil Preheat
The oil shall be preheated by a safety type water-to-water-to-oil preheating system in conjunction with
an electric preheater, each with thermostatic control. Both heaters shall be mounted, piped, and wired
on the boiler. Select one of the following:
a.
A6-53
09-09
Model CB 15-100 HP
Section A6
11. Gas Burner

a. Gas Burner Piping - Gas burner piping on all units shall include pressure
switch and plugged leakage test connection. The main gas valve(s) shall be
butterfly shutoff valve shall be provided as means for a tightness check of
the primary shutoff valve. An additional plug cock or butterfly valve shall
be furnished at entrance to gas train. Select one of the following:
1) 50 hp. Burner equipped as shown above.
2) 60 through 100 hp. High and low gas pressure switches shall be
provided.
3) Burner Turndown - Turndown shall be 4:1.
D. Boiler Flame Safeguard Controller and Control Panel
2. 4.5.1.1 Boilers with CB780E Control - Each boiler shall be factory equipped
with flame safeguard controller providing technology and functions equal to the
Controller shall be computerized solid state having sequence and flame-on lights and digital first out
fault code indications of flame safeguard trip functions. It shall include dynamic self-check logic. The
controller shall have a fixed operating sequence incapable of being manually altered. The sequence
shall include start, pre-purge, pilot and main fuel ignition run and post-purge cycles.
proving switch faults, running interlocks open, false flame signal and fuel valve open (when proof of
closure switch is furnished).
The controller shall have a run/test switch. It shall allow interruptions to sequence just after pre-purge,
during pilot ignition trial and run cycles for adjustments to firing rate motor, damper linkages and pilot
flame for minimum turndown tests.
3.
4.5.1.2 Control Panel: The control panel shall be mounted on the front door of
the boiler in a location convenient to the operator. The hinged metal cabinet will
have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key
type lock.
The panel shall have a removable sub-base for mounting the flame safeguard controller, blower motor
starter, and terminal blocks. For combination gas-oil and heavy oil fired boilers the panel will contain
the fuel selector and/or oil heater selector switch.
4. Lights
Red - low water.

5.
Control Switches
A6-54
09-09
Section A6
Model CB 15-100 HP
Burner On-Off.
Manual-Automatic.

6.
9. Control Panel: The control panel shall be mounted on the front door of the boiler
in a location convenient to the operator. The hinged metal cabinet will have
NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key type
lock.
The panel shall contain the boiler flame safeguard controller, indicating lights and selector switches.
Panel shall have a removable sub-base for mounting the flame safeguard controller, and terminal
blocks. For combination gas-oil and heavy oil fired boilers the panel will contain the fuel selector and/
or oil heater selector switch.
10. Oil, heat, and moisture resistant wire shall be used and identified with circuit
1.08
fuel-to-steam efficiency at 100% firing rate when burning natural gas and ________ fuel-to-steam
rating, if required). If the boiler(s) fail to achieve the corresponding guaranteed efficiency as
published, the boiler manufacturer will rebate, to the ultimate boiler owner, five thousand dollars
($5,000) for every full efficiency point (1.0%) that the actual efficiency is below the guaranteed level.
A.
1.
Natural Gas
Carbon, % (wt) = 69.98
2.
No. 2 Oil
Carbon, % (wt) = 85.8
3.
No. 6 Oil
Carbon, % (wt) = 86.6
Sulfur, % (wt) = 2.09
A6-55
09-09
Model CB 15-100 HP
B.
C.
D.
1.09
Section A6
Warranty
A. All equipment is to be guaranteed against defects in materials and/or workmanship for
a period of 12 months from date of start-up or 18 months from date of shipment,
whichever comes first.
EXECUTION
2.01
Shop Tests
A. The packaged boiler must receive factory tests to check the construction, controls, and
operation of the unit. All tests may be witnessed by the purchaser, if desired.
B. Start-up Service
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.
A6-56
09-09
Section A7
Model CBE Boilers
60-80 HP
CONTENTS
Three-Pass Dryback Design: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Five Square Feet of Heating Surface per Boiler Horsepower: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Furnace Location: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front and Rear Doors: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Natural Gas, No. 2 Oil, or Combination Burners Available: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler Options: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner/Control Options: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Fired - Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Connections - Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Connections - Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A7-3
A7-3
A7-3
A7-3
A7-3
A7-3
A7-3
A7-3
A7-4
A7-4
A7-4
A7-13
A7-13
A7-13
A7-13
A7-13
A7-15
A7-15
A7-15
A7-15
A7-15
A7-1
09-09
Model CBE Boilers 60-80 HP
Section A7
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-20

Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-20
Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-20
Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-20
Sample Specifications - Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-23
Sample Specifications - Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-29
ILLUSTRATIONS
Figure A7-1. Model CBE Steam Boiler Dimensions (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-7
Figure A7-2. Model CBE Hot Water Boiler Dimensions (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-9
Figure A7-3. Space Required to Open Rear Head on Model CBE Boilers Equipped with Davits . . . . . . . .A7-11
Figure A7-4. Model CBE Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-11
Figure A7-5. Model CBE Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-12
Figure A7-6. Typical Fuel Oil Supply Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-19
Figure A7-7. Boiler Room Length (Typical Layouts) - Model CBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-21
Figure A7-8. Boiler Room Width (Typical Layout) - Model CBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-22
TABLES
Table A7-1. Model CBE Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-6
Table A7-2. Model CBE Hot Water Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-6
Table A7-3. Heating Surface, Model CBE Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-14
Table A7-4. Model CBE Steam Volume and Disengaging Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-14
Table A7-5. Model CBE Steam Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-14
Table A7-6. Model CBE Hot Water Boiler Relief Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-16
Table A7-7. Model CBE Recommended Steam Nozzle Size
(To Maintain 4000 to 5000 fpm Nozzle Velocity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-16
Table A7-8. Model CBE Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-17
Table A7-9. Sound Pressure Levels in DbA (Profire F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-17
Table A7-10. Model CBE Burner Selections(Profire Burner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-18
Table A7-11. Minimum Required Gas Pressure Altitude Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-18
Table A7-12. Maximum Gas Consumption (CFH) for Natural Gas - Model CBE . . . . . . . . . . . . . . . . . . . .A7-18
Table A7-13. Minimum Required Gas Pressure at Entrance to Standard, FM and IRI Gas Trains Model CBE (Upstream of Gas Pressure Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-19
The following information applies to the Cleaver-Brooks Model CBE Boiler.
A7-2
09-09
Section A7

The Model CBE Boiler is available as a baseline alternative to the Cleaver-Brooks
Models CB Boilers. The Cleaver-Brooks Model CBE Boiler line provides a quality
product utilizing an economical boiler/burner design. Additionally, the boiler/burner
packaged UL and cUL label is available on all CBE sizes. The following features apply:
Three-Pass Dryback Design:
Three-pass design provides high flue gas velocities and low stack temperatures to
maximize efficiency.
Dryback design provides full access to boiler tubes, tube sheet, and furnace for ease
of maintenance.
Dryback design includes single rear tube sheet construction, which reduces tube
sheet stresses.
Five Square Feet of Heating Surface per Boiler Horsepower:

Good boiler efficiency.
Long boiler life.
Low Furnace Location:


Davit, front and rear doors, all sizes.
Provides access to front and rear tube sheet and furnace.
Reduced maintenance costs.

Natural gas or No. 2 oil compatibility.
Fuel changeover without burner adjustment.
PRODUCT OFFERING
Cleaver-Brooks Firetube Boilers are available in low pressure steam, high pressure
steam, and hot water designs. Burners are available to fire natural gas, No. 2 oil, or a
combination of oil and gas. The CBE boiler is:
60 - 80 hp.
Boiler Options:
Drain valves.
A7-3
09-09
Section A7

Blowdown valves.
Non-return valves.
Surface blowdown systems
Combustion relief door.
Blend pump.
Surge load baffles.
Seismic design.
Burner/Control
Options:

Lead/lag system.
High altitude design (up to 10,000 ft).
Special insurance and code requirements (e.g., IRI, FM, CSD1).
Special purpose indicator lights.
Main disconnect.
Elapsed time meter.
NEMA enclosures.
Circuit breaker.
Day/night controls.
Stack thermometer.
Fuel Options
Gas strainer.
Gas pressure gauge.
A7-4
09-09
Section A7

Dimensions and ratings for the Model CBE Boilers are shown in the following tables and
illustrations.
Table A7-1 Model CBE Steam Boiler Ratings
Table A7-2 Model CBE Hot Water Boiler Ratings
Figure A7-1 Model CBE Boiler Dimensions
Figure A7-2 Model CBE Steam Boiler Dimensions
Figure A7-3 Model CBE Boiler Space Requirements to Open Rear Door
Figure A7-4 Lifting Lug Location, Model CBE Boilers
Figure A7-5 Model CBE Boiler Mounting Piers
A7-5
09-09
Section A7
Table A7-1. Model CBE Steam Boiler Ratings

BOILER HP
60
70
80

Rated Capacity (lbs/steam/hr at 212
F)
2070
2415
2760
2009
2343
2678

Light Oil GPH (140,000 Btu/gal)
18
21
24
Gas CFH (1000 Btu)
2510
2930
3350
Gas (Therm/hr)
25.1
29.3
33.5
POWER REQUIREMENTS SEA LEVEL TO 1000 FT (60 HZ)

Oil Pump Motor hp (No. 2 oil)
Blower Motor - Series 100/200
3/4
3/4
Blower Motor - Series 700
3/4
1/2
3/4
Air Compressor Motor
**
**
**
350
400
BOILER DATA
Heating Surface sq-ft (Fireside)
300
* 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 Hot Water Boiler Ratings

BOILER HP
60
70
80

2009
2343
2678

18
21
24
Gas CFH (1000 Btu)
2510
2930
3350
Gas (Therm/hr)
25.1
29.3
33.5

Oil Pump Motor hp (No. 2 oil)
Blower Motor - Series 100/200
3/4
3/4
Blower Motor - Series 700
3/4
1/2
3/4
Air Compressor Motor
**
**
**
300
350
400
BOILER DATA
* Integral oil pump.

**No air compressor required (pressure atomized)
NOTE: All fractional hp motors will be single phase voltage; integral hp motors
will be three-phase voltage.
A7-6
09-09
Section A7
JJ
HH
I
GG
LL
L
FF
DD
J
T
O
D
AA
Q
E
W
N
M
X
C
W
H
DI
M
BOILER HP
60
70
80
LENGTHS
Overall Length
163-1/8
186-1/16
201-1/16
Shell Length
123-5/8
141-5/8
157-5/8
Base Frame Length
133-3/8
152-3/8
173-9/16
Rear Head Extension
7-7/8
7-7/8
7-7/8
Front Flange To Steam Outlet
49-1/4
60-1/4
70-1/4
Steam Outlet To Vent Outlet
65-1/2
72-1/2
78-1/2
Base Frame To Rear Head
22-1/4
22-1/4
22-1/4
WIDTHS
Overall Width
73
73
73
Boiler Centerline To Water

Column
39
39
39
Boiler Centerline To Lagging
26-1/2
26-1/2
26-1/2
Boiler Centerline To Aux. Water Column
LL
34
34
34
Base Outside
37-3/4
37-3/4
37-3/4
Figure A7-1. Model CBE Steam Boiler Dimensions (Page 1 of 2)
A7-7
09-09
Section A7
DI
M
BOILER HP
Base Inside
60
70
80
29-3/4
29-3/4
29-3/4
HEIGHTS
Base To Boiler Centerline
40
40
40
Boiler ID
48
48
48
Base To Vent Outlet
70-1/4
70-1/4
70-1/4
Base To Steam Outlet (15 psig)
70-1/4
70-1/4
70-1/4
Base To Steam Outlet (150 psig)
67-7/8
67-7/8
67-7/8
Base Frame
12
12
12
Base To Rear Davit
72-5/8
72-5/8
72-5/8
Base To Lifting Lug
AA
68-3/4
68-3/4
68-3/4
CONNECTIONS
Chemical Feed
1-1/4
1-1/4
1-1/4
Surface Blowoff (150 psig Only)
Steam Outlet (15 psig)
6A
6A
6A
Steam Outlet (150 psig)
Vent Outlet ID
10
12
12
Boiler Blowdown (36 Dia Only)
Boiler Blowdown (15 psig)
1-1/4
1-1/2
1-1/2
Boiler Blowdown (150 psig)
1-1/4
1-1/4
1-1/4
MISCELLANEOUS
Door Swing (Rear Minimum)
DD
30
30
30
Tube Removal Rear
FF
82
100
109
Tube Removal Front
GG
90
108
124
Min. Boiler Room Length For Tube Removal

Front
HH
244
280
312
Min. Boiler Room Length For Tube Removal

RearC
JJ
287
327
352
WEIGHTS
Normal Water Weight
3940
4720
5375
Shipping Weight (15 psig)
6455
7220
7715
6875
7690
8370
7415
8070
8800
NOTES:
1. All connections are threaded, except as noted.
2. Manway included on 125 - 350 hp.
A. 150 psig Flange.
B. 300
psigA7-1.
Flange.Model CBE Steam Boiler Dimensions (Page 2 of 2)
Figure
C.
Includes
4-foot
clearance in front of boiler.
A7-8
09-09
Section A7
JJ
HH
I
L
GG
AA
FF
DD
J
T
O
D
Q
E
W
N
M
BOILER HP
DIM
60
70
80
LENGTHS
Overall Length
163-1/8
186-1/16
201-1/16
Shell Length
123-5/8
141-5/8
157-5/8
Rear Frame Length
133-3/8
152-3/8
173-9/16
Rear Head Extension
7-7/8
7-7/8
7-7/8
Front Flange To Water Return
70-1/4
88-1/4
104-1/4
Water Return To Water Supply
24
24
24
Base Frame To Rear Head
22-1/4
22-1/4
22-1/4
Water Supply To Vent Outlet
20-1/2
20-1/2
20-1/2
WIDTHS
Overall Width
53
53
53
Boiler Centerline To Lagging
26-1/2
26-1/2
26-1/2
Base Outside
37-3/4
37-3/4
37-3/4
Base Inside
29-3/4
29-3/4
29-3/4
Figure A7-2. Model CBE Hot Water Boiler Dimensions (Page 1 of 2)
A7-9
09-09
Section A7
BOILER HP
DIM
60
70
80
HEIGHTS
Base To Boiler Centerline
40
40
40
Boiler ID
48
48
48
Base To Vent Outlet
70-1/4
70-1/4
70-1/4
Base To Supply & Return Ports (30 & 125 psig)
62-1/4
62-1/4
62-1/4
Base To Supply And Return Ports (150 psig)
70-1/4
70-1/4
70-1/4
Base Frame
12
12
12
Base To Rear Davit
72-5/8
72-5/8
72-5/8
Base To Lifting Lug
AA
68-3/4
68-3/4
68-3/4
CONNECTIONS
1-1/4
1-1/4
1-1/4
Air Vent
1-1/4
1-1/4
1-1/4
Hot Water Supply & Return

(30 & 125 psig)
Hot Water Supply & Return (150 psig)
4B
4B
4B
Vent Outlet ID
10
12
12
Boiler Drain
1-1/4
1-1/2
1-1/2
Boiler Drain
MISCELLANEOUS
Door Swing (Minimum Rear)
DD
30
30
30
Tube Removal Rear
FF
82
100
109
Tube Removal Front
GG
90
108
124
Min. Boiler Room Length For Tube Removal Front
HH
244
280
312
Min. Boiler Room Length For Tube Removal RearC
JJ
287
327
352
WEIGHTS
4340
5195
5920
6505
7270
7755
Shipping Weight (125 psig
6705
7740
8420
NOTES:
1. All connections are threaded, except as noted.
2. Manway included on 125 - 350 hp.
A. 150 psig flange.
B. 300 psig flange.
C. Includes 4 foot clearance in front of boiler.
Figure A7-2. Model CBE Hot Water Boiler Dimensions (Page 2 of 2)
A7-10
09-09
Section A7
BOILER HP
60 thru 100
DIMENSION (INCHES)
A
27
45
38
61
30
Figure A7-3. Space Required to Open Rear Head on Model CBE Boilers Equipped with Davits
NEAR SIDE
E (DIA OF HOLE)
FAR SIDE
BOILER HP

A
60
68
14
187
10
2-1/2
70
68
14
105
10
2-1/2
80
68
14
121
10
2-1/2
NOTE: A, B and C Dimensions may vary by 1/2 inch.
Figure A7-4. Model CBE Boilers Lifting Lug Location
A7-11
09-09
A F
Section A7
F
G
B
BOILER
HP
60
137
25-3/4
41-3/4
29-5/8
70
156
25-3/4
41-3/4
29-5/8
80
177
25-3/4
41-3/4
29-5/8
NOTE:
2. 6-inch high mounting piers recommended for use beneath the boiler base frame. The use of these
piers provides increased inspection accessibility to the piping beneath the boiler and added height for
washing down the area beneath the boiler.
Figure A7-5. Model CBE Boiler Mounting Piers
A7-12
09-09
Section A7
PERFORMANCE DATA
Contact your local Cleaver-Brooks authorized representative for emissions or additional information.
ENGINEERING DATA
The following engineering information is provided for Model CBE Firetube Boilers. Additional
detail is available from your local Cleaver-Brooks authorized representative.
Boiler Information
Table A7-3 shows heating surfaces for model CBE Firetube boilers.
Table A7-4 shows steam volume and disengaging area for model CBE Firetube boilers.
Table A7-5 lists quantity and outlet size for safety valves supplied on Model CBE steam boilers.
Table A7-6 lists quantity and outlet size for relief valves supplied on Model CBE hot water boilers.
Table A7-7 gives recommended steam nozzle sizes based on 4000-5000 fpm steam velocity on
Model CBE Boilers.
Blowdown Water
Requirements
Some local codes require blowdown tanks to be constructed in accordance with recommendations
of the National Board of Boiler and Pressure Vessel Inspectors.
The National Boards recommendations base the size of the blowdown tank on the removal of at
least 4 inches of water from the boiler.
Table A7-8 lists the approximate quantity of water represented by 4 inches of water at normal
operating level for Cleaver-Brooks Power Boilers.
Sound Level
Table A7-9 summarizes predicted sound pressure levels for Model CBE Boilers. These values are
based on standard motors. Optional motor types and altitude conditions can increase sound levels.
Units
The units for the sound level tables are dBA (decibels, measured on the A-weighted scale) in reference to 0.0002 microbars (20 micro-Newtons per square meter). They are standardly referenced
in specifying and reporting sound pressure levels on industrial equipment.
Test Method
The sound pressure levels in the above table were obtained from tests in accordance with the
"ABMA Test Code for the Measurement of Sound from Packages Boilers." In accordance with
this code, the sound pressure levels reported were measured on the boiler centerline 4-1/2 feet
vertically above the bottom of the base rails and 3 feet horizontally in front of the end of the
blower motor or front surface of the electrical cabinet.
Sound Level Meter
The sound level meter used complies with ANSI S1.4, Type 1 (Precision). The readings are taken
with the meter set for slow response.
Burner/Control
Information
Burner information is shown in Table A7-10. Note that the model selection may vary for actual
application factors (altitude, gas pressure, etc.).
A7-13
09-09
Section A7
Table A7-3. Heating Surface, Model CBE Boilers

BOILER HP

FIRESIDE
WATERSIDE
60
300
322
70
350
376
80
400
429
Table A7-4. Model CBE Steam Volume and Disengaging Area

BOILER HP
STEAM VOLUME (CU-FT)
STEAM RELIEVING AREA (SQ-IN)
HIGH PRESSURE A LOW PRESSURE B HIGH PRESSURE A LOW PRESSURE B

60
6.39
12.92
2936
3588
70
7.58
15.35
3486
4261
80
8.65
17.50
3974
4859
NOTE:
2. Values are based on standard controls. Optional controls may result in different values.
Table A7-5. Model CBE Steam Boiler Safety Valve Openings

VALVE
SETTING
15 PSIG STEAM
100 PSIG STEAM
125 PSIG STEAM
150 PSIG STEAM
BOILER NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF

HP
VALVES
SIZE
VALVES
SIZE
VALVES
SIZE
VALVES
REQ'D
(IN.)
REQ'D
(IN.)
REQ'D
(IN.)
REQ'D
200 PSIG STEAM
250 PSIG STEAM
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
60
1-1/2
1-1/2
1-1/4
1-1/4
70
1-1/2
1-1/2
1-1/4
1-1/4
80
2-1/2
1-1/2
1-1/2
1-1/4
1-1/4
NOTE:
1.Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on availability.
A7-14
09-09
Section A7

Gas Fired - Burners
Table A7-11 shows conversion factors for gas pressure at elevations over 700 ft above sea level.
Table A7-12 shows maximum gas consumption (CFH) for Natural Gas.
Table A7-13 shows minimum and maximum gas pressure requirements for Standard, FM and IRI
CBE Boiler gas trains.
For oversized or undersized gas trains or altitude above 1,000 feet, contact your local CleaverBrooks authorized representative.

The local gas company should be consulted for requirements and authorization for installation
and inspection of gas supply piping. Installation of gas supply piping and venting must be in
accordance with all applicable engineering guidelines and regulatory codes. All connections made
to the boiler should be arranged so that all components remain accessible for inspection, cleaning
and maintenance.
A drip leg should be installed in the supply piping before the connection to the gas pressure regulator. The drip leg should be at least as large as the inlet fitting supplied with the boiler. Consideration must be given to both volume and pressure requirements when choosing gas supply piping
size. Refer to the boiler dimension diagram provided by Cleaver-Brooks for the particular installation. Connections to the burner gas train should be made with a union, so that gas train components or the burner may be easily disconnected for inspection or service. Upon completion of the
gas piping installation, the system should be checked for gas leakage and tight shutoff of all
valves.

Oil-fired burners are equipped with an oil pump, which draws fuel from a storage tank and supplies pressurized oil to the burner nozzle(s). The burner supply oil pump has a greater capacity
than the burner requires for the maximum firing rate. Fuel not delivered to the nozzle is returned
to the storage tank. A two-pipe (supply and return) oil system is recommended for all installations. Figure A7-6 shows a typical fuel oil supply arrangement. Oil lines must be sized for the
burner and burner supply oil pump capacities.
The burner supply oil pump suction should not exceed 10" Hg. If a transfer pump is used, it must
have a pumping capacity at least equal to that of the burner pump(s). Supply pressure to the
burner pump should not exceed 3 psig.
A strainer must be installed in the supply piping upstream of the burner supply pump in order to
prevent entry of foreign material into the pump, fuel control valves, or burner nozzle(s). The
strainer must be sized for the burner supply pump capacity. A strainer mesh of 150 microns
(0.005") is recommended.
Install a check valve in the line to prevent draining of the oil suction line when the burner is not in
operation. Location of the check valve varies with the system, but usually it is located as close as
possible to the storage tank.
Installation of a vacuum gauge in the burner supply line between the burner oil pump and the
strainer is recommended. Regular observation and recording of the gauge indication will assist in
determining when the strainer needs servicing.
Upon completion of the oil piping installation, the system should be checked for oil or air leakage
and tight shutoff of all valves.
Boiler Room
Information
Stack Support
Capabilities
60-80 hp Model CBE Boilers can support up to 1000 lbs without additional support.
A7-15
09-09
Section A7
Table A7-6. Model CBE Hot Water Boiler Relief Valve Openings
VALVE SETTING
BOILER HP
30 PSIG HW
60 PSIG HW
100 PSIG HW
NO. OF OUTLET NO. OF OUTLET NO. OF

VALVE
SIZE
VALVE
SIZE
VALVE
S REQ'D (IN.) S REQ'D (IN.) S REQ'D
125 PSIG HW
OUTLET
SIZE
(IN.)
NO. OF
VALVE
S REQ'D
OUTLET
SIZE
(IN.)
60
1-1/4
70
1-1/4
80
1-1/4
1-1/4
NOTES:
1.Hot water relief valves are Kunkle #537.
Table A7-7. Model CBE Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity)
BOILER HP
OPERATING PRESSURE PSIG
60
70
80
15
30
40
50
75
100
125
150
2.5
2.5
2.5
200
2.5
2.5
2.5
250
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.
A7-16
09-09
Section A7
Table A7-8. Model CBE Blowdown Tank Sizing

Information
BOILER HP
WATER (GAL)
60
51
70
60
80
69
NOTE: Quantity of water removed from boiler by lowering normal water line 4"
Table A7-9. Sound Pressure Levels in DbA (Profire F)
BOILER HP
60
70
80
GAS
HIGH FIRE
77.0
75.0
76.5
LOW FIRE
78.0
74.0
76.5
NO. 2 OIL
HIGH FIRE
77.0
74.0
76.5
LOW FIRE
75.5
72.0
76.0
A7-17
09-09
Section A7
Table A7-10. Model CBE Burner Selections(Profire Burner)

BOILER HP
MAX ALTITIUDE
(FT)
BURNER SIZE
60
2000
70
3500
80
1500
Table A7-11. Minimum Required Gas Pressure Altitude Conversion
ALTITUDE
(FT)
CORRECTION FACTOR
ALTITUDE
(FT)
CORRECTION FACTOR
1000
1.04
6000
1.25
2000
1.07
7000
1.30
3000
1.11
8000
1.35
4000
1.16
9000
1.40
5000
1.21
To obtain minimum required gas pressure at altitudes above 700 feet, multiply the pressure
by the listed factors:
inches WC x 0.577 = oz/sq-in. oz/sq-in x 1.732 = inches WC.
i inches WC x 0.0361= psig. oz/sq-in x 0.0625 = psig.
psig x 27.71 = Inches WC. psig x 16.0 = oz/sq-in.
Table A7-12. Maximum Gas Consumption (CFH) for Natural Gas - Model CBE
BOILER HP
NATURAL GAS1000 (BTU/CU-FT)
60
2510
70
2930
80
3350
A7-18
09-09
Section A7
Table A7-13. Minimum Required Gas Pressure at Entrance to Standard, FM and IRI Gas
Trains - Model CBE (Upstream of Gas Pressure Regulator)
STD PIPE
BOILER HP
SIZE
(Inches)
MAX 1 PSIG INLET, MIN SUPPLY

PRESSURE (WC)
MAX 10 PSIG INLET**, MIN

SUPPLY PRESSURE (WC)
UL
FM
IRI
UL
FM
IRI
60
2*
11.0
11.0
11.5
13.0
13.0
13.5
70
2*
8.5
8.5
9.0
12.5
12.5
13.0
80
2*
11.0
11.0
11.5
14.5
14.5
15.0
* Gas pressure regulator is 1-1/2 inch.

** Use max 10 psig for all boilers destined for Canada.

A7-19
09-09

Boiler Room
Combustion Air
Section A7
When determining boiler room air requirements, the size of the room, air flow, and velocity of air
must be reviewed as follows:

recommended. Locate (1) at each end of the boiler room, preferably below a height of 7 feet.
This allows air to sweep the length of the boiler.
foot.
2.

C. Total recommended air = 10 cfm/bhp - up to 1000 feet elevation. Add 3 percent more per
3.

Example: Determine the area of the boiler room air supply openings for (1) 80 hp boiler at 800
feet altitude. The air openings are to be 5 feet above floor level.
Area Required: Area = cfm = 800/250 = 3.2 Sq-ft total.
Area/Opening: 3.2/2 = 1.6 sq-ft/opening (2 required).
Notice
Stack/Breeching
Size Criteria
The design of the stack and breeching must provide the required draft at each boiler flue gas outlet. Proper draft is critical to burner performance.
Although constant pressure at the flue gas outlet of the Model CBE is not required, it is necessary
to size the stack/breeching to limit flue gas pressure variation. The allowable pressure range is
0.25" W.C. to +0.25" W.C.
For additional information, please review Section I4, General Engineering Data (Stacks) and Section F, Stacks. Stack and breeching sizes should always be provided by a reputable stack supplier
who will design the stack and breeching system based on the above criteria. Your local CleaverBrooks authorized representative is capable of assisting in your evaluation of the stack/breeching
design.
A7-20
09-09
Section A7
FRONT
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
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.
If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and
working space.
2. Next shortest boiler room length (Dwg B) is obtained by allowing for possible future tube replacement
from the front of the boiler. Allowance is only made for minimum door swing at the rear.
If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and
working space.
3. A slightly longer boiler room (Dwg C) is obtained by allowing for possible future tube replacement from
the rear of the boiler. Allowance for door swing at the front provides sufficient aisle and working space at
the front.
Figure A7-7. Boiler Room Length (Typical Layouts) - Model CBE
A7-21
09-09
Section A7
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
BOILER HP
60-80
78
105
NOTES:
A allows for a clear 42" aisle between the water column on the boiler and the wall. If space permits, this aisle should be
widened.
42" - 60-80 hp
Figure A7-8. Boiler Room Width (Typical Layout) - Model CBE
A7-22
09-09
Section A7
Model CBE Boilers
60-80 HP Steam 15-300 psig
Sample Specification
Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-24
General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-24
Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-25
Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-25
Control Panel and Flame Safeguard Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-27
Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-27
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-27
Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-27
A7-23
09-09
Model CBE Boilers
Section A7
MODEL CBE BOILERS

60-80 HP Steam 15-300 psig
The following sample specification are provided by Cleaver-Brooks to assist you in meeting your
PART 1 GENERAL
1.1

A. The Steam Boiler shall be Cleaver-Brooks Model CBE, Fuel Series ______ (100,
200, 700), _____ hp designed for _____ psig (15, 150, 200, or other psig steam). The
maximum operating pressure shall be _____ psig.
B. 1.2 The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower
when fired with CS 12-48 No. 2 oil and/or natural gas, _____ Btu/cu-ft. Electrical
power available will be _____ Volt _____ Phase _____ Cycle and 115/1/160 for the
control circuit.
PART 2 PRODUCTS
2.1

A. The boiler shall be a three pass horizontal firetube updraft boiler with five (5) square
steel frame with forced draft burner and burner controls.
1. Approvals: Underwriters Laboratories Inc. The complete boiler package shall
be approved and listed as a unit by Underwriters Laboratories.
connections.
4. Refractory and insulation shall be contained in the rear smoke box and door;
door shall swing open for inspection.
appurtenances.
6. Front and rear tube sheets and all flues must be accessible for inspection and
cleaning when the doors are swung open. The boiler shall be furnished with
A7-24
09-09
Section A7
Model CBE Boilers

7.
The exhaust gas vent shall be located near the rear of the boiler on the top
60-80 hp. 1000 lbs
8.
Observation ports for the inspection of flame conditions shall be provided at

before shipment using a hard finished enamel coating.
2.2
Steam Boiler Trim

A. Water Column
water column to automatically actuate a motor driven feed water pump
2. Low Water Cutoff
The low water cutoff shall be included as an integral part of the boiler
feedwater control wired into the burner control circuit to prevent burner
operation if the boiler water level falls below a safe level.
Auxiliary low water cutoff manual reset shall be included, piped to the vessel, and
wired to the burner control circuit. A manual reset device shall be used on this
control.
shipped loose.
water column.
2.3
Burner and Controls

B. Blower
A7-25
09-09
Model CBE Boilers
Section A7
C.
D.

Combustion air damper and fuel control valve shall be operated by a single damper
control motor that regulates the flame according to load demand. Potentiometer type
position controls shall be provided to regulate operation of the damper control motor.
1. Fuel series 700 - Gas fired.
2. Fuel series 100 - Light oil (No. 2) fired.
3. Fuel series 200 - Light oil or gas fired.
Fuel Series 100 - Light oil (No. 2) fired.
Fuel Series 200 - Light oil or gas fired.
a.
4.
Burner Type - The burner shall be mounted at the front of the boiler and
be of high radiant multi-port type for gas. The burner shall be approved
for operation on natural gas fuel.
c. Gas Burner Piping
60-80 hp. Gas burner piping on all units shall include two (2) manual
shut-off valves, gas pressure regulator, one (1) motorized gas valve with
proof of closure switch, two (2) plugged leakage test connections, and
high and low gas pressure switches. The gas valve shall be wired to close
automatically in the event of power failure, flame failure, low water, or
any abnormal shutdown condition.
a. Burner Type - The burner shall be mounted at the front of the boiler, and
b. Ignition System - Select one of the following:
60-80 hp. The burner shall employ a direct spark ignition system. A high
voltage spark generated by a transformer shall be used to ignite the main
burner.
c. Oil Pump - An oil pump with the capacity of approximately twice the
Pump shall be an integral part of the burner and mechanically driven.
60 to 80 hp. Fuel oil piping on the unit shall include oil pressure
Oil Atomization Type-Select one of the following:
d.
e.
60-80 hp. Burner shall include a complete mechanical oil atomizing

system and be of the pressure atomizing type.
60-80 hp. The burner, mounted at the front of the boiler, shall be a
combination pressure atomizing type for oil and high radiant multi-port
type for gas. The burner shall be approved for operation with either CS1248 Commercial No. 2 oil or natural gas.
60-80 hp. Pump shall be an integral part of the burner and
A7-26
09-09
Section A7
Model CBE Boilers

mechanically driven.
1)
Oil Burner Piping - Select one of the following:

60-200 hp. Fuel oil piping on the unit shall include oil pressure
2) Oil Atomization Type - Select one of the following:
60-80 hp. Burner shall include a complete mechanical oil atomizing system
and be of the pressure atomizing type.
5.
Gas Burner Piping:

60-80 hp. Gas burner piping on all units shall include two (2) manual shut-off
valves, gas pressure regulator, one (1) motorized gas valve with proof of
closure switch, two (2) plugged leakage test connection, and high and low gas
pressure switches. The gas valves shall be wired to close automatically in the
event of power failure, flame failure, low water, or any abnormal shutdown
condition.
2.4

A. Control Panel
A factory prewired control panel shall be supplied with the boiler-burner package.
Panel may be mounted on the burner or boiler.
B. The panel will have a NEMA 1A rating and contain the flame safeguard controller,
burner motor starter, control circuit fuse, selector switches, indicating light and
terminal strips. Lights shall indicate load demand, 80 hp. The panel shall contain a
control circuit transformer and fuse protection.
C. The flame safeguard controller shall be a CB110 flame monitor with EPD170
2.5
____ percent at 100 percent of rating when burning natural gas and ________ fuelto-steam efficiency at 100% firing rate when burning oil (Contact your local
Cleaver-Brooks authorized representative for efficiency details).
PART 3 EXECUTION
3.1
WARRANTY
for a period of 12 months from date of start-up or 18 months from date of shipment,
3.2
Execution
1. Shop Tests
2. The packaged boiler must receive factory tests to check the construction,
controls, and operation of the unit. All tests may be witnessed by the
purchaser, if desired.
B. Start-up Service
services of a field representative for starting the unit and training the operator at
no additional costs.
A7-27
09-09
Model CBE Boilers
Section A7
A7-28
09-09
Section A7
Model CBE Hot Water Boiler
(60-350 hp, 30 psig, 125 psig)
Boiler Characteristics (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-30

Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-31
Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-31
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-33
A7-29
09-09
Section A7
Model CBE Hot Water Boiler (60-350 hp, 30 psig, 125 psig)
PART 1 GENERAL
1.01
BOILER CHARACTERISTICS (HOT WATER)

A. The Hot Water Boiler shall be Cleaver-Brooks Model CBE, Fuel Series ______
(100, 200, 700), _____ hp designed for _____ psig (30, 125, or other psig hot
water). The maximum water temperature will be _____ degree F, and the maximum
system temperature drop will be _____ degree F.
B. The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower
when fired with CS 12-48 No. 2 oil and/or natural gas, _____ Btu/cu-ft. Electrical
power available will be _____ Volt _____ Phase _____ Cycle and 115/1/160 for the
control circuit.
PART 2 PRODUCTS
1.02

A. 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.
1. Approvals: Underwriters Laboratories Inc. The complete boiler package shall
be approved and listed as a unit by Underwriters Laboratories.
connections.
line of the boiler. The boiler shall be designated to rapidly mix the return
water with the boiler water. Forced internal circulation shall be used.
5. Front and rear doors on the boiler shall be davited. Doors are to be sealed with
Kaowool gaskets and fastened tightly using heavy capscrews that thread into
replaceable brass nuts.
6. Refractory and insulation shall be contained in the rear smoke box and door;
door shall swing open for inspection.
appurtenances.
and cleaning when the doors are swung open. The shell must be furnished
with adequate handholes to facilitate boiler inspection and cleaning.
9. For boilers over 100 horsepower, a manhole shall be provided.
10. The exhaust gas vent shall be located near the rear of the boiler on the top
60-100 hp. 1000 lbs.
A7-30
09-09
Section A7

before shipment using a hand finished enamel coating.
1.03

A. Hot Water Connections
The hot water outlet and return connections shall be located on the top center line of the boiler. The
internal design of these connections shall provide forced internal circulation, mixing return water
with the hot water within the boiler.
B. 3.2 Dip Tube
The dip tube, an integral part of the hot water outlet, and an air vent tapping in the boiler shell must
be provided for removal of entrained air.
C. Low Water Cutoff
A low water cutoff control (manual reset) shall be mounted on the top centerline of the boiler wired
into the burner control circuit to prevent burner operation if boiler water falls below a safe level. A
manual reset device shall be used on this control.
D. Pressure and Temperature Gauges
Pressure and temperature gauges shall be mounted on the boiler with temperature sensing element
located adjacent to the hot water outlet.
E.
F.
Relief Valves
Water relief valves of a type and size to comply with ASME Code requirements
shall be shipped loose.
G. 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.
1.04
Burner
Burner operation shall be the full modulation principle. The burner shall always return to low fire
B.
4.2 Blower
3. 4.2.3 The impeller shall be cast aluminum, radial blade, carefully balanced,
and directly connected to the blower motor shaft.
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.
D.

A7-31
09-09
Section A7

1.

a. Burner Type - The burner shall be mounted at the front of the boiler and
ignition. An electronic detector shall monitor the pilot so that the
primary gas valve cannot open until pilot flame has been established.
The pilot train shall include one (1) shut-off valve, solenoid valve,
pressure regulator, and one (1) plugged leakage test connection (Canada
only).
c. Gas Burner Piping - Select one of the following:
A. 60-80 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas
pressure regulator, one (1) motorized gas valve with proof of closure switch, two (2) plugged
leakage test connections, and high and low gas pressure switches. The gas valve shall be wired to
close automatically in the event of power failure, flame failure, low water, or any abnormal
shutdown condition.
2.

a. Burner Type - The burner shall be mounted at the front of the boiler, and
b. Ignition System - Select one of the following:
60-80 hp. The burner shall employ a direct spark ignition system. A high voltage spark
generated by a transformer shall be used to ignite the main burner.
c.
Oil Pump - An oil pump with a capacity of approximately twice the

60-80 hp. Pump shall be an integral part of the burner and mechanically driven.
3. Oil Burner Piping - Select one of the following:

A. 60-80 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil
metering controls, two (2) solenoid oil shut-off valves, and pressure gauge all integrally
mounted on the unit.
4. Oil Atomization Type - Select one of the following:

A. 60-80 hp. Burner shall include a complete mechanical oil atomizing system and be of the
5.

a. Burner Type - Select one of the following:
60-80 hp. The burner, mounted at the front of the boiler, shall be a combination pressure
atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved
for operation with either CS12-48 Commercial No. 2 oil or natural gas.
6.
Gas Pilot - The gas pilot shall be premix type with automatic electric ignition.
cannot open until flame has been established. The pilot train shall include one
(1) manual shut-off valve, solenoid valve, and pressure regulator.
A7-32
09-09
Section A7

7.
Oil Burner
60-80 hp. Pump shall be an integral part of the burner and mechanically driven.
b. Oil Burner Piping - Select one of the following:

60-80 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil
metering controls, two (2) solenoid oil shut-off valves, and pressure gauge all integrally
mounted on the unit.
c. Oil Atomization Type - Select one of the following:

8. 60-80 hp. Burner shall include a complete mechanical oil atomizing system
and be of Gas Burner Piping - Select one of the following:
60-80 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas
pressure regulator, one (1) motorized gas valve with proof of closure switch, two (2)
plugged leakage test connection, and high and low gas pressure switches. The gas valves
shall be wired to close automatically in the event of power failure, flame failure, low water,
or any abnormal shutdown condition.
E.

1. Control Panel
A factory prewired control panel shall be supplied with the boiler-burner package. Panel may be
mounted on the burner or boiler.
2.
3.
4.
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
80 hp. The panel shall contain a control circuit transformer and fuse
protection.
1.05
A. The boiler must be guaranteed to operate at a minimum fuel-to-water efficiency of
____ percent at 100 percent of
rating when burning natural gas and ________ fuel-to-steam efficiency at 100%
firing rate when burning oil (Contact your local Cleaver-Brooks authorized
representative for efficiency details).
1.06
Warranty
for a period of 12 months from date of
start-up or 18 months from date of shipment, whichever comes first.
PART 3 EXECUTION
A.
B.
Shop Tests
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.
Start-up Service
services of a field representative for starting the unit and training the operator
A7-33
09-09
Firetube Boilers
A7-34
09-09
Section A8
MODEL CB OHIO SPECIAL BOILERS
CONTENTS
Unique Dimple Tube Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
358 Square Feet of Heating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Furnace Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A8-3
A8-3
A8-3
A8-3
A8-3
A8-4
A8-5
A8-10
A8-10
A8-15
A8-15
A8-17
A8-25
A8-1
09-09
Firetube Boilers
ILLUSTRATIONS
Figure A8-1. Model CB Ohio Special Steam Boiler Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . A8-7
Figure A8-2. Space Required to Open Rear Head on Model CB Ohio Special Boilers
Equipped with Davits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-9
Figure A8-3. Model CB Ohio Special Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-9
Figure A8-4. Model CB Ohio Special Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-10
Figure A8-5. Secondary Air Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-12
Figure A8-6. Complete Linkage Assembly, Combination Gas and Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-13
Figure A8-7. Gas Modulating Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-14
Figure A8-8. Model CB Ohio Special Gas Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-18
Figure A8-9. Typical Gas Piping Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-19
Figure A8-10. Model CB Ohio Special Firetube Boilers Standard Gas
Train Connection Size and Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-20
Figure A8-11. CB a Ohio Special Boilers, No. 2 Oil Connection Size,
Location and Recommended Line Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-20
Figure A8-12. No. 2 Oil Piping, Single Boiler Installation, Remote Oil Pump . . . . . . . . . . . . . . . . . . . . . . . A8-21
Figure A8-13. No. 2 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . . . . . . . . A8-21
Figure A8-14. No. 2 Oil Piping, Multiple Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-22
Figure A8-15. No. 2 Oil Transfer Tank Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-22
Figure A8-16. Boiler Room Length (Typical Layouts), Model CB Ohio Special . . . . . . . . . . . . . . . . . . . . . A8-23
Figure A8-17. Boiler Room Width (Typical Layout), Model CB Ohio Special . . . . . . . . . . . . . . . . . . . . . . A8-23
TABLES
Table A8-1. Model CB Ohio Special Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-6
Table A8-2. Model CB Ohio Special Boilers Heating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-10
Table A8-3. Model CB Ohio Special Boilers Steam Volume and Disengaging Area . . . . . . . . . . . . . . . . . . A8-11
Table A8-4. Model CB Ohio Special Boilers Steam Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . A8-11
Table A8-5. Model CB Ohio Special Firetube Boilers Recommended Steam Nozzle Size
(To Maintain 4000 to 5000 fpm Nozzle Velocity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-11
Table A8-6. Model CB Ohio Special Firetube Boilers Recommended Non-Return Valve Size . . . . . . . . . . A8-12
Table A8-7. Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-12
Table A8-8. CB Ohio Special Firetube Boilers Minimum Required Gas Pressure
at Entrance to Gas Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-14
Table A8-9. Minimum Required Gas Pressure Altitude Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-16
Table A8-10. Maximum Gas Consumption, Natural Gas and Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . A8-16
A8-2
09-09
Section A8

The Cleaver-Brooks Ohio Special Firetube boiler is designed, manufactured, and
packaged by Cleaver-Brooks specifically for operation in the state of Ohio, under the
rules and regulations for unattended units. The unique design of the Ohio Special Boiler
serves your steam needs and reduces unnecessary labor costs. All units are factory fire
tested and shipped as a package, ready for quick connection to utilities. In addition to the
features provided on all Cleaver-Brooks Firetube boilers, the following features apply to
the Ohio Specials.
Unique Dimple Tube Design:
Ensures high gas turbulence and increased efficiency without turbulators, spinners,
and other high maintenance devices.
Dimple tubes also reduce the film coefficient on the gas side to transfer more heat,
thus achieving greater output with less heating surface.
358 Square Feet of Heating Surface:

The greatest amount offered in any packaged boiler for unattended steam boiler
operation in Ohio - means long life and years of service at the high efficiencies.
Low Furnace Location:
PRODUCT OFFERING
Cleaver-Brooks Ohio Special Firetube boilers are available high pressure steam designs.
Burners are available to fire natural gas, light oil, or a combination of oil and gas.
Ohio Special Boilers include:
Four-pass dryback design (100 hp).
Two-pass dryback design (125 - 225 hp).
Two-pass wetback design (125 - 200 hp).
150, 200, and 250 psig high pressure steam
Available options: For option details, contact your local Cleaver-Brooks authorized
representative. In summary, options include the following:
Boiler Options
Drain valves.
Surge load baffles.
Seismic design.
Blowdown valves.
Non-return valves.
A8-3
09-09
Section A8
Special doors, davited, hinged, left swing.
Special base rails.
Weather-proofing.
Burner/Control Options
Special modulation controls.
Low NOx equipment.
Lead/lag system.
Special insurance and code requirements (e.g., IRI, FM, CSD1).
Remote contacts.
Additional relay points and indicator lights.
Main disconnect.
Elapsed time meter.
Voltmeter/micro-ampmeter.
NEMA enclosures.
Low fired hold controls.
Circuit breaker.
Day/night controls.
Fuel Options
Gas strainer.
Special pilot.
Alternate fuel firing.
Special oil pumps.

For dimension and rating information for Ohio Special boilers, refer to the following
Table A8-1. Model CB Ohio Special Steam Boiler Ratings.
Figure A8-1. Model CB Ohio Special Steam Boiler Dimensions.
Figure A8-2. Space Required to Open Rear Head on Model CB Ohio Special Boilers
A8-4
09-09
Section A8

Equipped with Davits.
Figure A8-3. Lifting Lug Locations, Model CB Ohio Special Boilers.
Figure A8-4. Model CB Ohio Special Boiler Mounting Piers.
PERFORMANCE DATA
For efficiency and emission data for Ohio Special Boilers, contact your local CleaverBrooks authorized representative.
A8-5
09-09
Section A8
Table A8-1. Model CB Ohio Special Steam Boiler Ratings

BOILER HP
100S
125S
150S
175S
200S
WEIGHT IN POUNDS
4625
7000
7000
8500
8500
Approx Wt -15 psig
7800
9300
9300
12600
12600
Approx Wt -150 psig
8500
9900
9900
13500
13500
Approx Wt - 200 psig
9000
10500
10500
14200
14200
5420
8673
8673
10485
10485
Steam - lbs/hr (212F)
3450
4313
5175
6038
6900
3348
4184
5021
5858
6695
APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITIES
Light Oil gph
30
37.4
44.8
52.5
59.8
(140,000 Btu/gal)
Nat Gas CFH
4185
5230
6277
7323
8369
(1000 Btu/cu-ft)
Nat Gas -Therms/hr
41.9
52.3
62.8
73.2
83.7
POWER REQUIREMENTS - ELECTRIC (60 Hz)
Blower Motor, hp (all models) 3
5
7-1/2
10
15
Oil Pump Motor, hp (No. 2 Oil) 1/3
1/2
1/2
1/2
1/2
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.
A8-6
09-09
225S
8500
12600
13500
14200
10485
7763
7531
67.5
9415
94.2
20
1/2
Section A8
RR/RF/RD
EE
I
LL
DD
BB
GG
FF
F
D
CC
Z
P
OO
J
H
S
KK
Q
N
M
ELECTRICAL SERVICE
CONNECTIONS
(CONTROL CIRCUIT
120/1/60)
SIGHT
PORT
R
W
.5"
C
A
MODEL HP
DIM
100S
125S
150S
175S
200S
225S
LENGTH
Overall
171-1/2
163-1/2
163-1/2
200-1/2
204-1/2
207-1/2
Shell
131
113
113
149
149
149
Base Frame
130
100
100
136
136
136
Front Head Extension (Ap- D

prox)
22
31
31
32
36
39
Rear Head Extension
18-1/2
19-1/2
19-1/2
19-1/2
19-1/2
19-1/2
Flange to Nozzle (15 psig)
65-1/2
53
53
74.5
74.5
74.5
Flange to Nozzle (150 psig)
72.5
53
53
66
66
66
Figure A8-1. Model CB Ohio Special Steam Boiler Dimensions - Sheet 1 of 2
A8-7
09-09
MODEL HP
DIM
100S
Section A8
125S
150S
175S
200S
225S
WIDTH
Overall
73
85
85
85
85
85
ID Boiler
48
60
60
60
60
60
39
45
45
45
45
45
KK
29
35
35
35
35
35
Center to Lagging
27
33
33
33
33
33
LL
34
40
40
40
40
40
Base-Outside
37-5/8
52-1/2
52-1/2
52-1/2
52-1/2
52-1/2
Base-Inside
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 Vent Outlet
70
85
85
85
85
85
66
77
77
77
77
77
Base Frame
12
12
12
12
12
12
16
16
16
16
16
16
CONNECTIONS
Chemical Feed
Feedwater, Right & Left
1-1/4
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
8 FLG
8 FLG
8 FLG
8 FLG
10 FLG
10 FLG
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
Blowdown-Front & Rear (150 W

psig)
1-1/4
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
Surface Blow (150 psig only)
Vent Stack Dia. (Flanged)
BB
12
16
16
16
16
16
CC
Rear Door Swing
DD
55
32
32
32
32
32
Front Door Swing
EE
55
67
67
67
67
67
Tube Removal, Rear
FF
123
103
103
139
139
139
Tube Removal, Front
GG
113
91
91
127
127
127
Min Room Length for Rear Tube RR

Removal
309
283
283
355
355
355
Min Room Length for Front Tube RF

Removal
299
236
236
308
308
308
Tube Removal thru Door
241
212
212
248
248
248
Steam Nozzle (15 psig)
Steam Nozzle (150 psig)
CLEARANCES
RD
NOTE: Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints.
A. Flanged 150 psig ANSI
B. Flanged 300 psig ANSI
Figure A8-1. Model CB Ohio Special Steam Boiler Dimensions - Sheet 2 of 2

A8-8
09-09
Section A8
DIMENSION (INCHES)
BOILER HP
27
48
38
60
26
CB 125S thru 225S 33
55
45
68
32
CB 100S
Figure A8-2. Space Required to Open Rear Head on Model CB Ohio Special Boilers Equipped with Davits
FRONT
FLANGE
E DIA. HOLE
CL
VIEW A
BOILER HP ALL
DIMENSIONS
(CB)
INCHES
D
D
NEAR
SIDE
FAR
SIDE
VIEW B
IN
100S
68
27
67
2-1/2
125S-150S
80
29-1/2 66
175S-225S
80
29-1/2 88
NOTE: A, B and C Dimensions may vary by 1/2 inch.
Figure A8-3. Model CB Ohio Special Boilers Lifting Lug Location
A8-9
09-09
Section A8
BOILER HP
CB 100S
130
26
CB 125S, 150S
100
39-1/2
42
29-5/8
8-1/4
57-1/2
44-1/2
10-1/4
CB 175S, 200S, 225S
136
39-1/2
57-1/2
44-1/2
10-1/4
NOTES:
2. 6-inch high mounting piers recommended for use beneath the boiler base frame. The use of these piers provides increased inspection accessibility
to the piping beneath the boiler and added height for washing down the area beneath the boiler.
Figure A8-4. Model CB Ohio Special Boiler Mounting Piers
ENGINEERING DATA
The following engineering information is provided for the Ohio Special Boilers. Ohio
Special boilers are designated by an S following the horsepower number. Additional
detail is available from your local Cleaver-Brooks authorized representative.
Boiler Information
Table A8-2 shows heating surfaces for Model CB Ohio Special Boilers.
Table A8-3 shows steam volume and disengaging area for Model CB Ohio Special
Boilers.
Table A8-4 lists quantity and outlet size for safety valves supplied on Model CB Ohio
Special Boilers.
Table A8-5 gives recommended steam nozzle sizes based on 4000-5000 fpm steam
velocity. Model CB Ohio Special Firetube Boilers.
Table A8-6 shows recommended non-return valve sizes for Model CB Ohio Special
Firetube Boilers.
Table A8-2. Model CB Ohio Special Boilers Heating Surface

BOILER
HP

FIRESIDE
WATERSIDE
100S
350
388
125S-150S
358
386
175S, 200S, 225S
358
384
A8-10
09-09
Section A8
Table A8-3. Model CB Ohio Special Boilers Steam Volume and Disengaging Area
BOILER HP
STEAM VOLUME CU-FT
HIGH PRESSURE A
LOW PRESSURE B
HIGH PRESSURE A
LOW PRESSURE B
100S
14.3
23.7
4367
4975
125S, 150S
28.4
38.9
5086
5473
175S, 200S, 225S
38.5
52.7
6899
7423
NOTES: Based on normal water level.

Table A8-4. Model CB Ohio Special Boilers Steam Boiler Safety Valve Openings
VALVE
15 PSIG STEAM
SETTING
100 PSIG STEAM
125 PSIG STEAM
150 PSIG STEAM
200 PSIG STEAM
250 PSIG STEAM
BOILER
HP
NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET
VALVES SIZE
VALVES SIZE
VALVES SIZE
VALVES SIZE
VALVES SIZE
VALVES SIZE
REQ'D
(IN.)
REQ'D
(IN.)
REQ'D
(IN.)
REQ'D
(IN.)
REQ'D
(IN.)
REQ'D
(IN.)
100S
2-1/2
1-1/2
1-1/2
1-1/4
125S
2-1/2
2-1/2
(1) 2
(1) 1-1/2
1-1/2
1-1/2
150S
2-1/2
2-1/2
1-1/2
1-1/2
175S
2-1/2
2-1/2
1-1/2
200S
2-1/2
2-1/2
225S
2-1/2
2-1/2
2-1/2
NOTE:
Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on availability.
Table A8-5. Model CB Ohio Special Firetube Boilers

Recommended Steam Nozzle Size
(To Maintain 4000 to 5000 fpm Nozzle Velocity)
BOILER HP
OPERATING
PRESSURE
PSIG
100S
125S
150S
175S
200S
225S
15
10
10
30
40
50
75
100
125
150
2.5
200
2.5
2.5
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.
A8-11
09-09
Section A8
Table A8-6. Model CB Ohio Special Firetube Boilers Recommended Non-Return Valve Size
BOILER
HP
BOILER CAPACITY
(LB/HR)
50
75

100
125
150
175
200
100S
3450
2-1/2
2-1/2
NA
NA
NA
NA
NA
125S
4313
2-1/2
2-1/2
2-1/2
NA
NA
NA
150S
5175
2-1/2
2-1/2
2-1/2
2-1/2
NA
175S
6038
2-1/2
2-1/2
2-1/2
2-1/2
NA
200S
6900
3*
2-1/2
2-1/2
225S
7736
2-1/2
2-1/2
NOTE:
Standard non-return valve selections limited to a maximum 2 to 1
turndown (50% of full boiler output); selection based on typical
valve sizing recommendations. For final valve selection contact your
authorized C-B representative. For high turndown applications see
Boiler Book Section I3, Table I3-2.
*Indicates pressure drop of less than 7.5 psig. All other selections are
less than 6 psig pressure drop.
Table A8-7. Blowdown Tank Sizing Information
BOILER HP
WATER (GAL)
100S
80
125S-150S
87
175S-225S
118
NOTE: Quantity of water removed from boiler by lowering normal water

line 4"
Figure A8-5. Secondary Air Flow Diagram
Blowdown Water
Requirements

A8-12
09-09
09-09
Section A8
J AC K S HAF T
OIL MODULAT ING
C AM
C AM
ADJ US T ING
SCREW
G AS MODULAT ING C AM
R OT AR Y AIR DAMP E R
J AC K S HAF T AR M
J AC K S HAF T
DR IV ING AR M
OIL MODULAT ING

C AM F OLLOWE R
45
C AM ADJ US T ING
SCREW
OIL ME T E R ING V ALV E

G AS MODULAT ING
C AM F OLLOWE R
G AS ME T E R ING
V ALV E
R OT AR Y AIR
DAMP E R
R OD
MODULAT ING
MOT OR R OD
R OT AR Y AIR
DAMP E R S HAF T
60
R OT AR Y AIR
DAMP E R AR M
MODULAT ING MOT OR

MOT OR
F UE L OIL
C ONT R OLLE R
B UT T E R F LY
G AS V ALV E R OD
OV E R T R AV E L LINK AG E
45
MODULAT ING
MOT OR AR M
NOT IC E :
S E T T ING S IN DIAG R AM
INDIC AT E LOW F IR E
S E T T ING OF LINK AG E .
S P R ING LOADE D
B UT T E R F LY G AS V ALV E AR M
B UT T E R F LY G AS V ALV E
Figure A8-6. Complete Linkage Assembly, Combination Gas and Oil
A8-13
09-09
Section A8
Figure A8-7. Gas Modulating Cam
Table A8-8. Gas pressure requirements, CB Ohio Special
Boiler HP
100
125
150
175
200
225
300
Gas Train Size (In.)

1.5
2
1.5
2
1.5
2
1.5
2
1.5
2
2.5
1.5
2
2.5
2
Min. Pressure
14 WC
9 WC
19 WC
13 WC
25 WC
17 WC
35 WC
21 WC
45 WC
30 WC
24 WC
56 WC
37 WC
31 WC
4.4 PSI
Table is based on Siemens gas train, which includes a regulating

actuator.
A8-14
09-09
Max. Pressure PSI

2
1
2
1
3
2
3
2
3
2
1.5
3
2.5
2
6.5
STANDARD
OVERSIZE
Section A8
Burner Information

The Ohio Special Firetube Boiler encompasses an integral front head that
includes the burner, combustion air fan, and controls as part of the boiler package
design.
The integral front head provides for burner/boiler design as a single unit
maximizing the compatibility between the boiler and burner.
Figure A8-5 shows secondary air flow in the Ohio Special Firetube Boiler. The
rotary air damper design provides standard turn down of 4:1.
Figure A8-6 shows a typical linkage assembly. The single point linkage layout
allows for easy adjustment and maximum repeatability of air/fuel ratios.
Included on all Ohio Special Boilers is an adjustable CAM assembly shown in
Figure A8-8.
Gas-Fired Burners
Table A8-8 shows regulated gas pressure requirements for gas trains for CB Ohio
Special Firetube Boilers.
Table A8-10 shows maximum gas consumption for natural gas and propane
vapor.
Figure A8-8 shows typical gas train components, and Figure A8-9 shows typical
gas train piping layouts for multiple boiler applications.
Figure A8-10 shows standard gas train sizes and locations for Model CB Ohio
Special Firetube Boilers.
Oil-Fired Burners
Figure A8-11 shows the oil connection sizes and locations for Ohio Special
Boilers firing No. 2 oil.
Figures A8-12 through A8-15 show typical oil systems and layouts.
Boiler Room
Information

100 hp Ohio Special Boilers can support up to 1,000 lbs without additional
support.
125-225 hp Ohio Special Boilers can support up to 2,000 lbs without additional
support.
A8-15
09-09
Section A8
Table A8-9. Minimum required gas pressure

altitude conversion
ALTITUDE
(FT)
CORRECTION
FACTOR
ALTITUDE
(FT)
CORRECTION
FACTOR
1000
1.04
6000
1.25
2000
1.07
7000
1.30
3000
1.11
8000
4000
1.16
9000
5000
1.21
Table A8-10. Maximum gas consumption, natural

gas and propane
BOILER
HP

NATURAL GAS
1000 (Btu/cu-ft)
PROPANE GAS
2550 (Btu/cu-ft)
1.35
100S
4185
1640
1.40
125S
5230
2050
150S
6280
2465
175S
7350
2870
200S
8370
3280
225S
9415
3690
To obtain minimum required gas pressure at altitudes above 700 feet,

multiply the pressure by the listed factors:
Boiler Room
Combustion Air
1.
A.Two (2) permanent air supply openings in the outer walls of the boiler room are
recommended. Locate (1) at each end of the boiler room, preferably below a height
of 7 feet. This allows air to sweep the length of the boiler.
B.Air supply openings can be louvered for weather protection, but they should not be
covered with fine mesh wire, as this type of covering has poor air flow qualities and
is subject to clogging by dust or dirt.
C.A vent fan in the boiler room is not recommended, as it could create a slight vacuum
under certain conditions and cause variations in the quantity of combustion air. This
can result in unsatisfactory burner performance.
D.Under no condition should the total area of the air supply openings be less than (1)
square foot.
Area (sq-ft) = cfm/fpm
2.
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
3.
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.
A8-16
09-09
Section A8
Notice
Stack/Breeching
Size Criteria
Although constant pressure at the flue gas outlet of the Ohio Special is not required, it is
necessary to size the stack/breeching to limit flue gas pressure variation. The allowable
pressure range is 0.25" W.C. to +0.25" W.C.
A8-17
09-09
Section A8
1
S
PILOT GAS LINE

FLOW
10
11
Gas
Supply
To
Burner
MAIN GAS LINE

UL
ITEM
1
2
3
4
5
6
7
8
9
10
11
DESCRIPTION
Pilot Shut Off Cock
Gas Pilot Valve
Butterfly Valve
100S
FM
125S 225S
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
100S
X
X
X
X
X
X
X
X
X
X
CSD-1
125S 225S
X
X
X
X
X
X
X
X
X
X
X
Figure A8-8. Model CB Ohio Special Gas Train Components
A8-18
09-09
100S
X
X
X
X
X
X
X
X
X
X
125S 225S
X
X
X
X
X
X
X
X
X
X
X
Section A8
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.
STREET GAS MAIN
MODEL
CB-OS
BOILERS
PLUG
COCK
MODEL
CB-OS
BOILERS
A
B
C
CONTRACTOR
CONNECTION
POINT
GAS TRAIN
ON BOILER

C. Gas meter.
The size of the gas line from the meter to the connection point at the boiler can
be very important if gas pressures are marginal. The gas line sizing is dependent on:
The local gas utility will advise the pressure that is available at the outlet of their
meter.
A8-19
09-09
Section A8
MODEL CB
BOILER
HP
CONNECTION SIZE
(IN.) (NPT)
LOCATION
DIMENSION
A (IN.)
100S
1 1/2
46 1/2
125S-200
1 1/2
52
55
225S
BOILER
FRONT
PLAN VIEW
Figure A8-10. Model CB Ohio Special Firetube Boilers Standard Gas Train Connection Size and Location
BHP
RECOMMENDED OIL LINEA SIZES

(STANDARD PIPE)
(IN.-IPS)
SUPPLY
AND
RETURN
CONN
SIZES (IN.)
(NPT)
A
(IN.)
100S
3/4
125S-225S
3/4
STORAGE
TANK TO
BOILER OR
PUMP
CONNECT
PUMP TO
BOILER
RETURN
LINE TO
TANK
11-1/2
12-1/2
NOTES: See No. 2 Oil Line Sizing Instruction for systems with other conditions
A. For suction line condition with a maximum of 10 Feet of lift and a total of 100 feet of
suction line.
Figure A8-11. CB Ohio Special Boilers, No. 2 Oil Connection Size, Location and Recommended Line Sizes
A8-20
09-09
Section A8
CHECK
VALVE
VACUUM
GAUGE
OIL PUMP
UNION
GATE VALVE
STRAINER
GATE VALVE
F.O.S.
RELIEF VALVE
F.O.R.
GATE VALVE
CHECK VALVE
BOILER
FRONT
BOILER
BASE FRAME
F.O.S.

F.O.R.
CONTRACTOR
CONNECTIONS
AT THIS POINT
VACUUM GAUGE
CHECK VALVE
GATE VALVE
STRAINER
GATE VALVE
F.O.S.
OIL
PUMP
NO. 2
F.O.R.
OIL PUMP NO. 1

UNION
GATE VALVE
RELIEF
VALVE
(100 PSIG)
GATE VALVE
CHECK VALVE
USE LAYOUT FOR: MODEL CB . . 100S - 225S

BOILER
FRONT
BOILER
BASE FRAME
F.O.S.
F.O.R.
CONTRACTOR
CONNECTIONS
AT THIS POINT
A8-21
09-09

VACUUM GAUGE
STRAINER
GATE VALVE
CHECK
VALVE
STANDBY
OIL PUMP
F.O.S.
GATE
VALVE
UNION
GATE VALVE
Section A8
RELIEF
VALVE
(100 PSIG)
F.O.R.
ADJUSTABLE
PRESSURE
RELIEF VALVE
(75 PSIG)
PRESSURE
GAUGE
GATE
VALVE
CHECK
VALVE
USE LAYOUT FOR: MODEL CB . . . . . . . 50 THRU 800 HP
USE LAYOUT FOR: MODEL CB . . . . . . . 100S - 225S

MODEL CBWRelief
. . . .valve
. 125S
200S
on the- boiler
BOILER
BASE FRAME
BOILER
FRONT
F.O.S.
CONTACTOR
CONNECTIONS
AT THIS POINT
F.O.R.
VENT
OIL TRANSFER TANK

AT LOCATION NEAR
BOILER
OIL LEVEL
TEST VALVE
OIL TRANSFER PUMP

NEAR STORAGE TANK
F.O.R.
GATE
CHECK
VALVE
VALVE STRAINER
F.O.S.
F.O.R.
F.O.S.
SUPPLY TO BOILER
TERMINAL BLOCK OR
TO BOILER OIL PUMP
RELIEF VALVE
(100 PSIG)
ITEM
SIZE
GATE
UNION VACUUM VALVE
GAUGE
DESCRIPTION


level switch
pump
connection
H
McD
G A
2"
3/16"
B
5"
3"
22"
60"
E
33"
3"
4" OR 6"
STD
BLACK
PIPE

A8-22
09-09
3/8" MTL
D 3/16"
Section A8
FRONT
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
DWG A - MODEL CB
DWG B - MODEL CB
DWG C - MODEL CB
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.
only made for minimum door swing at the rear. If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle
and working space.
3. A slightly longer boiler room for Model CB (Dwg C) is obtained by allowing for possible future tube replacement from the rear of the boiler.
Allowance for door swing at the front provides sufficient aisle and working space at the front.
Figure A8-16. Boiler Room Length (Typical Layouts), Model CB Ohio Special
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.
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
Figure A8-17. Boiler Room Width (Typical Layout), Model CB Ohio Special
A8-23
09-09
Section A8
Notes
A8-24
09-09
Section A8
Model CB Ohio Special Steam Boiler
100-225 hp, Steam 15, 150, 200, or 250 psig)

Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-27
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-32
A8-25
09-09
Section A8

100-225 hp, Steam 15, 150, 200, or 250 psig)
The following sample specifications are provided by Cleaver-Brooks to assist you in specifying
your customer's specific needs and application.
specification. Contact your local Cleaver-Brooks authorized representative for information on
special insurance requirements, special code requirements, optional equipment, or general
assistance in completing the specification.
PART 1 GENERAL
1.01

A. The Steam Boiler shall be Cleaver-Brooks Model CB Ohio Special Fuel Series
____ (100, 200, 700), ____ hp designed for ____ psig (15 or ____ psig steam). The
maximum operating pressure shall be ____ psig.
B. The boiler shall have a maximum output of ____ Btu/hr, or ____ horsepower when
fired with CS12-48 No. 2 oil and/or natural gas, ____ Btu/cu-ft. Electrical power
available shall be ____ Volt ____ Phase ____ Cycle and 115/1/60 for the control
circuit.
PART 2 PRODUCTS
2.01

A. The boiler shall be a multi-pass horizontal firetube updraft boiler with 350 square
feet of total heating surface for the 100 hp and 358 square feet of total heating
surface for the 125-225 hp boilers. It shall be mounted on a heavy steel frame with
integral forced draft burner and burner controls. The complete packaged boiler is
built as a unit with Underwriters Laboratories listed controls.
shall bear the UL/ULC label, except in the case where 50 Hz has been selected.
1.
B.
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.
and must receive authorized boiler inspection prior to shipment. A copy of
the inspection report shall be furnished the purchaser.
4. Rear refractory and insulation shall be contained in the formed door which
5. The boiler tubes shall not include swirlers, turbulators, or other add-on
devices.
A8-26
09-09
Section A8

6.
Front and rear tube sheets and all tubes must be fully accessible for inspection
and cleaning when the doors are swung open. The boiler shall be furnished
7. For boilers 125 horsepower and over, a manhole shall be provided.
100 hp 1000 lbs. and shall contain a stack thermometer.
125-225 hp 2000 lbs. and shall contain a stack thermometer.

9.
Observation ports for the inspection of flame conditions shall be provided at

10. The boiler insulation shall consist of a 2 inch fiberglass blanket under a
sectional preformed sheet metal lagging. This insulation must be readily
removable and capable of being reinstalled, if required.
11. The entire boiler base frame and other components shall be factory painted
before shipment using a hard-finish enamel coating.
2.02
STEAM BOILER TRIM

A. Water Column
A water column shall be located on the right hand side of the boiler complete with gauge glass set,
and water column blowdown valves.
B. Feedwater Pump Control
automatically actuate a motor driven feedwater pump maintaining the boiler water level within
normal limits.
C. Low Water Cutoff
the burner control circuit to prevent burner operation if the boiler water level falls below a safe
level.
D. Auxiliary Low Water Cutoff
Auxiliary low water cutoff shall be included, piped to the vessel, and wired to the burner control
E. Steam Pressure Gauge
connection.
F. Safety Relief Valves
G. Steam Pressure Controls
2.03
BURNER
Burner operation shall be full modulation principle. The burner shall always return to low fire
A8-27
09-09
Section A8
B.
Forced Draft Blower

1. All air for combustion shall be supplied by a forced draft blower mounted in
the front boiler door, above the burner, to eliminate vibration and reduce noise
level.
2. Maximum sound level of the boiler/burner package shall not exceed ____
dBA (when measured in accordance with ABMA Sound Test Standards).
control motor that regulates the fire according to load demand. Single point positioning controls
Refer to the following fuel series specifications:
Fuel series 700 - gas fired.
Fuel series 100 - light oil fired.
Fuel series 200 - light oil or gas fired.

E.

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.
2. Gas Pilot - The gas pilot shall be a premix type with automatic electric
ignition. An electronic detector shall monitor the pilot so that the primary gas
valve cannot open until pilot flame has been established. The pilot train shall
include two manual shut-off valves, solenoid valve, pressure regulator and
pressure gauge.
3. Gas Burner Piping - Gas burner piping on all units shall include pressure
regulating gas shutoff valve, motor operated with proof of closure switch and
plugged leakage test connection. The valve is spring return to start or stop the
gas burner and to close automatically in the event of power failure, flame
failure, low water or any safety shutdown condition. A lubricating plug 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:
100 hp High and low gas pressure switches shall be provided.
4.
5.
125-225 hp High and low gas pressure switches shall be provided. A second
motorized safety shutoff valve, plus an additional plugged leakage test
connection shall be provided.
Burner Turndown - Turndown range of the burner shall be 4:1 when firing
natural gas.
a. Fuel Series 100 - Light Oil Fired
b. Burner Type - The burner shall be integral with the front head of the
A8-28
09-09
Section A8

c.
Oil Pilot - The oil pilot shall be air atomizing type with automatic
electric ignition and include oil solenoid valve. An electronic detector
shall monitor the pilot so that the primary oil valve cannot open until
flame has been established.
d. Oil Pump - An oil pump with a capacity of approximately twice the
maximum burning rate shall be included. A separate motor driven pump
set, shipped loose to be installed in a location favorable to the oil storage
e. Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure
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
atomizing burner. A low oil pressure switch shall be included in the oil
piping.
f.
100 hp. Separate air compressor module mounted on boiler base rail with low atomizing air
pressure switch shall be provided.
125 hp-225 hp. Belt driven air compressor, lubricating air tank, oil level indicator, inlet air
filter, air pressure gauge, and low atomizing air pressure switch shall be provided.
6.
Burner Turndown - Turndown range of the burner shall be 4:1 when firing
No. 2 oil.
F. Fuel Series 200 - Light Oil or Gas Fired
annular gas entry on 125-225 hp and multi-port type for gas entry on 100 hp.
The burner shall be approved for operation with either CS12-48 Commercial
No. 2 Oil or natural gas.
3. Oil Burner
set, shipped loose, to be installed in a location favorable to the oil
storage tank, shall be provided.
b. Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure
piping.
c. Low pressure Air Atomizing - Select one of the following:
100 hp. Separate air compressor module mounted on boiler base rail with low atomizing air
A8-29
09-09
Section A8
pressure switch shall be provided.
125-225 hp. Belt driven air compressor, lubricating air tank, oil level indicator, inlet air
filter, air pressure gauge and low atomizing air pressure switch shall be provided.
d.
Gas Burner
1) Gas Burner Piping - gas burner piping on all units shall include
closure switch and plugged leakage test connection. The valve is
spring return to start or stop the gas burner and to close
automatically in the event of power failure, flame failure, low
water or any safety shutdown condition. A lubricating plug cock
or butterfly shutoff valve shall be provided as a means for a
tightness check of the primary shut off valve. An additional plug
cock or butterfly shutoff valve shall be furnished at entrance to gas
train. Select one of the following:
100 hp High and low gas pressure switches shall be provided.
125-225 hp High and low gas pressure switches shall be provided. A second motorized
safety shutoff valve, plus an additional plugged leakage test connection shall be provided.
e. Burner Turndown - Turndown range of the burner shall be 4:1.

G. Boiler Flame Safeguard Controller and Control Panel
1. CB780E Flame Safeguard Controller
Each boiler shall be factory equipped with flame safeguard controller providing technology and
functions equal to the Cleaver-Brooks Model CB780E.
Controller shall be computerized solid state having sequence and flame-on lights and digital first
out fault code indications of flame safeguard trip functions. It shall include dynamic self-check
logic. The controller shall have a fixed operating sequence incapable of being manually altered.
The sequence shall include start, pre-purge, pilot and main fuel ignition run and post-purge cycles.
proving switch faults, running interlocks open, false flame signal and fuel valve open (when proof
of closure switch is furnished).
The controller shall have a run/test switch. It shall allow interruptions to sequence just after prepurge, during pilot ignition trial and run cycles for adjustments to firing rate motor, damper linkages
and pilot flame for minimum turndown tests.
a.
cabinet will have NEMA 1A rating that includes a neoprene dust seal
and a Yale cabinet key type lock.
The panel shall have a removable sub-base for mounting the flame safeguard controller, blower
motor starter, and terminal blocks. For combination gas-oil fired boilers, the panel shall contain the
fuel selector switch.
b.
Lights
White - load demand.
A8-30
09-09
Section A8

Red - low water.
c.
Control Switches
Burner On-Off.
Manual-Automatic.
2.
d.Oil, heat and moisture resistant wire shall be used and identified with
e. All electrical equipment and wiring shall be in conformance with
f.
Boiler to be supplied with a control circuit transformer and fuse
protection for the control circuit.
Control Panel
a. The control panel shall be mounted on the front door of the boiler in a
location convenient to the operator. The hinged metal cabinet will have
NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet
key type lock.
b. The panel shall contain the boiler flame safeguard controller, blower
motor starter, indicating lights and selector switches.
c. Panel shall have a removable sub-base for mounting the flame safeguard
controller, blower motor starter, and terminal blocks. For combination
gas-oil fired boilers the panel shall contain the fuel selector switch.
d. Oil, heat, and moisture resistant wire shall be used and identified with
f.
2.04
____ percent from 25 to 100 percent of rating when burning natural gas and
________ fuel-to-steam efficiency at 100% firing rate when burning oil.
2.05
WARRANTY
PART 3 EXECUTION
A. Shop Tests
B.
Start-up Service
services of a field representative for starting the unit and timing the operator
A8-31
09-09
Section A8
A8-32
09-09
Section A9
Model CEW Ohio Special
100-225 HP
Table of Contents
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-3
Less than 360 Square Feet of Heating Surface: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-3
Front and Rear Doors: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-3
Natural Gas, No. 2 Oil, or Combination Burners Available: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-3
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-4
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-9
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-9
Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-9
Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-9
Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-10
Burner Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-10
Gas-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-10
Fuel Connections - Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-10
Fuel Connections - Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-10
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-11
Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-11
Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-11
Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-12
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-19
A9-1
09-09
Firetube Boilers
ILLUSTRATIONS
Figure A9-1. Model CEW Ohio Special Steam Boiler Dimensions (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . .A9-6
Figure A9-2. Space Required to Open Rear Head on Model CEW Ohio Special Boilers . . . . . . . . . . . . . . .A9-8
Figure A9-3. Model CEW Ohio Special Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-8
Figure A9-4. Model CEW Ohio Special Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-9
Figure A9-5. Typical Fuel Oil Supply Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-16
Figure A9-6. Boiler Room Length (Typical Layouts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-17
Figure A9-7. Boiler Room Width (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-17
TABLES
Table A9-1. Model CEW Ohio Special Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-5
Table A9-2. Model CEW Ohio Special Steam Volume and Disengaging Areas . . . . . . . . . . . . . . . . . . . . . .A9-13
Table A9-3. Model CEW Ohio Special Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . .A9-13
Table A9-4. Model CEW Ohio Special Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . .A9-14
Table A9-5. Model CEW Ohio Special Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . .A9-14
Table A9-6. Model CEW Ohio Special Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . .A9-15
Table A9-7. Altitude Correction for Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-15
Table A9-8. Model CEW Ohio Special Minimum and Maximum Required Gas Pressure at
Entrance to Standard, FM and IRI Gas Trains (Upstream of Gas Pressure Regulator) . . . . . . . . . . .A9-16
A9-2
09-09
Section A9

The Model CEW Ohio Special Firetube boiler is designed, manufactured, and packaged
by Cleaver-Brooks specifically for operation in the state of Ohio, under the rules and
regulations for unattended units. The unique design of the Ohio Special Boiler serves
your steam needs and reduces unnecessary labor costs. All units are factory fire tested
and shipped as a package, ready for quick connection to utilities. In addition to the
features provided on all Cleaver-Brooks Firetube boilers, the following features apply to
the Model CEW Ohio Specials.
Less than 360 Square Feet of Heating Surface:
The greatest amount offered in any packaged boiler for unattended steam boiler
operation in Ohio - means long life and years of service at the high efficiencies.
Davited, front and rear doors, all sizes.
Provides access to front and rear tube sheet.

adjustment.
PRODUCT OFFERING
Cleaver-Brooks Model CEW Ohio Special Boilers are available in low pressure steam
and high pressure steam designs. Burners are available to fire natural gas, No. 2 oil, or a
combination of oil and gas. Standard product offering is:
100 - 225 hp.
Three pass wetback design.
Boiler Options:
Drain valves.
Blowdown valves.
Non-return valves.
Surge load baffles.
Seismic design.
A9-3
09-09
Section A9
Lead/lag system.

Main disconnect.
Elapsed time meter.
NEMA enclosures.
Circuit breakers.
Day/night controls.
Stack thermometer.
Fuel Options:
Gas strainer.
Gas pressure gauge.

Dimensions and ratings for the Model CEW Ohio Special Boilers are shown in the
following tables and illustrations. The information is subject to change without notice.
Table A9-1. Model CEW Ohio Special Steam Boiler Ratings
Figure A9-1. Model CEW Ohio Special Steam Boiler Dimensions
Figure A9-2. Model CEW Ohio Special Boiler Space Requirements to Open Rear
Door
Figure A9-3. Lifting Lug Location, Model CEW Ohio Special Boilers
Figure A9-4. Model CEW Ohio Special Boiler Mounting Piers
A9-4
09-09
Section A9
Table A9-1. 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
3348
4184
5021
5858
6695
7532

29.9
37.4
44.8
52.3
59.8
67.2
Gas CFH (1000 Btu/ft3)
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)
Blower Motor, hp (NO. 2 oil& combination)
Blower Motor, hp
Air Comp. Motor, hp
1/2
1/2
1/2
1/2
1/2
1/2
7.5
10
1-1/2
7-1/2
10
WEIGHTS IN POUNDS
7430
7430
7430
8293
8293
8293
Approx. Wt. -15 psig
10311
10311
10311
11150
11150
11150
12558 12558 12558 13515 13515 13515
13632 13632 13632 14465 14465 14465
15079 15079 15079 16029 16029
N/A
BOILER DATA
354
354
354
358
358
358
NOTE: All fractional hp motors will be single phase voltage, integral hp motors will be 3phase voltage.
A9-5
09-09
Section A9
HH
GG
LL
L
DD
J
T
O
D
AA
Q
W
N
M
H
A
DIM
BOILER HP
100S150S
175S225S
(inches)
LENGTHS
Overall
207-1/2
228-1/2
Shell
157-3/8
170-3/8
Base Frame
174-7/8
196-1/2
13-1/2
13-1/2
63-7/8
56-1/4
OverallC
85
85
I. D. Boiler
60
60
45
45
Center to Lagging
33
33
LL
40
40
WIDTHS
Figure A9-1. Model CEW Ohio Special Steam Boiler Dimensions (Page 1 of 2)
A9-6
09-09
Section A9
DIM
BOILER HP
100S150S
175S225S
(inches)
Base Outside
52-1/2
52-1/2
Base Inside
44-1/2
44-1/2
46
46
Base to Vent Outlet
85
85
OA
86-1/2
86-1/2
82-3/8
82-3/8
Base Frame
12
12
16
16
Chemical Feed
1-1/2
1-1/2
Steam Nozzle (15 psig)A
10
Steam Nozzle (150 psig)B
Drain - Front & Rear (15 psig)
1-1/2
Blowdown - Front & Rear (150 psig)
1-1/2
1-1/2
Surface Blowoff (150 psig)
Surface Blowoff (15 psig)
1-1/2
1-1/2
BB
16
16
CC
10-1/8
10-1/8
Rear Door Swing
DD
36
36
GG
124
137
Min. Boiler Room Length For Tube Removal Front
RF
318
344
Min. Boiler Room Length For Tube Removal Thru Door
RD
276
297
HEIGHTS
Base to rear Door Davit
CONNECTIONS
MISCELLANEOUS
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 Ohio Special Steam Boiler Dimensions (Page 2 of 2)
A9-7
09-09
BOILER
HP
100S-225S
Section A9
DIMENSION (INCHES)
A
33
42
54
77
36
Figure A9-2. Space Required to Open Rear Head on Model CEW Ohio Special Boilers
FRONT
FLANGE
E DIA. HOLE
CL
VIEW A
FAR
SIDE
NEAR
SIDE
D
D
VIEW B
BOILER ALL DIMENSIONS IN INCHES

HP
A
B
100S150S
Steam
80
19
120-1/2
10
175S225S
Steam
80
19
133-1/2
10
Figure A9-3. Model CEW Ohio Special Boilers Lifting Lug Location
A9-8
09-09
Section A9
BOILER HP A
100S-150S
175
39-1/2
57-1/2
44-1/2
9-1/2
175S-225S
196-1/2
39-1/2
57-1/2
44-1/2
9-1/2
Figure A9-4. Model CEW Ohio Special Boiler Mounting Piers

NOTE:
All dimensions are in inches.
increased inspection accessibility to the piping beneath the boiler and added height for washing down the area
beneath the boiler.
PERFORMANCE DATA
Contact your local Cleaver-Brooks authorized representative for efficiencies or
additional information.
ENGINEERING DATA
The following engineering information is provided for Model CEW Ohio Special
Boilers. Model CEW Ohio Special Boilers are designated by an S following the
horsepower number. Additional detail is available from your local Cleaver-Brooks
Boiler Information
Table A9-2 shows steam volume and disengaging area for Model CEW Ohio Special
boilers.
Table A9-3 lists quantity and outlet size for safety valves supplied on Model CEW Ohio
Special boilers.
Table A9-4 gives recommended steam nozzle sizes on Model CEW Ohio Special
Boilers.
Table A9-5 shows recommended non-return valve sizes for Model CEW Ohio Special
Boilers.
A9-9
09-09

Blowdown Water
Requirements
Section A9

Table A10-6 lists the approximate quantity of water represented by 4 inches of water at
normal operating level for Cleaver-Brooks Model CEW Ohio Special Boilers.
Burner/Control
Information
Note that altitude correction and burner changes are required for higher altitudes which
may alter dimensions, motor hp and gas pressures.
Gas-Fired Burners
Table Table A9-7 shows correction factors for gas pressure at elevations over 700 ft
above sea level.
Table Table A9-8 shows minimum and maximum gas pressure requirements for
Standard, FM and IRI CEW Ohio Special Boiler gas trains upstream of the gas pressure
regulator.
For oversized or undersized gas trains or altitude above 1,000 feet, contact your local
venting must be in accordance with all applicable engineering guidelines and regulatory
codes. All connections made to the boiler should be arranged so that all components
remain accessible for inspection, cleaning and maintenance.
pressure regulator. The drip leg should be at least as large as the inlet fitting supplied with
the boiler. Consideration must be given to both volume and pressure requirements when
choosing gas supply piping size. Refer to the boiler dimension diagram provided by
Cleaver-Brooks for the particular installation. Connections to the burner gas train should
be made with a union, so that gas train components or the burner may be easily
disconnected for inspection or service. Upon completion of the gas piping installation,
the system should be checked for gas leakage and tight shutoff of all valves.
Oil-fired burners are equipped with an oil pump, which draws fuel from a storage tank
and supplies pressurized oil to the burner nozzle(s). The burner supply oil pump has a
greater capacity than the burner requires for the maximum firing rate. Fuel not delivered
to the nozzle is returned to the storage tank. A two-pipe (supply and return) oil system is
recommended for all installations. Figure A9-5 shows a typical fuel oil supply
arrangement. Oil lines must be sized for the burner and burner supply oil pump
capacities.
The burner supply oil pump suction should not exceed 10" Hg. If a transfer pump is used,
it must have a pumping capacity at least equal to that of the burner pump(s). Supply
pressure to the burner pump should not exceed 3 psig.
order to prevent entry of foreign material into the pump, fuel control valves, or burner
nozzle(s). The strainer must be sized for the burner supply pump capacity. A strainer
mesh of 150 microns (0.005") is recommended.
A9-10
09-09
Section A9

Install a check valve in the line to prevent draining of the oil suction line when the burner
is not in operation. Location of the check valve varies with the system, but usually it is
located as close as possible to the storage tank.
the strainer is recommended. Regular observation and recording of the gauge indication
will assist in determining when the strainer needs servicing.
Boiler Room
Information
Stack Support
Capabilities
100 - 225 hp Model CEW Ohio Special Boilers can support up to 2000 lbs without
additional support.
100 - 225 hp Model CEW Ohio Special Boilers can be reinforced to support up to 3000
lbs.
Boiler Room
Combustion Air
1.

recommended. Locate one (1) at each end of the boiler room, preferably below a height of
7 feet. This allows air to sweep the length of the boiler.
D. Under no condition should the total area of the air supply openings be less than one (1)
square foot.

2.

B. Ventilation Air = Maximum bhp x 2 cfm/bhp or a total of 10 cfm/bhp - up to 1000 feet
3.

Area Required: Area = cfm/fpm = 3000/250 = 12 Sq-ft total.
A9-11
09-09
Section A9
Notice
Stack/Breeching
Size Criteria
Although constant pressure at the flue gas outlet of the Model CEW Ohio Special is not
required, it is necessary to size the stack/breeching to limit flue gas pressure variation.
The allowable pressure range is 0.25 W.C. to +0.25 W.C. and up to +0.5 at high fire,
when an economizer is used.
The maximum pressure variation at any firing rate for the boiler is 0.25" W.C.
A9-12
09-09
Section A9

Table A9-2. Model CEW Ohio Special Steam Volume and Disengaging Areas
VALVE 15 PSIG STEAM 150
SETSTEAM
TING
PSIG 200
STEAM
PSIG 250
STEAM
PSIG
BOILER
HP
NO. OF
VALVE
S
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVE
S
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVE
S
REQ'D
OUTLET
SIZE
(IN.)
NO. OF OUTVALVE LET

S REQ'D SIZE
(IN.)
100S
2-1/2
1-1/2
1-1/2
1-1/4
125S
2-1/2
1-1/2
1-1/2
150S
1-1/2
1-1/2
175S
1-1/2
200S
2-1/2
2-1/2
225S
2-1/2
2-1/2
N/A
N/A
NOTE:
Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on availability.
Valve requirements can vary with special pressure settings.
Table A9-3. Model CEW Ohio Special Steam Boiler Safety Valve Outlet Size
BOILER STEAM VOLUME (CU-FT)
HP
HIGH PRESSURE LOW PRESSURE (B)
(A)
STEAM RELIEVING AREA (SQ-IN)

HIGH
(A)
PRESSURE LOW PRESSURE (B)
100S150S
23.5
27.1
5990
6221
175S225S
25.8
29.7
6566
6826
NOTE:
Based on normal water level.
Values are based on standard controls. Optional controls may result in different values.
A9-13
09-09
Section A9
Table A9-4. Model CEW Ohio Special Recommended Steam Nozzle Size
BOILER HP
OPERATING PRES- 100S 125S 150S 175S 200S 225S
SURE PSIG
15
10
10
30
40
50
75
100
125
150
2.5
200
2.5
2.5
NOTES:
2. Recommended steam nozzle sizes based on 4000 to 5000 FPM steam velocity.
3. All standard steam nozzle sizes for the 150 psig design pressure or greater are the same as 125 psig operating pressure on the above table. To increase or decrease the standard size, request the change with your local
4. For incremental operating pressures, see Table I3-1 Steam Systems Fundamentals
Table A9-5. Model CEW Ohio Special Recommended Non-Return Valve Size
BOILER
HP
BOILER CAPACI- OPERATING PRESSURES (PSIG)

TY
50
75
100
125
(LB/HR)
150
175
200
100S
3450
2-1/2
2-1/2
NA
NA
NA
NA
NA
125S
4313
2-1/2
2-1/2
2-1/2
NA
NA
NA
150S
5175
2-1/2
2-1/2
2-1/2
2-1/2
NA
175S
6037
2-1/2
2-1/2
2-1/2
2-1/2
NA
200S
6900
3*
2-1/2
2-1/2
225S
7762
2-1/2
2-1/2
NOTE:
Standard non-return valve selections limited to a maximum 2 to 1 turndown (50% of full boiler output); selection based on typical valve
sizing recommendations. For final valve selection contact your authorized C-B representative. For high turndown applications see Boiler
Book Section I3, Table I3-2.
A9-14
09-09
Section A9
Table A9-6. Model CEW Ohio Special Blowdown Tank Sizing Information
BOILER HP
WATER (GAL)
100S-150S
110
175S-225S
120
NOTE: Quantity of water removed from boiler by lowering normal water line 4".
Optional level controls can alter water quantities.

ALTITUDE
(FT)
CORRECALTITION
FAC- TUDE
TOR
(FT)
CORRECTION
FACTOR
1000
1.04
6000
1.25
2000
1.07
7000
1.30
3000
1.11
8000
1.35
4000
1.16
9000
1.40
5000
1.21

inches WC x 0.577 = oz/sq-in.
i inches WC x 0.0361= psig.
A9-15
09-09
Section A9
Table A9-8. Model CEW Ohio Special Minimum and Maximum Required Gas Pressure at
Entrance to Standard, FM and IRI Gas Trains (Upstream of Gas Pressure Regulator)
BOILER
HP
PRESSURE REQUIRED (WC)

PIPE SIZE
(Inches) MAX 1 PSIG INLET, MIN SUPPLY MAX 10 PSIG INLET, MIN SUPPLY
PRESSURE (WC)
PRESSURE (WC)
UL
FM
IRI
UL
FM
IRI
100S
14
14
15.5
19.5
19.5
21
125S
23.5
23.5
23.5
32.5
32.5
32.5
150S
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 CleaverBrooks representative.

A9-16
09-09
Section A9
FRONT
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
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.
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
BOILER HP
100S-225S
82
115
NOTES:
1. Recommended Minimum Distance Between Boiler and Wall. Dimension A allows for a
clear 42" aisle between the water column on the boiler and the wall. If space permits, this aisle
should be widened.
Dimension B between boilers allows for a clear aisle of 42.

A9-17
09-09
Section A9
Notes
A9-18
09-09
Section A9
Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-20
Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-21
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-24
A9-19
09-09
Section A9
MODEL CEW OHIO SPECIAL

PART 1 GENERAL
1.01
BOILER CHARACTERISTICS (STEAM 100-225 HP, STEAM 15, 150, 200 OR 250 PSIG)
A. The Steam Boiler shall be Cleaver-Brooks Model CEW Ohio Special, Fuel Series
______ (100, 200, 700), _____ hp designed for _____ psig (15, 150, 250 psig steam).
The maximum operating pressure shall be _____ psig.
circuit.
PART 2 PRODUCTS
2.01

A. The boiler shall be a three pass wetback horizontal firetube updraft boiler with less than
358 square feet of total heating surface. It shall be mounted on a heavy steel frame with
forced draft burner and burner controls. The complete packaged boiler is built as a unit
with Underwriters Laboratories listed controls.
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.
4. The rear door shall be insulated with a blanket material and a steel covering to give
the surface a hard durable finish.
appurtenances.
6. The boiler shall be furnished with a manhole and handholes to facilitate boiler
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.
8. Observation ports for the inspection of flame conditions shall be provided at each
end of the boiler.
9. The boiler insulation shall consist of a 2 inch blanket under a sectional preformed
sheet metal lagging. This insulation must be readily removable and capable of
being reinstalled, if required.
A9-20
09-09
Section A9

10. The entire boiler base frame and other components shall be factory painted before
2.02
STEAM BOILER TRIM

A. Water Column
A water column shall be located on the right hand side of the boiler complete with gauge glass set and
water column blowdown valves.
automatically actuate a motor driven feed water pump maintaining the boiler water level within normal
limits.
2. Low Water Cutoff
The low water cutoff shall be included as an integral part of the boiler feedwater control wired into the
burner control circuit to prevent burner operation if the boiler water level falls below a safe level.
The auxiliary low water cutoff shall be included, piped to the vessel, and wired to the burner control
circuit. A manual reset device shall be used for this control.
The steam pressure gauge shall be located at the front of the boiler and include cock and test connection.
The steam pressure controls to regulate burner operation shall be mounted near the water column.
2.03
BURNER AND CONTROLS

Burner operation shall be the full modulation principle. The burner shall always return to low fire
B.
Blower
1. All air for combustion shall be supplied by a forced draft blower mounted on the
burner, to eliminate vibration and reduce noise level.
3. The impeller shall be fabricated aluminum with radial blade, carefully balanced,
and directly connected to the blower motor shaft.
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).
A9-21
09-09
Section A9
Fuel series 200 - Light oil or gas fired (para 4.4.3).

1.

a. Burner Type - The burner shall be mounted at the front of the boiler and be of
high radiant multi-port type for gas. The burner shall be approved for
include one (1) shutoff valve, solenoid valve, and pressure regulator.
c. Gas Burner Piping - Select one of the following:
100 hp. Gas burner piping on all units shall include two (2) manual shutoff valves, gas pressure
connections, and high and low gas pressure switches. The gas valve shall be wired to close
condition.
125 - 225 hp. Gas burner piping on all units shall include two (2) manual shutoff valves, gas
pressure regulator, one (1) solenoid, one (1) motorized gas valve with proof of closure switch,
two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valve
shall be wired to close automatically in the event of power failure, flame failure, low water, or
2.
3.

a. Burner Type - The burner shall be mounted at the front of the boiler, and shall
be approved for operation with CS12-48, Commercial No. 2 oil.
include one (1) shutoff valve, solenoid valve, and pressure regulator.
c. Oil Pump - An oil pump with a capacity sufficient for the maximum burning
rate shall be included. Pump shall be motor driven and shipped loose to be
field installed near the oil storage tank. Oil pump motor starter shall also be
provided.
regulating device, oil metering controls, two (2) solenoid oil shutoff valves,
atomizing air proving switch, low oil pressure switch, and pressure gauge all
e. Oil Atomization Type - Burner shall be a low pressure air atomizing type,
including a shipped loose air compressor assembly.
a. Burner Type - The burner, mounted at the front of the boiler, shall be a
combination of low pressure air atomizing type for oil and high radiant multiport type for gas. The burner shall be approved for operation with either
CS12-48 Commercial No. 2 oil or natural gas.
b. Gas Pilot - The gas pilot shall be premix type with automatic electric ignition.
cannot open until pilot flame has been established. The pilot train shall
include one (1) manual shutoff valve, solenoid valve, and pressure regulator.
A9-22
09-09
Section A9

c.
Oil Burner
1) Oil Pump - An oil pump with a capacity sufficient for the maximum
burning rate shall be included. Pump shall be motor driven and shipped
loose to be field installed near the oil storage tank. Oil pump motor
starter shall also be provided.
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
3) Oil Atomization Type - Burner shall be a low pressure air atomizing
type, including a shipped loose air compressor assembly.
d. Gas Burner Piping - Select one of the following:
100 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure
connections, and high and low gas pressure switches. The gas valve shall be wired to close
condition.
125 - 225 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas
pressure regulator, one (1) solenoid, one (1) motorized gas valve with proof of closure switch,
two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves
shall be wired to close automatically in the event of power failure, flame failure, low water, or
E.

1. Control Panel
A factory prewired control panel shall be supplied with the boiler/burner package. Panel will be mounted
on the burner.
2.
3.
4.
The panel will have a NEMA 1A rating and contain the flame safeguard controller,
burner motor starter, air compressor motor starter, control circuit transformer and
fuses, selector switches, indicating lights and terminal strips. Lights shall indicate
load demand, flame failure, low water, and fuel valve open.
The panel shall contain fuse protection for the burner motor and air compressor
motor.
2.04
A. The boiler must be guaranteed to operate at a minimum fuel-to-steam efficiency of ____
percent at 100 percent of rating when burning natural gas and ________ fuel-to-steam
efficiency at 100% firing rate when burning oil (Contact your local Cleaver-Brooks
authorized representative for efficiency details).
2.05
WARRANTY
A. All equipment is to be guaranteed against defects in materials and/or workmanship for a
period of 12 months from date of start-up or 18 months from date of shipment,
A9-23
09-09
Section A9
PART 3 EXECUTION
A.
B.
Shop Tests
1. The packaged boiler must receive factory tests to check the construction, controls,
Start-up Service
1. After boiler installation is completed, the manufacturer shall provide the services of
costs.
A9-24
09-09
Section A10
MODEL CBR BOILERS
125 - 800 HP
CONTENTS

DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound Level Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Octave Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No. 6 Oil Piping, Storage Tank Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEAM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOT WATER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A10-3
A10-3
A10-13
A10-13
A10-13
A10-15
A10-15
A10-15
A10-15
A10-15
A10-15
A10-18
A10-18
A10-18
A10-18
A10-18
A10-19
A10-19
A10-27
A10-27
A10-27
A10-27
A10-31
A10-41
A10-1
09-09
Model CBR Boilers 125-800 HP
Firetube Boilers
ILLUSTRATIONS
Figure A10-1. Model CBR Steam Boiler Dimensions and Weights - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . A10-5
Figure A10-2. Model CBR Hot Water Boiler Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-7
Figure A10-3. Space Required to Open Rear Head on Model CBR Boilers Equipped with Davits . . . . . . . A10-10
Figure A10-4. Model CBR Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-11
Figure A10-5. Lifting Lug Locations, Model CBR Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-12
Figure A10-6. Predicted Stack Temperature Increase for Pressure Greater Than 125 psig . . . . . . . . . . . . . . A10-14
Figure A10-7. Typical Fuel Storage Tank Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-19
Figure A10-8. Typical Cross Section of Bundled Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-19
Figure A10-9. Schematic of Standard Alstrom Hot Water Safety-Type Preheating System . . . . . . . . . . . . . A10-20
Figure A10-10. Typical Gas Piping Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-22
Figure A10-11. No. 2 Oil Piping, Single Boiler Installation, Remote Oil Pump . . . . . . . . . . . . . . . . . . . . . . A10-23
Figure A10-12. No. 2 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . . . . . . . A10-23
Figure A10-13. No. 2 Oil Piping, Multiple Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-24
Figure A10-14. No. 2 Oil Transfer Tank Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-25
Figure A10-15. Boiler Room Length (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-28
Figure A10-16. Boiler Room Width (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-28
Figure A10-17. Breeching Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-29
TABLES
Table A10-1. Model CBR Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-4

Table A10-2. Model CBR Hot Water Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-4
Table A10-3. Steam Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-9
Table A10-4. Hot Water Boiler Relief Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-9
Table A10-5. Predicted Fuel-to-Steam Efficiencies (%), Model CBR Boilers, Natural Gas . . . . . . . . . . . . . A10-13
Table A10-6. Predicted Fuel-to-Steam Efficiencies (%), Model CBR Boilers - No.6 Oil . . . . . . . . . . . . . . . A10-14
Table A10-7. Predicted Fuel-to-Steam Efficiencies (%), Model CBR Boilers - No. 2 Oil . . . . . . . . . . . . . . A10-14
Table A10-8. Model CBR Boiler Emission Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-15
Table A10-9. Steam Volume and Disengaging Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-16
Table A10-10. Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity) . . . . . A10-16
Table A10-11. Recommended Non-Return Valve Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-17
Table A10-12. Model CBR Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-17
Table A10-13. Predicted Sound Levels (30 ppm NOx Systems) at High Fire . . . . . . . . . . . . . . . . . . . . . . . . A10-17
Table A10-14. CBR Gas Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-21
Table A10-15. Minimum Required Gas Pressure Altitude Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-21
A4-2
Section A10
MODEL CBR BOILERS 125 - 800 HP
125-800hp.
Steam and hot water.
Same available pressures as equivalent Model CB/CBLE/CBW/4WI.
Capable of firing natural gas, #2-#6 oil, bio-gas, digester gas or town gas.
Low NOx capabilitiesnatural gas only.
Containerization from 125-800 hp will reduce delivered to job site price for large
boilers that would otherwise be shipped on flatracks.
Enhanced heat transfer technology enables Cleaver-Brooks to reduce the number

of tubes, thus reducing the overall weight and shell diameters while maintaining
high fuel-to steam efficiency.
Integral burner design.
Allows interchangeability of burner spare parts for Models CB/CBLE/CBR.
Enables us to offer 50/60Hz with no price surcharge.
Corrugated furnace will be standard equipment.
.095 tubes will be standard. (.105 tubes can be supplied at an additional cost.)
Level master will be standard equipment.
The CBR can be ordered with Hawk ICS as well as all other boiler extras which
are available for Model CB/CBLE/4WI boilers.
Same factory warranty as is applied to all other Cleaver-Brooks products.
The CBR will be manufactured in the U.S. at our facility in Thomasville,

Georgia.
Locally available spare parts and after sales services through exclusive CleaverBrooks representatives around the world.
Dimensions and ratings for the Model CBR boilers are shown in the following
Table A10-1. Model CBR Steam Boiler Ratings
Table A10-2. Model CBR Hot Water Boiler Ratings
Table A10-3. Safety Valve Openings
Table A10-4. Relief Valve Openings
Figure A10-1. Model CBR Steam Boiler Dimensions
Figure A10-2 Model CBR Hot Water Boiler Dimensions
Figure A10-3. Space Required to Open Rear Head on Model CBR Boilers
Equipped with Davits
Figure A10-4. Model CBR Boiler Mounting Piers
Figure A10-5. Lifting Lug Locations, Model CBR Boilers
A10-3
09-09
Section A10
Table A10-1. Model CBR Steam Boiler Ratings

BOILER H.P.
125
150
200
250
300
350
400
500
600
700
800

0
from and at 212 F)
4313
5175
6900
8625
10350
12075
13800
17250
20700
24150
27600
4184
5021
6694
8368
10042
11715
13389
16736
20083
23430
26778
209.2
239.1

37.4
44.8
59.8
74.7
89.7
104.6
119.5
149.4
179.3
Heavy Oil gph (150,000 Btu/gal)
34.9
41.8
55.8
69.7
83.7
97.6
111.6
139.5
167.4
195.3
223.1
Gas CFH (1000 Btu)
5230
6276
8368
10460
12552
14644
16736
20920
25104
29288
33472
Gas (Therm/hr)
52.3
62.8
83.7
104.6
125.5
146.4
167.4
209.2
251.0
292.9
334.7

7 1/2
10
15
7 1/2
15
20
10
15
30
40
50
10
15
20
15
20
30
15
25
40
60
75
Oil Pump Motor, hp, No. 2 Oil
1/2
1/2
1/2
1/2
3/4
3/4
3/4
3/4
3/4
1/2
1/2
1/2
1/2
1/2
3/4
3/4
3/4
3/4
3/4
3/4
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7 1/2
7 1/2
7 1/2
7 1/2
7 1/2
7 1/2
7 1/2
7 1/2
459
459
641
1238
1226
1374
1794
2535
2535

Heavy Oil Heater kW
BOILER DATA
764
966
Notes:
A. Blower motor size for boiler operating pressures 125 psig and less, contact your local Cleaver-Brooks authorized representative for higher pressures and altitude.
B. Oil heater sized as a combination steam-electric heater. For straight electric heaters, contact your local Cleaver-Brooks authorized representative.
C. 10 KW Oil heater for low pressure.
Table A10-2. Model CBR Hot Water Boiler Ratings

BOILER H.P.
125
150
200
250
300
350
400
500
600
700
800
13389
16736
20083
23430
26778

4184
5021
6694
8368
10042
11715

37.4
44.8
59.8
74.7
89.7
104.6
119.5
149.4
179.3
209.2
239.1
Heavy Oil gph (150,000 Btu/gal)
34.9
41.8
55.8
69.7
83.7
97.6
111.6
139.5
167.4
195.3
223.1
Gas CFH (1000 Btu)
5230
6276
8368
10460
12552
14644
16736
20920
25104
29288
33472
Gas (Therm/hr)
52.3
62.8
83.7
104.6
125.5
146.4
167.4
209.2
251.0
292.9
334.7

7 1/2
10
15
7 1/2
15
20
10
15
30
40
50
10
15
20
15
20
30
15
25
40
60
75
1/2
1/2
1/2
1/2
3/4
3/4
3/4
3/4
3/4
1/2
1/2
1/2
1/2
1/2
3/4
3/4
3/4
3/4
3/4
3/4
7-1/2
7-1/2
7-1/2
7-1/2
7-1/2
7 1/2
7 1/2
7 1/2
10
10
10
10
10
1238
1226
1374
1794
2535
2535

Heavy Oil Heater kW
BOILER DATA
459
459
644
764
966
Notes:
A. Oil heater sized as a straight electric heater.
A10-4
09-09
Section A10
RR / RF / RD
GG
FF
A
Cl
ea
LL
L
ver
B ro
ok
B
BB
KK
Q
N
M
DD
X
OO
EE
W
F
Z
C
W
G
60" DIA. (125-200HP) ARE HINGED

67" DIA. (250-350HP) AS SHOWN
83" DIA. (400-800HP) SPECIAL DAVIT
Figure A10-1. Model CBR Steam Boiler Dimensions and Weights - Sheet 1 of 2
A10-5
09-09
Section A10
BOILER H.P.
DIM
125
150
200
250
300
LENGTHS
A
196.5
199.5
231.5
207
226
A
199.5
200.5
233.5
211
228
Shell
B
149
149
180
156
171
Base Frame
C
136
136
167
143
158
D
28
31
32
28
32
D
31
32
34
32
34
Rear Head Extension
E
19.5
19.5
19.5
23
23
F
0.5
0.5
0.5
0.5
0.5
G
12.5
12.5
12.5
12.5
12.5
H
90
90
96
96
98
H
84
84
96
96
98
Front Shell Extension
P
12
12
12
15
15
Over Tubesheets
V
137
137
168
141
156
WIDTHS
Overall Width
I
85
85
85
92
92
I.D. Boiler
J
60
60
60
67
67
K
45
45
45
48.5
48.5
KK
35
35
35
45.5
45.5
Center to Lagging
L
33
33
33
36.5
36.5
LL
40
40
40
43.5
43.5
Base Outside
M
52.5
52.5
52.5
51
51
Base Inside
N
44.5
44.5
44.5
43
43
HEIGHTS
Overall Height
OO
86
86
86
102.5
102.5
Base to Vent Outlet
O
85
85
85
94.5
94.5
Q
12
12
12
12
12
R
16
16
16
14
14
X
82.375 82.375 82.375
90.25
90.25
BOILER CONNECTIONS
S
1.5
1.5
2
2
2
T
1
1
1
1
1
U
8
8
10
10
12
U
4
4
4
6
6
W
1.5
1.5
2
2
2
W
1.5
1.5
1.5
1.5
1.5
Chemical Feed
Z
1
1
1
1
1
VENT STACK
BB
16
16
16
20
20
MINIMUM CLEARANCES
Rear Door Swing
DD
32
32
32
36
36
Front Door Swing
EE
67
67
67
75
75
Tube Removal - Rear
FF
139
139
170
143
157
Tube Removal - Front
GG
127
127
158
128
142
Thru Window or Door
RD
248
248
279
267
282
Front of Boiler
RF
308
308
370
320
349
Rear of Boiler
RR
355
355
417
374
403
WEIGHTS IN LBS
Normal Water Weight
6,950
6,950
8,350
8,400
9,050
Approx. Shipping Weight - (15 psig)
11,850 11,850 13,550 15,400 17,550
13,000 13,000 14,850 18,100 19,300
13,200 13,200 15,100 19,250 20,300
350
400
500
600
700
800
258
260
201
188
34
36
23
0.5
12.5
112
112
15
186
224
225
163
150
29
30
32
0.5
12.5
101
100
17
146
230
234
168
155
30
34
32
0.5
12.5
101
100
17
151
266
267
200
187
34
35
32
0.5
12.5
96
96.25
17
183
300
302
233
220
35
37
32
0.5
12.5
112
112.75
17
216
301
303
233
220
36
38
32
0.5
12.5
112
112.75
17
216
92
67
48.5
45.5
36.5
43.5
51
43
109
83
56.5
45.5
44.5
52.5
60
47
109
83
56.5
45.5
44.5
52.5
60
47
109
83
56.5
45.5
44.5
52.5
60
47
109
83
56.5
45.5
44.5
52.5
60
47
109
83
56.5
45.5
44.5
52.5
60
47
102.5
94.5
12
14
90.25
120.5
112
12
16
108
120.5
112
12
16
108
120.5
112
12
16
108
120.5
112
12
16
108
120.5
112
12
16
108
2.5
1
12
6
2
1.5
1
2.5
1
12
6
2
2
1
2.5
1
12
8
2
2
1
2.5
1
12
8
2
2
1
2.5
1
12
8
2
2
1
2.5
1
12
8
2
2
1
20
24
24
24
24
24
36
75
187
172
45
80
147
130
45
80
152
135
45
80
184
167
45
80
217
200
45
80
217
200
312
409
463
288
338
390
293
348
400
325
412
464
358
478
530
358
478
530
10,550
19,750
20,750
23,300
11,650
26,450
29,050
29,800
11,900
27,100
29,750
30,150
14,150
30,700
32,400
34,850
15,700
35,700
37,600
38,800
15,700
35,700
37,600
38,800
NOTES:
Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension
Note "A": ANSI 150 psig Flange
Note "B": ANSI 300 psig Flange
Figure A10-1. Model CBR Steam Boiler Dimensions and Weights - Sheet 2 of 2
A10-6
09-09
Section A10
RR / RF / RD
GG
D
I
L
Cl
ea
ver
B ro
ok
EE
BB
B
HH
Y
E
U
N
M
X
V
KK
DD
Z
OO
FF
W
G
60" DIA. (125-200HP) ARE HINGED

67" DIA. (250-350HP) AS SHOWN
83" DIA. (400-800HP) SPECIAL DAVIT
Figure A10-2. Model CBR Hot Water Boiler Dimensions - Sheet 1 of 2
A10-7
09-09
BOILER H.P.
Section A10
DIM
125
150
200
250
300
350
400
500
600
700
800
196.5
199.5
231.5
207
226
258
224
230
266
300
301
199.5
200.5
233.5
211
228
260
225
234
267
302
303
Shell
149
149
180
156
171
201
163
168
200
233
233
Base Frame
136
136
167
143
158
188
150
155
187
220
220
28
31
32
28
32
34
29
30
34
35
36
31
32
34
32
34
36
30
34
35
37
38
Rear Head Extension
19.5
19.5
19.5
23
23
23
32
32
32
32
32
LENGTHS
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
102
102
131
115.5
130.5
160.5
124.75
124.75
151.25
184.75
184.75
HH
136
136
167
143
157
187
151.75
151.75
182.75
216.25
216.25
Front Shell Extension
12
12
12
15
15
15
17
17
17
17
17
Over Tubesheets
137
137
168
141
156
186
146
151
183
216
216
Overall Width
75.5
75.5
75.5
82
82
82
100
100
100
100
100
I.D. Boiler
60
60
60
67
67
67
83
83
83
83
83
42.5
42.5
42.5
45.5
45.5
45.5
55.5
55.5
55.5
55.5
55.5
W IDTHS
KK
35
35
35
45.5
45.5
45.5
45.5
45.5
45.5
45.5
45.5
Center to Lagging
33
33
33
36.5
36.5
36.5
44.5
44.5
44.5
44.5
44.5
Base Outside
52.5
52.5
52.5
51
51
51
60
60
60
60
60
Base Inside
44.5
44.5
44.5
43
43
43
47
47
47
47
47
HEIGHTS
Overall Height
OO
86
86
86
102.5
102.5
102.5
120.5
120.5
120.5
120.5
120.5
Base to Vent Outlet
85
85
85
94.5
94.5
94.5
112
112
112
112
112
Height of Base Fram e
12
12
12
12
12
12
12
12
12
12
12
16
16
16
14
14
14
16
16
16
16
16
82.375
82.375
82.375
90.25
90.25
90.25
108
108
108
108
108
2.5
BOILER CONNECTIONS
W aterfill Connection (Both Sides)
1.5
1.5
2.5
2.5
2.5
2.5
2.5
W ater Return (See Note "A")
10
10
12
12
12
W ater Outlet (See Notes "A & B")
10
10
12
12
12
Drain-Front & Rear
1.5
1.5
Air Vent
1.5
1.5
1.5
1.5
1.5
1.5
BB
16
16
16
20
20
20
24
24
24
24
24
Rear Door Swing
DD
32
32
32
36
36
36
45
45
45
45
45
Front Door Swing
EE
67
67
67
75
75
75
80
80
80
80
80
Tube Removal - Rear
FF
139
139
170
143
157
187
147
152
184
217
217
Tube Removal - Front
GG
127
127
158
128
142
172
130
135
167
200
200
358
VENT STACK
MINIMUM CLEARANCES
MINIMUM BOILER ROOM LENGTH ALLOW ING FOR DOOR SWING AND TUBE REMOVAL FROM:
Thru Window or Door
RD
248
248
279
267
282
312
288
293
325
358
Front of Boiler
RF
308
308
370
320
349
409
338
348
412
478
478
Rear of Boiler
RR
355
355
417
374
403
463
390
400
464
530
530
Normal Water Weight
10,800
10,800
13,050
11,750
12,750
15,000
16,900
17,150
20,500
23,250
23,250
11,850
11,850
13,550
15,400
17,550
19,750
26,400
27,100
30,700
35,700
35,700
13,200
13,200
15,100
18,350
18,400
20,700
29,400
28,150
31,900
37,050
37,050
W EIGHTS IN LBS
Figure A10-2. Model CBR Hot Water Boiler Dimensions - Sheet 2 of 2
A10-8
09-09
Section A10

150 PSIG STEAM 200 PSIG STEAM 250 PSIG STEAM
NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF
OUTLET
BOILER HP
VALVES SIZE
VALVES SIZE
VALVES SIZE
VALVES
SIZE
REQ'D
REQ'D
REQ'D
REQ'D
(IN.)
(IN.)
(IN.)
(IN.)
125
(1) 1-1/2
(1) 1-1/4
(1) 1-1/4
(1) 1
150
(1) 1-1/2
(1) 1-1/4
1-1/4
(1) 1
(1) 1-1/4
200
2-1/2
1-1/2
(1) 1-1/2
(1) 1-1/4
1-1/4
250
(1) 2-1/2
(1) 3
(1) 2
(1) 1-1/2
1-1/2
(1) 1-1/2
(1) 1-1/4
300
(1) 2
(1) 1-1/2
1-1/2
350
(1) 2
(2) 3
(1) 2-1/2
(1) 2
(1) 1-1/2
(1) 2
400
(2) 3
(1) 2-1/2
(1) 2-1/2
(1) 2
(1) 1-1/2
(1) 2
500
2-1/2
(1) 2-1/2
(1) 2
600
(3) 3
(1) 2-1/2
(2) 2-1/2
(1) 2
2-1/2
(1) 2
(1) 2-1/2
700, 800
(3) 3
(2) 2-1/2
(2) 2-1/2
(1) 2
2-1/2
2-1/2

NO. OF OUTLET
125 PSIG HW
NO. OF OUTLET
150 PSIG HTHW

NO. OF
OUTLET
BOILER HP
VALVES
VALVES
VALVES
REQ'D
SIZE (IN.)
REQ'D
SIZE (IN.)
REQ'D
SIZE (IN.)
125
2-1/2
1-1/4
(1) 1-1/2 (1)

2
150
2-1/2
(1) 1-1/2 (1)

2
200
(1) 2-1/2 (1)

1-1/4
250
300
2-1/2
2-1/2
2-1/2
350
(2) 2-1/2 (1)

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

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

3
500
600
700, 800
(1) 2
(1) 21/2
(1) 2
(2) 21/2
(1) 1
(3) 21/2
(3) 2-1/2 (1)

2
(1) 1
(4) 21/2
(1) 1
(1) 21/2
(1) 1-1/4 (1)

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

2
(1) 2
(1) 21/2
(2) 3
(1) 21/2
3
NOTE: Relief valve is Kunkle #537 for 30# & 125#(Section IV) boiler and is
Kunkle #927 for 150# HTHW(Section I) boiler.
A10-9
09-09
Section A10
MINIMUM REAR
MAXIMUM SIDE
DIMENSIONS (INCHES)
BOILER
A
125-200
33"
55"
45"
68"
32"
250-350
36.5"
65"
51"
83"
35"
400-800
44.5"
86"
64"
99"
57"
H.P.
A
C
D
E
MAXIMUM REAR
MINIMUM SIDE
Figure A10-3. Space Required to Open Rear Head on Model CBR Boilers Equipped with Davits
A10-10
09-09
Section A10
F
B
F
D
FRONT VIEW
BOILER
H.P.
RIGHT SIDE VIEW
DIMENSIONS (INCHES)
A
6"
9"
136"
39.5"
57.5"
4"
44.5"
10"
9.75"
200
6"
9"
167"
39.5"
57.5"
4"
44.5"
10"
9.75"
250
6"
12"
143"
48"
72"
4"
56"
10"
22"
300
6"
12"
158"
48"
72"
4"
56"
10"
22"
350
6"
12"
188"
48"
72"
4"
56"
10"
22"
400-500
6"
14" 154.75" 51.38" 79.38"
6.5"
58.88"
12"
22.75"
600
6"
14" 186.75" 51.38" 79.38"
6.5"
58.88"
12"
22.75"
700-800
6"
14" 219.75" 51.38" 79.38"
6.5"
58.88"
12"
22.75"
125-150
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 A10-4. Model CBR Boiler Mounting Piers

A10-11
09-09
Section A10
FRONT
FLANGE
E DIA.
HOLE (TYP.)
C
NEAR
SIDE
FAR
SIDE
CL
FRONT VIEW
RIGHT SIDE VIEW
DIMENSIONS (INCHES)
BOILER
A
ALL
80.25"
29.75"
83.5"
10"
3"
ALL
80.25"
29.75"
114.5"
10"
3"
STEAM
87.12"
36"
84"
10"
3"
HOT WATER 87.12"
36"
93"
10"
3"
87.12"
36"
99"
10"
3"
HOT WATER 87.12"
36"
108"
10"
3"
87.12"
36"
129"
10"
3"
HOT WATER 87.12"
36"
138"
10"
3"
H.P.
125-150
200
250
300
350
400-500
600
700-800
STEAM
STEAM
ALL
105.5"
35.75"
99"
11"
3"
ALL
105.5"
35.75"
131"
11"
3"
ALL
105.5"
35.75"
164"
11"
3"
NOTE: A, B, AND C DIMENSIONS MAY VARY BY 1/2".
Figure A10-5. Lifting Lug Locations, Model CBR Boilers
A10-12
09-09
Section A10
PERFORMANCE DATA
Efficiency
Tables A10-5, A10-6, and A10-7 show predicted fuel-to-steam efficiencies (excluding
radiation and convection losses) for Cleaver-Brooks Model CBR Firetube boilers. For
specific efficiencies on firetube boiler offerings not listed here, contact your local
Emissions
The emission data included in this section (Table A10-8) consists of typical uncontrolled
emission levels for Cleaver-Brooks Model CBR Firetube Boilers.
Cleaver-Brooks Firetube boilers are available with the standard burner package for
Model CBR, or optional internal flue gas recirculation on.
The Cleaver-Brooks IFGR packages are integrated boiler/burner/control packages
designed specifically for Cleaver-Brooks boilers. For detailed information on CleaverBrooks IFGR packages, refer to Model CB (LE) in Section A2.
Notice
The data in Table A10-8 represents typical emission levels only. Guaranteed emission levels are available from your local Cleaver-Brooks authorized representative.
Table A10-5. Predicted Fuel-to-Steam Efficiencies (%), Model CBR Boilers, Natural Gas
BHP
125
150
200
250
300
350
400
500
600
700
800

% OF LOAD
25%
50%
75%
100%
84.4
84.5
84.0
83.4
84.3
84.4
83.7
83.0
84.5
84.9
84.5
84.1
84.2
84.2
83.5
82.6
84.4
84.5
84.0
83.4
84.6
85.1
84.8
84.5
84.8
84.3
83.6
82.7
84.7
84.2
83.4
82.5
85.0
84.8
84.4
83.8
85.3
85.3
85.1
84.8
85.2
85.3
85.0
84.6

% OF LOAD
25%
50%
75%
100%
81.6
81.8
81.5
81.0
81.5
81.6
81.2
80.7
81.7
82.2
82.0
81.7
81.4
81.5
80.9
80.3
81.5
81.8
81.5
81.0
81.8
82.4
82.3
82.1
82.0
81.8
81.1
80.4
82.0
81.7
81.0
80.1
82.3
82.3
81.9
81.4
82.6
82.8
82.7
82.4
82.5
82.7
82.6
82.3
A10-13
09-09
Section A10
Table A10-6. Predicted Fuel-to-Steam Efficiencies (%), Model CBR Boilers - No.6 Oil
BHP
125
150
200
250
300
350
400
500
600
700
800

% OF LOAD
25%
50%
75%
100%
88.3
88.4
87.8
87.2
88.2
88.2
87.5
86.8
88.4
88.8
88.4
87.9
88.1
88.0
87.3
86.4
88.3
88.4
87.8
87.1
88.5
89.0
88.7
88.3
88.6
88.1
87.3
86.5
88.6
88.0
87.2
86.2
88.9
88.7
88.2
87.6
89.2
89.2
89.0
88.6
89.1
89.1
88.9
88.5

% OF LOAD
25%
50%
75%
100%
85.3
85.6
85.2
84.7
85.2
85.4
84.9
84.3
85.5
85.9
85.7
85.5
85.1
85.2
84.6
84.0
85.3
85.5
85.2
84.7
85.6
86.1
86.1
85.9
85.8
85.5
84.8
84.0
85.7
85.4
84.6
83.8
86.1
86.1
85.7
85.1
86.3
86.6
86.4
86.2
86.3
86.5
86.3
86.0
Table A10-7. Predicted Fuel-to-Steam Efficiencies (%), Model CBR Boilers - No. 2 Oil
BHP
125
150
200
250
300
350
400
500
600
700
800

% OF LOAD
25%
50%
75%
100%
87.8
88.0
87.4
86.8
87.7
87.8
87.2
86.4
88.0
88.3
88.0
87.5
87.6
87.6
86.9
86.1
87.8
88.0
87.4
86.8
88.1
88.5
88.3
87.9
88.2
87.7
87.0
86.1
88.1
87.6
86.8
85.9
88.5
88.3
87.8
87.2
88.7
88.8
88.5
88.2
88.7
88.7
88.4
88.1

% OF LOAD
25%
50%
75%
100%
85.0
85.2
84.9
84.5
84.9
85.1
84.6
84.1
85.2
85.6
85.4
85.2
84.8
84.9
84.3
83.7
85.0
85.2
84.9
84.4
85.3
85.8
85.7
85.6
85.5
85.2
84.5
83.8
85.4
85.1
84.4
83.6
85.7
85.7
85.4
84.9
86.0
86.2
86.1
85.8
85.9
86.2
86.0
85.7
A10-14
09-09
Section A10

Table A10-8. Model CBR Boiler Emission Data
ESTIMATED LEVELS - UNCONTROLLED
POLLUTANT
NO. 2 OILB
NATURAL GAS
60 PPM
SYSTEM
30 PPM
SYSTEM
NO. 6 OILC
60 PPM System
30 PPM System
ppmA
50/150B
50/150B
50
50
95
Lb/MMBtu
0.04/0.11
0.04/0.11
0.04
0.04
0.075
CO
ppmA
60
30
185
140
502
Lb/MMBtu
0.07
0.035
0.25
0.187
0.67
NOx
ppmA
278
278
278
Lb/MMbtu
0.001
0.001
0.52
0.52
0.52
SOx
ppmA
10
10
70
Lb/MMBtu
0.004
0.004
0.002
0.002
0.035
0.01
0.025
0.256
0.160
HC/VOCs
ppmA
Lb/MMBtu
0.01
PM
NOTES:
Refer to Section E for detailed emission information.
A. ppm levels are given on a dry volume basis and corrected to 3% oxygen (15% excess air)
B. CO emission is 50 ppm when boiler is operating above 50% of rated capacity. CO emission is 150 ppm when boiler is operating below 50% of rated
capacity.
Based on fuel constituent levels of:
Conradson carbon residue = 16% by weight
ENGINEERING DATA
The following engineering information is provided for Model CBR Firetube Boilers.
Additional detail is available from your local Cleaver-Brooks authorized representative.
Blowdown Water
Requirements

Sound Level
Table A10-13 summarizes predicted sound pressure levels for Model CBR Boilers.
These values are based on standard motors. Optional motor types and altitude
conditions can increase sound levels.
Units
The units for the sound level tables are dBA (decibels, measured on the A-weighted
scale) in reference to 0.0002 microbars (20 micro-Newtons per square meter). They are
standardly referenced in specifying and reporting sound pressure levels on industrial
equipment.
Test Method
The sound pressure levels in Table A10-13 were obtained from tests in accordance with
the "ABMA Test Code for the Measurement of Sound from Packaged Boilers." In
accordance with this code, the sound pressure levels reported were measured on the
cabinet.
Sound Level Meter
The sound level meter used complies with ANSI S1.4, Type 1 (Precision). The readings
are taken with the meter set for slow response.
A10-15
09-09
Section A10
BOILER HP
125
150
200
250
300
350
400
500
600
700
800
STEAM VOLUME CU-FT

(A)
(B)
61.8
67.7
61.8
67.7
75.8
83
53.7
64.7
59.4
71.5
70.8
85.3
84.7
98.8
84.7
98.8
102.6
119.7
121.1
141.3
121.1
141.3

(A)
(B)
7675
7790
7675
7790
9403
9561
8093
8453
8957
9345
10670
11145
10627
11016
10627
11016
12873
13363
15206
15768
15206
15768
NOTE:
Table A10-10. Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity)
OPERATING PRESSURE
BOILER HP
PSIG
125
150
200
250
300
350
400
500
600
700
800
15
8
8
10
10
12
12
12
12
12
12
12
30
6
6
8
8
8
10
10
10
12
12
12
40
6
6
6
8
8
8
10
10
10
12
12
50
6
6
6
6
8
8
8
10
10
10
12
75
4
4
6
6
6
8
8
8
8
10
10
100
4
4
6
6
6
6
6
8
8
8
10
125
4
4
4
6
6
6
6
8
8
8
8
150
3
4
4
4
6
6
6
6
6
8
8
200
2.5
3
4
4
4
4
6
6
6
6
6
250
2.5
3
3
4
4
4
4
6
6
6
6
NOTES:
2. Standard nozzle size for 15-psi steam boiler is as listed above for 15-psig operating pressure
3. Standard steam nozzle for a 150-psig or higher design steam boiler is listed above for 125-psig operqting pressure.
It will be changed only if requested at the time of order.
4. For expanded operating pressure table, see Table I3-1 (System Fundamentals)
5. Shaded area denotes special surge load baffles must be installed.
A10-16
09-09
Section A10

BOILER BOILER CAPACITY

HP
(LBS/HR)
125
4313
150
5175
200
6900
250
8625
300
10350
350
12025
400
13800
500
17210
600
20700
700
24150
800
27600
NOTE:
50
3
3
3*
4
4
4
5
6
6
6
6
75
2-1/2
3
3
3*
4
4
4
5
6
6
6

100
125
150
175
200
2-1/2 2-1/2
NA
NA
NA
2-1/2 2-1/2 2-1/2 2-1/2
NA
3
3
3
2-1/2 2-1/2
3
3
3
3
3
4
3*
3
3
3
4
4
4
3*
3
4
4
4
4
4
5
4
4
4
4
5
5
5
4
4
6
5
5
5
5
6
6
6
5
5
250
NA
NA
2-1/2
3
3
3
3*
4
4
4
5
Valve sizes (300 psig flanges) given in inches.

Standard No n-Return valve selectio ns limited to a maximum 2 to 1turndo wn (50% o f full bo iler o utput)
NA Indicates that there is not a standard 2:1 turndown valve selection available
* Indicates pressure drop of less than 7.5psig. All other selections are less than 6 psig pressure drop
Selection based on typical valve sizing recommendations. For final valve selection contact your authorized C-B representative. For high turndown applications see Boiler Book Section I3, Table I3-2.
Table A10-12. Model CBR Blowdown Tank Sizing Information

BOILER HP
WATER (GAL)
125
136
150
136
200
167
250
145
300
161
350
191
400
190
500
190
600
230
700
272
800
272
NOTE: Quantity of water

removed from boiler by lowering
Table A10-13. Predicted Sound Levels (30 ppm NOx Systems) at High Fire
BHP
Sound Level-dbA
125
84
150
84
200
84
250
83
300
84
350
85
400
84
500
85
600
85
700
88
800
90
A10-17
09-09
Section A10
Sound Pressure
On large size boilers, the need for auxiliary equipment, and the necessary
interconnecting piping, make it impractical (and sometimes impossible) to provide a
boiler testing environment that is suitable for obtaining the data needed to develop Sound
Pressure Power levels.
Typical Values
Sound pressure levels (dBA) for identical boilers will vary between boiler rooms. In
addition, variations will occur between different people using different sound meters on
the same boiler. And finally, no two boilers can be expected to give precisely the same
(dBA).
Octave Band
When predicting sound pressures in octave bands (e.g., dBA at 125 Hz), even greater
variations between boilers, between sound meters, and between operators can be
expected. These larger variations in the low and high frequencies make octave band
levels a less reliable method of reporting than A-scale sound levels. (Since A-scale sound
levels are dominated by mid-frequency sounds, the A-scale sound levels between two
boilers can be in reasonable agreement even though the low and high frequencies of
octave band measurement do not closely correspond).
Gas-Fired Burners
Table A10-14 shows gas pressure requirements for Model CBR Boilers.
Oil-Fired Burners
Fuel oil consumption information is shown on the boiler rating sheets in the Dimensions
and Ratings Section.
Figure A10-14 shows the detail of an oil transfer tank (day tank) typically utilized to
provide a storage reservoir between the oil system supply pump and the boiler oil pump.
No. 6 Oil Piping,

Storage Tank Heating
If the oil viscosity exceeds 4,000 SSU at the pumping temperature, tank preheating is
required.
Based on the climate conditions for the job location, the minimum pumping temperature
can be predicted, and the viscosity for the particular oil at this pumping temperature can
be determined.
It is recommended to provide for tank and/or line heating on all No. 6 oil installations to
ensure against high viscosities at decreased pumping temperatures. The following are
two common methods:
1. Provide a tank suction heater and bundle the steam or water tracers from the tank to
the oil heater.
2. Provide electric heating equipment on the oil lines and/or in the storage tank.
Notice
The temperature in the oil suction line should not exceed 130 F as higher temperatures
could cause vapor binding of the oil pump and decreased oil flow.
See Figure A10-7 and Figure A10-8 for an example of (No. 1 above) tank heating
method.
See Figure A10-9 for an example of a preheating system.
A10-18
09-09
Section A10

OIL RETURN
OIL SUCTION
STEAM OR HOT WATER
MANHOLE
OIL STORAGE
TANK

AND SUPPLY SYSTEMS.
OIL RETURN
TO TANK
INSULATION
CONDENSATE OR
HOT WATER FROM
TANK HEATER
+
+
SEE NOTES
1 AND 2
OIL SUCTION
Note 1: The outer jacket of the four line

bundle should be protected by a waterproof
covering to protect the lines and insulation
from moisture damage. Tar paper and hot
asphalt sealer have been successfully used as
a waterproof covering.
Note 2: When the bundle runs under
driveways or other traffic areas, a heavy
duty outer jacket of reinforced concrete,
vitrified tile, or a corrugated steel is
recommended.
STEAM OR HOT WATER

TO TANK HEATER
Figure A10-8. Typical Cross Section of Bundled Lines
A10-19
09-09
Section A10
WATER RETURN TO
SIDE OF BOILER
OIL RETURN FROM BOILER

GATE
VALVE
MINIMUM 200 F
WATER FROM SIDE
OF BOILER
OIL TO BURNER
BOILER WATER PUMP

(CONTROLLED BY THERMOSTAT
IN OIL LINE)
ELECTRIC
HEATER
F.O.S.
F.O.R.
CONTRACTOR CONNECTIONS
(AT BOILER BASE FRAME)
BOILER WATER-TO-HEAT
TRANSFER SOLUTION-TO-OIL
HEAT EXCHANGER
(ALSTROM HEATER)
In order to properly preheat No. 6 oil, the minimum recommended boiler water temperature is 200 F. Some No. 6 oils
must be preheated up to 210 F, and higher boiler water temperatures are then desirable.
Although lower boiler water temperatures can be used, this condition means that the electric preheater will be doing
more of the work. It is more economical to use higher temperature boiler water for preheating than to use lower temperature water which increases the electric preheating load.
To ensure the most trouble-free, dependable preheating system, a boiler water-to-water-to-oil preheating system is furnished as standard equipment and is mounted, piped and wired on the boiler. This safety type system or double heat
exchanger eliminates the possibility of an oil leak fouling the boiler, oil heater, piping, control valves, and circulating
pumps. Insurance companies recognize this as the best system for the application.
The standard system does not have provisions for a hot water line to a storage tank heater.
Figure A10-9. Schematic of Standard Alstrom Hot Water Safety-Type Preheating System
A10-20
09-09
Section A10
Table A10-14. CBR Gas Pressure Requirements
Boiler HP
125
150
200
250
300
350
400
500
600
700
800
CBR 30 PPM
Gas Train
Pressure Range
Size, in
PSI
1.5
1.5
1.5
2
1.5
2
1.5-2
2
3
1.5-2
2
2.5
3
1.5-2
2
2.5
3
1.5-2.5
2-2.5
2.5
3
2-2.5
2.5
2.5-3
3
2-3
2.5-3
3
4
2.5-3
3
4
CBR 60 PPM
Gas Train
Pressure Range
Size, in
PSI
0.8 - 3.0
1.0 - 3.0
1.6 -4.0
1.1 - 1.6
2.7 - 5.0
1.8 - 2.7
3.5 - 5.0
2.5 - 3.5
1.6 - 2.5
4.0 - 6.0
3.0 - 4.0
2.2 - 3.0
1.4 - 2.2
4.8 - 7.0
3.3 - 4.8
2.3 - 3.3
1.4 - 2.3
7.0 - 10
5.1 - 7.0
3.5 - 5.1
2.1 - 3.5
7.3 - 10
5.1 - 7.3
4.3 - 5.1
2.9 - 4.3
9.0 - 10.0
5.7 - 9.0
3.8 - 5.7
2.8 - 3.8
7.3 - 10
5.0 - 7.3
3.6 - 5.0
1.5
1.5
1.5
2
1.5
2
1.5-2
2
3
1.5-2
2
2.5
3
1.5-2
2
2.5
3
1.5-2.5
2-2.5
2.5
3
2-2.5
2.5
2.5-3
3
2-3
2.5-3
3
4
2.5-3
3
4
increases in size after the regulating valve. The first number is
the customer connection size.
0.7 - 3.0
1.0- 3.0
1.6 -4.0
1.1 - 1.6
2.7 - 5.0
1.8 - 2.7
3.5 - 5.0
2.5 - 3.5
1.6 - 2.5
4.0 - 6.0
2.9 - 4.0
2.1 - 2.9
1.4 - 2.1
4.7 - 7.0
3.1 - 4.7
2.3 - 3.1
1.4 - 2.3
7.0 - 10
5.1 - 7.0
3.5 - 5.1
2.1 - 3.5
7.3 - 10
5.0 - 7.3
4.3 - 5.0
2.9 - 4.3
9.0 - 10.0
5.7 - 9.0
3.8 - 5.7
2.8 - 3.8
7.3 - 10
5.0 - 7.3
3.6 - 5.0
UNDERSIZE
STANDARD
OVERSIZE
Table A10-15. Minimum Required Gas Pressure Altitude Conversion

ALTITUDE
(FT)
CORRECTION
FACTOR
ALTITUDE
(FT)
CORRECTION
FACTOR
1000
1.04
6000
1.25
2000
1.07
7000
1.30
3000
1.11
8000
1.35
4000
1.16
9000
1.40
5000
1.21
To obtain minimum required gas pressure at altitudes above 700 feet,

multiply the pressure by the listed factors:
A10-21
09-09
Section A10
This figure illustrates the basic gas valve arrangement on Cleaver-Brooks Model CBR Boiler and
shows the contractor's connection point. The valves and controls between the contractor 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.
STREET GAS MAIN
PLUG
COCK
A
B
C
CONTRACTOR
CONNECTION
POINT
GAS TRAIN
ON BOILER

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:
The local gas utility will advise the pressure that is available at the outlet of their meter.
A10-22
09-09
Section A10
CHECK
VALVE
VACUUM
GAUGE
OIL PUMP
UNION
GATE VALVE
STRAINER
GATE VALVE
F.O.S.
RELIEF VALVE
F.O.R.
GATE VALVE
CHECK VALVE
BOILER
FRONT
BOILER
BASE FRAME
F.O.S.
F.O.R.
CONTRACTOR
CONNECTIONS
AT THIS POINT

VACUUM GAUGE
CHECK VALVE
GATE VALVE
STRAINER
GATE VALVE
F.O.S.
OIL
PUMP
NO. 2
F.O.R.
OIL PUMP NO. 1

UNION
GATE VALVE
RELIEF
VALVE
(100 PSIG)
GATE VALVE
CHECK VALVE

BOILER
FRONT
BOILER
BASE FRAME
F.O.S.
F.O.R.
CONTRACTOR
CONNECTIONS
AT THIS POINT
A10-23
09-09
CHECK
VALVE
Section A10
VACUUM GAUGE
STRAINER
GATE VALVE
F.O.S.
GATE
VALVE
F.O.R.
STANDBY
OIL PUMP
ADJUSTABLE
PRESSURE
RELIEF VALVE
(75 PSIG)
UNION
GATE VALVE
RELIEF
VALVE
(100 PSIG)
PRESSURE
GAUGE
GATE VALVE
CHECK VALVE
USE LAYOUT FOR: MODEL CBR. . . . . . . 125 THRU 800 HP

Relief valve on the boiler must
be set at 100 psig so that
adjustable pressure relief
valve in the loop
BOILER
FRONT
BOILER
BASE FRAME
CONTRACTOR
CONNECTIONS
AT THIS POINT
F.O.S.
F.O.R.
A10-24
09-09
Section A10
VENT
OIL TRANSFER TANK

AT LOCATION NEAR
BOILER
OIL LEVEL
TEST VALVE
OIL TRANSFER PUMP

NEAR STORAGE TANK
F.O.R.
GATE
CHECK
VALVE
VALVE STRAINER
F.O.S.
F.O.R.
F.O.S.
SUPPLY TO BOILER
TERMINAL BLOCK OR
TO BOILER OIL PUMP
RELIEF VALVE
(100 PSIG)
ITEM
SIZE
GATE
UNION VACUUM VALVE
GAUGE
DESCRIPTION

level switch
pump
connection
H
McD
G A
2"
3/16"
B
5"
3"
22"
60"
E
33"
3"
4" OR 6"
STD
BLACK
PIPE

3/8" MTL
D 3/16"
Figure A10-14. No. 2 Oil Transfer Tank Detail

A10-25
09-09

Boiler Room
Information
Section A10

Figure A10-16. shows typical boiler room width requirements.
Stack Support
Capabilities
Cleaver-Brooks Firetube Boilers 125 hp through 800 hp can support up to 2,000 lbs
without additional support.
Firetube sizes 250 hp through 800 hp can be reinforced to support 3,000 lbs.
Stack/Breeching Size
Criteria
Although constant pressure at the flue gas outlet of the Model CBR is not required, it is
necessary to size the stack/breeching to limit flue gas pressure variation. For boiler sizes
125 800 horsepower, the allowable pressure range is 0.25" W.C. to +0.25" W.C.
Boiler Room
Combustion Air
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.
foot.
Area (sq-ft.) = cfm/fpm

C. Total recommended air, 10 cfm/bhp - up to 1000 feet elevation. Add 3 percent more per
3. Acceptable air velocity in boiler room (fpm).

A10-26
09-09
Section A10
Notice
A10-27
09-09
Section A10
FRONT
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
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.
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.
BOILER HP
A
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
125-200
250-350
400-800
Dimension A
87
91
99"
Dimension B
120
127
149"
NOTES:
"A" allows for a "clear" 42" aisle between the water column on the
boiler and the wall. If space permits, this aisle should be widened.
42" - 125-200 hp
48" - 250-350 hp
60" - 400-800 hp
A10-28
09-09
Section A10
TIGHT SEAL
CLEANOUT
STACK
MANUAL
DAMPER
LOCK (OPEN)
CLEANOUT
DRAIN
CONNECTION

MAXIMUM 10
CONE ANGLE
NOTE: These stack breeching arrangements for

multiple boilers are typical and not intended for your
specific design requirements. For additional
information, review Section F, Stacks.


local CLeaver-Brooks authorized representative is
capable of assisting in your evaluation of stack and
breeching design.
TIGHT SEAL
CLEANOUT
TIGHT SEAL
CLEANOUT
STACK
MANUAL
DAMPER
LOCK (OPEN)
STACK
MANUAL
DAMPER
LOCK (OPEN)
CLEANOUT
CLEANOUT
DRAIN
CONNECTION
DRAIN
CONNECTION
A10-29
09-09
Section A10
Model CBR Steam Boiler
125-800 hp, Steam 15, 150, 200, or 250 psig)

Boiler Shell (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-32
Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-34
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-39
A10-31
09-09
Section A10

125-800 hp, Steam 15, 150, 200, or 250 psig)
The following sample specifications are provided by Cleaver-Brooks to assist you in specifying
your customer's specific needs and application.
specification. Contact your local Cleaver-Brooks authorized representative for information on
special insurance requirements, special code requirements, optional equipment, or general
assistance in completing the specification.
PART 1 GENERAL
1.01

A. The Steam Boiler shall be Cleaver-Brooks Model CBR Fuel Series ____ (100, 200,
700), ____ hp designed for ____ psig (15 or ____ psig steam). The maximum
operating pressure shall be ____ psig.
B. The boiler shall have a maximum output of ____ Btu/hr, or ____ horsepower when
fired with CS12-48 No. 2 oil and/or natural gas, ____ Btu/cu-ft. Electrical power
available shall be ____ Volt ____ Phase ____ Cycle and 115/1/60 for the control
circuit.
PART 2 PRODUCTS
2.01

A. The boiler shall be a two-pass horizontal firetube updraft boiler with __________
square feet of total heating surface for the _______ hp boiler. It shall be mounted
on a heavy steel frame with integral forced draft burner and burner controls. The
complete packaged boiler is built as a unit with Underwriters Laboratories listed
controls.
shall bear the UL/cUL label, except in the case where 50 Hz has been selected.
1.
2.02
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.
BOILER SHELL (STEAM)

and must receive authorized boiler inspection prior to shipment. A copy of
the inspection report shall be furnished the purchaser.
4. Rear refractory and insulation shall be contained in the formed door which
5. The boiler tubes shall be rifled tube design, extending heat transfer surfaces.
A10-32
09-09
Section A10

6.
Front and rear tube sheets and all tubes must be fully accessible for inspection
and cleaning when the doors are swung open. The boiler shall be furnished
7. For boilers 125 horsepower and over, a manhole shall be provided.
125-225 hp 2000 lbs. and shall contain a stack thermometer.
10. The boiler insulation shall consist of a 2 inch fiberglass blanket under a
sectional preformed sheet metal lagging. This insulation must be readily
removable and capable of being reinstalled, if required.
11. The entire boiler base frame and other components shall be factory painted
before shipment using a hard-finish enamel coating.
2.03
STEAM BOILER TRIM

1. WATER COLUMN/LOW WATER CUTOFF AND WATER LEVEL
CONTROL SYSTEM
(150-250 psig design): Shall be a CB LEVEL MASTER Water level control
system and shall be comprised of a microprocessor-based electronic
controller, a non-contact, non-wearing, continuously reading absolute level
sensor and pressure chamber. The control system shall be designed as follows:
The electronic controller shall be panel mounted and operate in ambient
temperatures from 32 degrees F to 125 degrees F, the pressure chamber shall
be boiler mounted and operate to pressures of 250PSIG and the level sensor
shall operate to pressures of 250 PSIG and temperatures to 400 degrees F. The
pressure containing components shall be constructed in accordance with
ASME Code. A shielded, four conductor cable with ground shall be run in
metal conduit between the level sensor and the controller. Supply power shall
be 115VAC-1 phase- 60 Hz. All wiring shall be in compliance with the
National Electrical Code.
The pressure chamber shall have a sight glass mounted on the side. The level
sensor shall have an accuracy of.01" or greater. The electronic controller shall
have level and error indicating lights, alphanumeric display for messaging,
reset/menu switch and the following features:
a. Continuous Level Indication
b. Low Water Cutoff & Alarm
c. High Water Alarm
d. Low & High Water Warning
e. Full Modulating Control of Modulating Feedwater Control Valve
f.
Continuous Monitoring of Float Operation
g. Column Blowdown Detection and Reminder
h. Auto or Manual Reset
i.
Real Time Clock
j.
Alarm Annunciation
k. Alarm History Files with Time Stamp
l.
Water Column Blowdown Record
m. Auxiliary Low Water Cutoff Check
A10-33
09-09
Section A10
n.
o.
RS 232 Interface
Maximum Contacts Rating 15 amps Resistive Load
B. Feedwater Pump Control

automatically actuate a motor driven feedwater pump maintaining the boiler water level within
normal limits.
C. Low Water Cutoff
the burner control circuit to prevent burner operation if the boiler water level falls below a safe
level.
D. Auxiliary Low Water Cutoff
Auxiliary low water cutoff shall be included, piped to the vessel, and wired to the burner control
E. Steam Pressure Gauge
connection.
F. Safety Relief Valves
G. Steam Pressure Controls
2.04
BURNER
Burner operation shall be full modulation principle. The burner shall always return to low fire
B.
Forced Draft Blower

1. All air for combustion shall be supplied by a forced draft blower mounted in
the front boiler door, above the burner, to eliminate vibration and reduce noise
level.
2. Maximum sound level of the boiler/burner package shall not exceed ____
dBA (when measured in accordance with ABMA Sound Test Standards).
control motor that regulates the fire according to load demand. Single point positioning controls
Refer to the following fuel series specifications:
Fuel series 700 - gas fired.

Fuel series 100 - light oil fired.
Fuel series 200 - light oil or gas fired.
A10-34
09-09
Section A10

Series 400 (heavy oil and gas) and series 600 (heavy oil only) also available. Check with your
local Cleaver-Brooks representative for specification details.
1.
2.

boiler and of high radiant annular gas entry on 125-225 hp. and of high
radiant multi-port type for gas burner 300-800 hp.The burner shall be
approved for operation on natural gas fuel.
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.
regulating gas shutoff valve, motor operated with proof of closure
switch and plugged leakage test connection. The valve is spring return
to start or stop the gas burner and to close automatically in the event of
power failure, flame failure, low water or any safety shutdown
condition. A lubricating plug 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 second motorized safety shutoff valve, plus an additional
plugged leakage test connection shall be provided.
plugged leakage test connection shall be provided. A valve proving
switch shall be located between the safety shutoff valves.
d. Burner Turndown - Turndown range of the burner shall be 4:1 when
firing natural gas.
natural gas.
2) 250-800 hp. Turndown range of the burner shall be 10:1 when
firing natural gas with a 60 or 30 ppm LE option.
3) Gas Pilot - The gas pilot shall be premix type with automatic
that the primary fuel valve cannot open until flame has been
b. Oil Pump - An oil pump with a capacity of approximately twice the
set, shipped loose to be installed in a location favorable to the oil storage
A10-35
09-09
Section A10
c.
d.
e.
f.
piping.
plugged leakage test connection shall be provided.
plugged leakage test connection shall be provided. A vent valve
natural gas.
2) 250-800 hp. Turndown range of the burner shall be 10:1 when
firing natural gas with a 60 or 30 ppm LE option.
Fuel series 200 - Light Oil or Gas Fired
1) Burner Type - The burner, integral with the front head of the boiler,
shall be a combination of the low pressure air atomizing type for
oil and high radiant annular gas entry on 125-225 hp and multi-port
type for gas entry on 100 hp. The burner shall be approved for
operation with either CS12-48 Commercial No. 2 Oil or natural
gas.
2) Gas Pilot - The gas pilot shall be premix type with automatic
that the primary fuel valve cannot open until flame has been
3) Oil Burner
Oil Pump - An oil pump with a capacity of approximately twice the
maximum burning rate shall be included. A separate motor driven
pump set, shipped loose, to be installed in a location favorable to
the oil storage tank, shall be provided.
Oil Burner Piping - Fuel oil piping on the unit shall include oil
pressure regulating devices, oil metering controls, solenoid shutoff
valves, pressure gauges and fuel strainer, all integrally mounted on
the unit. A fuel oil controller shall be provided to 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.
Low pressure air atomizing - Separate air compressor module
A10-36
09-09
Section A10

g.
Gas Burner
1) Gas Burner Piping - gas burner piping on all units shall include
closure switch and plugged leakage test connection. The valve is
spring return to start or stop the gas burner and to close
automatically in the event of power failure, flame failure, low
water or any safety shutdown condition. A lubricating plug cock
or butterfly shutoff valve shall be provided as a means for a
tightness check of the primary shut off valve. An additional plug
cock or butterfly shutoff valve shall be furnished at entrance to gas
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.
300-800 hp. High and low gas pressure switches shall be
provided. A second motorized safety shutoff valve, plus and
additional plugged leakage test connection shall be provided.
A valve proving switch shall be located between the safety
shutoff valves.
2)

250-800 hp. Turndown range of the burner shall be 10:1 when
firing natural gas and 8:1 on No. 2 oil.
E.
Boiler Flame Safeguard Controller and Control Panel

1. CB780E Flame Safeguard Controller
Each boiler shall be factory equipped with flame safeguard controller
providing technology and functions equal to the Cleaver-Brooks Model
CB780E.
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.
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).
adjustments to firing rate motor, damper linkages and pilot flame for
minimum turndown tests.
a.
cabinet will have NEMA 1A rating that includes a neoprene dust seal
A10-37
09-09
Section A10
and a Yale cabinet key type lock.
The panel shall contain the boiler flame safeguard controller, blower
The panel shall have a removable sub-base for mounting the flame
safeguard controller, blower motor starter, and terminal blocks. For
combination gas-oil fired boilers, the panel shall contain the fuel selector
switch.
b.
Lights
White - load demand.
Red - low water.
c.
Control Switches
Burner On-Off.
Manual-Automatic.
d.
2.
Oil, heat and moisture resistant wire shall be used and identified with
f.
Control Panel
a. The control panel shall be mounted on the front door of the boiler in a
location convenient to the operator. The hinged metal cabinet will have
NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet
key type lock.
b. The panel shall contain the boiler flame safeguard controller, blower
c. 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.
d. Oil, heat, and moisture resistant wire shall be used and identified with
f.
2.05
The boiler must be guaranteed to operate at a minimum fuel-to-steam efficiency of ____ percent
from 25 to 100 percent of rating when burning natural gas and ________ fuel-to-steam efficiency at
100% firing rate when burning oil.
F.
A10-38
09-09
Section A10

Natural Gas
Carbon, % (wt) = 69.98
No. 2 Oil
Carbon, % (wt) = 85.8
No. 6 Oil
Carbon, % (wt) = 86.6
Sulfur, % (wt) = 2.09
2.06
WARRANTY
PART 3 EXECUTION
A. Shop Tests
B.
Start-up Service
services of a field representative for starting the unit and timing the operator
A10-39
09-09
Section A10
Model CBR Hot Water Specifications
(125-800 hp, 30 psig, 125 psig)
Table Of Contents
Boiler Characteristics (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-42
Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-43
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-48
Shop Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-48
A10-41
09-09
Model CBR Hot Water Boiler Specifications
Firetube Boilers

(125-800 hp, 30 psig, 125 psig)
PART 1 GENERAL
1.1

A. The Hot Water Boiler shall be Cleaver-Brooks Model CBR, Fuel Series ______ (100, 200,
700), _____ hp designed for _____ psig (30, 125 psig, or other hot water). The maximum
water temperature shall be _____ degree F, and the maximum system temperature drop
shall be _____ degrees F.
B. The boiler shall have a maximum output of _____ Btu/hr., or _____ horsepower when
available shall be _____Volt _____ Phase _____ Cycle.
PART 2 PRODUCTS
2.1

A. The boiler shall be a two-pass horizontal firetube updraft boiler with __________ square
feet of total heating surface for the _______ hp boiler. It shall be mounted on a heavy steel
frame with integral forced draft burner and burner controls. The complete packaged boiler
is built as a unit with Underwriters Laboratories listed controls.
The complete package boiler shall be approved as a unit by Underwriters Laboratories and shall
bear the UL/cUL label, except in the case where 50 Hz has been selected.
1.
B.
The boiler shall be completely pre assembled and fire tested at the factory. The unit
shall be ready for immediate mounting on floor or simple foundation and ready for
attachment of water, steam, fuel, electrical, vent and blowdown connections.
____________________ (Factory Mutual, Industrial Risk Insurance, ASME CSD1).
Boiler Shell (Hot Water)
must receive authorized boiler inspection prior to shipment. A copy of the inspection
report shall be furnished to the purchaser.
2. The hot water return and outlet connections shall be located on the top center line of
the boiler. The boiler shall be designated to rapidly mix the return water with the
boiler water. Forced internal circulation shall be used.
5. Front and rear doors on the boiler shall be hinged or davited. Doors are to be sealed
with fiberglass tadpole gaskets and fastened tightly using heavy capscrews that
thread into replaceable brass nuts.
7. The boiler tubes shall be rifled tube design, extending heat transfer surfaces.
A10-42
09-09
Firetube Boilers

8.
C.
D.
E.
F.
Front and rear tube sheets and all flues must be fully accessible for inspection and
cleaning when the doors are swung open. The shell must be furnished with adequate
handholes to facilitate boiler inspection and cleaning.
9. A manhole shall be provided.
10. The exhaust gas vent shall be located near the front of the boiler on the top center
line and shall be capable of supporting 2000 lbs and shall contain a stack
thermometer.
Observation ports for the inspection of flame conditions shall be provided at each end of
the boiler.
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.
shipment using a hand finish enamel coating.
Emission Controls
1. Boiler shall be equipped with a low emission (LE) option for guaranteed NOx
performance at ________ ppm, dry volume basis and corrected to 3% O2 when
firing natural gas.
2. The low emission option shall include an integral front head, burner, and boiler
package, providing NOx reduction through an internal flue gas recirculation system
using the combustion air fan, internal recirculation valve, and enhanced boiler design
to achieve the guaranteed NOx levels. The emission control system shall not use an
external fan, control valve, and piping. Boiler fuel-to-steam efficiency and rated
boiler capacity shall be guaranteed while the boiler is operating at the low NOx
performance levels.
3. Burner, boiler, and low NOx system shall be manufactured as a package by a single
manufacturer. The Low Emission Option to the CB Boiler shall included factory
testing as a package, and shall bear the UL packaged label. The boiler nameplate
shall include the approved UL low NOx boiler model designation. No field assembly
of the burner or low NOx equipment shall be required.
2.2

A. Low Water Cutoff
A low water cutoff control (manual reset) shall be mounted on the top centerline of the
boiler wired into the burner control circuit to prevent burner operation if boiler water falls
below a safe level.
Pressure and temperature gauges shall be mounted on the boiler with temperature sensing
element located adjacent to the hot water outlet.
C. Relief Valves
Water relief valves of a type and size to comply with ASME Code requirements shall be
shipped loose.
Temperature controls to regulate burner operation shall be mounted on the unit with
temperature sensing elements located adjacent to the hot water outlet. Controls shall be
high limit (manual reset), operating limit (auto reset), and firing rate control.
2.3
Burner and Controls

Burner operation shall be full modulation principle. The burner shall always return to low
A10-43
09-09
B.
C.
D.
Firetube Boilers
fire position for ignition.

Blower
1. Air for combustion shall be supplied by a forced draft blower mounted in the front
boiler door, above the burner, to eliminate vibration and reduce noise level.
3. The impeller shall be cast aluminum, radial blade, carefully balanced, and directly
Potentiometer type position controls shall be provided to regulate operation of the damper
control motor (remove this sentence when CB-HAWK flame safeguard is used).
Series 400 (heavy oil and gas) and series 600 (heavy oil only) and available.
Check with your local Cleaver-Brooks representative for specification details.
1.

a. Burner Type - The burner shall be integral with the front head of the boiler and
operation on natural gas fuel and equipped with an LE option.
b. Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition.
An electronic detector shall monitor the pilot so that the primary gas valve
gauge.
regulating gas shutoff valve, motor operated with proof of closure switch and
plugged leakage test connection. The main gas valve(s) shall be wired to close
automatically in the event of power failure, flame failure, low water or any
safety shutdown condition. A lubricating plug cock or butterfly shutoff valve
shall be provided as a means for a tightness check of the primary shut off valve.
An additional plug cock on butterfly valve shall be furnished at entrance to gas
1) 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.
2) 300-800 hp. High and low gas pressure switches shall be provided. A
second motorized safety shutoff valve, plus an additional plugged leakage
test connection shall be provided. A valve proving switch shall be located
between the safety shutoff valves.
1) 125-200 hp. Turndown range of burner shall be 4:1 when firing natural
gas.
A10-44
09-09
Firetube Boilers

2)
2.
3.
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.
a. Burner Type - The burner shall be integral with the front head of the boiler, and
shall be a low pressure air atomizing type approved for operation with CS1248, Commercial No. 2 oil and equipped with an LE option.
b. Oil Pilot - The oil pilot shall be air atomizing type with automatic electric
ignition and include oil solenoid valve. An electronic detector shall monitor
the pilot so that the primary oil valve cannot open until flame has been
established.
c. Oil Pump - An oil pump with a capacity of approximately twice the maximum
burning rate shall be included. Separate motor driven pump set, shipped loose
to be installed in a location favorable to the oil storage tank, shall be provided.
gauges and fuel strainer, all integrally mounted on the unit. A fuel oil controller
shall be provided to combine all of the fuel oil controls into a single casting
which is mounted on the front door of the unit. A single tip retractable nozzle
shall be used for the low pressure air atomizing burner. A low oil pressure
switch shall be included in the oil piping.
e. Low Pressure Air Atomizing - Separate air compressor module mounted on
f.
1) 125 hp through 200 hp. Turndown range shall be 4:1 when firing No. 2
oil.
2) 250 hp through 800 hp. Turndown range shall be 8:1 when firing No. 2
oil.
a. Burner Type - The burner, integral with the front head of the boiler, shall be a
CS12-48 Commercial No. 2 Oil or natural gas. The burner shall be equipped
with an LE option.
b. Gas Pilot - The gas pilot shall be premix type with automatic electric ignition.
c. Oil Burner
shipped loose, to be installed in a location favorable to the oil storage
A10-45
09-09
Firetube Boilers
2)
piping.
3) Low pressure air atomizing - Separate air compressor module mounted on
d. Gas Burner
1) Gas Burner Piping - Gas burner piping on all units shall include pressure
and plugged leakage test connection. The main gas valve(s) shall be
butterfly shutoff valve shall be provided as a means for a tightness check
of the primary shut off valve. An additional plug cock or butterfly valve
shall be furnished at entrance to gas train. Select one of the following:
125-250 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.
300-800 hp. High and low gas pressure switches shall be provided. A second motorized safety
shutoff valve, plus and additional plugged leakage test connection shall be provided. A valve
proving switch shall be located between the safety shutoff valves.
e. Burner Turndown - Select one of the following:
250-800 hp. Turndown range of the burner shall be 10:1 when firing natural gas and 8:1 on No. 2
oil. (Consult your local Cleaver-Brooks authorized representative regarding high turndown
capability based on available gas pressure and No. 2 oil turndown capabilities when utilizing LE
Options to achieve NOx levels of 25 or 20 ppm when firing natural gas.)
E.
Boiler Flame Safeguard Controller and Control Panel

flame safeguard controller providing technology and functions equal to the
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.
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).
A10-46
09-09
Firetube Boilers

adjustments to firing rate motor, damper linkages and pilot flame for minimum
turndown tests.
b.
Control Panel - The control panel shall be mounted on the front door of the
boiler in a location convenient to the operator. The hinged metal cabinet shall
key type lock.
The panel shall contain the boiler flame safeguard controller, blower motor
starter, indicating lights and selector switches.
The panel shall have a removable sub-base for mounting the flame safeguard
controller, blower motor starter, and terminal blocks. For combination gas-oil
fired boilers the panel shall contain the fuel selector switch.

c.
Lights
Red - low water.
d.
Control Switches
Burner On-Off.
Manual-Automatic.
e.
f.
g.
h.
i.
j.
k.
2.4
Control Panel: The control panel shall be mounted on the front door of the
boiler in a location convenient to the operator. The hinged metal cabinet shall
key type lock.
The panel shall contain the boiler flame safeguard controller, indicating lights
Panel shall have a removable sub-base for mounting the flame safeguard
controller, and terminal blocks. For combination gas-oil fired boilers the panel
shall contain the fuel selector switch.
Oil, heat, and moisture resistant wire shall be used and identified with circuit
A. The boiler manufacturer shall guarantee that, at the time of startup, the boiler will achieve
A10-47
09-09
Firetube Boilers
________ fuel-to-steam efficiency at 100% firing rate when burning natural gas and
________ fuel-to-steam efficiency at 100% firing rate when burning oil (add efficiency
guarantees at 25%, 50%, and 75% of rating, if required). If the boiler(s) fail to achieve the
corresponding guaranteed efficiency as published, the boiler manufacturer will rebate, to
the ultimate boiler owner, five thousand dollars ($5,000) for every full efficiency point
(1.0%) that the actual efficiency is below the guaranteed level.
B.
Natural Gas
Carbon,% (wt) = 69.98
Sulfur,% (wt) = 0.0
No. 2 Oil
Sulfur,% (wt) = 0.2
No. 6 Oil
C.
D.
E.
Efficiencies are based on ambient air temperature of 80 F, relative humidity of 30%, and
15% excess air in the exhaust flue gas.
Efficiencies are based on manufacturers published radiation and convection losses. (For
Cleaver-Brooks radiation and convection losses, see Boiler Efficiency Facts Guide,
publication number CB-7767).
PART 3 EXECUTION
3.1
Warranty
3.2
Shop Tests
A. The packaged boiler must receive factory tests to check the construction, controls, and
operation of the unit. All tests may be witnessed by the purchaser, if desired.
B. Start-up Service
1. After boiler installation is completed, the manufacturer shall provide the services of
costs.
A10-48
09-09
Section A11
OPTIMIZED BOILER PACKAGE
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A11-3
A11-3
A11-3
A11-8
A11-8
A11-10
ILLUSTRATIONS
Dimension Diagram, Optimized Boiler Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-4

Efficiencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-8
Piping Diagram, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-9
TABLES
Dimensions, Optimized Boiler Package (Model CB-LE Boiler) . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-5

Dimensions, Optimized Boiler Package (Model 4WI Boiler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-6
Economizer weights, C2X condensing economizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-7
09-09
A11-1
Section A11
This section describes the Cleaver-Brooks Optimized Boiler Package (OBP), which combines a premium C-B
firetube dry-back or wet-back boiler with additional C-B equipment for maximum system performance. For
more information on individual package components, see these Boiler Book sections:
Section A1 CB-LE Boilers
Section A2 4WI Boilers
Section D Controls (Hawk ICS Advanced System w/Parallel Positioning)
Section G Economizers (Model C2X 2-Stage Condensing Economizer)
A11-2
09-09
Section A11
The Cleaver-Brooks Optimized Boiler Package combines a CB-LE or 4WI high
pressure steam boiler with the C2X 2-stage condensing economizer. The boiler,
economizer, and burner are exactly matched, resulting in reduced energy usage and
the best possible performance without compromising boiler capacity. The OBP is
capable of delivering up to 90% fuel-to-steam efficiency.
90% fuel-to-steam efficiency
Maximum heat recovery
Boiler fan motor and impeller are exactly matched with the economizer,
providing the most compact/efficient system possible
Utilization of cool makeup water in the economizer upper coil enables the
system to operate in condensing mode more than any other design, further
maximizing efficiency
Entire system is controlled by Advanced Hawk ICS with O2 Trim to ensure

maximum combustion efficiency
Design eliminates steaming in the economizer coils, reducing scaling and stress
Deaerator preheated during cold startup
Variable Speed Drive for combustion air fan reduces electrical usage (optional)
Reduced installation cost and improved appearance - economizer is fully

supported by the boiler shell, eliminating additional support structures
Automatic near-condensing operation when firing oil
PRODUCT OFFERING
CB-LE or 4WI 250-800 HP high pressure steam firetube boiler; 80-125 psig
operating pressure with natural gas and/or #2 oil firing
Model C2X 2-stage condensing economizer
Hawk ICS Advanced control system (single boiler systems) or CEC control
system (multiple boilers)
C-B Level Master water level control
Modulating feedwater valve with three-valve bypass
Feedwater stop and check valves
Economizer pressure relief valves for both coils
Valve package for optimum efficiency and continuous flow through economizer

Optimized Boiler Package dimensions are given in Figure A11-1, Table A11-1 and
Table A11-2.
Economizer wet and dry weights are shown in Table A11-3.
A11-3
09-09
Section A11
Figure A11-1. Dimension Diagram, Optimized Boiler Package
V
S
E
P
U
I
A
J
B
G
A11-4
09-09
L
K
Section A11
Table A11-1. Dimensions, Optimized Boiler Package (Model CB-LE Boiler)
Dimension (see Figure A11-1) - all
dimensions in inches
Boiler HP
250-300
350
400
500
600
700
800
A Economizer width
72
72
72
82
82
90
90
B Economizer height
62
72
72
73
84
87
97
C Boiler height w/economizer support
117
117
117
137
137
137
137
D Boiler width (not incl. trim & panel)
91
91
91
111
111
111
111
E Econ. door swing
70
70
70
80
80
88
88
179
189
209
210
221
224
234
28
28
24
30
30
33
33
10.5
10.5
13
13
13
13
13
I Stack center to econ. manifold
26
26
27
30
30
33
33
J Makeup inlet to base
26
30
30
30
34
34
38
L Center to feedwater inlet manifold
22
22
22
25
25
28
28
M Center to feedwater outlet manifold
16
16
16
19
19
22
22
N Feedwater outlet to base
29
33
33
33
37
37
41
O Makeup outlet to base
56
66
66
68
76
77
88
P Center to makeup inlet manifold
16
16
16
19
19
22
22
Q Center to makeup outlet manifold
22
22
22
25
25
28
28
R Makeup in
2 NPT
2 NPT
3 150# Flg 3 150# Flg 3 150# Flg 3 150# Flg 3 150# Flg
S Makeup out
2 NPT
2 NPT
3 150# Flg 3 150# Flg 3 150# Flg 3 150# Flg 3 150# Flg
T Feedwater in
2 NPT
2 NPT
2 NPT
2.5 NPT
2.5 NPT
2.5 NPT
2.5 NPT
U Feedwater out
2 NPT
2 NPT
2 NPT
2.5 NPT
2.5 NPT
2.5 NPT
2.5 NPT
20
20
24
24
24
24
24
F Overall height
G Boiler flange to econ. front
H Stack center to boiler flange
K Feedwater inlet to base
V Stack (by others)
A11-5
09-09
Section A11
Table A11-2. Dimensions, Optimized Boiler Package (Model 4WI Boiler)
Dimension (see Figure A11-1) - all
dimensions in inches
Boiler HP
250-300
350-400
500
600
700
800
A Economizer width
72
72
82
82
90
90
B Economizer height
62
72
73
84
87
97
C Boiler height
117
126
137
137
146
146
D Boiler width
91
99
111
111
121
121
E Econ. door swing
70
70
80
80
88
88
179
198
210
221
233
243
28
24
30
30
33
33
10.5
13
13
13
13
13
I Stack center to makeup manifold
26
27
30
30
33
33
J Makeup inlet to base
26
30
30
34
34
38
K Feedwater inlet to base
L Center to feedwater inlet manifold
22
22
25
25
28
28
M Center to feedwater outlet manifold
16
16
19
19
22
22
N Feedwater outlet to base
29
33
33
37
37
41
O Makeup outlet to base
56
66
65
76
77
88
P Center to makeup inlet manifold
16
16
19
19
22
22
Q Center to makeup outlet manifold
22
22
25
25
28
28
F Overall height
G Boiler flange to econ. front
H Stack center to boiler flange
R Makeup in
2 NPT
3 150# Flg 3 150# Flg 3 150# Flg
3 150# Flg
3 150# Flg
S Makeup out
2 NPT
3 150# Flg 3 150# Flg 3 150# Flg
3 150# Flg
3 150# Flg
T Feedwater in
2 NPT
2 NPT
2.5 NPT
2.5 NPT
2.5 NPT
2.5 NPT
U Feedwater out
2 NPT
2 NPT
2.5 NPT
2.5 NPT
2.5 NPT
2.5 NPT
20
24
24
24
24
24
V Stack (by others)
A11-6
09-09
Section A11
Table A11-3. Economizer weights, C2X condensing economizer
4WI Boilers
Boiler HP
250-300
350-400
500
600
700
800
Economizer
Model
C2X-2M386AL
C2X-2M3A6AL
C2X-2R3A6AL
C2X-2R3B6AL
C2X-2S3B6AL
C2X-2S3C6AL
Economizer
Dry Weight
1980
2220
2520
2820
3240
3720
Economizer
Wet Weight
2130
2410
2730
3070
3530
4060
CBLE Boilers
Boiler HP
250-300
350-400
500
600
700
800
Economizer
Model
C2X-2M386AL
C2X-2M3A6AL
C2X-2R3A6AL
C2X-2R3B6AL
C2X-2S3B6AL
C2X-2S3C6AL
Economizer
Dry Weight
1980
2220
2520
2820
3240
3720
Economizer
Wet Weight
2130
2410
2730
3070
3530
4060
A11-7
09-09
Section A11
PERFORMANCE DATA
Figure A11-2 shows CB-LE and 4WI efficiencies using the C2X 2-stage economizer.
Efficiencies are based on the following conditions:
C-B published stack-loss method and condensate removal

Ambient air temperature of 80 deg F
15% excess air in exhaust
Feed water at 227 deg F circulated through lower economizer stage
Includes C-B published radiation and convection losses
Figure A11-2. Optimized Boiler efficiencies
CBLE & 4WI Boiler Efficiency with 2-stage economizer

Natural Gas, Operating 80-125 psig
91
90
0
Efficiency %
Makeup water @50 F
89
88
87
86
85
84
25
50
75
100
% Makeup water
ENGINEERING DATA
Figure A11-3 shows a typical piping configuration for the Optimized Boiler Package.
A11-8
09-09
Section A11
Figure A11-3. Typical piping diagram, Optimized Boiler Package
2
3
4
5
6
7
8
2
3
7
5
7
8
2
NOTE: Deaerator piping (including shutoff valves and check valves), boiler feed
system, and stack not included. See brochure CB-8183 for additional details.
See also Boiler Book Section G - Economizers for additional piping configurations.
A11-9
09-09
Section A11
SPECIFICATIONS
Optimized Boiler Package

The following sample specification is provided by Cleaver-Brooks to assist you in
meeting your customers specific needs and applications.
The Optimized Boiler Package shall cover the Four-Pass Firetube Boiler (Wetback or
Dryback), 250-800hp, 80-125 psig operating pressure with Natural Gas and/or #2
Oil operation.
The Optimized System Package shall include the following:
150psig boiler design pressure
60ppm NOx on Natural Gas (options available to 9ppm)
Advanced Hawk ICS Control Package (single boiler) or CEC control system
(multiple boilers)
Parallel Positioning Control with FGR
O2 Trim with Cleaver Brooks Probe
Level Master water level control
Modulating boiler feedwater valve with three-valve bypass
Mounted boiler feedwater stop and check valves
Two Stage Condensing Economizer
Economizer Pressure Relief Valves for both coils
Automatic three-way system make-up water valve
Upper coil recirculating pump system
Lower coil bypass orifice and solenoid valve
Integrated economizer support structure
The single boiler Optimized Boiler Package includes the Advanced Hawk ICS control
system with parallel positioning - a totally integrated control system embodying
precise boiler/burner management control and safety with logic-based ancillary
devices and functions. The Hawk ICS also controls the condensing economizer
system, ensuring maximum efficiency during all operating scenarios.
Mulltiple boiler installations use the CEC (Condensing Economizer Control) system.
The CEC provides boiler and economizer control for up to four boilers each equipped
with a C2X 2-stage economizer.
When firing natural gas, the system is controlled to maximize condensing. This is
accomplished by routing all of the available cold makeup water through the upper
economizer coil before it enters the deaerator. Water from the deaerator is then
routed through the lower coil before it is used as boiler feed water.
A11-10
09-09
Section A11
When firing #2 oil, the system is controlled to operate in the near-condensing mode
and not in the condensing mode. Condensing operation would cause sulfur from the
#2 oil to combine with condensate, forming sulfuric acid which would destroy the
metallic components. In near-condensing mode, any cold makeup water is routed to
the dearator and not through the upper coil. The recirculation pump skid provides a
small flow through the upper coil to prevent steaming. Water from the deaerator is
routed through the lower coil before it is used as boiler feed water.
1) Steam Boiler (250-800 hp, Steam 80-125 psig)
a) Boiler Characteristics
i) The Steam Boiler shall be a packaged Cleaver-Brooks high turn-down
boiler
ii) Model CBLE (4-Pass Dryback) or Model 4WI (4-Pass Wetback)
iii) Fuel Series ______ (700 Gas Only or 200 Gas/Oil)
iv) Horsepower _____
v) Designed for _150_ psig
vi) Maximum operating pressure shall be _____ psig (between 80-125
psig)
b) General Boiler Design
i) The boiler shall be a horizontal Firetube updraft boiler mounted on a
heavy steel frame with integral forced draft burner and burner controls.
ii) The boiler shall be designed to accommodate a rectangular economizer
supporting its weight directly off the boiler shell. No additional
economizer supports shall be required.
c) Refer to appropriate Steam Boiler Sample Specification for additional boiler
requirements.
2) Economizer
a)The economizer shall be a Cleaver Brooks 2-Stage Condensing type
economizer.
b)Model to be C2X type rectangular economizer.
c)Economizer shall be designed to support outlet stack up to 500 lb. without
external reinforcement or supports.
d)Economizer to have integral condensate collection system with a single
connection for removal.
3) Exhaust Gases
a)Exhaust gas temperature entering economizer: _____F
b)Exhaust gas temperature exiting economizer: _____F
c)Percent efficiency gain: _____%
d)Inner liner of the stack to be stainless steel construction.
e)The stack out of the economizer shall weigh no more than 500 lb.
A11-11
09-09
Section A11
f)If field conditions require stack lengths which will exceed the 500 lb. weight
limit, additional considerations will be made for field support of excess stack
(by others).
4) Make-Up Water
a)System make-up water to be softened and treated to Cleaver Brooks
recommended levels.
b)Make-up water temperature as supplied to first stage (upper coil) of
economizer: _____F
c)Make-up water flow rate: _____ gpm at _____ psig
d)Make-up water amount: _____% (0-100%)
e)Make-up water temperature exiting the first stage (upper coil) of economizer:
_____F
f)Make-up water percent efficiency gain: _____%
g)Make-up water to be piped from the outlet of the economizer to the deaerator
inlet.
5) Boiler Feedwater
a)Boiler feedwater shall be field piped from the deaerator to the inlet of the
second stage (or lower coil) of the economizer.
b)Feedwater temperature entering the economizer to be: ______F
c)Feedwater temperature exiting the economizer to be: ______F
d)Boiler feedwater percent efficiency gain: _____%
6) Installation and Start-up
a)All equipment to be installed in strict compliance with the manufacturers
installation instructions along with applicable State, local, NFPA and other
governing standards.
b)The manufacturer's representative shall provide start-up and instruction of
each new boiler system, including burner, boiler and economizer control
systems as specified herein. Start-up and instruction shall cover all
components assembled and furnished by the manufacturer.
7) Efficiency Guarantee
a)The boiler manufacturer shall guarantee that, at the time of startup, the boiler
will achieve _____ fuel-to-steam efficiency at 100% firing rate when burning
natural gas and _____ fuel-to-steam efficiency at 100% firing rate when
burning oil (add efficiency guarantees at 25%, 50%, and 75% of rating, if
required). If the boiler(s) fails to achieve the corresponding guaranteed
efficiency as published, the boiler manufacturer will rebate, to the ultimate
boiler owner, ten thousand dollars ($10,000) for every full efficiency point
(1.0%) that the actual efficiency is below the guaranteed level at 100%
firing rate.
A11-12
09-09
Section A11
b)The specified boiler efficiency is based on the following conditions.
i)Fuel specification used to determine boiler efficiency:
(1)Natural Gas
(a)Carbon, % (wt) = 69.98
(b)Hydrogen, % (wt) = 22.31
(c)Sulfur, % (wt) = 0.0
(d)Heating value, Btu/lb = 21,830
(2)No. 2 Oil
(a)Carbon, % (wt) = 85.8
(b)Hydrogen, % (wt) = 12.7
(c)Sulfur, % (wt) = 0.2
(d)Heating value, Btu/lb = 19,420
c)Efficiencies are based on ambient air temperature of 80 F, relative humidity of
d)Efficiencies are based on manufacturers published radiation and convection
losses. (For Cleaver-Brooks radiation and convection losses, see Boiler
Efficiency Facts Guide, publication number CB-7767).
e)Any efficiency verification testing will be based on the stack loss method.
A11-13
09-09
Section A11
A11-14
09-09
Section B1
Flexible Watertube Boilers
TABLE OF CONTENTS

Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outdoor Reset Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B1-3
B1-4
B1-5
B1-5
B1-12
B1-12
B1-12
B1-12
B1-13
B1-13
B1-15
B1-18
B1-21
B1-21
B1-27
B1-1
07-09
Model FLX Boilers
Figure B1-1.
Figure B1-2.
Figure B1-3.
Figure B1-4.
Figure B1-5.
Figure B1-6.
Commercial Boilers
Illustrations
Model FLX Hot Water Boiler Dimensions (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . B1-8
Model FLX Steam Boiler Dimensions (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-10
Model FLX Tube Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-13
Model FLX Oil Burner Supply Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-16
Model FLX Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-17
Model FLX Breeching Arrangement - Single or Multiple Boiler Installation . . . . . . . . . B1-19
TABLES
Table B1-1. Model FLX Watertube Boiler Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-4

Table B1-2. Model FLX Hot Water Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-7
Table B1-3. Model FLX Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-7
Table B1-4. Expected Emissions (ppm, corrected to 3% O2), Natural Gas Fired Boiler . . . . . . . . . . B1-12
Table B1-5. Model FLX Hot Water Boiler Flow Rates and Pressure Drops . . . . . . . . . . . . . . . . . . B1-12
Table B1-6. Model FLX Circulating Rates, Hot Water Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-14
Table B1-7. Model FLXMinimum Over Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . B1-14
Table B1-8. Model FLX Boiler Heat Release Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-14
Table B1-9. Model FLX Burner Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-15
Table B1-10. Model FLX Minimum Required Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-15
Table B1-11. Model FLX Sound Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-17
Table B1-12. Model FLX Combustion Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-19
This section contains information on the Flexible Watertube boiler. The product model name is FLX for factory-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
07-09
Commercial Boilers
Model FLX Boilers

Patented Vessel and Tube Design:
Ensures that all tubes are subject to radiant heat from the burner flame.
Creates high water-flow-rates at all loads, and increases heat transfer

throughout the boiler.
Large Downcomer, Located Outside the Fire Zone:

Guarantees positive natural internal circulation, minimizing the impact of
exterior pumping conditions.
True Tangent-Wall Design:
No fins or strips to substitute for tubes.
Ensures maximum cooling and uniform heat transfer throughout the boiler.
Five-Pass Boiler Design:

Creates high flue gas velocities to rapidly and efficiently transfer heat to the
water.
Higher efficiencies compared to other tangent-tube designs.
1.5-Inch Diameter Tube Design:

Eliminates possible damage from thermal shock stresses.
Prolongs equipment life.
Swedge-Fitted Tube Attachment:

Eliminates the need for rolling or welding tubes.
Lessens repair or replacement requirements.
Ease of tube replacement reduces downtime.
Burner Supported by the Front Door:

No crane/hoist is required to remove burner and components for inspection.
Provides easy inspection access.
Insulated Construction:
Reduces thermal losses.
Increases efficiency.
Low NOx Capability:

NOx reduction to <15 ppm available.
Meets stringent emission requirements with no loss in operating

performance.
ASME Construction:
Ensures high quality design and manufacturing standards.
Ensures safety and reliability.
Cleaver-Brooks Forced Draft Burner:

Provides high pressure drop for low CO and maximum combustion
performance.
B1-3
07-09
Model FLX Boilers
Commercial Boilers
Reduces stack draft requirements.
Optimum fuel and air mixing.
Long-life reverse curve impeller.
Ensures maximum combustion efficiency, as low as 10% excess air.
Burner/Boiler by single manufacturer.
Removable Side Panels:

Provides easy access for inspection.
Ensures containment of furnace gases.
Rugged construction for durability.
20-Year Pressure Vessel Warranty:

Guaranteed to last.
Backed by Cleaver-Brooks.
Field Erectable (Optional):

Complete package for ease of assembly.
Pieces fit through standard doorway.
PRODUCT OFFERING
Information in this section applies to steam and hot water boiler sizes ranging from
1.5 to 12 MMBtu/hr input, as shown in Table B1-1
The Flexible Watertube Boiler is a five-pass steel boiler with flexible tubes formed
and arranged to direct the flow of combustion gases through the boiler. The pressure
vessel conforms to Section I or Section IV of the ASME Code, and consists of the
Table B1-1. Model FLX Watertube Boiler Sizes
MODEL
CAPACITY
INPUT
BTU/HR
HEAT OUTPUT
BTU/HR
EQUIV
HP
FLX-150
1,500,000
1,200,000
36
FLX-200
2,000,000
1,600,000
48
FLX-250
2,500,000
2,000,000
60
FLX-300
3,000,000
2,400,000
72
FLX-350
3,500,000
2,800,000
84
FLX-400
4,000,000
3,200,000
96
FLX-450
4,500,000
3,600,000
108
FLX-500
5,000,000
4,000,000
119
FLX-550
5,500,000
4,400,000
132
FLX-600
6,000,000
4,800,000
143
FLX-700
7,000,000
5,600,000
167
FLX-800
8,000,000
6,400,000
191
FLX-900
9,000,000
7,200,000
215
FLX-1000
10,000,000
8,000,000
239
FLX-1100
11,000,000
8,800,000
263
FLX-1200
12,000,000
9,600,000
287
NOTES:
1. Design Pressure: 150 psig Hot Water, 15 psig Steam, 150 psig
Steam.
2. Also available in Model FLE (field erectable).
B1-4
07-09
Commercial Boilers
Model FLX Boilers

formed tubes and the external downcomer connected to the top and bottom drums.
The heated area of the pressure vessel is contained within a gas-tight, insulated
casing that is composed of removable, formed-steel panels. The boiler/burner
package is manufactured by Cleaver-Brooks and UL/cUL approved as a package.
Standard Equipment
Equipment described below is for the standard boiler offering.

1. Boiler:
A. All boilers are designed and constructed in accordance with the ASME Code
and are mounted on an integral frame. All refractories for boiler and burner
are installed.
B. Factory fire test.
2. Cleaver-Brooks ProFire Forced Draft Burner:
A. Mounted on a hinged backing plate for easy access to furnace.
B. Pressure atomizing type for No. 2 oil burner. This includes the oil pump.
C. Stainless steel flame-retention type combustion head for gas, with UV
scanner, and gas pressure regulator.
D. External access to flame scanner for ease of maintenance.
3. Water/Steam Controls:
A. ASME safety relief valve(s).
B. Pressure and temperature gauges for hot water boilers.
C. Pressure gauge for steam boilers.
D. Operating and limit controls:
E. High limit control - manual reset.
F. Operating limit control - automatic reset.
G. Modulating or proportional controller.
H. Low water cutoff:
I. Probe type - hot water.
J. Float type main and probe type auxiliary- steam.
K. Pump Control - steam boilers.
Notice
Hot water boilers with design pressures up to 150 psig, and with design
temperatures less than 250 F, are constructed under Section IV of the ASME Code,
and H stamped for low- pressure heating boilers.
Notice
Steam boilers with design pressure of 30 psig, and maximum allowable operating
pressure of 15 psig, are constructed under Section IV of the ASME Code, and H
stamped for low pressure heating boilers.
Notice
Steam boilers with design pressure of 150 psig are constructed under Section I of
the ASME code and S stamped for high pressure steam boilers.
4. Altitude: Standard boilers attain full ratings at altitudes up to 2,000 feet.
Altitude compensation for most models is available for altitudes up to 10,000
ft above sea level.
Optional Equipment
For option details, contact your local Cleaver-Brooks authorized representative. In

summary, options include the following:
B1-5
07-09
Model FLX Boilers
Commercial Boilers
1. Boiler Options
Auxiliary low water cut-off (hot water).
Stack thermometer.
Insulated downcomer(s).
Drain valves.
Additional screwed tappings.
Packaged for field erection.
2. Burner/Control Options
Special burner modulation controls.
Low NOx burner.
Lead/lag system.
High altitude design - up to 10,000 ft.
Special insurance and code requirements (e.g., IRI, FM, ASME CSD-1).
Remote contacts.
Additional relay points and indicator lights.
Main disconnect (fusible/circuit breaker).
Elapsed time meter.
NEMA enclosures.
Key lock panel.
System pump interlock.
Low fire hold controls.
Assured low fire cut-off.
Flow switches.
High stack temperature cut-off/alarm.
Remote emergency shutoff (115V).
3. Fuel Options
Oversized gas trains.
Gas strainer.
Remote oil pump set.
Special pilot.
Direct spark oil ignition.
B1-6
07-09
Commercial Boilers
Model FLX Boilers
Table B1-2. Model FLX

Hot 1:
Water Boiler Ratings
Table
MODEL NO.
1000
1100
1200
150
200
250
300
350
400
450
500
550
600
700
800
900
Fuel Consumption .......Gas (cfh)A 1500

Oil (gph)B 10.7
2000
14.3
2500
17.9
3000
21.4
3500
25.0
4000
28.6
4500
32.1
5000
35.7
5500
39.3
6000
42.9
7000
50.0
8000
57.2
9000 10000 11000 12000

64.3 71.4
78.6
85.7
Output (MBH) ..............Gas Firing 1200

Oil Firing 1245
1600
1660
2000
2075
2400
2490
2800
2905
3200
3320
3600
3735
4000
4150
4400
4565
4800
4980
5600
5810
6400
6640
7200
7470
8000
8300
8800
9130
9600
9960
36
48
60
72
84
96
108
119
131
143
167
191
215
239
263
287
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
7000
8000
9000 10000 11000 12000
15
20
25
30
35
40
45
50
55
60
70
80
Shipping Weight (lbs)
3900
3900
3900
5000
5000
6100
6100
6100
6100
6100
8500
8500
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
1/2A
3/4A
3/4A
3/4A
1A
1A
2A
7-1/2
10
10
15
3/4B
1B
1B
1B
Approximate bhp
Natural Gas Input: CFH (1000
Btu)
Natural Gas: Therms/Hour
Blower Motor hp
1-1/2B 1-1/2B
90
100
110
120
8500 10000 10000 10000
3B
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
600
700
800
900
Fuel Consumption ...Gas(h)A 1500

Oil (gph)B 10.7
2000
14.3
2500
17.9
3000
21.4
3500
25.0
4000
28.6
4500 5000 5500 6000

32.2 35.7 39.3 42.9
7000
50.0
8000
57.2
9000 10000 11000 12000

64.3 71.4
78.6
85.7
1237
1649
2062
2479
2887
3299
3711
4124 4536 4949
5773
6598
7422
8248
9072
9897
Output (MBH) .......Gas Firing 1200

Oil Firing 1245
1600
1660
2000
2075
2400
2490
2800
2905
3200
3320
3600 4000 4400 4800

3735 4150 4565 4980
5600
5810
6400
6640
7200
7470
8000
8300
8800
9130
9600
9960
107
143
167
191
215
239
263
287
4500 5000 5500 6000
7000
8000
9000 10000 11000 12000
70
80
Rated Capacity: lbs steam/hr
500
1100
1200
36
48
60
72
84
96
Natural Gas Input:

CFH (1000Btu)
1500
2000
2500
3000
3500
4000
15
20
25
30
35
40
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
85
85
85
95
95
140
140
140
140
140
210
210
210
252
252
252
1/2A
3/4B
3/4A
1B
3/4A
1B
2A
3B
7-1/2
10
10
15
Operating Water Content

(US gal)
Blower Motor hp
3/4A
1A
1A
1B 1-1/2B 1-1/2B
45
50
131
1000
Approximate bhp
Natural Gas: Therms/Hour
119
550
55
60
90
100
110
120
NOTES: 212 F feedwater.
A. Natural Gas @ 1000 Btu/cu-ft.

B. No. 2 Oil @ 140,000 Btu/gal.
B1-7
Model FLX Boilers
MODEL NO.
A - Length Of Base
Commercial Boilers
150
200
250
300
350
400
450
500
550
600
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)
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
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
15
15
15
17
17
21
21
21
21
21
18-3/4
L - Upper/lower Drum OD
O - Diameter Of Bolt Circle

P - Flue Gas Outlet Flange OD
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
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
1-1/2
1-1/2
1-1/2
11/2
1-1/2
U - Rear Downcomer (NPS) Size
V - Relief Valve Outlet (160 lb)
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
159-3/4
159-3/4
T - Drain Connection
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
NOTES:
1. Measurements in inches.
2. Rear drain connection on Model 600 and larger specification subject to chang
without notice.
3. Models 150 thru 350 supplied with one front drain only.
4. Contact your local Cleaver-Brooks authorized representative regarding total

length for altitude-compensated boilers.
5. Inlet and outlet flanges: Model 150 thru 900 - studded flange.
Models 1000 thru 1200 - nozzle flange.
Figure B1-1. Model FLX Hot Water Boiler Dimensions (1 of 2)

B1-8
07-09
Commercial Boilers
MODEL NO.
A - Length Of Base
Model FLX Boilers
700
800
900
1000
1100
1200
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.
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
20-1/2
20-1/2
20-1/2
26-1/2
26-1/2
26-1/2
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
U - Rear Downcomer (NPS) Size
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
213-7/8
213-7/8
L - Upper/lower Drum OD
O - Diameter Of Bolt Circle

P - Flue Gas Outlet Flange OD
V - Relief Valve Outlet (160 lb)

W - Total Length (See Note 4)
181-7/16 181-7/16 181-7/16 213-7/8
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
Figure B1-1. Model FLX Hot Water Boiler Dimensions (2 of 2)

B1-9
07-09
Model FLX Boilers
MODEL NO.
Commercial Boilers
150
A. Length of Base
200
250
300
350
400
450
500
550
600
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)

B1 - Top of Lifting Lug
85-3/4
85-3/4
85-3/4
90
90
86-13/16 86-13/16 86-13/16 90-13/16 90-13/16
C. Boiler Width
93-7/8
93-7/8
93-7/8
93-7/8
93-7/8
94-7/8
94-7/8
94-7/8
94-7/8
94-7/8
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
60
60
60
64
64
67
67
67
67
67
E. Center of Lower Drum to Bottom
8-13/16
8-13/16
8-13/16
8-13/16
8-13/16
9-7/8
9-7/8
9-7/8
9-7/8
9-7/8
F. Center of Burner Opening to Bottom
25-7/8
25-7/8
25-7/8
31-3/4
31-3/4
35-3/4
35-3/4
35-3/4
35-3/4
35-3/4
D. Center of Lower Drum - Center Upper

Drum
G. Center of FG Outlet to Rear of Jacket

H. Drum Clearance Past Base - Front
J. Tube Removal Clearance
14-11/16 14-11/16 14-11/16

15-1/8
15-1/8
15-1/8
14-5/8
14-5/8
17-1/8
17-1/8
17-1/8
17-1/8
17-1/8
15-1/8
15-1/8
15-1/2
15-1/2
15-1/2
15-1/2
15-1/2
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.
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
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
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
26-9/16
O. Diameter of Bolt Circle (FG Outlet)
R. Drum Clearance Past Base - Rear

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
T. Drain Connection (15 psig)
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
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

W. Height of Steam Nozzle
86-13/16 86-13/16 86-13/16 90-13/16 90-13/16
X. Height of Stack Flange
94-7/8
94-7/8
94-7/8
94-7/8
94-7/8
95-3/8
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
Y. Relief Valve Outlet Size (Qty) (15 psig)
2-1/2
2-1/2
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
(2)
1-1/4
(2)
1-1/4
(2)
1-1/4
(2)
1-1/4
(2)
1-1/4
3/4
3/4
3/4
3/4
3/4
Z. Feed Water Connection Size

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
50-3/8
50-3/8
50-3/8
50-3/8
36-3/8
36-3/8
36-3/8
AA. Total Length (See Note)
114-1/4
114-1/4
114-1/4 124-3/16 124-3/16 145-3/4
4x5
4x5
4x5
4x5
39-3/8
1
46-7/8
ZZ.Steam Nozzle Location

Inspection Handhole Size (Lower)
39-3/8
1
46-7/8
4x5
50-3/8
145-3/4 152-9/16 152-9/16 152-9/16
4x5
Note: Contact your local Cleaver-Brooks authorized representative regarding total length for altitude-compensated boilers.
* flg = Class 150# F.F.
Figure B1-2. Model FLX Steam Boiler Dimensions (1 of 2)

B1-10
07-09
4x5
4x5
4x5
4x5
Commercial Boilers
Model FLX Boilers
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
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
D. Center of Lower Drum - Center Upper Drum
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
8 flg.
8 flg.
8 flg.
10 flg.
10 flg.
10 flg.
4 flg.
4 flg.
4 flg.
6 flg.
6 flg.
6 flg.
10-3/4
10-3/4
10-3/4
10-3/4
10-3/4
10-3/4
18
18
18
24
24
24
L. Lower Drum OD
M. Flue Gas Outlet ID
N. No. of Holes in Flue Gas Outlet Flange
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
13
13
13
O. Diameter of Bolt Circle (FG Outlet)
R. Drum Clearance Past Base - Rear

S. Burner Clearance (See Note 4, page B1-7)
25-1/16 25-1/16 25-1/16
20-1/2
20-1/2
20-1/2
32-3/8
32-3/8
32-3/8
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
U. Downcomer (NPS) Size
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
(2) 2-1/2 (2) 2-1/2 (2) 2-1/2
(2) 3
(2) 3
(2) 3
(2) 1-1/2 (2) 1-1/2 (2) 1-1/2
(2) 2
W. Height of Steam Nozzle
(2) 2
(2) 2
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
4x5
4x5
Z. Feed Water Connection Size
Inspection Handhole Size (Lower)
4x5
4x5
4x5
4x5
Figure B1-2. Model FLX Steam Boiler Dimensions (2 of 2)

B1-11
07-09
Model FLX Boilers
Commercial Boilers

Ratings for steam and hot water boilers are shown in Table B1-2 andTable B1-3. Dimensions for steam and hot water boilers are shown in Figure B1-1 and Figure B1-2.
PERFORMANCE DATA
Efficiency
Fuel-to-steam (fuel-to-water) efficiency is based on specific operating conditions (fuel, pressure, temperature). Nominal efficiency on all FLX hot water and low pressure steam boilers
is 81% firing natural gas, and 84% firing No. 2 oil. For high pressure steam applications,
contact your local Cleaver-Brooks representative for expected efficiencies.
Emissions
Expected emissions for natural gas fired FLX boilers are shown in Table B1-4.
Table B1-4. Expected Emissions (ppm, corrected to

3% O2), Natural Gas Fired Boiler
FLUE GAS
COMPONENT
HIGH-FIRE
LEVELA PPMV
LOW-FIRE
LEVELB PPMV
CO
<100
<100
NOx
P70
P70
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
B1-12
07-09
Commercial Boilers
Model FLX Boilers
ENGINEERING DATA
Boiler Information
Flow Rates and Pressure Drops

Flow rates and pressure drops for the FLX hot water boilers are shown in Table B1-5. This
table can be used to determine the boiler pressure drop in relation to full boiler output and
system temperature drop.
Table B1-6 can be used to determine the maximum gpm circulating rate in relation to full
boiler output and system temperature drop. The maximum gpm can be determined by knowing the boiler size and expected system temperature drop.
System Operating Parameters (Hot Water)

System over pressure requirements are shown in Table B1-7.
Minimum return water temperature is 140 F; minimum supply (boiler outlet) water temperature is 150 F in order to prevent fireside corrosion.
System Operating Parameters (Steam Boilers)

The following operating limitations must be observed for optimum operation of the boiler:
1. Minimum make-up temperature 60 F.
2. Maximum make-up rate (for on/off make-up control) 2.0 times the evaporation rate.
3. Minimum operating pressure 6 psig. on low pressure steam and 40 psig. on high pressure
steam.
4. Maximum operating pressure 12 psig. on low pressure steam.
5. Maximum load tracking rate 0 - 100% load or 100% - 0 load, 30 seconds on low
pressure steam and 20% per minute on high pressure steam.
Maximum boiler water chemistry parameters: Silica: 150 ppm; specific conductance: 3500
mho/cm un-neutralized; total alkalinity: 300 ppm as CaCO3; hardness: 0; oxygen: 7 ppb;
pH: 7 - 10; total iron: 0.05 ppm; oil matter: 1 ppm.
Boiler Heat Release Information

Boiler heat release information is shown in Table B1-8.
Tube Attachment
Construction of the Flexible Watertube Boiler includes a special tube-to-drum attachment
that requires no welding or rolling (see Figure B1-3). The tube is fitted with a tapered ferrule,
which is press-fit into the tube hole in the drum. The ferrule is welded to the tube at the factory for both new and replacement tubes, so no field welding is required. The tube is held in
place with a keeper plate.
This tube attachment design reduces repair and maintenance costs, and also reduces the
cost of field erection of new units.
Figure B1-3. Model FLX Tube Attachment

B1-13
07-09
Model FLX Boilers
Commercial Boilers
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
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
Table B1-7. Model FLX Minimum Over

Pressure Requirements
MAXIMUM
MINIMUM SYSTEM
OUTLET
PRESSURE
TEMPERATURE
(PSIG)
(F)
180
190
200
210
220
230
240
12
15
18
21
24
27
30
MODEL
NO.
FURNACE
PROJECTED
AREA (FT2)
FURNACE
VOLUME
(FT3)
FLX-150
FLX-200
FLX-250
FLX-300
FLX-350
FLX-400
FLX-450
FLX-500
FLX-550
FLX-600
FLX-700
FLX-800
FLX-900
FLX-1000
FLX-1100
FLX-1200
38.4
38.4
38.4
48.7
48.7
70.6
70.6
70.6
70.6
70.6
104.6
104.6
104.6
128.9
128.9
128.9
24.2
24.2
24.2
34.9
34.9
54.7
54.7
54.7
54.7
54.7
94.6
94.6
94.6
116.5
116.5
116.5
B1-14
07-09
FURNACE
FURNACE
HEAT
HEAT
RELEASE RELEASE BTU/
BTU/HR (FT3)
HR (FT2)
61,983
82,645
103,306
85,960
100,287
73,126
82,267
91,408
100,548
109,689
73,996
84,567
95,137
85,837
94,421
103,004
39,063
52,083
65,104
61,602
71,869
56,657
63,739
70,822
77,904
84,986
66,922
76,482
86,042
77,580
85,337
93,095
Commercial Boilers
Model FLX Boilers

Table B1-10. Model FLX Minimum Required Gas
Pressure
Table B1-9. Model FLX Burner Characteristics

MODEL NO.
FLX-150
BURNER
MAXIMUM INPUT BURNER MODEL
MBH
1500
PFVLG-15
FAN MOTOR (3450

RPM) VOLTAGE
MIN. GAS
MIN. GAS
STD GAS
PRESSURE PRESSURE
MODEL NO. TRAIN SIZE
(IN.W.C.)
(IN.W.C.)
(IN.) Note 3
Note 4
Note 5
115/230/1/60
FLX-200
2000
PFVLG-20
115/230/1/60
FLX-250
2500
PFVLG-25
115/230/1/60
FLX-300
3000
PFVLG-30
115/230/1/60
FLX-350
3500
PFVLG-35
208/230/1/60
FLX-400
4000
PFVLG-40
208/230/1/60
FLX-450
4500
PFVLG-45
208-230/460/3/60
FLX-500
5000
PFVLG-50
230/460/3/60
FLX-550
5500
PFVLG-55
230/460/3/60
FLX-600
6000
PFVLG-60
460/3/60
FLX-700
7000
PFVLG-70
460/3/60
FLX-800
8000
PFVLG-80
460/3/60
FLX-900
9000
PFVLG-90
460/3/60
FLX-1000
10000
PFVLG-100
460/3/60
FLX-1100
11000
PFVLG-110
460/3/60
FLX-1200
12000
PFVLG-120
460/3/60
BURNER
MODEL
FLX-150
11.2
12.5
FLX-200
19.4
21.7
PFVG-15
PFVG-20
FLX-250
1.5
12.4
15.7
PFVG-25
FLX-300
1.5
15.9
20.7
PFVG-30
FLX-350
1.5
15.5
22.0
PFVG-35
FLX-400
1.5
18.7
27.2
PFVG-40
FLX-450
16.0
26.7
PFVG-45
FLX-500
17.6
21.0
PFVG-50
FLX-550
22.9
27.1
PFVG-55
FLX-600
20.0
24.9
PFVG-60
FLX-700
25.2
31.9
PFVG-70
FLX-800
2.5
19.9
22.2
PFVG-80
FLX-900
2.5
24.7
27.7
PFVG-90
Notes:
1 Burner model selection shown is subject to changed and is based on actual
application (altitude, gas pressure, reduced NOx, etc.)
FLX-1000
2.5
31.6
31.6
PFVG-100
FLX-1100
2.5
37.3
37.3
PFVG-110
2 Standard voltage for Canadian applications is 575/3/60.
FLX-1200
2.5
38.2
38.2
PFVG-120
Notes:
1. Table is based on 1,000 Btu/cu.ft natural gas and elevation to 1000
feet.
3 Burner operation is Full Modulation on Elite Series and for the Econo series
Low High Low for units 150 - 600 and modulated firing on 700 and greater.
4 Burner models shown are for combination gas/oil firing. For straight gas,
delete the letter L, and for straight oil, delete the letter G.
2. Minimum gas pressure also applies to 200 fuel series.

3. As an option, the standard gas train can be replaced with an
oversized design to reduce inlet gas pressure requirements.
4. Use this column for all U.S. Installations.
5. Use this column for all Canadian Installations.
Burner/Control
Information
Burner information is shown inTable B1-9. Note that the model selection may vary for actual
application factors (altitude, gas pressure, etc.).
Minimum Required Gas Pressures

Approximate gas pressure required at rated input is shown in Table B1-10. For oversized gas
trains or altitudes above 1,000 feet, contact your local Cleaver-Brooks authorized representative.

The local gas company should be consulted for requirements and authorization for installation and inspection of gas supply piping. Installation of gas supply piping and venting must
be in accordance with all applicable engineering guidelines and regulatory codes. All connections made to the boiler should be arranged so that all components remain accessible for
inspection, cleaning and maintenance.
A drip leg should be installed in the supply piping before the connection to the gas pressure
regulator. The drip leg should be at least as large as the inlet fitting supplied with the boiler.
Consideration must be given to both volume and pressure requirements when choosing gas
B1-15
07-09
Model FLX Boilers
Commercial Boilers
supply piping size. Refer to the boiler dimension diagram provided by Cleaver-Brooks for the
particular installation. Connections to the burner gas train should be made with a union, so
that gas train components or the burner may be easily disconnected for inspection or service. Upon completion of the gas piping installation, the system should be checked for gas

Oil-fired burners are equipped with an oil pump, which draws fuel from a storage tank and
supplies pressurized oil to the burner nozzle(s). The burner supply oil pump has a greater
capacity than the burner requires for the maximum firing rate. Fuel not delivered to the nozzle is returned to the storage tank. A two-pipe (supply and return) oil system is recommended for all installations. Figure B1-4 shows a typical fuel oil supply arrangement. Oil
lines must be sized for the burner and burner supply oil pump capacities.
Figure B1-4. Model FLX Oil Burner Supply Pump Installation

The burner supply oil pump suction should not exceed 10" Hg. If a transfer pump is used, it
must have a pumping capacity at least equal to that of the burner pump(s). Supply pressure
to the burner pump should not exceed 3 psig.
order to prevent entry of foreign material into the pump, fuel control valves, or burner nozzle(s). The strainer must be sized for the burner supply pump capacity. A strainer mesh of
150 microns (0.005") is recommended.
Install a check valve in the line to prevent draining of the oil suction line when the burner is
not in operation. Location of the check valve varies with the system, but usually it is located
as close as possible to the storage tank.
the strainer is recommended. Regular observation and recording of the gauge indication will
assist in determining when the strainer needs servicing.
B1-16
07-09
Commercial Boilers
Model FLX Boilers

Table B1-11. Model FLX Sound Levels
SOUND LEVEL
FIRING RATE
MODEL NO.
150
200
250
300
350
400
450
500
550
600
700
800
900
1000 1100 1200
Low Fire (dBA)
75
75
76
75
75
77
78
79
79
79
81
81
83
79
82
85
High Fire (dBA)
76
76
77
76
76
78
79
80
80
80
82
82
83
81
83
86
Measurement: Three feet from front center of boiler, and 3-1/2 feet above boiler base. Measurements are decibel
ratings on the A-weighted scale, registered without addition of sound attenuators, mufflers, or silencers. Sound
pressure data taken on combination fuel burners firing oil. Sound pressure levels firing natural gas will be 0.5
dBA lower.
MODEL NO.
SIDES
A
TOP
B
FRONT
C
REAR
D
FLX-150 - 250
28
18
48
24
FLX-300 - 350
32
18
48
24
FLX-400 - 600
34
18
60
24
FLX-700 1200
40
18
60
24
NOTE: Top Dimension from boiler to top of stack based

on stack selection.
Figure B1-5. Model FLX Clearance Requirements
B1-17
03-08
07-09
Model FLX Boilers
Commercial Boilers
Sound Levels (dBA)

Refer toTable B1-11 for sound level information.
Outdoor Reset
Control
Cleaver-Brooks does not recommend the use of outdoor controls which reset the boiler
water outlet temperature below 150 F, or the utilization of the boiler as a system thermostat.

The boiler must be installed on a non-combustible floor. If the floor is not level, piers, or a
raised pad, slightly larger in length and width than the boiler base dimensions, will make
boiler installations and leveling easier. Installation on a raised pad or piers will make boiler
drain connections more accessible. The floor, pad, or piers must be of sufficient load bearing
strength to safely support the operating weight of the boiler and any additional equipment
installed with it. Approximate operating weights for Model FLX series steam and hot water
boilers are shown in Dimensions and Ratings.
After the boiler is in place it must be leveled. Both side-to-side and front-to-back level can
be verified using the vertical connection between the upper and lower drums at the back of
the boiler. If shims are required to level the boiler, the weight of the boiler must be evenly
distributed at all points of support.
The boiler must be installed so that all components remain accessible for inspection, cleaning, or maintenance. Field- installed piping and electrical connections to the burner and
boiler must be arranged to allow removal of the casing panels, and swinging of the burner.
Minimum clearances to walls or other obstructions and combustible materials are shown
iFigure B1-5. The top view shaded sections in Figure B1-5show areas that must be kept
clear of field installed connections to the boiler for access or maintenance purposes.
A positive means of supplying a volume of outside air for complete fuel combustion is
required. Proper ventilation of the boiler room must be provided. The amount of air
required, and the required duct and air supply opening areas, are determined by the maximum fuel input rating of the burner and the altitude of the installation. Refer to Table B112. Air inlets must be sized in accordance with applicable engineering guidelines and regulatory code.
Breechings
For single boiler installations, use breeching of the same diameter as the vent outlet on the
boiler. For multiple boiler installations, and when a number of boilers of the same size
(input) are to be connected to a common breeching, use the table on Figure B1-6 to size the
breeching diameter. For more information on breechings and stacks, refer to Stacks, Section F.

Flextube boilers can support up to 200 lbs without additional support.
B1-18
07-09
Commercial Boilers
Model FLX Boilers
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
(lb/hr) 1207
Comb
Air
(Dry)
1609
2012
2414
2817
3219
3621
4024
4426
4828
5633
6438
7243
8048
8853
9657
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
Gas
(Dry)
(lb/hr) 1278
1704
2130
2556
2983
3409
3835
4261
4687
5113
5965
6817
7669
8521
9373
10225
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
B1-19
07-09
Model FLX Boilers
Commercial Boilers
Notes
B1-20
07-09
Section B1
Model FLX Boilers
(Steam Boiler Specifications)
Boiler Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-22
General Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-22
Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-22
Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-23
Burner Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-23
Pilot Gas Train for Each Burner (Mounted, Piped, and Wired) . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-24
Oil Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-24
Gas Valve Train for Each Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-24
Burner Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-25
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-26
Field Erectable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-26
The following sample specifications are provided by Cleaver-Brooks to assist you in specifying your customers
specific needs and application. A separate specification is provided for hot water boiler and steam boiler
packages.
B1-21
FLX Steam Boiler Specifications
Section B1
PART 1 GENERAL
1.1
BOILER CAPACITY
A. The _____ (low or high) pressure steam boiler shall be CleaverBrooks Model FLX (FLE for field erected) designed for _______ (15
or 150) psig steam.
B. The boiler shall have a maximum output of __________ lbs/hr at
____ psig when fired with No. 2 oil and/or natural gas, ________
Btu/cu-ft. Electrical power available will be ________ Volt, _______
phase, _____ Hz.
PART 2 PRODUCTS
2.1
GENERAL DESIGN
A. The boiler shall be of a two-drum flexible watertube design with a
tangent tube waterwall furnace mounted on a heavy steel frame.
Top, bottom and sides of the furnace shall be water cooled.
B. The boiler pressure vessel shall be constructed in accordance with
ASME Boiler Code, and must receive authorized boiler inspection
prior to shipment. A copy of the inspection report shall be furnished
to the purchaser. The complete packaged boiler - burner unit shall
be listed by Underwriters Laboratories, and shall have the UL/cUL
label affixed to the front head.
1. The boiler drums shall be furnished with handholes to facilitate
2. Boiler tubes shall be 1.5" diameter, 0.095" wall thickness, and
shall be easy to remove and replace without expanding or
welding the tube attachment to the drums.
3. The boiler shall have sufficiently sized downcomers to provide
positive natural internal circulation.
4. The burner shall be mounted on a hinged backing plate for easy
access to furnace.
C. Observation ports for the inspection of flame conditions shall be
provided at rear end of the boiler and in the burner assembly at the
front end.
D. The tangent wall tubes shall be covered with 1-1/2 inches of
insulation under a gas-tight, 16-gauge inner casing. There shall be 2
inches of insulation between the inner and outer casing. The outer
casing shall be 20 gauge. The boiler base frame and other
components shall be factory-painted before shipment, using a hard
enamel finish.
2.2
STEAM BOILER TRIM

A. The following items shall be installed on the boiler:
1. Low Water Cutoff - A low water cut-off control of the float-type
shall be mounted in a water column to the upper drum. It is to
be wired to the burner control circuit to prevent burner
operation if the boiler water falls below proper levels.
2. Feedwater Pump Control - The boiler feedwater pump control
switch shall be included. It shall provide automatic actuation of
a motor-driven feedwater pump, or solenoid valve, to maintain
the boiler water level within normal limits.
B1-22
Section B1

3.
4.
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.
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).
2.3
BURNER AND CONTROLS

A. The boiler shall be provided with a UL/cUL approved fuel burning
system in full accordance with the requirements of state, provincial
and local codes, the local gas utility, and other applicable regulatory
bodies. The boiler shall be a Cleaver-Brooks Profire burner.
B. (Option as required)
C. The complete fuel burning system shall further be in full accordance
with Factory Mutual (FM) requirements.
D. The complete fuel burning system shall further be in full accordance
with Industrial Risk Insurers (IRI) requirements.
2.4
BURNER DESCRIPTION
A. Option (specify 1, 2, or 3)
1. The burner shall include a gas burner having rated capacity to
burn ________ MMBtu/hr of ______ Btu/cu-ft of __________
gas at a pressure of _______ (lbs/sq-inch) (inches of water
column) at the inlet of the burner gas control train.
2. The burner shall include an oil burner having rated capacity to
burn ______ gph of No. 2 fuel oil.
3. The burner shall include a combination gas-oil burner having
rated capacity to burn _______ MMBtu/hr of _____ Btu/cu-ft
gas at a pressure of _________ lbs/sq-inch (inches of water
column) at the inlet to the burner gas control train (or _______
gph of No. 2 fuel).
B. The burner shall be forced draft type with full firing rate modulation.
All combustion air shall be furnished by the burner fan, which shall
be an integral part of the burner. Each burner motor shall not be
larger than ______ hp, ____ phase.
C. Option (specify 1, 2, or 3)
1. The gas burner shall burn the specified quantity of fuel without
objectionable vibration, noise, or pulsation, with not more than
15% excess air and less than 100 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 __ ppm
(corrected to 3% O2) NOx emissions.
2. The light oil burner shall burn the specified quantity of fuel
without objectionable vibration, noise, or pulsation, with not
more than 15% excess air and a maximum of No. 1 smoke
spot, as measured on the Bacharach Scale.
B1-23
Section B1
3.
D.
E.
F.
G.
H.
2.5
The gas-oil burner shall burn the specified quantity of fuel

more than 15% excess air and less than 100 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 __ ppm (corrected to
3% O2) NOx emissions.
Primary-secondary air control shall be a design function of the
combustion head. Combustion heads requiring an internal
adjustment shall not be acceptable.
The burner shall be equipped with an aluminum reverse curve fan
for lower fan motor hp requirements and self-cleaning
characteristics.
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.
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.
The burner shall be factory fire-tested to ensure proper operation
before shipment.
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.
B1-24
2.6
OIL BURNER
A. The oil burner shall be of the mechanical pressure atomizing type.
B. A two-stage oil pump shall be provided for each burner as an
integral part of the burner.
C. Two approved automatically operated safety shutoff valve(s) shall be
provided in the oil supply line to the burner valves to be piped in
series but wired parallel.
D. Supply an oil pressure gauge to indicate the discharge oil pump
pressure.
E. Install a manual valve, fuel oil filter, or strainer and vacuum gauge
on the suction side of the oil pump (optional).
F.
Install a fusible-link-actuated oil safety shutoff valve in the oil supply
line between the oil tank and the manual gate valve at the oil pump
(optional).
G. Oil pressure monitoring shall be provided by an approved pressure
switch interlocked to accomplish a non-recycling safety shutdown in
the event of low oil pressure (optional).
2.7
GAS VALVE TRAIN FOR EACH BURNER

A. Provide a pressure gauge to indicate the gas burner manifold
pressure (optional).
Section B1

B.
C.
Furnish and install one manually operated, ________ inch, ball valve
upstream of all valves.
Provide one _______ inch, main gas pressure regulator (of tight
shutoff type) with vent to outside atmosphere, in accordance with
local codes.
Specify a tight shutoff type gas pressure regulator when the inlet gas pressure exceeds 1-1/2 psig.
D.
E.
F.
G.
H.
2.8
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.
Provide a second _______ inch, automatically operated gas safety
shutoff valve to operate simultaneously with the above gas valve.
A manually operated gas valve shall be located downstream of both
automatic gas valves to permit leakage testing of the valves.
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).
BURNER CONTROLS
A. The full modulation of the burner shall be controlled by steam
pressure by means of a pressure control.
B. An additional high limit safety pressure control of the manual reset
type shall be provided to control the burner.
C. Pre-purge and post-purge operation of the burner fan shall be
provided per current UL/cUL requirements.
D. The burner shall utilize a CB12E type flame safeguard programmer
incorporating LED indicator lights to annunciate the current
operating status of the burner.
E. A manual restart of the burner shall be necessary in the event of
shutdown due to flame failure.
F.
All three-phase motors shall be controlled and protected by an
automatic starter with thermal overload protection. The starter shall
be inter-locked to prevent burner operation when over-load relays are
tripped out.
G. Supply a burner-mounted diaphragm air flow switch to prevent the
energization of the main fuel valves in the event of insufficient
combustion air, or to provide safety shutdown in the event of
combustion air interruption.
H. A factory-wired control cabinet shall be supplied and mounted on
the burner. The control cabinet shall house the flame safeguard
control, programming timer, burner motor starter, fuses, control
circuit transformer, control switches, indicating lamps and relays as
required.
I.
Provide four individual lights with nameplates on the control cabinet
to indicate call for heat, main fuel valve on, low water, and
main flame failure.
B1-25
Section B1
J.
Option (specify A or B)
1. The changing from one fuel to the other shall be manual by
means of a fuel selector switch. No burner adjustments shall be
required to switch from one fuel to the other.
2. Changing from one fuel to the other shall be automatically
controlled by the outdoor temperature switch, or other external
device. No burner adjustment shall be required to switch from
one fuel to the other.
The burner shall be equipped with suitable fuel and air controls to
assure smooth main flame ignition. The burner shall utilize a
proportional air flow damper design, including independent low-fire
and high-fire air flow shutter assemblies for ease of adjustment and
consistent excess air performance throughout the firing range.
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.
Pre-ignition pure air flow rate shall not be less than 60% maximum
firing rate air flow. Interlocks shall be provided to monitor and prove
60% air flow purge when air inlet louvers are automatically opened
to obtain this rate.
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.
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.
K.
L.
M.
N.
O.
PART 3 EXECUTION
3.1
WARRANTY
All equipment is to be guaranteed against defects in material and/or workmanship
for a period of 12 months from the date of start-up or 18 months from the date of
shipment, which ever comes first. In addition the boiler pressure vessel shall be
warranted against damage resulting from thermal stress for a period of 20 years
from date of shipment provided the boiler is operated and maintained in accordance
with the conditions specified in the owners Operator and Maintenance Manual.
Refer to the FLX Boiler warranty.
3.2
FIELD ERECTABLE
The specified boiler/burner package shall be shipped disassembled for field
assembly. All pieces and components must fit through a standard doorway.
Assembly shall be accomplished with ordinary hand tools, with no welding or rolling
required. Major casing components are to be shipped with insulation and refractory
installed for ease of assembly.
B1-26
Section B1
Model FLX Boilers
(FLX Hot Water Boiler Specifications)
Boiler Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pilot Gas Train for Each Burner (Mounted, Piped, and Wired)
Oil Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Valve Train for Each Burner . . . . . . . . . . . . . . . . . . . . .
Burner Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Field Erectable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . B1-28
. . . . . . . . . . . . . . . . . . . . . . . . B1-28
. . . . . . . . . . . . . . . . . . . . . . . . B1-28
. . . . . . . . . . . . . . . . . . . . . . . . B1-29
. . . . . . . . . . . . . . . . . . . . . . . . B1-30
. . . . . . . . . . . . . . . . . . . . . . . . B1-30
. . . . . . . . . . . . . . . . . . . . . . . . B1-30
. . . . . . . . . . . . . . . . . . . . . . . . B1-31
. . . . . . . . . . . . . . . . . . . . . . . . B1-32
. . . . . . . . . . . . . . . . . . . . . . . . B1-32
packages.
B1-27
FLX Hot Water Boiler Speecifications
Section B1
PART 1 GENERAL
1.1
BOILER CAPACITY
A. The hot water boiler shall be Cleaver-Brooks Model FLX (FLE for
field erected), designed for 160 psig (hot water). Maximum water
temperature shall be _______ F, and maximum system temperature
drop shall be _______ F.
B. The boiler shall have a maximum output of ____________ Btu/hr
when fired with No. 2 oil, and/or ________________ Btu/cu- ft when
fired with natural gas. Available electrical power will be _____ Volt,
_____ phase, ____ Hz.
PART 2 PRODUCTS
2.1

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

A. The following items will be installed on the boiler.
1. Low Water Cut-Off: A probe-type, low water cut-off control
shall be mounted in the upper drum. It is to be wired to the
burner control circuit to prevent burner operation if the boiler
water falls below a safe level.
2. Miscellaneous: A combustion temperature and pressure gauge
shall be mounted on the boiler. Temperature controls, for
regulation of burner operation, shall be mounted on the boiler
and the temperature sensing element shall be located adjacent
to the boiler outlet. Water relief valves (shipped loose) shall be
of a type and size to comply with ASME Code requirements.
B1-28
Section B1
FLX Hot Water Boiler Specifications

2.3
BURNER AND CONTROLS

A. The boiler shall be provided with a UL/cUL approved fuel burning
system in full accordance with the requirements of state, provincial
and local codes, the local gas utility, and other applicable regulatory
bodies. The burner shall be a Cleaver-Brooks ProFire burner or
approved equal.
B. Option (specify 1.) or 2.), as required)
1. The complete fuel burning system shall be in full accordance
with Factory Mutual (FM) requirements.
2. The complete fuel burning system shall be in full accordance
with Industrial Risk Insurers (IRI) requirements.
C. Burner Description
1. Option (specify a, b, or c)
a. The boiler shall include a gas burner having rated capacity
to burn ________ MMBtu/hr of ______ Btu/cu-ft of
__________ gas at a pressure of _______ (lbs/sq-in.)
(inches of water column) at the inlet of the burner gas
control train.
b. The boiler shall include an oil burner having rated
capacity to burn ______ gph of No. 2 fuel oil.
c. The boiler shall include a combination gas-oil burner
having rated capacity to burn _______ MMBtu/hr of Btu/
cu-ft ______ gas at a pressure of _________ (lbs/sq-in.)
(inches of water column) at the inlet to the burner gas
control train or _______ gph of No. 2 fuel.
2. The burner shall be forced draft type with full firing rate
modulation. All combustion air shall be furnished by the burner
fan, which shall be an integral part of the burner. Each burner
motor shall not be larger than ______ hp, ____ phase.
D. Option (specify 1.), 2.), or 3.))
1. The gas burner shall burn the specified quantity of fuel without
objectionable vibration, noise, or pulsation, with not more than
15% excess air and less than 100 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 __ ppm
(corrected to 3% O2) NOx emissions.
2. B. The light oil burner shall burn the specified quantity of fuel
more than 15% excess air and a maximum of No. 1 smoke
spot, as measured on the Bacharach Scale.
3. C. The gas-oil burner shall burn the specified quantity of fuel
more than 15% excess air and less than 100 ppm (corrected to
3% O2) CO in the products of combustion on gas firing, and a
maximum of No. 1 smoke spot, as measured on the Bacharach
Scale when burning oil. In addition, when firing gas, the burner
shall be guaranteed to produce less than __ ppm (corrected to
3% O2) NOx emissions.
B1-29

E.
F.
G.
H.
I.
Section B1
Primary-secondary air control shall be a design function of the

combustion head. Combustion heads requiring an internal
adjustment shall not be acceptable.
The burner shall be equipped with an aluminium reverse curve fan
for lower fan motor hp requirements and self-cleaning
characteristics.
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.
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.
The burner shall be factory fire-tested to ensure proper operation
before shipment.
2.4
PILOT GAS TRAIN FOR EACH BURNER (MOUNTED, PIPED, AND

WIRED)
A separate pilot gas cock, gas pressure regulator, and pilot safety shutoff gas valve,
shall be provided for the ignition gas supply.
2.5
OIL BURNER
A. The oil burner shall be of the mechanical pressure atomizing type.
B. A two-stage oil pump shall be provided for each burner as an
integral part of the burner.
C. Two approved automatically operated safety shutoff valve(s) shall be
provided in the oil supply line to the burner valves to be piped in
series but wired parallel.
D. Supply an oil pressure gauge to indicate the discharge oil pump
pressure.
E. Install a manual valve, fuel oil filter, or strainer and vacuum gauge
on the suction side of the oil pump (optional).
F.
Install a fusible-link-actuated oil safety shutoff valve in the oil supply
line between the oil tank and the manual gate valve at the oil pump
(optional).
G. Oil pressure monitoring shall be provided by an approved pressure
switch interlocked to accomplish a non-recycling safety shutdown in
the event of low oil pressure (optional).
2.6
GAS VALVE TRAIN FOR EACH BURNER

A. Provide a pressure gauge to indicate the gas burner manifold
pressure (optional).
B. Furnish and install one manually operated, ________ inch, ball valve
upstream of all valves.
C. Provide one _______ inch, main gas pressure regulator (of tight
shutoff type) with vent to outside atmosphere, in accordance with
local codes.
Notice
Specify a tight shutoff type gas pressure regulator when the inlet gas pressure
exceeds 1-1/2 psig.
B1-30
Section B1
FLX Hot Water Boiler Specifications

D.
E.
F.
G.
2.7
Provide one ________ inch, automatically operated motorized safety

gas valve. One safety shutoff valve shall be proven closed during preignition by proof of valve closure interlock switch on valve.
Provide a second _______ inch, automatically operated gas safety
shutoff valve to operate simultaneously with the above gas valve.
A manually operated gas valve shall be located downstream of both
automatic gas valves to permit leakage testing of the valves.
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).
BURNER CONTROLS
A. The full modulation of the burner shall be controlled by water
temperature by means of a temperature control.
B. An additional high limit safety temperature control of the manual
reset type shall be provided to control the burner.
C. Pre- and post- operation of the burner fan shall be provided per
current UL/cUL requirements.
D. The burner shall utilize a Fireye CB120E type flame safeguard
programmer, incorporating LED indicator lights to annunciate the
current operating status of the burner.
E. A manual restart of the burner shall be necessary in the event of
shutdown due to flame failure.
F.
All three-phase motors shall be controlled and protected by an
automatic starter with thermal overload protection. The starter shall
be inter-locked to prevent burner operation when over-load relays are
tripped out.
G. Supply a burner-mounted diaphragm air flow switch to prevent
energizing the main fuel valves in the event of insufficient
combustion air, or to provide safety shutdown in the event of
combustion air interruption.
H. A factory-wired control cabinet shall be supplied and mounted on
the burner. The control cabinet shall house the flame safeguard
control, programming timer, burner motor starter, fuses, control
circuit transformer, control switches, indicating lamps, and relays as
required.
I.
Provide four individual lights with nameplates on the control cabinet
to indicate call for heat, main fuel valve on, low water, and
main flame failure.
J. Option (specify 1.) or2.))
1. The changing from one fuel to the other shall be manual by
means of a fuel selector switch. No burner adjustments shall be
required to switch from one fuel to the other.
2. Changing from one fuel to the other shall be automatically
controlled by an outdoor temperature switch, or other external
device. No burner adjustment shall be required to switch from
one fuel to the other.
B1-31

K.
L.
M.
N.
O.
PART 3 EXECUTION
Section B1
The burner shall be equipped with suitable fuel and air controls to
assure smooth main flame ignition. The burner shall utilize a
proportional air flow damper design, including independent low-fire
and high-fire air flow shutter assemblies for ease of adjustment and
consistent excess air performance throughout the firing range.
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.
Pre-ignition pure air flow rate shall not be less than 60% maximum
firing rate air flow. Interlocks shall be provided to monitor and prove
60% air flow purge when air inlet louvers are automatically opened
to obtain this rate.
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.
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.
3.1
WARRANTY
All equipment is to be guaranteed against defects in material and/or workmanship
for a period of 12 months from the date of start-up or 18 months from the date of
shipment, which ever comes first. The boiler pressure vessel shall be warranted
against damage resulting from thermal stress for a period of 20 years from date of
shipment, provided the boiler is operated and maintained in accordance with the
conditions specified in the owners Operating and Maintenance Manual.
3.2
FIELD ERECTABLE
The specified boiler/burner package shall be shipped disassembled for field
assembly. All pieces and components must fit through a standard doorway.
Assembly shall be accomplished with ordinary hand tools, with no welding or rolling
required. Major casing components are to be shipped with insulation and refractory
installed for ease of assembly.
B1-32
Section B2
Model 4 Boilers
CONTENTS

Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insurance/Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Feedwater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B2-3
B2-4
B2-4
B2-7
B2-7
B2-8
B2-15
B2-15
B2-16
B2-16
B2-16
B2-17
B2-17
B2-20
B2-20
B2-27
B2-1
03-08
Section B2
Figure
Figure
Figure
Figure
Model 4 Boilers
ILLUSTRATIONS
B2-1. Model 4 Dimension Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-9
B2-2. Model 4 Standard Pilot and Main Gas Trains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-2
B2-3. Boiler room air supply - Engineered Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-19
B2-4. Typical gas header piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-26
TABLES
Table B2-1. Model 4 Boiler Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5

Table B2-2. Model 4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-10
Table B2-3. Model 4 Steam Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-11
Table B2-4. Recommended Steam Nozzle Size (to maintain 4000 to 5000 fpm nozzle velocity) . . . B2-11
Table B2-5. Min. req. NATURAL GAS pressure STANDARD UL, FM, & XL GAP gas trains . . . . . . . B2-13
Table B2-6. Min. req. NATURAL GAS pressure OVERSIZED UL, FM, & XL GAP gas trains . . . . . . . B2-13
Table B2-7. Min. req. PROPANE GAS pressure STANDARD UL, FM, & XL GAP gas trains . . . . . . . B2-14
Table B2-8. Min. req. PROPANE GAS pressure OVERSIZED UL, FM, & XL GAP gas trains . . . . . . . B2-14
Table B2-9. Safety valve outlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-15
Table B2-10. Predicted efficiency, 10 psig operating (includes radiation and convection losses) . . . B2-15
Table B2-11. Model 4 emission data - Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16
Table B2-12. Model 4 emission data - No. 2 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16
Table B2-13. Feedwater makeup rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-17
Table B2-14. Water quality parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-17
Table B2-15. Model 4 fuel, combustion air, and flue gas flow rates . . . . . . . . . . . . . . . . . . . . . . . B2-19
Table B2-16. Gas line capacity - Schedule 40 metallic pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-22
This section contains information on the Model 4 Commercial Watertube Boiler product line for low and high
pressure steam applications. Sizes range from 1.5 to 6 MMBtu/hr. The Model 4 Boiler is an excellent choice
where high outputs are needed but space limitations exist. The model number designation is 1500 through
6000, representing MBtu/hr input (1,500,000 to 6,000,000 Btu/hr).
Fuel series designation is as follows:
Series 100: No. 2 oil firing.
Series 700: Natural gas firing.
Series 200: No. 2 oil/natural gas firing.
Design pressure designation is stated as 15 psig, 150 psig, and 250 psig for steam. For example, an M4P700-2500-150ST boiler designates a gas-fired, 2,500,000 Btu/hr, 150 psig, steam boiler.
B2-2
04-02
Model 4 Boilers
Section B2

The following features and benefits apply to the Model 4 Boiler product line.
33" Cased Width:
Boiler fits through most standard doorways.
Reduced installation costs.
Direct Driven, Vibration-Free Centrifugal Impeller:
Quiet operation.
Sound levels below 79 dBA.
Ideal for noise critical areas such as hospitals, churches, etc.
Minimum Refractory:
Membrane waterwalls reduce the need for refractory by 95%.
Reduced maintenance costs and refractory repair requirements.
Membrane Waterwalls:
Enhanced heat transfer area in compact design.
Full water wall furnace improves heat transfer for high efficiency.
Small Boiler Footprint:
Savings of up to 50% in floor space.
Weighs up to 40% less than Comparable Boilers:
Lower freight and rigging costs.
Reduced structural requirements.
Standard Built-in Soot Washers:
Boiler fireside cleaning without shutdown.
Maintains peak boiler performance.
Packaged Forced Draft Burner:
High pressure drop design.
Improved combustion efficiency.
Burner/Windbox Davit:
Easy access to furnace with swing-open windbox.
Reduced maintenance costs.
Steam Design Pressures to 500 psig (optional):
High performance in a compact design.
Proven vessel design for high design pressure applications.
B2-3
03-08
Section B2
Model 4 Boilers
PRODUCT OFFERING
The Model 4 (M4) Boiler is a compact carbon steel, extended fin, watertube boiler.
Heat transfer design is configured in a "3-pass" gas travel across the watertube
surfaces. The pressure vessel is constructed to conform to the A.S.M.E. Code, either
Section IV for low pressure steam @ 15 PSIG MAWP (maximum allowable working
pressure) or Section I for MAWP greater than 15 PSIG.
The vessel (boiler) consists of two rows on each side of the vessel, of formed
seamless tubes with extended fin surfaces and downcomers connected to the steam
drum and lower drum. To reduce standby losses, the vessel is insulated with a
fiberglass blanket and removable steel jacket.
Complete with an integral burner for either No.2 fuel oil or Natural Gas, the
complete burner/boiler package is UL Approved, listed, and labeled.
Standard Equipment
The standard boiler/burner package is described below. Optional controls, trim, and
devices may be added to meet project requirements. Some of those options are
noted following this standards list.
1. Boiler
A. Designed, constructed, and hydrostatically tested in accordance with the
A.S.M.E. Boiler and Pressure Vessel Code. The complete vessel is mounted on a
structural steel frame.
B. Steam drum includes a hand hole in the rear head for drum water side
inspection. Connections are included for the following:
Feedwater Makeup w/internal dispersion tube.
Surface Blowoff.
Steam Supply.
Safety Relief Valve.
C. Lower Drum includes hand holes at each end for waterside inspection. A drain/
blowoff tapping is provided at the front, bottom centerline.
D. Soot washer lances are provided on each side of the vessel between the two
rows of tubes for fireside cleaning. Soot washer drains are located at the bottom of
the boiler, with connections to drain located on each side of the lower drum at the
rear.
E. Refractory is limited to the furnace floor, lower drum, and burner throat tile.
High temperature insulation is installed on the front water wall and furnace access
door.
F. Two lifting eyes are provided on the top centerline of the upper drum for ease of
installation.
G. Furnace inspection/access door is provided in the furnace front wall.
H. The exhaust gas vent is located at the top rear centerline of the boiler. A stack
thermometer is shipped loose for field installation by the installing contractor into
the stack.
I. The complete vessel is fully insulated (2" fiberglass blanket) under a preformed,
sectional steel jacket.
J. Factory painted using hard-finish enamel.
B2-4
03-08
Model 4 Boilers
Section B2
Table B2-1. Model 4 Boiler Sizes
MODEL
NO.
INPUT
MBH
HEAT
OUTPUT
MBH
EQUIV
HP
1500
1500
1200
35
1237
3100
2000
2000
1600
47
1649
3100
2500
2500
2000
59
2062
3700
3000
3000
2400
71
2474
3700
3500
3500
2800
83
2887
4100
4000
4000
3200
95
3299
4100
4500
4500
3600
107
3711
4700
5000
5000
4000
119
4124
4700
6000
6000
4800
143
4949
5400
STEAM SHIPPING
OUTPUT WEIGHT
LB/HR
LBS
NOTE: Steam output from and at 212 F.
2. Forced Draft Burner

A. The burner is a high radiant multi-port type approved for operation on natural gas
and a pressure atomizing type approved for operation with commercial grade No. 2
fuel oil.
B. Consisting of the fan which is direct connected to the fan motor, wind box, air
damper that is linkage connected to a damper drive motor, the complete assembly is
factory mounted and tested.
C. To ensure proper air for pre purge and combustion is provided by the fan, a
combustion air proving switch is provided.
D. The complete burner/wind box swings open via a davit arm attached to the upper
drum. This permits fireside inspection of the furnace and burner internals.
E. Responding to steam demand from the drum mounted pressure control, the burner
operates in the low-high-low-off firing mode. Ultra-violet (UV) flame scanner is
provided for flame presence during firing.
F. An Ignition transformer is provided.
G. Ignition is direct spark on straight oil fired burners, and gas pilot on straight gas or
combination gas/oil burners.
H. Oil Train consists of the following:
4 Solenoid Shutoff Valves providing low fire, intermediate transitional firing from low
to high and high fire.
An oil pump is mounted (belt driven from the fan motor) for pressure atomization of
the fuel oil.
Oil Pressure Gauge.
Suction and return tubing connected to an oil connection block.
Gas Train consists of the following:
Primary gas shutoff valve with integral proof of closure switch.
A manual shutoff valve located ahead of the primary gas valve.
B2--5
04-02
Section B2
Model 4 Boilers
A plugged leakage test connection and a second manual shutoff valve for tightness
checking of the primary shutoff valve.
Separate Gas Pressure Regulators for the pilot train and main gas train.
Low Gas Pressure and High Gas Pressure Switches for units at 3000 and greater.
A second motorized gas valve is provided in addition to the primary valve on size
6000 units.
The pilot gas train includes a manual shutoff valve and solenoid shutoff valve.
3. Boiler Trim and Controls

A. 15 psig or 150 psig set A.S.M.E. safety relief valves.
B. Steam pressure gauge with inspectors test cock and connection.
C. Primary Water Column complete with gauge glass and column drain valve.
D. Low Water cutoff switch and pump control switch, integrally mounted in the
primary water column.
E. Auxiliary Low Water Cutoff, manual reset type.
F. Steam Pressure Controls:
Operating Limit.
Excess Steam Pressure (High Limit), manual reset.
Burner firing rate, low high low.
4. Burner Control Panel and Controls

A. The control panel is enclosed within a NEMA 1A Rated enclosure, mounted on
the burner wind box at approximately eye level height.
B. Mounted within or on the control panel box are the following controls. Panel
wiring is factory tested.
Combustion Flame Safeguard Control, Model CB120 that provides pre purge, post
purge, trial for ignition, main flame/burner operation, and safety shutdown.
Fan Motor Starter wired into the non recycling circuit of the flame safeguard
control.
Indicating Lights for low water, flame failure, load demand, and fuel valve on.
Burner On/Off Switch.
Damper Positioning Switch.
Fuel Selector Switch for combination fuel fired burners.
Control Circuit Step-down Transformer with primary fuse protection.
Terminals for interface wiring connection of controls.
Oil, heat, and moisture resistant wire used. Each wire is number coded relative to
the wiring diagram.
5. Electric Service Panel

An electric service panel (entrance box) is provided on the side of the boiler for all
external wiring connections to remote control devices and the main power for the
boiler. Wiring to this panel eliminates the need to disconnect wiring when the front
burner wind box is opened for burner or boiler servicing.
B2-6
03-08
Model 4 Boilers
Optional Equipment
Section B2
For more detailed information on optional equipment, contact your local CleaverBrooks authorized representative. In summary, options include the following:
1. Boiler
Larger pressure gauges or specific manufacturer type.

Bottom Drain Valves for low pressure applications.
Bottom Blowoff Valves for high pressure applications.
Surface Blowoff Valve with internal collector pipe.
Feedwater Stop and Check Valves.
Steam Stop Valve.
ASME Hydro Test of Valves and Valve Piping.
Design pressures above 150 PSIG.
Full Modulation Firing on Gas.

Lead/Lag Control.
Day-Night Controls.
Low Fire Hold Control.
Elapsed Time Meter.
Alarm with silence switch.
Additional Indicator Lights.
Main Power Disconnect.
Remote Oil Pump.
Optional NEMA Enclosures.
Special Fan Motor requirements (TEFC).
3. Fuel Options
Insurance/Codes
Automatic Fuel Changeover (combination burner).

Propane Fuel Firing.
Special Gas Pressure Regulators.
Dual Pilots (gas and oil).
Gas strainer.
The boiler package can be equipped to meet various insurance or code

requirements. Some of these insurance/code requirements are:
Factory Mutual (FM)

XL GAP (Formerly GE GAP/IRI).
A.S.M.E. CSD-1.
A. Factory Mutual (FM Global) - Recommended guidelines as described by FM

pertain to boilers rated at greater than 2.5 MMBtu/hr input on gas and 2.8 MMBtu/
hr input on oil. Boilers that are labeled and tested in accordance with an
independent testing lab such as UL or CSA and are below these inputs are exempt
from these recommendations.
The Model 4 boiler is UL listed and labeled. In addition to the standard UL
requirements the following are needed to comply with FM when required.
Alarm Bell with silence switch for low water and safety shutdowns.
Low Oil Pressure Switch if the oil pump is not direct driven from the fan motor.
B. XL GAP (Formerly GE GAP/IRI) Recommended guidelines as described by XL

GAP pertain to boilers rated at 400,000 Btu/hr input to 12.0 MMBtu/hr input. For
these boilers, the requirements are the same as for A.S.M.E CSD-1 requirements.
Above 12.0 MMBtu/hr input, the requirements defer to the NFPA 85 standards for
single burner boilers.
B2-7
03-08
Section B2
Model 4 Boilers
C. A.S.M.E. CSD-1 - Recommended guidelines as described by this Code pertain to

boilers rated at 400,000 Btu/hr input to 12.0 MMBtu/hr input. Above 12.0
MMBtu/hr input, the requirements defer to the NFPA 85 standards for single burner
boilers. For the sizes this Code covers, the requirements are as follows, in addition
to the standard UL package:
Low Oil Pressure Switch for oil firing

" Pressure Control Piping
If gas supply is > 5 psig, a relief valve is required after the gas pressure regulator in
the main and pilot gas trains.
Lever Handled shutoff cock for the pilot gas train.
Non-fused disconnect to remove boiler from all sources of power.

For layout purposes, the nominal dimensions and connections for the Model 4
Standard Package Boiler are shown in Figure B2-1 and Table B2-2. Ratings of each
boiler size are noted in Table B2-3. Additional information is shown in the following
figures, tables, and illustrations.
Table B2-4: Recommended steam nozzle sizes for high pressure boilers operating at
lower and higher pressures.
Figure B2-2: Standard gas train dimensions and components.
Table B2-5: Natural Gas Pressure Requirements, standard gas train size.
Table B2-6: Natural Gas Pressure Requirements, oversized gas train.
Table B2-7: Propane Gas Pressure Requirements, standard gas train size.
Table B2-8: Propane Gas Pressure Requirements, oversized gas train.
Table B2-9: Safety Valve Outlet Sizes.
B2-8
03-08
Model 4 Boilers
Section B2
Figure B2-1. Model 4 Dimension Drawing
B2-9
03-08
Section B2
Model 4 Boilers
Table B2-2. Model 4 Dimensions
Note 1
1500
2000
2500
3000
Boiler Size
3500
4000
4500
5000
6000
All Dimensions are in inches
Lengths
A
Overall
84.25
84.25
100.25
100.25
117.375
117.375
136.75
136.75
152.375
Pressure Vessel w/casing
61
61
77
77
92.375
92.375
109
109
124.625
Base Frame
54
54
69.625
69.625
85.25
85.25
101
101
116.5
C1
Base to Burner/Windbox
9.625
9.625
9.625
9.625
9.625
9.625
10
10
10
C2
Base Frame Anchor Holes
51.5
51.5
67.125
67.125
82.75
82.75
98.375
98.375
114
30.375
CC
D
DD
HH
Rear Casing to Stack Connection
25.8
25.8
26.25
26.25
26.25
26.25
30.375
30.375
Burner/W indbox Extension
20.1
20.1
20.1
20.1
21.9
21.9
24.6
24.6
24.6
Front Casing to Steam Nozzle
17.25
17.25
25.25
25.25
30.75
30.75
37.375
37.375
45.25
Steam Nozzle to Safety Valve 15#
12
12
11.5
11.5
13
13
17
12
12
17
17
17
17
17
Widths
E
Overall
53.25
53.25
53.25
53.25
53.25
53.25
53.25
53.25
53.25
32.4
32.4
32.4
32.4
32.4
32.4
32.4
32.4
32.4
Center to Opt. Aux. Water Colum n
26.6
26.6
26.5
26.6
26.6
26.6
26.6
26.6
26.6
Center to Outside Casing
16.375
16.375
17.375
16.375
16.375
16.375
16.375
16.375
16.375
Base Frame Inside
20
20
20
20
20
20
20
20
20
Base Frame Outside
28
28
28
28
28
28
28
28
28
Soot Washers, Center to Center
21.4
21.4
21.4
21.4
21.4
21.4
21.4
21.4
21.4
Boiler Centerline to Soot Washer
10.7
10.7
10.7
10.7
10.7
10.7
10.7
10.7
10.7
Boiler Centerline to Base Centerline
12
12
12
12
12
12
12
12
12
Boiler Centerline to Soot Drain
5.25
5.25
5.25
5.25
5.25
5.25
5.25
5.25
5.25
Overall [Base to Stack Connection]
78.75
78.75
78.75
78.75
78.75
78.75
78.75
78.75
78.75
Base to Steam Nozzle 150#
74.75
75.75
74.75
74.75
74.75
74.75
78
78
78
75
75
75
75
78.25
78.25
78.25
78.25
78.25
O1
Base to Stack Box.
77.8
77.8
77.8
77.8
77.8
77.8
77.8
77.8
77.8
O2
Base to Top of Control Panel
83.25
83.25
83.25
83.25
83.25
83.25
83.25
83.25
83.25
Heights
OO
Base to Surface Blowoff
59.25
59.25
59.25
59.25
59.25
59.25
59.25
59.25
59.25
Base to Feedwater Inlet
57.25
57.25
57.25
57.25
57.25
57.25
57.25
57.25
57.25
Base to Soot Washer Lance
55.5
55.5
55.5
55.5
55.5
55.5
55.5
55.5
55.5
Height of Base
OS
Base to Oil Supply Connection
27.75
27.75
27.75
27.75
27.75
27.75
27.75
27.75
27.75
OR
Base to Oil Return Connection
25.75
25.75
25.75
25.75
25.75
25.75
25.75
25.75
25.75
BB.
OD Stack - Sleeve Connection
Connections
12
12
12
12
12
12
16
16
16
Bottom Drum Blow Down, 15# [one]
1.25
1.25
1.25
1.25
1.5
1.5
1.5
1.5
1.5
T1
1.25
1.25
1.25
1.25
1.25
1.25
1.25
1.25
1.25
Steam Nozzle, 15#
Steam Nozzle, 150#
2.5A
2
3A
2
3A
2
3A
2
3A
2
4B
2
4B
2
4B
2
0.75
Soot Washer Drains [Two]
2.5A
2
Surface Blow off [One]
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
Feedwater Inlet [One]
Soot Washer [Two]
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
Oil Supply and Return
0.5
GG
JJ
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
Relief Valve, 15#
2.5
2.5
2.5
Relief Valve, 150#
1.25
1.25
1.25
1.5
1.5
1.5
1.5
Clearances
EE
Burner/W indbox 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 Burner/Windbox Swing

and 30" Rear Aisle Space.
124
124
140
140
155
155
172
172
187
RD
Allowance for Tube Removal Each

Side and Burner/Windbox Swing.
93
93
93
93
93
93
93
93
93
NOTES:
1. The above dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction via certified
prints. For 200 PSIG design pressure and greater, contact Milwaukee Sales for certified prints.
2. Allow sufficient space at rear of boiler for removal of soot washer lance.
3. For access to the furnace, a 13" x 21" access door is provided behind the front door.
4. Control Panel may be larger (up to 4" in height) if certain control options are provided.
A. Connection is a Female Pipe Thread.
B. Connection is a 150# Flange, Flat Face.
B2-10
03-08
Model 4 Boilers
Section B2
Table B2-3. Model 4 Steam Ratings
1500
2000
2500
3000
3500
4000
4500
5000
6000
Rated Capacity - Steam (lbs. steam/hr

o
from & at 212 F.)
1,237
1,649
2,062
2,474
2,887
3,299
3,711
4,124
4,949
Rated Steam Capacity [kg/hr from and at

100 C]
461.7
615.5
769.6
923.4
1,077.5
1,231.3
1,385.0
1,539.2
1,847.2
Output Btu/hr [1,000 Btu/h]
Boiler SIZE
Ratings [Note A]
1,200
1,600
2,000
2,400
2,800
3,200
3,600
4,000
4,800
Output Kcal/Hr [1,000 Kcal/h]
302
403
504
605
706
806
907
1,007
1,210
Output KW
348
464
580
696
812
928
1,044
1,160
1,392
6,052
Approximate Fuel Consumption At Rated Capacity [ Input - Note B]

Natural Gas [ft3 /hr] - 15# Steam
1,511
1,538
2,500
3,038
3,487
4,025
4,494
5,050
1,572
2,133
2,597
3,117
3,590
4,155
4,657
5,194
6,233
Natural Gas [m /hr] - 15# Steam
42.8
43.5
70.8
86
98.7
114.0
127.0
143.0
171.4
Natural Gas [m3 /hr] - 150# Steam
Natural Gas [ft /hr] - 150# Steam

3
44.5
60.4
73.5
88.3
101.6
117.6
131.8
147.0
176.5
Propane Gas [ft /hr] - 15# Steam
604
615
1,000
1,215
1,395
1,610
1,798
2,020
2,421
629
853
1,039
1,247
1,436
1,662
1,863
2,078
2,493
Propane Gas [m3 /hr] - 15# Steam
17
17.4
28.3
34.4
39.5
45.6
51
57.2
68.5
Propane Gas [m3 /hr] - 150# Steam
17.8
24.1
29.4
35.3
40.7
47
52.7
58.8
70.6
No.2 Oil Fuel - 15# Steam, gph
10
14
17
21
24
28
31
35
42
11
15
18
22
25
28.9
32
36
43
No.2 Oil Fuel - 15# Steam, liters/hour
38
53
64
79
91
106
117
132
159
No.2 Oil Fuel - 150# Steam, liters/hour
41
56
68
82
95
109
121
136
163
3/4
1-1/2
1-1/2
1-1/2
Power Requirements - 3 Phase 60 Hz Standard [Note C]

Blower Motor HP - Gas Firing
Blower Motor HP - Oil or Combination
Belt Driven from the Blower Motor
Oil Pump for Oil or Combination

Minimum Ampacity
Blower Motor - Gas Firing Only, 230V
1.53
3.3
4.7
15
Blower Motor - Gas Firing Only, 460V
0.77
1.7
2.4
4.5
4.5
4.5
7.5
Blower Motor - Oil or Combination, 230V
4.7
4.7
15
15
Blower Motor - Oil or Combination, 460V
2.4
2.4
4.5
7.5
4.5
4.5
7.5
Control Circuit
1.7
1.7
1.7
1.9
1.9
1.9
2.4
2.4
2.4
Operating Weight, lbs.
3,758
3,758
4,566
4,566
5,175
5,175
5,991
5,991
6,900
Operating Weight, kg
1,399
1,399
1,704
1,704
1,932
1,932
2,236
2,236
2,575
Water Content Normal, gallons
79
79
104
104
130
130
156
156
181
Water Content Normal, liters
299
299
394
394
492
492
591
591
685
Water Content Flooded, gallons
109
109
145
145
177
177
213
213
245
Weights
Water Content Flooded, liters
413
413
549
549
670
670
806
806
927
3,100
3,100
3,700
3,700
4,100
4,100
4,700
4,700
5,400
Shipping Weight, approxim ate kg

1,157
1,157
1,381
1,381
1,530
1,530
1,754
1,754
Notes:
A. Ratings shown for elevation to 1000 Feet. For ratings above 1000 Feet, contact your local Cleaver-Brooks Representative.
3,
3,
B. Input calculated with Nat. Gas @ 1000 Btu/ft Propane @ 2500 Btu/ft and Oil @ 140,000Btu/gal.
C. For altitudes above 1000 Feet, contact your local Cleaver-Brooks authorized representative for verification of capacity rating.
2,015
Shipping Weight, approxim ate lbs.
Table B2-4. Recommended Steam Nozzle Size (to maintain 4000 to 5000 fpm nozzle velocity)
Operating
Pressure
(PSIG)
1500
2000
2500
3000
3500
4000
4500
5000
6000
15
20
30
40
2-1/2
50
2-1/2
65
2-1/2
2-1/2
75
2-1/2
2-1/2
95 - 125A
150
2-1/2
2-1/2
1-1/2
2-1/2
2-1/2
2-1/2
200
1-1/2
1-1/2
1-1/2
2-1/2
2-1/2
2-1/2
250 - 400
1-1/2
1-1/2
1-1/2
1-1/2
2-1/2
BOILER SIZE
A. Standard nozzle size for 150 PSIG MAWP Boiler Design

Example 1: Size 3500, 150# boiler to operate @ 30 PSIG requires 4" steam nozzle in lieu of
standard 3" nozzle.
standard 3" nozzle.
B2-11
03-08
Section B2
Model 4 Boilers
Figure B2-2. Model 4 Standard Pilot and Main Gas Trains
ITEM
Pilot
PART DESCRIPTION
SIZES
INCHES
Sizes 1500 TO 2500
Main
1
Butterfly Valve
Pilot Shutoff Cock
Pilot Gas Regulator
1/2
Pilot Solenoid Valve
1/2
Manual Shutoff Valve
1-1/2
Main Gas Regulator
1-1/2
Motorized Valve with P.O.C.
1-1/2
1/2
Size 3000
1-1/2
6
5
Butterfly Valve
Pilot Shutoff Cock
Pilot Gas Regulator
1/2
1/2
1-1/2
Main Gas Regulator
1-1/2
Butterfly Valve
Pilot Shutoff Cock
1/2
Pilot Gas Regulator
1/2
1/2
Main Gas Regulator
Butterfly Valve
Pilot Shutoff Cock
Pilot Gas Regulator
1/2
1/2
Main Gas Regulator
2-1/2
Motorized Valve (std)
10
1/2
1/4
1-1/2
1/4
Sizes 3500 to 5000
9
6
5
1-1/2
1/4
2
1/4
Size 6000
6
5
6
5
10
B2-12
03-08
2
1/2
1/4
1/4
Model 4 Boilers
Section B2
Table B2-5. Minimum required NATURAL GAS pressure at entrance to STANDARD UL, FM, & XL GAP gas
trains (upstream of gas pressure regulator)
BOILER
SIZE
INLET PIPE
SIZE
(inches)
HONEYWELL
VALVE SIZE
(inches)
MIN ("W.C.)
MAX ("W.C.)
1500
1.5
1.5
4.4
28.0
1500
2000
1.5
1.5
8.4
28.0
2000
2500
1.5
1.5
12.9
28.0
2500
3000
1.5
1.5
17.1
28.0
3000
3500
2.0
2.0
11.3
28.0
3500
4000
2.0
2.0
13.6
28.0
4500
2.0
2.0
12.2
28.0
4000
4500
5000
2.0
2.0
16.8
28.0
5000
PRESSURE REQUIRED
2.0
2.0
21.5
28.0
6000
Note: For altitude above 1000 feet, contact your local Cleaver-Brooks representative.
Natural Gas @ 1000 Btu/cu-ft, specific gravity @ 0.65
REQUIRED FUEL
FLOW (SCFH)
6000
Table B2-6. Minimum required NATURAL GAS pressure at entrance to OVERSIZED UL, FM, & XL GAP gas
PRESSURE REQUIRED
HONEYWELL
VALVE SIZE
(inches)
2.0
MIN ("W.C.)
MAX ("W.C.)
REQUIRED FUEL
FLOW (SCFH)
1500
INLET PIPE
SIZE
(inches)
2.0
2.3
28.0
1500
2000
2.0
2.0
4.8
28.0
2000
2.0
2.0
6.5
2.5
2.5
5.7
28.0
2500
2.0
2.0
9.0
2.5
2.5
6.8
28.0
3000
3.0
3.0
6.0
2.5
2.5
9.7
3.0
3.0
7.1
2.5
2.5
11.8
3.0
3.0
8.5
2.5
2.5
9.8
3.0
3.0
5.6
2.5
2.5
12.9
3.0
3.0
7.1
4.0
4.0
5.6
2.5
2.5
17.5
3.0
3.0
10.0
BOILER
SIZE
2500
3000
3500
4000
4500
5000
6000
3500
4000
4500
28.0
5000
28.0
6000
4.0
4.0
7.9
B2-13
03-08
Section B2
Model 4 Boilers
Table B2-7. Minimum required PROPANE GAS pressure at entrance to STANDARD UL, FM, & XL GAP gas
PRESSURE REQUIRED
HONEYWELL
VALVE SIZE
(inches)
1.5
MIN ("W.C.)
1500
INLET PIPE
SIZE
(inches)
1.5
2000
1.5
1.5
BOILER
SIZE
MAX ("W.C.)
REQUIRED FUEL
FLOW (SCFH)
6.7
28.0
600
10.5
28.0
800
2500
1.5
1.5
13.3
28.0
1000
3000
1.5
1.5
17.0
28.0
1200
3500
2.0
2.0
14.3
28.0
1400
4000
2.0
2.0
16.5
28.0
1600
4500
2.0
2.0
14.8
28.0
1800
5000
2.0
2.0
16.4
28.0
2000
2.0
2.0
19.6
28.0
6000
Propane @ 2500 Btu/cu-ft, specific gravity @ 1.6
2400
Table B2-8. Minimum required PROPANE GAS pressure at entrance to OVERSIZED UL, FM, & XL GAP gas
BOILER
SIZE
INLET PIPE
SIZE
(inches)
HONEYWELL
VALVE SIZE
(inches)
MIN ("W.C.)
MAX ("W.C.)
REQUIRED FUEL
FLOW (SCFH)
1500
2.0
2.0
5.9
28.0
600
2000
2.0
2.0
9.0
28.0
800
2.0
2.0
10.8
2.5
2.5
10.5
28.0
1000
2.0
2.0
13.8
2.5
2.5
12.9
28.0
1200
3.0
3.0
12.6
2.5
2.5
13.6
3.0
3.0
12.6
2.5
2.5
15.8
3.0
3.0
14.5
2.5
2.5
13.8
3.0
3.0
12.1
2.5
2.5
14.8
3.0
3.0
12.5
4.0
4.0
12.0
2.5
2.5
18.0
3.0
3.0
15.0
2500
3000
3500
4000
4500
5000
6000
PRESSURE REQUIRED
1400
1600
1800
28.0
2000
28.0
2400
4.0
4.0
14.1
B2-14
03-08
Model 4 Boilers
Section B2
Table B2-9. Safety valve outlet size
SAFETY VALVE SETTING
15 PSIG STEAM
150 PSIG STEAM
Boiler Size
VALVES
REQ'D
OUTLET SIZE
(IN.)**
VALVE
CAPACITY
VALVES
REQ'D
OUTLET SIZE
(IN.)**
1500
2000
2500
3000
3500
4000
4500
5000
6000
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2-1/2
2-1/2
2-1/2
3
3161 lbs/hr
3161 lbs/hr
3161 lbs/hr
3161 lbs/hr
3161 lbs/hr
4676 lbs/hr
4676 lbs/hr
4676 lbs/hr
6942 lbs/hr
1
1
1
1
1
1
1
1
1
1
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
1-1/2
2
VALVE
CAPACITY
1651
2585
2585
2585
4240
4240
4240
4240
6596
lbs/hr
lbs/hr
lbs/hr
lbs/hr
lbs/hr
lbs/hr
lbs/hr
lbs/hr
lbs/hr
** Fem ale Pipe Thread Connection [FPT]
PERFORMANCE DATA
Efficiency
Efficiency data provided in Table B2-10 is based on low pressure steam operation.
For high pressure steam operation contact your local Cleaver-Brooks authorized
representative for expected efficiency data.
Table B2-10. Predicted efficiency, 10 psig operating (includes radiation and convection losses)
Boiler Size
Gas Fuel
Firing Rate
Oil Fuel
Firing Rate
Low Fire
81.6
81.1
High Fire
81.9
80.0
Low Fire
84.1
83.6
High Fire
84.4
82.5
81.6
81.3
81.6
81.5
80.3
81.5
84.1
83.8
84.1
84.0
82.8
84.0
4000
4500
5000
81.3
81.1
81.3
80.7
80.9
80.0
83.8
83.6
83.8
83.0
83.4
82.5
6000
81.6
79.8
84.1
82.4
1500
2000
2500
3000
3500
B2-15
03-08
Section B2
Emissions
Model 4 Boilers
The following tables give typical emission levels for Nature Gas and No. 2 Oil.
Please contact your local Cleaver-Brooks authorized representative if an emission
guarantee is required.
Table B2-11. Model 4 emission

data - Natural Gas
POLLUTANT
ppm
UNCONTROLLED
lb/MMBtu
0.15
ppm
100
lb/MMBtu
0.12
NOx
HC/
VOCs
ppm
lb/MMBtu
ppm
0.001
lb/MMBtu
0.016
ppm
lb/MMBtu
0.07
187
ppm
0.248
270
SOx
lb/MMBtu
HC/
VOCs
0.01
90
NOx
40
PM
lb/MMBtu
ppm
UNCONTROLLED
CO
SOx
lb/MMBtu
POLLUTANT
xx200
CO
ppm
Table B2-12. Model 4 emission

data - No. 2 Oil
ppm
lb/MMBtu
ppm
0.515
50
0.025
PM
lb/MMBtu
0.025
NOTES:
Based on fuel oil constituent levels:
Fuel bound nitrogen = 0.05% (max) by weight.
Sulfur = 0.5% (max) by weight.
Ash = 0.01% (max) by weight.
ENGINEERING DATA
The following engineering information is provided for the Model 4 steam boiler.
Additional information may be obtained from your local Cleaver-Brooks authorized
representative.
Feedwater
Steam boilers require make-up water for steam production. This make-up can be a
combination of condensate return and raw make-up, 100% condensate return or
100% raw make-up. Proper treatment of make-up water and boiler water is
essential to the longevity and performance of the boiler. Table B2-13 shows the rate
of make-up required and Table B2-14 shows the recommended water quality
guidelines.
As a minimum, raw make-up should be piped into a water softener and then to a
feed tank, which also can be the container that receives the system condensate
returns. Chemical feed is recommended to be fed via a quill into the water makeup line feeding the boiler.
B2-16
03-08
Model 4 Boilers
Section B2
Table B2-13. Feedwater makeup rates
Table B2-14. Water quality parameters
Boiler Size
Gallons/Minute
Parameter
Boiler Water Limit
1500
2.5
pH
8.3 - 10.5
2000
3.3
Iron
0.1 ppm
2500
4.1
Oxygen
0.1 mg/liter
3000
Specific Conductivity
2000 mho/cm
3500
5.8
Suspended Solids
4000
6.6
Total Hardness
300 ppm
0 ppm as CaCO3
4500
7.5
5000
8.3
6000
9.9
Blowdown
As steam is produced, unwanted solids are left behind in the boiler water and
become concentrated within the vessel. If these constituents are allowed to adhere
to the heat transfer surfaces, they will impede the flow of energy into the water.
Their removal requires proper blowdown that will include bottom and possibly
surface blowoff. For proper TDS control, surface blowoff with a TDS monitoring
device is recommended. Local codes will dictate the manner of treating the
blowdown affluent.
Boiler Stacks
General - The Model 4 boiler operates with a positive vent pressure and a vent gas
temperature that is non-condensing. Therefore, the stack must be a positive
pressure design.
Proper design and installation of the flue gas venting is critical to efficient and safe
operation of the burner. The vent should be designed with proper supports and
clearances from combustible materials. Use insulated vent pipe spacers where the
vent passes through walls and roofs.
stack connection. Although constant pressure at the flue gas outlet is not required,
it is necessary to size the breeching and stack to limit flue gas pressure variations.
Consideration of the draft must be given where lengthy runs of breeching or
unusually high stacks are employed. Please note: the allowable pressure range for
design of the stack and breeching is negative 0.25" w.c. (-62 Pa) to a positive 0.25"
w.c. (+62 Pa) for proper light offs and combustion. NOTE: This pressure range does
not pertain to the boiler room; that is, the boiler room must be neutral or slightly
positive, never negative when using air from the boiler room for combustion.
When two or more Model 4 boilers are connected to a common breeching/stack,
one should evaluate the affects of pressure variations that may occur during boiler
sequencing while boilers are firing. It may be determined that some type of
mechanical draft system be employed to ensure proper draft at each boiler is
maintained.
Combustion Air - The burner for each boiler must be supplied with adequate volume
of uncontaminated air to support proper combustion and equipment ventilation. Air
shall be free of chlorides, halogens, fluorocarbons, construction dust or other
contaminants that are detrimental to the burner or boiler heating surfaces.
Combustion air can be supplied by means of conventional venting, that is, with
combustion air drawn from the area immediately surrounding the boiler (boiler room
B2-17
03-08
Section B2
Model 4 Boilers
is neutral or slightly positive pressure), or with a direct vent to outside the boiler
room where air is drawn directly from the exterior of the building. Regardless of the
method, all installations must comply with NFPA 54 (National Fuel Gas Code NFGC) for U.S. installations and CAN/CSA B149/.1 and B149.2 for Canadian
installations.
Engineered Design - When determining boiler room air requirements for the boiler,
the "Engineered Design" method may be used. Following this method, consideration
must be given to the size of the boiler room, airflow, and air velocity as follows:
A. Two permanent air supply openings in the outer walls of the boiler room are
recommended. Locate one at each end of the boiler room, preferably below a height
of 7 feet. This allows air to sweep the length of the boiler. Refer to Figure B2-3.
B. Air supply openings can be louvered for weather protection, but they should not
be covered with a fine mesh wire, as this type of covering has poor air flow qualities
and is subject to clogging with dirt and dust.
C. A vent fan in the boiler room is not recommended as it could create a slight
vacuum under certain conditions and cause variations in the quantity of combustion
air. This can result in unsafe burner performance.
D. It is forbidden to have the total area of the air supply openings at less than one
square foot.
E. Size the openings by using the formula (Area in ft2 = cfma/fpma), where cfma =
cubic feet per minute of air; fpma = feet per minute of air.
F. Amount of air required (cfm):
1. Combustion Air = Maximum boiler horsepower (bhp) times 8 cfm.
2. Ventilation Air = Maximum boiler horsepower (bhp) times 2 cfm.
3. Total Air = 10 cfm per bhp (up to 1000 feet elevation, add 3% more per 1000
feet of added elevation).
G. Acceptable air velocity in the boiler room (fpm):
1. From floor to 7 feet high = 250 fpm.
2. Above 7 feet from boiler room floor = 500 fpm.
Example of required air openings (Engineered Method):
Determine the area of the boiler room air supply openings for [2] size 4500 Model
4 boilers at 750 feet elevation; each have a rating of 107 boiler horsepower. The
air openings will be 5 feet above the floor level.
The total boiler horsepower (bhp): 107 x 2 = 214 bhp.
From F.3 above, total air required = 214 bhp x 10 = 2140 cfm.
Air Velocity: From G.1 above = 250 fpm.
Area required: From the formula in E above, 2140 cfm/250 fpm = 8.56 square
feet total.
Area opening: 8.56 divided by 2 = 4.28 ft2 per opening (2 required).
Notice
See Table B2-15 for combustion air and flue gas flow.
B2-18
03-08
Model 4 Boilers
Section B2
Table B2-15. Model 4 fuel, combustion air, and flue gas flow rates
Boiler Size
1500
Fuel Consumpion
2500
3000
3500
4000
4500
5000
6000
Gas
cfh
1500
1500
2500
3000
3500
4000
4500
5000
6000
Oil
gph
10.72
14.29
17.86
21.43
25.00
28.57
32.14
35.71
42.85
scfh
15,480
20,640
25,800
30,960
36,120
41,280
46,440
51,600
61,920
lb/hr
1207
1609
2012
2414
2817
3219
3621
4024
4828
scfh
17,049
22,733
28,414
34,098
39,782
45,463
51,147
56,831
68,196
Gas
Combustion Air
Oil
Gas
Flue Gas
Oil
Notes:
2000
A.
B.
C.
lb/hr
1269
1692
2115
2538
2961
3384
3808
4231
5077
scfh
17,520
23,360
29,200
35,040
40,880
46,720
52,560
58,400
70,080
lb/hr
1,278
1,704
2,130
2,556
2,983
3,409
3,835
4,261
5,113
scfh
17,914
23,886
29,855
35,827
41,799
47,769
53,741
59,713
71,655
lb/hr
1,357
1,809
2,261
2,714
3,166
3,618
4,070
4,523
5,427
Gas consumption, expressed in cubic feet per hour, is based on 1,000 Btu/cu.ft gas value.
Oil consumption,expressed in pounds per hour, is based on 140,000 Btu/gal oil value.
Oil supply lines must be sized for 125 gph pumping rate. Oil pump suction pressure to be -10" Hg to 3 psig.
Figure B2-3. Boiler room air supply - Engineered Design

GAS
VENT
FRESH AIR OPENING
FRESH AIR OPENING
EXTERIOR WALL
EXTERIOR WALL
B2-19
03-08
Section B2
Oil Piping
Model 4 Boilers
General - Oil operation of the Model 4 boiler requires proper oil to the standard
burner mounted oil pump. As the combustion of oil utilizes mechanical pressure
atomization, line sizing to the pump must be sufficient to provide 125 gph of oil to
the suction side of the pump.
Oil Train Components - Oil flow to the burner is controlled by four solenoid valves.
The oil flows through a primary or safety shutoff valve into a manifold block. This
valve and the low fire valve are energized simultaneously by the flame safeguard
control and when opened, allow flow of oil to the low fire nozzle.
As the damper motor moves to high fire position, the damper motor end switches
close to energize in sequence, the intermediate and then high fire oil valve. The
purpose of the intermediate valve is to smooth the transition from low to high fire by
balancing the oil input with increasing flow of air.
High fire rating of the burner is obtained when all three nozzles are firing, assuming
proper oil pressure and normally sized nozzles.
Gas Piping
General - The Model 4 boiler requires appropriate gas supply pressure and volume
for proper operation and long burner life. The gas requirements specified in this
section must be satisfied to ensure efficient and stable combustion. Installation
must follow these guidelines and of the local authorities that have installation
jurisdiction.
Gas Train Components - Model 4 boilers are equipped with a gas train that meets
the requirements of UL as standard. These components also comply with the
recommendations of FM, XL GAP (formerly IRI/GE GAP) and ASME CSD-1. The
gas train and its components have been designed and tested to operate for the
highest combustion efficiency.
Gas Pressure Requirements - For proper and safe operation, each Model 4 boiler
requires a stable gas pressure supply. The pressure requirements are listed in
previous sections for standard gas train size, and oversized trains for reduced
available pressure.
Gas Piping - Model 4 units are standardly equipped with a gas pressure regulator.
If upstream pressure to the standard regulator will be greater than 1 psig, an
additional upstream regulator should be provided with a pressure relief valve.
For buildings or boiler rooms with gas supply pressure exceeding 28" w.c., a "full
lockup" type regulator is recommended along with proper overpressure protection.
In addition to the regulator, a plug type or "butterball" type gas shutoff cock should
be provided upstream of the regulator for use as a service valve. This is also
required to provide positive shutoff and isolate the boiler gas train during gas piping
tests.
Drip legs are required on any vertical piping at the gas supply to each boiler so that
any dirt, weld slag, or debris can deposit in the drip leg rather than into the boiler
gas train. The bottom of the drip leg should be removable without disassembling
any gas piping. The connected piping to the boiler should be supported from pipe
supports and not supported by the boiler gas train or the bottom of the drip leg.
All gas piping and components to the boiler gas train connection must comply with
NFPA 54, local codes, and utility requirements as a minimum. Only gas approved
fittings, valves, or pipe should be used. Standard industry practice for gas piping is
normally Schedule 40 black iron pipe and fittings.
B2-20
03-08
Model 4 Boilers
Section B2
Gas Supply Pipe Sizing - For proper operation of a single unit or multiple units, we
recommend that the gas pipe be sized to allow no more than 0.3" w.c. pressure
drop from the source (gas header or utility meter) to the final unit location. The gas
supplier (utility) should be consulted to confirm that sufficient volume and normal
pressure are provided to the building at the discharge side of the gas meter or
supply pipe (for installations of new boilers into an existing building, gas pressure
should be measured with a manometer to ensure sufficient pressure is available).
A survey of all connected gas using devices should be made. If appliances other
than the boiler are connected to the gas supply line, then a determination should be
made of how much flow volume (cfh = cubic feet per hour) will be demanded at
one time and the pressure drop requirements when all appliances are operating.
The total length of gas piping and all fittings must be considered when sizing the gas
piping. Total equivalent length should be calculated from the utility meter or source
to the final connection. As a minimum guideline, gas piping Tables B2 - 16 through
B2 - 20 should be used. The data in these tables is from the NFPA source book,
2006 edition.
B2-21
03-08
Section B2
Model 4 Boilers
Table B2-16. Gas line capacity - Schedule 40 metallic pipe
Pipe Size
Nominal
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
Actual I.D.
1.049
1.380"
1.610"
2.067"
2.469"
3.068"
Length in feet
**Maximum Capacity in Cubic Feet of Gas per Hour (cfh)
514
1,060
1,580
3,050
4,860
8,580
10
363
726
1,090
2,090
3,340
5,900
20
284
583
873
1,680
2,680
4,740
30
243
499
747
1,440
2,290
4,050
40
215
442
662
1,280
2,030
3,590
50
195
400
600
1,160
1,840
3,260
60
179
368
552
1,060
1,690
3,000
70
167
343
514
989
1,580
2,790
80
157
322
482
928
1,480
2,610
90
148
304
455
877
1,400
2,470
100
131
269
403
777
1,240
2,190
125
119
244
366
704
1,120
1,980
150
109
209
336
648
1,030
1,820
175
102
185
313
602
960
1,700
200
**Fuel: Natural Gas
**Inlet Pressure: Less than 2.0 psi
**Pressure Drop: 0.30" w.c.
**Specific Gravity: 0.60
4"
4.026"
17,500
12,000
9,660
8,290
7,330
6,640
6,110
5,680
5,330
5,040
4,460
4,050
3,720
3,460

Pipe Size
1-1/4"
1-1/2"
2"
2-1/2"
3"
1.380"
1.610"
2.067"
2.469"
3.068"
678
1,390
2,090
4,020
6,400
11,300
10
466
957
1,430
2,760
4,400
7,780
20
374
768
1,150
2,220
3,530
6,250
30
320
657
985
1,900
3,020
5,350
40
284
583
873
1,680
2,680
4,740
50
257
528
791
1,520
2,430
4,290
60
237
486
728
1,400
2,230
3,950
70
220
452
677
1,300
2,080
3,670
80
207
424
635
1,220
1,950
3,450
90
195
400
600
1,160
1,840
3,260
100
173
355
532
1,020
1,630
2,890
125
157
322
482
928
1,480
2,610
150
144
296
443
854
1,360
2,410
175
134
275
412
794
1,270
2,240
200
**Fuel: Natural Gas
Nominal
Actual I.D.
Length in feet
1"
1.049"
B2-22
03-08
4"
4.026"
23,100
15,900
12,700
10,900
9,600
8,760
8,050
7,490
7,030
6,640
5,890
5,330
4,910
4,560
Model 4 Boilers
Section B2

Pipe Size
Nominal
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
4"
Actual I.D.
Length in
feet
0.622
0.824
1.049"
1.380"
1.610"
2.067"
2.469"
3.068"
4.026"
10
1,510
3,040
5,560
11,400
17,100
32,900
52,500
92,800
189,000
20
1,070
2,150
3,930
8,070
12,100
23,300
57,100
65,600
134,000
30
869
1,760
3,210
6,590
9,880
19,000
30,300
53,600
109,000
40
753
1,520
2,780
5,710
8,550
16,500
26,300
46,400
94,700
50
673
1,360
2,490
5,110
7,650
14,700
23,500
41,500
84,700
60
615
1,240
2,270
4,660
6,980
13,500
21,400
37,900
77,300
70
569
1,150
2,100
4,320
6,470
12,500
19,900
35,100
71,600
80
532
1,080
1,970
4,040
6,050
11,700
18,600
32,800
67,000
90
502
1,010
1,850
3,810
5,700
11,000
17,500
30,900
63,100
100
462
954
1,710
3,510
5,260
10,100
16,100
28,500
58,200
125
414
836
1,530
3,140
4,700
9,060
14,400
25,500
52,100
150
372
751
1,370
2,820
4,220
8,130
13,000
22,900
46,700
175
344
695
1,270
2,601
3,910
7,530
12,000
21,200
43,300
200
318
642
1,170
2,410
3,610
6,960
11,100
19,600
40,000
500
192
401
717
1,470
2,210
4,250
6,770
12,000
24,400
1000
132
275
493
1,010
1,520
2,920
4,650
8,220
16,800
1500
106
221
396
812
1,220
2,340
3,740
6,600
13,500
**Fuel: Natural Gas

**Inlet Pressure: 2.0 psi
**Pressure Drop: 1.0 psi
B2-23
03-08
Section B2
Model 4 Boilers

Pipe Size
Nominal
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
4"
Actual I.D.
Length in
feet
0.622
0.824
1.049"
1.380"
1.610"
2.067"
2.469"
3.068"
4.026"
10
2,350
4,920
9,270
19,000
28,500
54,900
87,500
155,000
316,000
20
1,620
3,380
6,370
13,100
19,600
37,700
60,100
106,000
217,000
30
1,300
2,720
5,110
10,500
15,700
30,300
48,300
85,400
174,000
40
1,110
2,320
4,380
8,990
13,500
25,900
41,300
75,100
149,000
50
985
2,060
3,880
7,970
11,900
23,000
36,600
64,800
132,000
60
892
1,870
3,520
7,220
10,300
20,300
33,200
58,700
120,000
70
821
1,720
3,230
6,640
9,950
19,200
30,500
54,000
110,000
80
764
1,600
3,010
6,180
9,260
17,800
28,400
50,200
102,000
90
717
1,500
2,820
5,800
8,680
16,700
26,700
47,100
96,100
100
677
1,420
2,670
5,470
8,200
15,800
25,200
44,500
90,300
125
600
1,250
2,360
4,850
7,270
14,000
22,300
39,500
80,500
150
544
1,140
2,140
4,400
6,590
12,700
20,200
35,700
72,900
175
500
1,050
1,970
4,040
6,060
11,700
18,600
32,900
67,100
200
465
973
1,830
3,760
5,640
10,900
17,300
30,600
62,400
500
283
593
1,120
2,290
3,430
6,610
10,300
18,600
38,000
1000
195
407
897
1,380
2,360
4,550
7,240
12,000
26,100
1500
156
327
616
1,270
1,900
3,650
5,820
10,300
21,000
**Fuel: Natural Gas

B2-24
03-08
Model 4 Boilers
Section B2

Pipe Size
Nominal
Actual
I.D.
Length
in feet
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
4"
0.622
0.824
1.049"
1.380"
1.610"
2.067"
2.469"
3.068"
4.026"
10
3,190
6,430
11,800
24,200
36,200
69,700
111,000
196,000
401,000
20
2,250
4,550
8,320
17,100
25,600
49,300
78,600
139,000
283,000
30
1,840
3,720
6,790
14,000
20,900
40,300
64,200
113,000
231,000
40
1,590
3,220
5,880
12,100
18,100
34,900
55,600
98,200
200,000
50
1,430
2,880
5,260
10,800
16,200
31,200
49,700
87,900
179,000
60
1,300
2,630
4,800
9,860
14,800
28,500
45,400
80,200
164,000
70
1,200
2,430
4,450
9,130
13,700
26,400
42,000
74,300
151,000
80
1,150
2,330
4,260
8,540
12,800
24,700
39,300
69,500
142,000
90
1,060
2,150
3,920
8,050
12,100
23,200
37,000
65,500
134,000
100
979
1,980
3,620
7,430
11,100
21,400
34,200
60,400
123,000
125
876
1,770
3,240
6,640
9,950
19,200
30,600
54,000
110,000
150
786
1,590
2,910
5,960
8,940
17,200
27,400
48,500
98,900
175
728
1,470
2,690
5,520
8,270
15,900
25,400
44,900
91,600
200
673
1,360
2,490
5,100
7,650
14,700
23,500
41,500
84,700
500
384
802
1,510
3,100
4,650
8,950
14,300
25,200
51,500
1000
264
551
1,040
2,130
3,200
6,150
9,810
17,300
35,400
1500
212
443
834
1,710
2,570
4,940
7,880
13,900
28,400
**Fuel: Natural Gas

B2-25
03-08
Section B2
Model 4 Boilers
Figure B2-4. Typical gas header piping
B2-26
03-08
Section B2
Model 4 Boiler
Submittals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guarantees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Design Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shop Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
StartUp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation and Maintenance Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B2-28
B2-28
B2-28
B2-28
B2-28
B2-29
B2-33
B2-34
B2-34
B2-34
B2-34
B2-35
The following sample specifications are provided by Cleaver-Brooks to assist you in specifying your customers specific
needs and application.
B2-27
03-08
Model 4 Steam Boiler Specifications

PART 1 GENERAL
PART 2 PRODUCTS
Section B2
1.1
SUBMITTALS
A. The manufacturer shall supply ____ copies of a dimensional drawing
indicating all relevant unit dimensions, layout and required
clearances.
B. The manufacturer shall supply ____ copies of a ladder type wiring
diagram to include all internal unit wiring, external connections, and
power supply requirements.
C. The manufacturer shall supply a copy of the authorized inspection
report, to the purchaser, upon completion and shipment of the unit.
1.2
CODES
A. The boiler shall be designed, constructed, and hydrostatically tested
in accordance with the ASME Boiler and Pressure Vessel Code.
B. The boiler shall be wired in accordance with the rules of the
National Electric Code.
C. All electrical equipment shall be in conformity with the Underwriters
D. The complete boilerburner package shall be approved by
Underwriters Laboratories and shall bear a UL label.
E. The boiler shall be built to comply with the following insurances
_______________. (Factory Mutual, XL-GAP, ASME CSD1)
1.3
GUARANTEES
A. The complete boiler package shall be warranted from defects in
materials and/or workmanship for a period of not less than 18
months from shipment or 12 months from unit startup.
2.1
TYPE
A. The boiler shall be a watertube type steam boiler with all steel
membrane walls.
B. The boiler shall be a three gas pass type boiler mounted on a heavy
duty steel frame.
C. The boiler shall have an integral forced draft burner and burner
controls.
D. The boiler shall be a Cleaver Brooks Model 4, series ________ (100
= No. 2 oil, 200 = No. 2 oil and gas, 700 = gas) steam boiler.
2.2
DESIGN CRITERIA
A. The boiler shall be designed in accordance with the ASME Boiler
and Pressure Code Section _____ (IV for low pressure, I for high
pressure).
B. The boiler shall be designed for _____ psig (15, 150, 250, 350, or
500). The maximum operating pressure will be _____ psig.
C. The boiler shall be designed for a maximum output of ________ lbs/
hr of steam, or _________ bhp. The boiler shall develop ________
lbs/hr of steam when operating at ______ psig with a feedwater
temperature of ______ F.
D. Electrical power available will be _______ volts, _______ phase,
______ Hz.
B2-28
03-08
Section B2

E.
2.3
The maximum sound level shall not exceed 80 dBA measured 3 feet
in front of the boiler.
PRODUCT DESIGN
A. Pressure Vessel
1. The upper drum shall have a 20" OD, manufactured from SA
53 Gr. B seamless pipe, with a minimum wall thickness of
0.375".
2. The lower drum shall have an 85/8" OD, manufactured from
SA53 Gr. B seamless pipe, with a minimum wall thickness of
0.322".
3. The generating tubes shall be 2" OD, manufactured from SA
178 Gr. A tubing, with a minimum wall thickness of 0.095".
4. The boiler shall have two downcomers, located at the rear of
the boiler, and be totally insulated from the generating tubes.
These shall be a minimum of 21/2" OD, manufactured from
SA178 Gr. A tubing, with a minimum wall thickness of .105".
5. The upper drum shall have an inspection opening, located at
the rear of the unit, to allow internal inspection, and shall be a
minimum of 4"x6".
6. The lower drum shall have inspection openings, located at the
front and rear of the unit, to allow internal inspection, and shall
be a minimum of 4-7/8" x 5-7/8".
7. The boiler shall have inspection openings in the convection
area.
8. A feedwater tapping and integral feedwater distribution pipe
shall be located in the upper drum. The distribution pipe shall
blend the feedwater with the boiler water.
9. A 3/4" surface blowoff connection shall be located in the rear
head of the upper drum.
10. A _____" bottom blowoff connection shall be located in the
lower drum.
B. Refractory
1. Refractory shall be limited to the furnace floor to insulate the
lower drum, and to the burner throat tile.
2. High temperature insulation shall be installed on the front wall
of the furnace.
C. Insulation and Casing
1. The boiler insulation shall be a minimum of 2" fiberglass, and
shall cover the entire pressure vessel.
2. The insulation shall be covered with a corrugated metal
lagging.
3. The metal lagging and insulation shall be arranged for easy
removal and installation if required.
4. The front head (windbox) shall be attached with a davit arm,
gasket sealed, and bolted. The front head shall swing open to
provide full access to the furnace chamber and burner throat
tile.
B2-29
03-08
Section B2
5.
Observation ports shall be provided at each end of the boiler for

visual inspection of the pilot and main flame conditions.
Two lifting eyes shall be located on top of the boiler.
The exhaust gases shall vent at the rear of the boiler, on the top
centerline.
6.
7.
D.
E.
Trim
1. The water column shall be located on the left side of the boiler.
It shall be piped with unions for easy removal.
2. A gauge glass set, gauge glass blowdown valve, and water
column blowdown valve shall be provided.
3. The boiler feedwater control switch shall be included as an
integral item of the water column. It shall provide automatic
actuation of a motor driven feedwater pump or valve to
maintain the boiler water level within normal limits.
4. The primary low water cutoff switch shall be an integral part of
the water column. It shall be wired into the burner control
circuit preventing burner operation if the boiler water level falls
below the designated safe level.
5. A steam pressure gauge shall be located at the front end of the
boiler and shall include a cock and test connection.
6. A safety relief valve shall be provided of a size and type to
comply with ASME Code requirements. The safety relief valve
set pressure shall be ______ psig.
7. A high limit pressure control shall be provided. It shall be a
manual reset type and shall be wired to prevent burner
operation and lockout if excessive steam pressure occurs.
8. An operating limit control shall be provided. It shall be wired to
provided on off control of the burner at operating set points.
9. A firing rate control shall be provided. It shall control the firing
rate of the burner based on the boiler load.
10. An auxiliary low water cutoff shall be provided (manual reset
type). It shall be wired into the burner control circuit preventing
burner operation if the boiler water level falls below the
designated safe level.
11. A stack thermometer shall be shipped loose for field
installation.
Soot Cleaning
1. Soot washer lances shall be provided in the convection area of
the boiler measuring the full length of the pressure vessel.
2. Each lance shall be provided with a shutoff valve and the
assembly shall be capable of rotating 360 degrees. This shall
ensure complete washing of the convection zone while the
boiler is operating in the low fire mode.
3. Soot washer troughs shall be provided at the bottom of the
boiler. These shall be furnished for each convection side and
shall The soot washer troughs shall be provided with 2" drain
connections at the rear of the boiler, and shall have inspection/
cleanout openings at the front of the boiler.
B2-30
03-08
Section B2

F.
G.
H.
Burner Design General

1. The burner shall be integral to the windbox.
2. All air for combustion shall be supplied by a forced draft blower
mounted in the windbox, above the burner, to minimize noise
and vibration level.
3. The blower motor shall be an open drip proof type with a
minimum service factor of 1.15.
4. The impeller shall be an enclosed centrifugal fan type, properly
5. The combustion air damper shall be integral to the windbox
and shall be operated by a single damper motor.
6. The burner shall remain in the low fire position during ignition
and until main flame has been established.
7. A combustion air proving switch shall be provided to ensure
adequate air for pre-purge and combustion.
Burner Design Gas
1. The burner shall be the high radiant multiport type approved
for operation with natural gas.
2. The burner shall operate on the _______________ (lowhigh
low or full modulation) principle and must return to the low fire
position prior to ignition.
3. Automatic electric ignition of the premix gas pilot shall be
furnished. An electric scanner, of the UV principle, shall
monitor the pilot, preventing the primary fuel valve from
opening until the pilot flame has been established.
4. The single combustion air damper motor shall operate the gas
butterfly valve. The damper motor shall regulate the fire
according to system demand in response to the firing rate
control.
Burner Design No. 2 Oil
1. The burner shall be the pressure atomizing type approved for
operation with commercial grade No. 2 oil.
2. The burner shall operate on the lowhighlow principle, and
must return to the low fire position prior to ignition.
and until main flame has been proven. The ignition period
shall be monitored with an electric scanner, of the UV principle,
to confirm the presence of the low fire oil flame.
4. Automatic electric ignition of the low fire oil supply shall be
provided with a minimum 10,000 volt transformer and heavy
duty electrodes.
Notice
Optional insurance compliance may require a premix gas pilot in lieu of direct spark
ignition.
B2-31
03-08
Section B2
5.
I.
J.
[Optional] Automatic electric ignition of the premix gas pilot

shall be furnished. An electric scanner, of the UV principle,
shall confirm the pilot prior to the delivery of the low fire oil
supply.
6. The single combustion air damper motor shall operate the low
and high fire oil valves. The damper motor shall regulate the
fire according to system demand in response to the firing rate
control.
Burner Design Gas and No. 2 Oil
1. The burner shall be the high radiant multiport type for gas and
shall be the pressure atomizing for oil. The burner must be
approved for operation with either natural gas or commercial
grade No. 2 oil.
2. The burner shall operate on the lowhighlow principle, and
and until main flame has been proven.
furnished. An electric scanner, of the UV principle, shall
monitor the pilot, preventing the primary fuel valve from
opening until the pilot flame has been established.
5. The single combustion air damper motor shall operate the low
and high fire oil valves and the gas butterfly valve. The damper
motor shall regulate the fire according to system demand in
response to the firing rate control.
Main Gas Train
1. The gas burner piping shall include a primary gas shutoff valve.
It shall be controlled by the programming relay to start or stop
the burner and to close automatically in the event of power
failure, flame failure, or a low water condition.
2. A manual shutoff valve shall be located ahead of the primary
gas valve.
3. A plugged leakage test connection and a second manual shutoff
valve shall be provided as a means for a tightness check of the
primary shutoff valve.
4. A gas pressure regulator shall be factory mounted and piped for
pressure regulation to the burner.
5. Gas Train Components
a. [Sizes 15002500] The primary gas shutoff valve shall
be motorized with a proof of closure switch.
b. [Sizes 30005000] The primary gas shutoff valve shall
be motorized with a proof of closure switch. High and low
gas pressure switches shall be provided.
c. [Size 6000] The primary gas shutoff valve shall be
motorized with a proof of closure switch. A second gas
safety shutoff valve and an additional plugged leakage test
cock shall be provided. High and low gas pressure
switches shall be provided.
B2-32
03-08
Section B2

K.
L.
2.4
Natural Gas Pilot Train

1. A pilot gas pressure regulator shall be factory mounted and
piped for pressure regulation of the pilot gas to the burner.
2. The pilot gas train shall include a safety shutoff valve. It shall
be controlled by the programming relay to start the burner.
3. A manual shutoff valve shall be located ahead of the pilot gas
pressure regulator.
2.3.12 Oil System
1. An oil pump shall be provided. The oil pump, integral with the
burner, shall include a builtin relief valve and selfcleaning
strainer.
2. The oil pump shall be belt driven from the blower motor.
3. The fuel oil system shall include supply and return tubing to a
terminal block, an oil pressure gauge, shutoff cock, and four
solenoid oil shutoff valves. These items shall be factory
mounted and piped on the front head (windbox).
BURNER MANAGEMENT SYSTEM

A. Control Panels
1. The control panel shall be a NEMA 1 rated panel and have a
key lock.
2. The control panel shall be mounted on the front head of the
boiler and shall be conveniently located for the boiler operator.
3. The panel shall contain the blower motor starter, control circuit
fuses, control circuit transformer, and control switches. A
damper selector switch shall be provided to permit selection of
automatic or manual selection of low or high firing.
4. A terminal board shall be provided to which all wires entering
or leaving the panel shall be connected.
5. The panel shall include four indicating lights to show operating
conditions of: red = low water; red = flame failure; white =
load demand; and white = fuel valve open. The lights and
switches shall be located on the panel switch ledge.
6. All electrical service connections shall be made to an electrical
entrance box to be mounted on the right hand side of the boiler.
7. All electrical wiring shall be oil, heat, and moisture resistant
and shall be number coded.
B. Combustion Safeguard Control
1. A combustion safeguard control (program relay) shall be
provided to control ignition, starting, and stopping of the
burner. It shall provide precombustion and postcombustion
purge periods and shall stop burner operation in the event of
ignition, pilot, or main flame failure. Trial for ignition shall be
limited to 10 seconds.
2. The boiler shall be provided with a combustion safeguard
controller that provides technology and functions equal to the
Cleaver Brooks Model CB120E.
B2-33
03-08
Section B2
3.
The combustion safeguard control shall be microprocessor

based, with selfdiagnostics, nonvolatile memory, and a
message center with a vocabulary of 42 different messages.
Messages shall scroll across an alphanumeric display and
provide sequence status and flame failure mode information.
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.
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.
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.
The controller shall also have the following functions: display
history of operating hours and totals of completed onoff
cycles; provide a constant flame signal strength readout; and
have provisions for remote display capability and Modbus
communication.
4.
5.
6.
7.
PART 3 EXECUTION
3.1
SHOP TESTS
A. The pressure vessel shall be hydrostatically tested in accordance
with ASME requirements.
B. The boiler will be test fired by the manufactured, prior to shipment,
to verify proper and safe operation.
3.2
SHIPMENT
A. Painting
1. The entire boiler, base frame, and other components shall be
factory painted, before shipment, using a hard finish enamel.
2. The boiler surface shall be cleaned/prepared for painting using
manufacturer's specifications and standard industrial painting
practices.
B. Preparation
1. All boiler openings shall be plugged/covered prior to shipment.
2. The boiler shall be skid mounted and protected with a weather
resistant covering.
3. All shipped loose components shall wrapped in protective
material and packaged in a separate container(s).
3.3
INSTALLATION
3.4
STARTUP
A. The boiler startup shall be performed by a factory trained
representative and will be done in accordance with the
manufacturer's recommended procedures.
B2-34
03-08
Section B2

B.
The boiler startup shall include boiler operator training and shall
cover boiler operation, water treatment, and maintenance of the
unit.
3.5
OPERATION AND MAINTENANCE MANUALS
Manufacturer shall supply _____ copies of the Operating & Maintenance Manual.
B2-35
03-08
Section B2
Notes
B2-36
03-08
Section B3
MODEL 5 BOILERS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5
Special Insurance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-7
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-20
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-20
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-20
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-21
Feedwater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-21
Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-21
Boiler Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-21
Oil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-23
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-23
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-31
B3-1
09-09
Model M5 Boilers
Commercial Boilers
ILLUSTRATIONS
Model 5 Steam Boiler Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-8
Model 5 Low Water Volume Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-11
Standard Gas Train Model 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-16
Boiler Room Air Flow - Engineered Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-23
TABLES
Model 5 Boiler Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4
Model 5 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-9
Model 5 connection sizes and clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-10
Model 5 Low Water Volume dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-12
Model 5 Low Water Volume connection sizes and clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-13
Model 5 Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-14
Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity) . . . . . . . . . . . . B3-15
Model 5 Oil Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-15
Model M5 min. req. Natural Gas pressure UL, FM & XL GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-17
Model M5 min. req. Natural Gas pressure UL, FM & XL GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-17
Model M5 min. req. Propane Gas pressure UL, FM & XL GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-18
Model M5 min. req. Propane Gas pressure UL, FM & XL GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-19
Safety Valve Outlet Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-19
Predicted Efficiency, 10 PSIG operating (includes radiation and convection losses) . . . . . . . . . . . . . . B3-20
Model 5 Emission Data, Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-20
Emission Data, No. 2 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-20
Gas line capacity - Schedule 40 metallic pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-25
Sound Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-29
Water Quality Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-29
Feedwater Make-up Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-29
Model 5 Fuel, Combustion Air, and Flue Gas Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-30
The Model 5 Commercial Watertube Boiler product line is used for low and high pressure steam applications. Sizes
range from 1.5 to 8 MMBtu/hr. The Model 5 Boiler is an excellent choice where high outputs are required but space
limitations exist. The model number designation is 1500 through 8000, representing MBtu/hr input (1,500,000 to
8,000,000 Btu/hr).
Fuel series designation is as follows:
Series 100: No. 2 oil firing.
Series 700: Natural gas firing.
Series 200: No. 2 oil/natural gas firing.
Design pressure designation is stated as 15 psig, 150 psig, and 250 psig for steam, and 140 psig for hot water. For
example, a Model M5P-700-2500-150 boiler designates a gas-fired, 2,500,000 Btu/hr, 150 psig, steam boiler.
B3-2
09-09
Commercial Boilers
Model M5 Boilers

33" Cased Width:
Boiler fits through most standard doorways.
Direct Driven, Vibration-Free Centrifugal Impeller:
Quiet operation.
Sound levels below 80 dbA.
Ideal for noise critical areas such as hospitals, churches, etc.
Minimum Refractory:
Membrane waterwalls reduce the need for refractory by 95%.
Reduced maintenance costs and refractory repair requirements.
Membrane Waterwalls:
Enhanced heat transfer area in compact design.
Sealed combustion chamber improves heat transfer for high efficiency.
Small Boiler Footprint:
Savings of up to 50% in floor space.
Weighs up to 40% less than Comparable Boilers:
Lower freight and rigging costs.
Reduced structural requirements.
Standard Built-in Soot Washers:
Boiler cleaning without shutdown.
Maintains peak boiler performance.
Packaged Forced Draft Burner:
High pressure drop design.
Improved combustion efficiency.
Low Water Volume Design (optional):
Meets various provincial operating engineer codes and regulations.
Reduced operating costs.
High and low pressure steam.
Steam Design Pressures to 500 psig:
High performance in a compact design.
Proven vessel design for high design pressure applications.

B3-3
09-09
Model M5 Boilers
Commercial Boilers
PRODUCT OFFERING
The Model 5 (M5) Boiler is a compact carbon steel, extended fin, watertube boiler.
Heat transfer design is configured in a "3-pass" gas travel across the watertube
surfaces. The pressure vessel is constructed to conform to the A.S.M.E. Code,
either Section IV for low pressure steam @ 15 PSIG MAWP (maximum allowable
working pressure) or Section I for MAWP greater than 15 PSIG.
The vessel (boiler) consists of two rows on each side of the vessel, of formed
seamless tubes with extended fin surfaces and downcomers connected to the steam
drum and lower drum. To reduce standby losses, the vessel is insulated with a
fiberglass blanket and removable steel jacket.
Complete with an integral burner for either No.2 fuel oil or Natural Gas, the
complete burner/boiler package is CSA International Approved, listed, and labeled.
Standard Equipment
The standard boiler/burner package is described below. Optional controls, trim, and
devices may be added to meet project requirements, and some of those options are
noted, following this standards list.
1. Boiler
A. Designed, constructed, and hydrostatically tested in accordance with the
A.S.M.E. Boiler and Pressure Vessel Code. The complete vessel is mounted on a
structural steel frame.
B. Steam drum includes a hand hole in the rear head for drum water side
inspection. Connections are included for the following:
Feedwater Makeup w/internal dispersion tube.
Table B3-1. Model 5 Boiler Sizes

MODEL
NO.
INPUT
MBH
HEAT
OUTPUT
MBH
EQUIV
HP
STEAM SHIPPING
OUTPUT WEIGHT
LB/HR
LBS
1500
1500
1200
35
1237
3100
2000
2000
1600
47
1649
3100
2500
2500
2000
59
2062
3700
3000
3000
2400
71
2474
3700
3500
3500
2800
83
2887
4100
4000
4000
3200
95
3299
4100
4500
4500
3600
107
3711
4700
5000
5000
4000
119
4124
4700
6000
6000
4800
143
4949
5400
8000 LWV
8000
6320
194
6516
6200
NOTE: Steam output from and at 212 F.

LWV = Low Water Volume.
B3-4
09-09
Commercial Boilers
Model M5 Boilers
Surface Blowoff.
Steam Supply.
Safety Relief Valve.
C.Lower Drum includes hand holes at each end for waterside inspection. A drain/
blowoff tapping is provided at the front, bottom centerline.
D.Soot washer lances are provided on each side of the vessel between the two rows
of tubes for fireside cleaning. Soot washer drains are located at the bottom of the
boiler, with connections to drain located on each side of the lower drum at the rear.
E.Refractory is limited to the furnace floor, lower drum, and burner throat tile. High
temperature insulation is installed on the front water wall and furnace access door.
F.Two lifting eyes are provided on the top centerline of the upper drum for ease of
installation.
G.Furnace inspection/access door is provided in the furnace rear wall.
The exhaust gas vent is located at the top rear centerline of the boiler. A stack
thermometer is shipped loose for field installation by the installing contractor into
the stack.
I.The complete vessel is fully insulated (2" fiberglass blanket) under a preformed,
sectional steel jacket.
J.Factory painted using hard-finish enamel.
1. Steam Boiler Control Standard Equipment (15 to 150 psig)
A. ASME safety relief valve(s).
B. Steam pressure gauge.
C. Pressure controls:
High limit control-manual reset.
Operating limit control.
High-low fire control (full modulation for gas firing).
D. D. Low water cutoff with pump control.

E. E. Water column gauge glass set and fittings.
F. F. Auxiliary low water cut-off.
G. G. Combustion air proving switch.
2. Electrical Control Panel
A. Mounted at eye level on the front head of the boiler.
B. NEMA rating 1A with gasket dust seal.
C. Contains electronic program relay and switches.
3. Miscellaneous
A. The boiler is Canadian Standards Association (CSA) approved and bears the
CSA label.
Optional Equipment
Optional Equipment
For more detailed information on optional equipment, contact the local CleaverBrooks authorized representative. In summary, options include the following:
1. Boiler
B3-5
09-09
Model M5 Boilers
Commercial Boilers
Larger pressure gauges or specific manufacturer type.
Bottom Drain Valves for low pressure applications.
Bottom Blowoff Valves for high pressure applications.
Surface Blowoff Valve with internal collector pipe.
Feedwater Stop and Check Valves.
Steam Stop Valve.
ASME Hydro Test of Valves and Valve Piping.
Design pressures above 150 PSIG.
Full Modulation Firing on Gas.
Lead/Lag Control.
Day-Night Controls.
Low Fire Hold Control.
Elapsed Time Meter.
Alarm with silence switch.
Additional Indicator Lights.
Main Power Disconnect.
Remote Oil Pump.
Optional NEMA Enclosures.
Special Fan Motor requirements (TEFC).
3. Fuel Options
Automatic Fuel Changeover (combination burner).
Propane Fuel Firing.
Special Gas Pressure Regulators.
Dual Pilots (gas and oil).
Gas strainer.
"Guarded Plant" status equipment.
4.Low Water Volume Design Options (LWV)
5.Guarded Plant Requirements
Notice
*Not required for low pressure steam applications.
Special Insurance
Requirements
The boiler package can be equipped to meet various insurance or code

requirements. Some of these insurance/code requirements are:
Factory Mutual (FM)
B3-6
09-09
Commercial Boilers
Model M5 Boilers
XL GAP (Formerly GE GAP/IRI).
A.S.M.E. CSD-1.
Factory Mutual (FM Global) - Recommended guidelines as described by FM pertain
to boilers rated at greater than 2.5 MMBtu/hr input on gas and 2.8 MMBtu/hr input
on oil. Boilers that are labeled and tested in accordance with an independent
testing lab such as UL or CSA and are below these inputs are exempt from these
recommendations.
The Model 5 boiler is CSA listed and labeled. In addition to the standard CSA
requirements the following are needed to comply with FM when required.
Alarm Bell with silence switch for low water and safety shutdowns.
Low Oil Pressure Switch if the oil pump is not direct driven from the fan motor.
XL GAP (Formerly GE GAP/IRI) Recommended guidelines as described by XL GAP
pertain to boilers rated at 400,000 Btu/hr input to 12.0 MMBtu/hr input. For these
boilers, the requirements are the same as for A.S.M.E CSD-1 requirements. Above
12.0 MMBtu/hr input, the requirements defer to the NFPA 85 standards for single
burner boilers.
A.S.M.E. CSD-1 - Recommended guidelines as described by this Code pertain to
boilers rated at 400,000 Btu/hr input to 12.0 MMBtu/hr input. Above 12.0
MMBtu/hr input, the requirements defer to the NFPA 85 standards for single burner
boilers. . For the sizes this Code covers, the requirements are as follows, in addition
to the standard CSA package:
Low Oil Pressure Switch for oil firing all sizes.
" Pressure Control Piping
If gas supply is > 5 psig, a relief valve is required after the gas pressure regulator in
the main and pilot gas trains.
Lever Handled shutoff cock for the pilot gas train.
Non-fused disconnect to remove boiler from all sources of power.

For layout purposes, the nominal dimensions and connections for the Model 5
Standard Boiler Packages are shown in Figure B3-1 and Tables B3-1 and B3-2.
Low Water Volume (LWV) Package Boiler Dimensions are shown on Figure B3-2
and Table B3-3 and B3-4. Ratings of each boiler size are noted in Table B3-5.
Additional information is shown in the following figures, tables, and illustrations.
Table B3-6 Recommended steam nozzle sizes for high pressure boilers operating at
lower and higher pressures.
Table B3-7 Model 5 Oil Fuel Requirements.
Figure B3-3 Standard gas train.
Tables B3-8 to B3-11 Gas pressure requirements.
Table B3-12 Safety Valve Outlet Sizes.
B3-7
09-09
Model M5 Boilers
Commercial Boilers
Figure B3-1. Model 5 Steam Boiler Dimension Diagram
B3-8
09-09
Commercial Boilers
Model M5 Boilers
1500
Note 1
2000
2500
3000
Boiler Size
3500
4000
4500
5000
6000
All Dimensions are in Inches
Lengths
A
Overall
69.7
69.7
85.8
85.8
104.4
104.4
121.1
121.1
136.7
51.25
51.25
67.375
67.375
83
83
99.625
99.625
115.25
108
Base Fram e
45.5
45.5
61.1
61.1
76.75
76.75
92.4
92.4
C1
Base to Front Head
C2
Base Fram e Anchor Holes
43
43
58.5
58.5
74.5
74.5
90
90
105.5
CC
17.2
17.2
17.7
17.7
17.7
17.7
21.8
21.8
21.8
13
13
13
13
16
16
16
16
16
16.4
16.4
24.4
24.4
30.1
30.1
36.75
36.75
44.6
D
DD
HH

12
12
11.5
11.5
13
13
17
Steam Nozzle to Safety Vavle 150#
12
12
17
17
17
17
17
57.5
57.5
57.5
57.5
57.5
57.5
57.5
57.5
57.5
33
33
33
33
33
33
33
33
33
Widths
E
Overall
Center to Aux. Water Column
23.5
23.5
23.5
23.5
23.5
23.5
23.5
23.5
23.5
16.5
16.5
16.5
16.5
16.5
16.5
16.5
16.5
16.5
Base Fram e Inside
20
20
20
20
20
20
20
20
20
Base Fram e Outside
28
28
28
28
28
28
28
28
28
21.5
21.5
21.5
21.5
21.5
21.5
21.5
21.5
21.5
10.75
10.75
10.75
10.75
10.75
10.75
10.75
10.75
10.75
12
12
12
12
12
12
12
12
12
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
78.25
78.25
78.25
78.25
78.25
78.25
78.25
78.25
78.25
84.5
84.5
84.5
84.5
84.5
84.5
84.5
84.5
84.5
73.5
73.5
73.5
73.5
76.5
76.5
76.5
76.5
76.5
O1
73.5
73.5
73.5
73.5
73.5
73.5
76.5
76.5
76.5
Base to Steam Drum Centerline

Drum Centerline To Surface Blowoff,
Std. Design & 15# Low W ater Volume.
[See Note C]
Drum Centerline To Surface Blowoff;
High Pressure Design Low Water
Volume. [See Note D]
62.25
62.25
62.25
62.25
62.25
62.25
62.25
62.25
62.25
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
54
Heights
OO
OO1
P1
P1
R
Base to Sootwasher Lance
54
54
54
54
54
54
54
54
Height of Base
OS
26.625
26.625
26.625
26.625
26.625
26.625
26.625
26.625
26.625
OR
24.625
24.625
24.625
24.625
24.625
24.625
24.625
24.625
24.625
Table B3-1. Model 5 Dimensions
B3-9
09-09
Model M5 Boilers
Commercial Boilers
Connections
BB
12
12
12
12
12
12
16
16
16
T
T1
1.25
1.25
1.25
1.25
1.5
1.5
1.5
1.5
1.5
1.25
1.25
1.25
1.25
1.25
1.25
1.25
1.25
1.25
Steam Nozzle, 15#
4A
4A
4A
4A
6B
6B
6B
6B
6B
Steam Nozzle, 150#

2.5
2
2.5
2
0.75
Soot Washer [Two]
GG
JJ
3
2
3
2
3
2
3
2
4
2
4
2
4
2
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
Relief Valve, 15#
1.5
2.5
2.5
2.5
2.5
Relief Valve, 150#
0.75
1.25
1.25
1.25
1.25
1.5
33
Clearances
EE
Front Door Swing
33
33
33
33
33
33
33
33
FF
30
30
30
30
30
30
30
30
30
RF
Allowance for Front Door Swing and

30" Rear Aisle Space.
133
133
149
149
167
167
184
184
200
RD
Allowance for Tube Removal Each

Side and Front Door Swing.
94
94
94
94
94
94
94
94
94
NOTES:
1. The above dimensions, while sufficiently accurate for layout purposes must be confirmed for construction via certified prints. For
200 PSIG design pressure and greater, contact Milwaukee Sales for certified prints.
4. Control Panel may be larger [up to 4" in height] if certain control options are provided.
A. Connection is a Female Pipe Thread.
B. Connection is a 150# Flange, Flat Face.
C. When optional internal collector pipe is requested, tapping will be 4.5" from drum centerline.
D. When optional internal collector pipe is requested, tapping will be 6.8" from drum centerline.
Table B3-2. Model 5 connection sizes and clearances
B3-10
09-09
OO
N
W
Rear Sight Port
Handhole 4 x 6
9 1/4
FF
CC
JJ
BB
09-09
C
C2
HH
RF
DD
C1
T
D
GG
Control Panel
EE
2 1/2
Inspection
Opening
OS OR
F
H
OO1
Aux Low
Water Cutoff
Commercial Boilers
Model M5 Boilers
Figure B3-2. Model 5 Low Water Volume Dimension Diagram
B3-11
Model M5 Boilers
Commercial Boilers
Note 1
7500
Boiler Size
8000
All Dimensions are in Inches
Lengths
A
Overall
190.1
190.1
138.7
138.7
Base Fram e
117.4
129.9
C1
Base to Front
C2
Base Fram e Anchor Holes
112.4
127.4
21.8
21.8
Burner Extension
56.5
56.5
CC
D
DD
63
63
II
Steam Nozzle to Safety Vavle 150#
17
17
Overall
57.5
57.5
33
33
Center to Aux. Water Column
23.5
23.5
16.5
16.5
20
Widths
Base Fram e Inside
20
Base Fram e Outside
28
28
21.5
21.5
10.75
10.75
12
12
3.5
3.5
78.25
Heights
OO
78.25
OO1
84.5
84.5
O1
73.25
73.25
Base to Surface Blowoff
58.5
58.5
Base to Feedwater Inlet
55.75
55.75
Base to Sootwasher Lance
54
54
Height of Base
OS
26.625
26.625
OR
24.625
24.625
NOTES:
1. The above dimensions, while sufficiently accurate for layout purposes, must be
confirmed for construction via certified prints. For 200 PSIG design pressure and
greater, contact Milwaukee Sales for certified prints.
Table B3-3. Model 5 Low Water Volume dimensions
B3-12
09-09
Commercial Boilers
Model M5 Boilers
Connections
BB.
T1

18
18
1.25
1.25
Steam Nozzle, 150#
0.75
0.75
Soot Washer [Two]
0.25
0.25
GG
0.5
0.5
JJ
Relief Valve, 150#
Clearances
EE
Clearance from Control Panel
36
36
FF
30
30
RF
Allowance for Front Burner Removal

and 30" Rear Aisle Space.
220
220
NOTES:
1. The above dimensions, while sufficiently accurate for layout purposes, must be
confirmed for construction via certified prints. For 200 PSIG design pressure and
greater, contact Milwaukee Sales for certified prints.
Table B3-4. Model 5 Low Water Volume connection sizes and clearances
B3-13
09-09
Model M5 Boilers
Boiler SIZE
Commercial Boilers
1500
2000
2500
3000
3500
4000
4500
5000
6000
7500 LWV 8000 LWV
1,237
1,649
2,062
2,474
2,887
3,299
3,711
4,124
4,949
6,186
6,600
Rated Steam Capacity [kg/hr from

and at 100 C]
561.0
748.0
935.0
1,122.0
1,309.0
1,496.0
1,683
1,871.0
1,847.2
2,806
2,993.7
Output Btu/hr [1,000 Btu/h]
1,200
1,600
2,000
2,400
2,800
3,200
3,600
4,000
4,800
6,000
6,400
Output Kcal/Hr [1,000 Kcal/h]
302
403
504
605
706
806
907
1,007
1,210
1,512
1,613
Output KW
348
464
580
696
812
928
1,044
1,160
1,392
1,740
1,856
Ratings [Note A]
Rated Capacity - Steam (lbs.
o
steam/hr from & at 212 F.)
Approximate Fuel Consumption At Rated Capacity [ Input - Note B]

3
1,465
2,000
2,450
2,952
3,456
3,950
4,444
4,938
5,925
NA
NA
1,538
2,077
2,564
3,117
3,590
4,155
4,657
5,194
6,233
7594
8205
41.5
56.6
69.4
80.8
97.9
111.9
125.8
139.8
167.7
NA
NA
Natural Gas [m 3/hr] - 150# Steam
43.5
58.8
72.6
88.3
101.6
117.6
131.8
147.0
176.5
215
232.4
586
800
980
1,181
1,382
1,580
1,778
1,975
2,370
NA
NA
615
831
1,026
1,247
1,436
1,662
1,863
2,078
2,493
3038
3282
Propane Gas [m /hr] - 15# Steam
16.6
22.6
27.7
33.4
39.1
44.7
50.3
55.9
67.1
NA
NA
17.4
23.5
29.1
35.3
40.7
47.1
52.7
58.8
70.6
86
92.9
10
14
17
21
24
28
31
35
42
NA
NA
No.2 Oil Fuel - 150# Steam , gph
11
15
18
22
25
28.9
32
36
43
54
59
No.2 Oil Fuel - 15# Steam, lph
38
53
64
79
91
106
117
132
159
NA
NA
No.2 Oil Fuel - 150# Steam , lph
41
56
68
82
95
109
121
136
163
204
223
7.5
7.5
7.5
7.5

3
Power Requirements - 3 Phase 60 Hz Standard [Note C]

Blower Motor HP - Gas Firing
Blower Motor HP - Oil or Comb.
Direct Drive from Fan

Motor
Belt Driven from the Blower Motor
Oil Pump for Oil or Combination

Minimum Ampacity
Blower Motor - Gas, 230V
15
22
22
Blower Motor - Gas, 460 V
4.5
4.5
4.5
7.5
11
11
Blower Motor - Oil or Comb, 230 V
15
15
22
22
Blower Motor - Oil or Comb., 460V
4.5
7.5
4.5
4.5
7.5
11
11
Blower Motor - Gas, 575 V
1.6
1.6
1.6
1.6
1.6
2.4
2.4
2.4
4.1
6.1
6.1
Blower Motor - Oil or Comb., 575V
1.6
1.6
1.6
1.6
2.4
4.1
2.4
2.4
4.1
6.1
6.1
Control Circuit
1.7
1.7
1.7
1.9
1.9
1.9
2.4
2.4
2.4
2.5
2.5
Weights
Operating Weight, lbs.
3,643
3,643
4,445
4,445
5,040
5,040
5,858
5,858
6,753
6,920
6,920
Operating Weight, kg
1,652
1,652
2,016
2,016
2,286
2,286
2,657
2,657
3,063
3,139
3,139
Water Content Normal, Imp.gals
54.4
54.4
74.9
74.9
94
94
116.1
116.1
135.7
71.1
71.1
Water Content Normal, liters
248
248
340
340
428
428
528
528
617
324.7
324.7
Water Content Flooded, Imp. gals
79.94
79.94
109.08
109.08
135.7
135.7
166.5
166.5
194.01
Water Content Flooded, liters
363.4
363.4
459.9
459.9
616.9
616.9
756.9
756.9
881.99
Shipping Weight, approximate lbs.
3,100
3,100
3,700
3,700
4,100
4,100
4,700
4,700
5,400
6,200
6,200
Shipping Weight, approximate kg
1,406
1,406
1,678
1,678
1,860
1,860
2,132
2,132
2,449
2,812
2,812
Notes:
A. Ratings shown for elevation to 1000 Feet. For ratings above 1000 Feet, contact your local Cleaver-Brooks Representative.
B. Input calculated with Nat. Gas @ 1000 Btu/ft3, Propane @ 2500 Btu/ft3, and Oil @ 140,000Btu/gal.
C. For altitudes above 1000 Feet, contact your local Cleaver-Brooks authorized representative for verification of capacity rating.
Table B3-5. Model 5 Steam Boiler Ratings
B3-14
09-09
Commercial Boilers
Model M5 Boilers
Table B3-6. Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity)
Operating
Pressure
(PSIG)
1500
2000
2500
3000
3500
4000
4500
5000
6000
15
20
30
40
2-1/2
50
2-1/2
65
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
1-1/2
2-1/2
2-1/2
2-1/2
1-1/2
1-1/2
1-1/2
2-1/2
2-1/2
2-1/2
1-1/2
1-1/2
1-1/2
1-1/2
2-1/2
75
95 - 125
150
200
250 - 400
BOILER SIZE
A. Standard nozzle size for 150 PSIG MAWP Boiler Design

standard 3" nozzle.
standard 3" nozzle.
Table B3-7. Model 5 Oil Fuel Requirements

BOILER
MODEL
1500 2000 2500 3000 3500 4000 4500 5000 6000 8000 LWV
OIL
USAGEA
(GPH)
10.7
14.3
17.9
21.4
25.0
28.6
32.7
35.7
42.8
57.2
NOTES:
1.Oil supply lines to be sized for 125 gph pumping rates.
2.Oil pump suction pressure -10 Hg to 3 psig.
A.Usage Based on #2 Fuel @ 140,000 Btu/gal.
B3-15
09-09
Model M5 Boilers
Commercial Boilers
PILOT GAS TRAIN

ITEM
PART
SIZE (IN.)
SIZE 1500 - 3000

1
Gas Inlet
Shutoff Cock
1-1/2
Main Regulator
Pilot Regulator
1/2
Solenoid Valve
1/2
Valve (POC)
Low Gas Pressure (Switch or Sensor)
1/2
1-1/2
1-1/2
MAIN GAS TRAIN
1/4
10
Shutoff Valve
1-1/2
1/4
11
Butterfly Valve
1-1/2
SIZES 3500 TO 5000

1
Gas Inlet
Shutoff Cock
Main Regulator
Pilot Regulator
1/2
Solenoid Valve
1/2
Valve (POC)
1/4
1/4
1/2
10
Shutoff Valve
11
Butterfly Valve
Gas Inlet
Shutoff Cock
Main Regulator
Pilot Regulator
1/2
Solenoid Valve
1/2
Valve (STD)
Valve (POC)
1/4
1/4
SIZE 6000 To 8000

2
1/2
2-1/2
2
2
10
Shutoff Valve
11
Butterfly Valve
Figure B3-3. Standard Gas Train Model 5
B3-16
09-09
Commercial Boilers
Model M5 Boilers
Table B3-8. Model M5 minimum required Natural Gas pressure at entrance to the standard UL, FM & XL GAP
gas trains (upstream of gas pressure regulator).
BOILER
SIZE
INLET PIPE
SIZE
(inches)
HONEYWELL
VALVE SIZE
(inches)
MIN ("W.C.)
MAX ("W.C.)
REQUIRED FUEL
FLOW (SCFH)
1500
1.5
1.5
4.3
28.0
1500
2000
1.5
1.5
8.4
28.0
2000
2500
1.5
1.5
11.3
28.0
2500
3000
1.5
1.5
14.9
28.0
3000
PRESSURE REQUIRED
3500
2.0
2.0
10.0
28.0
3500
4000
2.0
2.0
11.9
28.0
4500
2.0
2.0
11.5
28.0
4000
4500
5000
2.0
2.0
16.0
28.0
5000
2.0
2.0
20.4
28.0
6000
2.5
19.9
19.9
28.0
8000 LW V
6000
8000
Table B3-9. Model M5 minimum required Natural Gas pressure at entrance to the oversized standard UL, FM
& XL GAP gas trains (upstream of gas pressure regulator).
PRESSURE REQUIRED
HONEYWELL
VALVE SIZE
(inches)
2.0
MIN ("W.C.)
MAX ("W.C.)
REQUIRED FUEL
FLOW (SCFH)
1500
INLET PIPE
SIZE
(inches)
2.0
2.3
28.0
1500
2000
2.0
2.0
4.8
28.0
2000
2.0
2.0
6.5
2.5
2.5
5.7
28.0
2500
2.0
2.0
9.0
2.5
2.5
6.8
28.0
3000
3.0
3.0
6.0
2.5
2.5
9.7
3.0
3.0
7.1
28.0
3500
2.5
2.5
11.8
3.0
3.0
8.5
28.0
4000
2.5
2.5
9.8
3.0
3.0
5.6
28.0
4500
2.5
2.5
12.9
28.0
5000
28.0
6000
BOILER
SIZE
2500
3000
3500
4000
4500
5000
6000
3.0
3.0
7.1
4.0
4.0
5.6
2.5
2.5
17.5
3.0
3.0
10.0
4.0
4.0
7.9
3.0
3.0
9.8
28.0
4.0
4.0
5.6
8000 LW V
8000
B3-17
09-09
Model M5 Boilers
Commercial Boilers
Table B3-10. Model M5 minimum required Propane Gas pressure at entrance to the standard UL, FM & XL
GAP gas trains (upstream of gas pressure regulator).
PRESSURE REQUIRED
HONEYWELL
VALVE SIZE
(inches)
1.5
MIN ("W.C.)
1500
INLET PIPE
SIZE
(inches)
1.5
2000
1.5
1.5
BOILER
SIZE
MAX ("W.C.)
REQUIRED FUEL
FLOW (SCFH)
6.7
28.0
600
10.5
28.0
800
2500
1.5
1.5
13.3
28.0
1000
3000
1.5
1.5
17.0
28.0
1200
3500
2.0
2.0
14.3
28.0
1400
4000
2.0
2.0
16.5
28.0
1600
4500
2.0
2.0
14.8
28.0
1800
5000
2.0
2.0
16.4
28.0
2000
2.0
2.0
19.6
28.0
6000
2.0
2.0
19.6
28.0
8000 LW V
B3-18
09-09
2400
3200
Commercial Boilers
Model M5 Boilers
Table B3-11. Model M5 minimum required Propane Gas pressure at entrance to the oversized standard UL,
FM & XL GAP gas trains (upstream of gas pressure regulator).
BOILER
SIZE
INLET PIPE
SIZE
(inches)
HONEYWELL
VALVE SIZE
(inches)
MIN ("W.C.)
MAX ("W.C.)
REQUIRED FUEL
FLOW (SCFH)
1500
2.0
2.0
5.9
28.0
600
2000
2.0
2.0
9.0
28.0
800
2.0
2.0
10.8
2.5
2.5
10.5
28.0
1000
2.0
2.0
13.8
2.5
2.5
12.9
28.0
1200
3.0
3.0
12.6
2.5
2.5
13.6
3.0
3.0
12.6
28.0
1400
2.5
2.5
15.8
3.0
3.0
14.5
28.0
1600
2.5
2.5
13.8
3.0
3.0
12.1
28.0
1800
2.5
2.5
14.8
3.0
3.0
12.5
28.0
2000
4.0
4.0
12.0
2.5
2.5
18.0
3.0
3.0
15.0
28.0
2400
4.0
4.0
14.1
2.5
2.5
13.8
2500
3000
3500
4000
4500
5000
6000
8000 LW V
PRESSURE REQUIRED
28.0
3.0
3.0
12.1
3200
Table B3-12. Safety Valve Outlet Sizes

SAFETY VALVE SETTING
15 PSIG STEAM
Boiler Size
1500
2000
2500
3000
3500
4000
4500
5000
6000
8000 LWV
VALVES
REQ'D
OUTLET SIZE
(IN.)**
150 PSIG STEAM

VALVE
CAPACITY
1
2
3161 lbs/hr
1
2
3161 lbs/hr
1
2
3161 lbs/hr
1
2
3161 lbs/hr
1
2
3161 lbs/hr
1
2-1/2
4676 lbs/hr
1
2-1/2
4676 lbs/hr
1
2-1/2
4676 lbs/hr
1
3
6942 lbs/hr
NA
NA
NA
** Fem ale Pipe Thread Connection [FPT]
VALVES
REQ'D
OUTLET SIZE
(IN.)**
1
1
1
1
1
1
1
1
1
1
1
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
1-1/2
2
2
VALVE
CAPACITY
1651
2585
2585
2585
4240
4240
4240
4240
6596
lbs/hr
lbs/hr
lbs/hr
lbs/hr
lbs/hr
lbs/hr
lbs/hr
lbs/hr
lbs/hr
B3-19
09-09
Model M5 Boilers
Commercial Boilers
PERFORMANCE DATA
Efficiency data provided in Table B3 - 13 is based on low pressure steam operation.
For high pressure steam operation contact your local Cleaver-Brooks authorized
representative for expected efficiency data.
Efficiency
Table B3-13. Predicted Efficiency, 10 PSIG operating (includes radiation and convection losses)
Boiler Size
Gas Fuel
Firing Rate
Oil Fuel
Firing Rate
Low Fire
81.6
81.1
High Fire
81.9
80.0
Low Fire
84.1
83.6
High Fire
84.4
82.5
81.6
81.3
81.6
81.5
80.3
81.5
84.1
83.8
84.1
84.0
82.8
84.0
4000
4500
5000
81.3
81.1
81.3
80.7
80.9
80.0
83.8
83.6
83.8
83.0
83.4
82.5
6000
81.6
79.8
84.1
82.4
1500
2000
2500
3000
3500
The following tables denote typical emission levels for Natural Gas and No. 2 Oil.
Please contact your local Cleaver-Brooks authorized representative if an emission
guarantee is required.
Emissions
Notice
The data in these tables represent typical emission levels only. Please contact your
local Cleaver-Brooks authorized representative if an emission guarantee is required, or for emission level information not shown in these tables.
Table B3-14. Model 5 Emission Data, Natural Gas

POLLUTANT
Table B3-15. Emission Data, No. 2 Oil

POLLUTANT
UNCONTROLLED
UNCONTROLLEDB
CO
ppmA
lb/MMBtu
200
0.15
CO
ppmA
lb/MMBtu
90
0.07
NOx
ppmA
lb/MMBtu
100
0.12
NOx
ppmA
lb/MMBtu
187
0.248
SOx
ppmA
lb/MMBtu
1
0.001
SOx
ppmA
lb/MMBtu
278
0.515
HC/VOCs
ppmA
lb/MMBtu
40
0.016
HC/VOCs
ppmA
lb/MMBtu
50
0.025
PM
ppmA
lb/MMBtu
0.01
PM
ppmA
lb/MMBtu
0.025
NOTES:
A. ppm levels corrected to 3% O2 dry basis.
B. Based on the following fuel oil constituents.
Fuel-bound nitrogen = 0.05% (max) by weight.
Sulfur = 0.5% (max) by weight.
Ash = 0.01% (max) by weight.
A. ppm levels corrected to 3% O2 dry basis.
B3-20
09-09
Commercial Boilers
Model M5 Boilers
ENGINEERING DATA
The following engineering information is provided for the Model 5 steam boiler.
Additional information may be obtained from your local Cleaver-Brooks authorized
representative.
Feedwater
combination of condensate return and raw make-up, 100% condensate return or
100% raw make-up. Proper treatment of make-up water and boiler water is
essential to the longevity and performance of the boiler. Table B3-23 depicts the
rate of make-up required and Table B3-22 shows the recommended water quality
guidelines.
As a minimum, raw make-up should be piped into a water softener and then to a
feed tank, which also can be the container that receives the system condensate
returns. Chemical feed is recommended to be fed via a quill into the water make-up
line feeding the boiler.
Blowdown
As steam is produced; unwanted solids are left behind in the boiler water and
become concentrated within the vessel. If these constituents are allowed to adhere
to the heat transfer surfaces, they will impede the flow of energy into the water.
Their removal requires proper blowdown that will include bottom and possibly
surface blowoff. For proper TDS control, surface blowoff with a TDS monitoring
device is recommended. Local codes will dictate the manner of treating the
blowdown affluent.
Boiler Stacks
General - The Model 5 boiler operates with a positive vent pressure and a vent gas
temperature that is non-condensing.
pressure design.
Therefore, the stack must be a positive
operation of the burner. The vent should be designed with proper supports and
vent passes through walls and roofs.
stack connection. Although constant pressure at the flue gas outlet is not required,
it is necessary to size the breeching and stack to limit flue gas pressure variations.
Consideration of the draft must be given where lengthy runs of breeching are
employed or unusually high stacks. Please note: the allowable pressure range for
design of the stack and breeching is negative 0.25" w.c. (-62 Pa) to a positive 0.25"
w.c. (+62 Pa) for proper light offs and combustion. NOTE: This pressure range
does not pertain to the boiler room, that is, the boiler room must be neutral or
slightly positive, never negative when using air from the boiler room for combustion.
When two or more Model 5 boilers are connected to a common breeching/stack,
one should evaluate the affects of pressure variations that may occur during boiler
sequencing while boilers are firing. It may be determined that some type of
mechanical draft system be employed to ensure proper draft at each boiler is
maintained.
Combustion Air - The burner for each boiler must be supplied with adequate volume
of uncontaminated air to support proper combustion and equipment ventilation. Air
B3-21
09-09
Model M5 Boilers
Commercial Boilers
combustion air drawn from the area immediately surrounding the boiler (boiler
room is neutral or slightly positive pressure), or with a direct vent to outside the
boiler room where air is drawn directly from the exterior of the building. Regardless
of the method, all installations must comply with NFPA 54 (National Fuel Gas Code
- NFGC) for U.S. installations and CAN/CSA B149/.1 and B149.2 for Canadian
installations.
Engineered Design - When determining boiler room air requirements for the boiler,
the "Engineered Design" method may be used.
Following this method,
consideration must be given to the size of the boiler room, airflow, and air velocity
as follows:
Two permanent air supply openings in the outer walls of the boiler room are
recommended. Locate one at each end of the boiler room, preferably below a
height of 7 feet. This allows air to sweep the length of the boiler. Refer to Figure
B3 - 4.
Air supply openings can be louvered for weather protection, but they should not be
covered with a fine mesh wire, as this type of covering has poor air flow qualities
and is subject to clogging with dirt and dust.
A vent fan in the boiler room is not recommended as it could create a slight vacuum
under certain conditions and cause variations in the quantity of combustion air.
This can result in unsafe burner performance.
It is forbidden to have the total area of the air supply openings at less than one
square foot.
Size the openings by using the formula (Area in ft2 = cfma/fpma), where cfma =
Amount of air required (cfm):
Combustion Air = Maximum boiler horsepower (bhp) times 8 cfm.
Ventilation Air = Maximum boiler horsepower (bhp) times 2 cfm.
Total Air = 10 cfm per bhp (up to 1000 feet elevation, add 3% more per 1000 feet
of added elevation).
Acceptable air velocity in the boiler room (fpm):
From floor to 7 feet high = 250 fpm.
Above 7 feet from boiler room floor = 500 fpm.
Determine the area of the boiler room air supply openings for (2) size 4500 Model
5 boilers at 750 feet elevation; each have a rating of 107 boiler horsepower. The
air openings will be 5 feet above the floor level.
The total boiler horsepower (bhp): 107 x 2 = 214 bhp.
From (F.3) above, total air required = 214 bhp x 10 = 2140 cfm.
Air Velocity: From (G.1) above = 250 fpm.
Area required: From the formula in E above, 2140 cfm/250 fpm = 8.56 square
feet total.
B3-22
09-09
Commercial Boilers
Model M5 Boilers
Area opening: 8.56 divided by 2 = 4.28 ft2 per opening (2 required).
Notice
See Table B3-24 for combustion air and flue gas flow.
Figure B3-4. Boiler Room Air Flow - Engineered Design
GAS
VENT
FRESH AIR OPENING
FRESH AIR OPENING
EXTERIOR WALL
EXTERIOR WALL
Oil Piping
General - Oil operation of the Model 5 boiler requires proper oil to the standard
burner mounted oil pump. As the combustion of oil utilizes mechanical pressure
atomization, line sizing to the pump must be sufficient to provide 125 gph of oil to
the suction side of the pump.
Oil Train Components - Oil flow to the burner is controlled by four solenoid valves.
The oil flows through a primary or safety shutoff valve into a manifold block. This
valve and the low fire valve are energized simultaneously by the flame safeguard
control and when opened, allow flow of oil to the low fire nozzle.
As the damper motor moves to high fire position, the damper motor end switches
close to energize in sequence, the intermediate and then high fire oil valve. The
purpose of the intermediate valve is to smooth the transition from low to high fire by
balancing the oil input with increasing flow of air.
High fire rating of the burner is obtained when all three nozzles are firing, assuming
proper oil pressure and normally sized nozzles.
Gas Piping
General - The Model 5 boiler requires appropriate gas supply pressure and volume
for proper operation and long burner life. The gas requirements specified in this
section must be satisfied to ensure efficient and stable combustion. Installation
B3-23
09-09
Model M5 Boilers
Commercial Boilers
must follow these guidelines and of the local authorities that have installation
jurisdiction.
Gas Train Components - Model 5 boilers are equipped with a gas train that meets
the requirements of UL as standard. These components also comply with the
recommendations of FM, XL GAP (formerly IRI/GE GAP) and ASME CSD-1. The
gas train and its components have been designed and tested to operate for the
highest combustion efficiency.
Gas Pressure Requirements - For proper and safe operation, each Model 5 boiler
requires a stable gas pressure supply. The pressure requirements are listed in
previous sections for standard gas train size, and oversized trains for reduced
available pressure.
Gas Piping - Model 5 units are standardly equipped with a gas pressure regulator.
If upstream pressure to the standard regulator will be greater than 1 psig, an
additional upstream regulator should be provided with a pressure relief valve.
For buildings or boiler rooms with gas supply pressure exceeding 28" w.c., a "full
lockup" type regulator is recommended along with proper overpressure protection.
In addition to the regulator, a plug type or "butterball" type gas shutoff cock should
be provided upstream of the regulator for use as a service valve. This is also
required to provide positive shutoff and isolate the boiler gas train during gas piping
tests.
any dirt, weld slag, or debris can deposit in the drip leg rather than into the boiler
gas train. The bottom of the drip leg should be removable without disassembling
any gas piping. The connected piping to the boiler should be supported from pipe
supports and not supported by the boiler gas train or the bottom of the drip leg.
normally Schedule 40 block iron pipe and fittings.
Gas Supply Pipe Sizing - For proper operation of a single unit or multiple units, we
recommend that the gas pipe be sized to allow no more than 0.3" w.c. pressure
drop from the source (gas header or utility meter) to the final unit location. The gas
supplier (utility) should be consulted to confirm that sufficient volume and normal
pressure are provided to the building at the discharge side of the gas meter or
supply pipe. (For installations of new boilers into an existing building, gas pressure
should be measured with a manometer to ensure sufficient pressure is available).
A survey of all connected gas using devices should be made. If appliances other
than the boiler are connected to the gas supply line, then a determination should be
made of how much flow volume (cfh = cubic feet per hour) will be demanded at
one time and the pressure drop requirements when all appliances are operating.
The total length of gas piping and all fittings must be considered when sizing the
gas piping. Total equivalent length should be calculated from the utility meter or
source to the final connection. As a minimum guideline, gas piping Tables B3 - 16
through B3 - 20 should be used. The data in these tables is from the NFPA source
book, 2006 edition.
B3-24
09-09
Commercial Boilers
Model M5 Boilers
Pipe Size
Nominal
1"
1-1/4"
1-1/2"
2"
2-1/2"
Actual I.D.
1.049
1.380"
1.610"
2.067"
2.469"
Length in feet
**Maximum Capacity in Cubic Feet of Gas per
514
1,060
1,580
3,050
4,860
10
363
726
1,090
2,090
3,340
20
284
583
873
1,680
2,680
30
243
499
747
1,440
2,290
40
215
442
662
1,280
2,030
50
195
400
600
1,160
1,840
60
179
368
552
1,060
1,690
70
167
343
514
989
1,580
80
157
322
482
928
1,480
90
148
304
455
877
1,400
100
131
269
403
777
1,240
125
119
244
366
704
1,120
150
109
209
336
648
1,030
175
102
185
313
602
960
200
**Fuel: Natural Gas
3"
3.068"
Hour (cfh)
8,580
5,900
4,740
4,050
3,590
3,260
3,000
2,790
2,610
2,470
2,190
1,980
1,820
1,700
4"
4.026"
17,500
12,000
9,660
8,290
7,330
6,640
6,110
5,680
5,330
5,040
4,460
4,050
3,720
3,460

Pipe Size
1-1/4"
1-1/2"
2"
2-1/2"
3"
1.380"
1.610"
2.067"
2.469"
3.068"
678
1,390
2,090
4,020
6,400
11,300
10
466
957
1,430
2,760
4,400
7,780
20
374
768
1,150
2,220
3,530
6,250
30
320
657
985
1,900
3,020
5,350
40
284
583
873
1,680
2,680
4,740
50
257
528
791
1,520
2,430
4,290
60
237
486
728
1,400
2,230
3,950
70
220
452
677
1,300
2,080
3,670
80
207
424
635
1,220
1,950
3,450
90
195
400
600
1,160
1,840
3,260
100
173
355
532
1,020
1,630
2,890
125
157
322
482
928
1,480
2,610
150
144
296
443
854
1,360
2,410
175
134
275
412
794
1,270
2,240
200
**Fuel: Natural Gas
Nominal
Actual I.D.
Length in feet
1"
1.049"
4"
4.026"
23,100
15,900
12,700
10,900
9,600
8,760
8,050
7,490
7,030
6,640
5,890
5,330
4,910
4,560
B3-25
09-09
Model M5 Boilers
Commercial Boilers

Pipe Size
Nominal
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
4"
Actual I.D.
Length in
feet
0.622
0.824
1.049"
1.380"
1.610"
2.067"
2.469"
3.068"
4.026"
10
1,510
3,040
5,560
11,400
17,100
32,900
52,500
92,800
189,000
20
1,070
2,150
3,930
8,070
12,100
23,300
57,100
65,600
134,000
30
869
1,760
3,210
6,590
9,880
19,000
30,300
53,600
109,000
40
753
1,520
2,780
5,710
8,550
16,500
26,300
46,400
94,700
50
673
1,360
2,490
5,110
7,650
14,700
23,500
41,500
84,700
60
615
1,240
2,270
4,660
6,980
13,500
21,400
37,900
77,300
70
569
1,150
2,100
4,320
6,470
12,500
19,900
35,100
71,600
80
532
1,080
1,970
4,040
6,050
11,700
18,600
32,800
67,000
90
502
1,010
1,850
3,810
5,700
11,000
17,500
30,900
63,100
100
462
954
1,710
3,510
5,260
10,100
16,100
28,500
58,200
125
414
836
1,530
3,140
4,700
9,060
14,400
25,500
52,100
150
372
751
1,370
2,820
4,220
8,130
13,000
22,900
46,700
175
344
695
1,270
2,601
3,910
7,530
12,000
21,200
43,300
200
318
642
1,170
2,410
3,610
6,960
11,100
19,600
40,000
500
192
401
717
1,470
2,210
4,250
6,770
12,000
24,400
1000
132
275
493
1,010
1,520
2,920
4,650
8,220
16,800
1500
106
221
396
812
1,220
2,340
3,740
6,600
13,500
**Fuel: Natural Gas

B3-26
09-09
Commercial Boilers
Model M5 Boilers
Pipe Size
Nominal
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
4"
Actual I.D.
Length in
feet
0.622
0.824
1.049"
1.380"
1.610"
2.067"
2.469"
3.068"
4.026"
10
2,350
4,920
9,270
19,000
28,500
54,900
87,500
155,000
316,000
20
1,620
3,380
6,370
13,100
19,600
37,700
60,100
106,000
217,000
30
1,300
2,720
5,110
10,500
15,700
30,300
48,300
85,400
174,000
40
1,110
2,320
4,380
8,990
13,500
25,900
41,300
75,100
149,000
50
985
2,060
3,880
7,970
11,900
23,000
36,600
64,800
132,000
60
892
1,870
3,520
7,220
10,300
20,300
33,200
58,700
120,000
70
821
1,720
3,230
6,640
9,950
19,200
30,500
54,000
110,000
80
764
1,600
3,010
6,180
9,260
17,800
28,400
50,200
102,000
90
717
1,500
2,820
5,800
8,680
16,700
26,700
47,100
96,100
100
677
1,420
2,670
5,470
8,200
15,800
25,200
44,500
90,300
125
600
1,250
2,360
4,850
7,270
14,000
22,300
39,500
80,500
150
544
1,140
2,140
4,400
6,590
12,700
20,200
35,700
72,900
175
500
1,050
1,970
4,040
6,060
11,700
18,600
32,900
67,100
200
465
973
1,830
3,760
5,640
10,900
17,300
30,600
62,400
500
283
593
1,120
2,290
3,430
6,610
10,300
18,600
38,000
1000
195
407
897
1,380
2,360
4,550
7,240
12,000
26,100
1500
156
327
616
1,270
1,900
3,650
5,820
10,300
21,000
**Fuel: Natural Gas

B3-27
09-09
Model M5 Boilers
Commercial Boilers
Pipe Size
Nominal
Actual
I.D.
Length
in feet
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
4"
0.622
0.824
1.049"
1.380"
1.610"
2.067"
2.469"
3.068"
4.026"
10
3,190
6,430
11,800
24,200
36,200
69,700
111,000
196,000
401,000
20
2,250
4,550
8,320
17,100
25,600
49,300
78,600
139,000
283,000
30
1,840
3,720
6,790
14,000
20,900
40,300
64,200
113,000
231,000
40
1,590
3,220
5,880
12,100
18,100
34,900
55,600
98,200
200,000
50
1,430
2,880
5,260
10,800
16,200
31,200
49,700
87,900
179,000
60
1,300
2,630
4,800
9,860
14,800
28,500
45,400
80,200
164,000
70
1,200
2,430
4,450
9,130
13,700
26,400
42,000
74,300
151,000
80
1,150
2,330
4,260
8,540
12,800
24,700
39,300
69,500
142,000
90
1,060
2,150
3,920
8,050
12,100
23,200
37,000
65,500
134,000
100
979
1,980
3,620
7,430
11,100
21,400
34,200
60,400
123,000
125
876
1,770
3,240
6,640
9,950
19,200
30,600
54,000
110,000
150
786
1,590
2,910
5,960
8,940
17,200
27,400
48,500
98,900
175
728
1,470
2,690
5,520
8,270
15,900
25,400
44,900
91,600
200
673
1,360
2,490
5,100
7,650
14,700
23,500
41,500
84,700
500
384
802
1,510
3,100
4,650
8,950
14,300
25,200
51,500
1000
264
551
1,040
2,130
3,200
6,150
9,810
17,300
35,400
1500
212
443
834
1,710
2,570
4,940
7,880
13,900
28,400
**Fuel: Natural Gas

B3-28
09-09
Commercial Boilers
Model M5 Boilers
Table B3-21. Sound Levels
BOILER SIZE (BHP)
SOUND LEVEL /
FIRING RATE
1500
(35)
2000
(47)
2500
(59)
3000
(71)
3500
(83)
4000
(95)
4500
(107)
5000
(119)
6000
(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
8000
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.
Table B3-22. Water Quality Requirements

Parameter
Boiler Water Limit
pH
8.3 - 10.5
Iron
0.1 ppm
Oxygen
0.1 mg/liter
2000 mho/cm
Suspended Solids
300 ppm
0 ppm as CaCO3
Total Hardness
Table B3-23. Feedwater Make-up Rates

Boiler Size
Gallons/Minute
1500
2.5
2000
3.3
2500
4.1
3000
3500
5.8
4000
6.6
4500
7.5
5000
8.3
6000
8000
9.9
13.2
B3-29
09-09
Model M5 Boilers
Commercial Boilers
Table B3-24. Model 5 Fuel, Combustion Air, and Flue Gas Flow Rates
Boiler Size
1500
Fuel Consum ption
2500
3000
3500
4000
4500
5000
6000
8000 LWV
8000
Gas
cfh
1500
1500
2500
3000
3500
4000
4500
5000
6000
Oil
gph
10.72
14.29
17.86
21.43
25.00
28.57
32.14
35.71
42.85
scfh
15,480
20,640
25,800
30,960
36,120
41,280
46,440
51,600
61,920
lb/hr
1,207
1,609
2,012
2,414
2,817
3,219
3,621
4,024
4,828
scfh
17,049
22,733
28,414
34,098
39,782
45,463
51,147
56,831
68,196
Gas
Combustion Air
Oil
Gas
Flue Gas
Oil
Notes:
2000
A.
B.
C.
lb/hr
1,269
1,692
2,115
2,538
2,961
3,384
3,808
4,231
5,077
scfh
17,520
23,360
29,200
35,040
40,880
46,720
52,560
58,400
70,080
lb/hr
1,278
1,704
2,130
2,556
2,983
3,409
3,835
4,261
5,113
scfh
17,914
23,886
29,855
35,827
41,799
47,769
53,741
59,713
71,655
lb/hr
1,357
1,809
2,261
2,714
3,166
3,618
4,070
4,523
5,427
Gas consumption, expressed in cubic feet per hour, is based on 1,000 Btu/cu.ft gas value.
Oil consumption,expressed in pounds per hour, is based on 140,000 Btu/gal oil value.
Oil supply lines must be sized for 125 gph pumping rate. Oil pum p suction pressure to be -10" Hg to 3 psig.
B3-30
09-09
Section B3
Model 5 Boilers
Boiler Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Soot Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler Trim/Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Water Volume Design (LWV), 150 Psig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Water Volume Design (LWV), 15 Psig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Fired Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Fired Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas-Oil Fired Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner and Flame Failure Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..
..
..
..
..
..
..
..
..
..
..
..
..
B3-32
B3-32
B3-33
B3-33
B3-33
B3-34
B3-34
B3-34
B3-35
B3-36
B3-37
B3-38
B3-38
B3-31
09-09
Section B3
PART 1 GENERAL
1.1
BOILER CAPACITY
A. The steam boiler shall be a Cleaver-Brooks Model 5, Series (100,
200, 700) rated at _________ lbs/hr or _____ boiler horsepower
designed for (15, 150, 250, 350 or 500) psig steam. The
maximum boiler operating pressure will be ______ psig. (Series
100 is a No.2 oil fired burner; Series 200 is a gas or No.2 oil fired
burner; Series 700 is a straight gas burner).
B. The boiler shall have a maximum output of ________ Btu/hr or
______ boiler horsepower when fired with (No.2 oil) or (natural gas
@ __________ Btu/cu-ft). The boiler shall develop ________ lbs/hr
when operating at ______ psig with feedwater temperature at
_______ o F. The boiler safety relief valve(s) shall be set at _____
psig.
C. Electrical power to the boiler shall be ______ volts, ______ phase,
____ Hz. All electrical service connections shall be made to an
electrical entrance box mounted on the right hand side of the boiler.
PART 2 PRODUCTS
2.1
BOILER DESCRIPTION
A. The boiler shall be an all steel membrane wall watertube design
with 3-pass gas travel. It shall be mounted on a heavy duty steel
frame with an integral forced draft burner and burner controls. The
complete package, boiler-burner unit, shall be certified, tested, and
labeled by CSA (Canadian Standard Association). The package
shall be completely assembled and receive a factory fire test prior to
shipment.
B. The boiler shell must be constructed and hydrostatically tested in
accordance with the A.S.M.E. Boiler and Pressure Vessel Code
Section I or IV and receive an authorized boiler inspection. A copy
of the inspection report shall be furnished to the purchaser.
C. Two downcomers shall be located at the rear of the boiler and totally
insulated from the generating tubes. The downcomers shall be 2-1/
2" OD for 35 and 47 hp; 3" OD for 59 to 83 hp, and 4" OD for 95
hp and greater. Material shall be SA-178A. The 2-1/2" and 3"
downcomers shall have 0.105" wall while the 4" downcomers shall
have 0.135" wall. The generating tubes shall be 2" OD, SA-178
Grade A with 0.095" wall thickness.
D. The upper drum shall be 20" OD Schedule 20, SA-53-B seamless
pipe with 0.375" wall. The lower drum shall be 6" nominal pipe
size, SA-53-B seamless pipe with 0.312" wall up through 150 psig
design.
E. Two lifting eyes shall be located on the top centerline of the upper
drum.
F.
Refractory shall be limited to the furnace floor, lower drum, burner
throat tile, and the formed rear furnace access door. High
temperature insulation shall be installed on the front water wall of
the furnace.
G. Observation ports shall be provided at each end of the boiler for
B3-32
09-09

H.
I.
J.
K.
L.
Section B3
The exhaust gas vent shall be located at the top rear centerline of
the boiler. A stack thermometer shall be shipped loose for field
installation by the installing contractor into the stack.
Inspection openings shall be provided in the convection area.
The lower drum shall include capped plugs in the front and rear
drum heads, and a handhole shall be provided in the rear upper
drum head for waterside inspection
The vessel shall be insulated with a minimum of 2" fiber glass
blanket. This insulation shall be covered with a sheet metal jacket.
The jacket and insulation shall be arranged for easy removal and
reinstallation if required.
The entire boiler jacket, base frame, and other components shall be
factory painted using hard finish enamel.
2.2
SOOT CLEANING
A. Soot washer lances shall be provided in the upper convection area of
the boiler, measuring the full length of the pressure vessel. Each
lance assembly shall be capable of rotating 360 degrees. This shall
ensure complete washing of the convection zone while the boiler is
operating in the low fire mode.
B. Soot washer drain troughs shall be provided at the bottom of the
boiler. These shall be furnished for each convection side running the
full length of the boiler with 2" drain connections at the bottom rear.
Inspection/cleanout openings for each trough shall be located at the
front of the boiler.
2.3
BOILER CONNECTIONS
A. The steam nozzle shall be located on the top centerline of the upper
drum and sized for steam velocity not to exceed 5000 fpm.
B. A feedwater tapping and an integral feedwater distribution pipe shall
be located in the upper drum. This distribution pipe shall blend the
feedwater with the boiler water.
C. A " surface blowoff tapping shall be provided in the rear head of
the upper drum.
D. For blowdown or boiler drain, a tapping shall be provided in the
bottom of the lower drum near the front of the boiler.
2.4
BOILER TRIM/CONTROLS
A. The primary water column shall be located on the left side of the
boiler when facing the burner. It shall be piped with union
connections for easy removal and include a full size column
blowdown valve. A gauge glass with gauge glass valves shall be
mounted to the water column.
B. A primary low water cutoff switch shall be an integral part of the
water column and shall be wired into the burner control circuit to
prevent burner operation in the event of an unsafe water level
condition.
C. To maintain proper and safe water level within the boiler, an integral
feed pump control switch shall be included within the primary water
column. This switch may be wired to a control relay for pump on/off
operation or wired to control a solenoid water make-up valve.
B3-33
09-09
Section B3

D.
E.
F.
G.
A secondary low water cutoff control of the manual reset type shall
be provided on the right hand side of the boiler, when facing the
burner. This control shall include a switch wired into the burner
circuit to prevent burner operation in the event that the primary low
water control did not function properly during an unsafe water level
condition. A control blowdown valve shall be included for
maintenance and periodic testing of the level device.
For visual indication of the internal boiler pressure, a steam pressure
gauge shall be mounted near the water column and shall include an
inspector's test cock and test connection point.
For burner operation, a minimum of three controls shall be
provided: one auto reset type for burner start and stop control, one
for burner firing rate (modulation on gas or low high low on oil), and
one manual reset type for burner shutdown in the event of excessive
steam pressure within the boiler.
In compliance with the A.S.M.E. Code, a Code rated safety relief
valve(s) shall be provided. This valve(s) may be shipped loose to
prevent any damage during shipment.
2.5
LOW WATER VOLUME DESIGN (LWV), 150 PSIG
For applications requiring the use of a low water volume vessel, the following trim,
controls and design shall be provided:
A.
B.
C.
D.
E.
The primary water column shall be located on the left side of the
boiler when facing the burner, and shall be a McDonnell-Miller
#193-7 or approved equal. It shall be piped with union
connections for easy removal and include a full size column
blowdown valve. A gauge glass with gauge glass valves shall be
mounted to the water column.
The primary water level control and water level cut-off settings shall
be installed at a level that limits the total water content within the
boiler to 75 U.S. Gallons (283.9 liters) or less at full operating
capacity.
Feedwater into the boiler shall be controlled by means of an electric
proportional feedwater valve, Worchester or approved equal,
complete with stop valve, check valve, and 3-valve by-pass.
Controls shall be provided to comply with "Guarded Plant" status
requirements.
The upper and lower drums shall be properly insulated to prevent
heat transfer onto these surfaces during combustion.
2.6
LOW WATER VOLUME DESIGN (LWV), 15 PSIG
For applications requiring the use of a low water volume vessel, the following trim,
controls and design shall be provided:
A.
B.
2.7
Controls shall be provided to comply with "Guarded Plant" status

requirements.
The upper and lower drums shall be properly insulated to prevent
heat transfer onto these surfaces during combustion.
BURNER
A. Models 1500 - 6000; all air for combustion shall be supplied by a
B3-34
09-09
B.
C.
D.
2.8
Section B3
forced draft blower mounted in the front head (wind box) above the
burner, to minimize vibration and reduce noise emissions. The
impeller shall be an enclosed centrifugal fan type, properly balanced
and direct connected to the motor shaft. Sound level shall not
exceed 80 dBA measured 3 feet in front of the burner.
Models 7500 - 8000; all air for combustion shall be supplied by a
forced draft blower mounted within the fan housing of the externally
mounted burner. The burner shall be a CB Profire Series V. The fan
shall be a squirrel cage design, properly balanced and direct
connected to the motor. Sound level shall not exceed 85 dBA
measured 3 feet in front of the burner.
When firing gas, the burner shall operate on the full modulation
mode and shall be positioned at the low position for the ignition
sequence, and shall remain in the low fire position during ignition
For oil operation, the burner shall operate on the low-high-low
principle and shall be positioned at the low position for the ignition
sequence, and shall remain in the low fire position during ignition
GAS FIRED BURNER

A. The burner shall be a high radiant multi-port type approved for
operation on natural gas.
B. Automatic electric ignition of the premix gas pilot shall be furnished.
An ultra violet (UV) flame detector shall monitor the pilot, preventing
the primary fuel valve from opening until the pilot flame has been
established. The gas pilot assembly shall include a pilot solenoid
shutoff valve, pilot regulator, and manual shutoff cock.
C. A single damper motor shall control the combustion air inlet damper
and the fuel input control valve (butterfly type) via linkage
connections. The damper motor shall modulate the burner in
accordance with system demand, responding to the boiler mounted
modulating pressure control.
D. Gas burner piping shall include a primary safety shutoff valve,
controlled by the burner flame safeguard control to start or stop the
burner. The valve shall close automatically in the event of a power
failure, excess steam pressure, low or high gas pressure, or a low
water condition.
E. A main gas pressure regulator shall be piped in the gas train to
regulate the incoming pressure for proper burner operating pressure
including an upstream manual shutoff valve.
F.
For tightness checking of the primary shutoff valve, a plugged
leakage test connection and a lubricated plug cock shall be
provided.
G. The primary shutoff valve shall be of the motorized type.
H. For sizes 6000 - 8000, a second motorized gas valve shall be
provided and piped in series with the primary shutoff valve.
I.
Low and High gas pressure switches of the manual reset type shall
be mounted and wired to prevent burner operation if gas pressure is
above or below the settings of these switches.
B3-35
09-09
Section B3

J.
2.9
To prove proper air is available for pre purge and combustion, a

combustion air proving switch shall be provided.
OIL FIRED BURNER

A. The burner shall be a pressure atomizing type approved for
operation with commercial grade No. 2 fuel oil.
B. For 1500 through 6000 units,
1. Automatic electric spark ignition for the low fire oil supply shall
be provided with a 10,000 volt ignition transformer and heavy
duty electrodes. The ignition period shall be monitored with
an electronic scanner of the UV principle to confirm the
presence of the low fire oil flame.
2. A single damper motor shall control the combustion air inlet
damper and the fuel input control valves via linkage
connections. The damper motor shall operate the burner in
accordance with system demand, responding to the boiler
mounted low high low pressure control.
3. For fuel input control, 4 solenoid type fuel oil valves shall be
piped and wired onto the front head of the boiler. Two valves
shall be used for low fire ignition and the other two for high fire
operation.
4. The fuel oil system shall include supply and return tubing to an
oil terminal block, oil pressure gauge, and shutoff cock.
5. An oil pump shall be provided and shall be integral with the
burner. The pump shall include a built-in pressure relief valve
and self cleaning strainer. Operation of the pump shall be via
belt connection to the fan motor.
C. For 7500 - 8000 units, automatic electric ignition of the premix gas
pilot shall be furnished. An ultra violet (UV) flame detector shall
monitor the pilot, preventing the primary fuel valve from opening
until the pilot flame has been established. The gas pilot assembly
shall include a pilot solenoid shutoff valve, pilot regulator, and
manual shutoff cock.
1.
A single damper motor shall control the combustion air inlet
damper and the fuel input control valve via linkage
connections. The damper motor shall modulate the burner in
mounted modulating pressure control.
2. For fuel input control, metering type fuel oil valve shall be
piped and onto the burner housing. Two solenoid valves shall
be used for safety shutoff.
3. The fuel oil system shall include supply and return tubing to an
oil terminal block, oil pressure gauge, low oil pressure
interlock, and shutoff cock.
4. An oil pump shall be provided and shall be shipped loose with
the burner. The pump shall include a built-in pressure relief
valve and self cleaning strainer. Operation of the pump shall
be via oil pump starter mounted and wired in the burner
control panel.
B3-36
09-09

2.10
Section B3
GAS-OIL FIRED BURNER

A. A. General
1. The burner shall be a high radiant multi-port type approved for
operation on natural gas and shall be a pressure atomizing type
approved for operation with commercial grade No. 2 fuel oil.
furnished. An ultra violet (UV) flame detector shall monitor the
pilot, preventing the primary fuel valve from opening until the
pilot flame has been established. The gas pilot assembly shall
include a pilot solenoid shutoff valve, pilot regulator, and
manual shutoff cock.
3. A single damper motor shall control the combustion air inlet
damper and the fuel input control valve via linkage
connections. The damper motor shall regulate the burner in
mounted pressure control.
4. To prove proper air is available for pre purge and combustion, a
combustion air proving switch shall be provided.
B. Gas System
1. Gas burner piping shall include a primary safety shutoff valve,
controlled by the burner flame safeguard control to start or stop
the burner. The valve shall close automatically in the event of a
power failure, excess steam pressure, low or high gas pressure,
or a low water condition.
2. A main gas pressure regulator shall be piped in the gas train to
regulate the incoming pressure for proper burner operating
pressure including an upstream manual shutoff valve.
3. For tightness checking of the primary shutoff valve, a plugged
leakage test connection and a lubricated plug cock shall be
provided.
4. The primary shutoff valve shall be of the motorized type.
5. For sizes 6000 - 8000, a second motorized gas valve shall be
provided and piped in series with the primary shutoff valve.
6. Low and High gas pressure switches of the manual reset type
shall be mounted and wired to prevent burner operation if gas
pressure is above or below the settings of these switches.
C. Oil System
1. For 1500 through 6000 units,
a. For fuel input control, 4 solenoid type fuel oil valves shall
be piped and wired onto the front head of the boiler. Two
valves shall be used for low fire ignition and the other two
for high fire operation.
b. The fuel oil system shall include supply and return tubing
to an oil terminal block, oil pressure gauge, and shutoff
cock.
c. An oil pump shall be provided and shall be integral with
the burner. The pump shall include a built-in pressure
relief valve and self cleaning strainer. Operation of the
pump shall be via belt connection to the fan motor.
B3-37
09-09
Section B3

2.
For 7500 - 8000 units,

a. For fuel input control, metering type fuel oil valve shall be
piped and onto the burner housing. Two solenoid valves
shall be used for safety shutoff.
b. The fuel oil system shall include supply and return tubing
to an oil terminal block, oil pressure gauge, low oil
pressure interlock, and shutoff cock.
c. An oil pump shall be provided and shall be shipped loose
with the burner. The pump shall include a built-in
pressure relief valve and self cleaning strainer. Operation
of the pump shall be via oil pump starter mounted and
wired in the burner control panel.
2.11
BURNER AND FLAME FAILURE CONTROLLER
A third party listed and approved safeguard control shall be provided to control
ignition, starting and stopping the burner, and provide pre-combustion and post
combustion air purge. The control shall stop and prevent burner operation in the
event of ignition, pilot, or main flame failures. Trial for ignition shall be limited to
10 seconds.
A.
B.
C.
D.
E.
F.
2.12
The flame safeguard control shall be a microprocessor based burner

management control system, designed to provide proper burner
sequencing, ignition, and flame monitoring protection.
Through SMART LED's, the control shall provide current operating
status and lockout information in the event of a safety shutdown.
A separate preconfigured program module shall plug in to the
microprocessor control.
For trouble shooting and retrieving history, a VFD format display
shall be mounted onto the control. This alpha numeric display shall
provide 2 lines by 16 characters per line display of operating
conditions, fault conditions, flame signal strength, and burner run
history.
In addition to the VFD display, LED Indicator Lights shall be
provided integral with the control for Fan, Open Damper, Close
Damper, Auto Operation, and Ignition.
The control shall be a CB120E or equal.
BURNER CONTROL PANEL

A. The control panel shall be mounted at the front of the boiler on the
burner fan housing (windbox) and conveniently located for the
operator. It shall be mounted within a NEMA 1A type enclosure and
include a key lock.
B. Factory mounted and wired components and controls shall include
the following:
1. Fan Motor Starter
2. Fan Motor Fuses
3. Control Circuit Transformer with fuses
4. Oil Pump Starter (size 7500 - 8000 units) firing oil.
5. Terminals for wiring connections
B3-38
09-09
Section B3
6.
7.
8.
9.
C.
Flame Safeguard Control

Burner On/Off Switch
Manual Damper Positioning Switch
Indicating lights for low water, flame failure, load demand, and
fuel valve on.
All electrical equipment shall be in conformity with CSA. Oil, heat,
and moisture resistant wire shall be used and number coded relative
to the wiring diagram.
B3-39
09-09
Section B3
Model 5 Boilers
(Hot Water Boiler Specifications)
Boiler Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-42
Boiler Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-42
Soot Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-43
Boiler Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-43
Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-43
Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-29
Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-44
No.2 Oil and Gas Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-45
Burner and Flame Failure Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-45
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-46
packages.
B3-41
09-09
Section B3
Model 5 Hot Water BoilerSpecifications
PART 1 GENERAL
1.1
BOILER CAPACITY
A. The hot water boiler shall be Cleaver-Brooks Model 5, Series ______
(100, 200, 700), _______ bhp, designed for 140 psig hot water.
The maximum supply temperature will be ______ F, and the
minimum return water temperature will be _______ F. The
minimum operating temperature of the boiler shall be 170 F. (Series
100 - No. 2 oil; 200 - No. 2 oil and gas; 700 - gas.)
B. The boiler shall have a maximum output of ______ Btu/hr, or _____
hp, when fired with No.2 oil and/or natural gas _______ Btu/cu-ft.
Safety relief valves shall be set at _______ psig.
C. Electrical power available will be ______ volts, _______ phase,
_______ Hz. All electrical service connections shall be made to an
electrical entrance box mounted on the right hand side of the boiler.
PART 2 PRODUCTS
2.1
BOILER DESCRIPTION
A.
B.
C.
D.
E.
F.
G.
H.
I.
The boiler shall be an all steel membrane wall watertube boiler with
3-pass gas travel. It shall be mounted on a heavy duty steel frame
with integral forced draft burner and burner controls. The complete
packaged boiler-burner unit shall be approved by Canadian Standard
Association and shall have the CSA label affixed to the front head.
The boiler shall be completely assembled and fire tested at the
factory.
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
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
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.
B3-42
09-09

J.
Section B3
The boiler insulation shall be a minimum of 2" fiber glass blanket.

This insulation shall be covered with a corrugated sheet metal
lagging. The lagging and insulation shall be arranged for easy
removal and reinstallation if required. The entire boiler, base frame,
and other components shall be factory painted before shipment
using a hard finish enamel.
2.2
SOOT CLEANING
A. Soot washer lances shall be provided in the convection area of the
boiler measuring full length of the pressure vessel. Each lance shall
be provided with a shutoff valve and the assembly shall be capable
of rotating 360 F. This shall ensure complete washing of the
convection zone while the boiler is operating in the low fire mode.
B. Soot washer troughs shall be provided at the bottom of the boiler.
These shall be furnished for each convection side running the full
length of the boiler with 2" drain connections at the boiler rear.
Inspection/cleanout openings for each trough shall be located at the
front of the boiler.
2.3
BOILER CONNECTIONS
A. The hot water outlet connection shall be located on the top
centerline of the boiler and the return connection shall be located at
the rear of the lower drum. The design of the boiler shall provide jet
induced circulation, which shall mix the return water with the hot
water within the boiler.
B. A dip tube shall be included as an integral part of the hot water
outlet. An air vent tapping shall be located on the top centerline of
the boiler for connection to an expansion tank.
C. Handholes shall be provided at the end of the lower drum and in the
rear of the upper drum for inspection of the water side surfaces.
2.4
BOILER TRIM
A. The low water cutoff switch shall be a probe type, mounted in the
top center-line of the boiler. It shall be wired into the burner control
circuit to prevent burner operation if the boiler water falls below a
proper level.
B. A minimum of three controls shall be provided: one auto reset type
for burner on-off control, one for burner firing rate, and one manual
reset type for burner cutout on excessive water temperature. The
sensing elements shall be located adjacent to the outlet connection.
C. A hot water circulating pump shall be mounted between the supply
and return water connections (standard on ASME Section IV heating
boilers only). This pump will blend the supply and the system return
water. It will ensure a minimum continuous circulation at all times
to a level of 10 boiler water changes per hour.
D. A combination pressure-temperature gauge shall be located on the
boiler.
E. Water relief valves shall be provided of a type and size to comply
with ASME Code requirements.
B3-43
09-09
Section B3

2.5
BURNER
A. Burner Description
1. All air for combustion shall be supplied by a forced draft blower
mounted in the front head (windbox), above the burner, to
minimize vibration and noise level.
2. The impeller shall be an enclosed centrifugal fan type, properly
balanced and directly connected to the blower motor shaft.
3. The maximum sound level shall not exceed 80 dBA measured
3 feet in front of the boiler.
4. The oil burner shall operate on the low-high-low principle and
5. The gas burner shall operate on the full modulation system and
B. Gas Fired Burner
1. The burner shall be integral with the front head of the boiler
and shall be the high radiant multi-port type approved for
operation with natural, manufactured, or mixed gas.
furnished. A UV flame detector shall monitor the pilot,
preventing the primary fuel valve from opening until the pilot
flame has been established.
3. A single damper motor shall control the combustion air damper
and the butterfly gas valve. The damper motor shall regulate
the fire according to system demand in response to the boiler
mounted temperature/pressure control.
4. The gas burner piping system on the unit shall include a
primary gas shutoff valve. It shall be controlled by the
programming relay to start or stop the burner and to close
automatically in the event of power failure, flame failure,
excessive pressure or temperature, high or low gas pressure, or
a low water condition. A lubricated shutoff cock shall be
located ahead of the primary valve for manual shutoff.
5. A plugged leakage test connection and a lubricated plug cock
are provided as a means for a tightness check of the primary
shutoff valve.
6. A gas pressure regulator shall be factory mounted and piped for
proper pressure regulation to the burner.
7. Gas Train Components
8. The primary shutoff valve shall be a motorized type. High and
low gas pressure switches shall be provided.
C. No. 2 Oil Fired Burner
1. The burner shall be integral with the front head of the boiler. It
shall be the pressure atomizing type approved for operation
with commercial grade No.2 oil.
2. The burner shall operate on the low-high-low principle, and
must return to the low-fire position prior to ignition.
B3-44
09-09

3.
4.
Section B3
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.
5.
The combustion air damper, low-fire, and high-fire oil valves

shall be operated by a single damper control motor. This motor
shall regulate the fire according to system demand in response
to the boiler mounted high-low fire temperature/pressure
control.
2.6
OIL SYSTEM
A. An oil pump shall be provided. The oil pump, integral with the
burner, shall include a built-in relief valve and self- cleaning strainer.
The pump shall be belt driven from the blower motor.
B. The fuel oil system shall include supply and return tubing to a
terminal block, oil pressure gauge, shutoff cock, and four solenoid oil
shutoff valves. These items shall be factory mounted on the front
head.
2.7
NO.2 OIL AND GAS BURNER

A. General
1. The burner shall be integral with the front head of the boiler. It
shall be the pressure atomizing type for oil and high radiant
multi-port type for gas. The burner must be approved for
operation with either commercial grade No.2 oil or natural gas.
2. The oil burner shall operate on the low-high-low principle, and
must return to the low-fire position prior to ignition.
3. The gas burner shall operate on the full modulation system and
4. The burner shall remain in the low-fire position during ignition
provided. A UV flame detector shall monitor the pilot to prevent
the primary fuel valve from opening until the pilot flame has
been established.
6. A single damper motor shall control the combustion air
damper, high and low fire oil valves, and the butterfly gas
valve. The damper motor shall regulate the fire according to
system demand in response to the boiler mounted high-low fire
temperature/pressure control.
B. Oil System
1. An oil pump shall be included. The oil pump, integral with the
burner, shall include a built-in relief valve and self-cleaning
strainer. The pump shall be belt-driven from the blower motor.
B3-45
09-09
Section B3

2.
C.
Gas
1.
2.
3.
D.
2.8
Gas
1.
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.
System
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.
Train Components
The primary shutoff valve shall be a motorized type. High and
low gas pressure switches shall be provided.
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 ignition shall be limited to 10
seconds.
2.9
CONTROL PANEL
A. The control panel shall be mounted on the front head of the boiler
and shall be conveniently located for the operator. It shall be a
NEMA 1A rated enclosure and have a Yale key lock.
B. Each boiler shall be factory-equipped with a flame safeguard
controller that provides technology and functions equal to the
Cleaver-Brooks Model CB100.
C. Flame safeguard controller shall be microprocessor based, with selfdiagnostics, 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 postpurge cycles.
D. Controller shall be the non-recycle type for maximum safety that will
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.
B3-46
09-09

E.
F.
G.
Section B3
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:
1. Display history of operating hours and totals of completed onoff cycles.
2. Provide a constant flame signal strength read-out.
3. 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.
1. A terminal board shall be provided to which all wires entering
or leaving the panel shall be connected.
2. All electrical equipment shall be in conformity with the
Canadian Standard Association requirements. Oil, heat and
moisture resistant wire shall be used and shall be number
coded.
3. A low fire hold timer shall be mounted in the panel and wired
to hold the boiler in a low firing mode, for a minimum of 10
minutes, each time the boiler cycles on. This low fire hold timer
ensures gradual boiler warm up.
B3-47
09-09
Section B3
Notes
B3-48
09-09
Section B4
Electric Resistance Boilers
Steam or Hot Water
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Equipment - Steam Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Equipment - Water Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
....
....
....
....
....
....
....
....
....
. . . . B4-3
. . . . B4-4
. . . . B4-4
. . . . B4-6
. . . . B4-8
. . . . B4-9
. . . . B4-31
. . . . B4-32
. . . . B4-39
B4-1
09-09
Section B4
Electric Boilers
ILLUSTRATIONS
Figure B4-1.
Figure B4-2.
Figure B4-3.
Figure B4-4.
Figure B4-5.
Model WB Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model S Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model CR Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model HSB Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model IWH Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B4-10
B4-11
B4-12
B4-13
B4-14
TABLES
Table B4-1 Standard Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B4-2 Model WB Ratings 208V, 240V Suppplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B4-3 Model WB Ratings 380V, 415V Suppplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B4-4 Model WB Ratings 480V, 600V Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B4-5 Model S/CR Ratings 208V, 240V Supplies) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B4-6 Model S/CR Ratings 380V, 415VV Supplies) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B4-7 Model S/CR Ratings 480V Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B4-8 Model S/CR Ratings 600V Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B4-9 Model HSB Ratings 380V, 415V Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B4-10 Model HSB Ratings 480V Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B4-11 Model HSB Ratings 600V Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B4-12 Model IWH Ratings 208V, 240V Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B4-15 Model WB Max Flow Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B4-16 Model WB Minimum Over Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . .
Table B4-17 kW per pound of steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B4-18 Electric Boilers Required Water Quality Parameters . . . . . . . . . . . . . . . . . . . . . . . .
B4-9
B4-15
B4-16
B4-19
B4-21
B4-22
B4-23
B4-25
B4-27
B4-28
B4-29
B4-30
B4-30
B4-31
B4-33
B4-35
B4-36
B4-37
This section contains information on the complete line of Cleaver-Brooks electric boilers with kilowatt output ratings from 12 to 3,375 kW. Electric boilers are typically utilized for applications where stringent environmental
regulations and boiler space requirements are critical.
B4-2
09-09
Electric Boilers
Section B4

In applications where electric power is more economically available than fossil fuels, or where fossil fuel
combustion and the handling of combustion by-products are unacceptable, electric boilers offer a viable
alternative.
Compact Design
Electric boilers are typically one-quarter to one-half the size of fuel fired boilers with similar BTU per hour
output. The smaller footprint reduces the overall boiler room space.
No Stack Requirements
With no products of combustion to contend with, installation costs are reduced by the elimination of stack
requirements. This means the unit can be located anywhere in the building and the exterior of the building is
not compromised with an unsightly stack, particularly helpful in tall or high rise buildings.
Emissions
Because there is no combustion, electric boilers are 100% emission free. This is beneficial in meeting total
emissions of the project site or in areas where fuel combustion emissions are not tolerated.
Quiet Operation
Elimination of combustion noise and minimal moving parts results in extremely quiet operation, virtually no
noise emissions. Very beneficial in applications such as hospitals, nursing homes, schools, and the like.
High Efficiency
With minimum radiation losses and not having the losses associated with combustion equipment the electric
boiler will provide nearly 100% efficiency at all operating points.
Ease of Maintenance
The absence of high maintenance combustion equipment and the use of solid state control devices reduce the
complexity and number of moving parts.
Electric elements are easily accessible and replaceable either individually or in flange mounted groups.
Pressure vessel components are not subjected to thermal stresses induced by high temperature differentials and
cycling encountered with fossil fuel combustion.
Quality Construction
ISO 9001:2001 certified manufacturing process ensures the highest degree of manufacturing standards are
always followed.
ASME Code construction ensures high quality design, safety, third party inspection, and reliability, and stamped
accordingly.
Each unit is tested and certified in accordance with UL or cUL and the Label is affixed attesting to meeting the
latest UL requirements for packaged electric boilers.
B4-3
09-09
Section B4
Electric Boilers
Progressive Sequencing Modulation

By individually controlling the heating the heating elements with solid state digital step controllers, only the
amount of heat required in response to the system demand is achievable. Virtually unlimited input control is
available with optional solid state analog current controllers, which reduces on/off cycling, excellent load
tracking, and reduced operating costs.
Designed For Heating Applications
Electric boilers are able to withstand virtually any return water temperature. With combustion by-products and
high temperature differentials eliminated, condensation and thermal shock do not limit return water
temperatures.
Because of the design characteristics, the electric boiler is well suited for applications utilizing indoor/outdoor
reset controls, radiant floor heating, snow melt systems, and ground source heat pump systems
For potable water applications, the IWH can be used with the optional epoxy lining or with the optional
stainless steel trim.
PRODUCT OFFERING
Information in this section applies to electric resistance steam or hot water boiler sizes ranging from 12 kW
through 3375 kW for operation on 208, 240, 380, 480, 575 or 600 volts, thee phase power supplies.
Installation is for indoor use only.
The complete package has been tested and certified in accordance with U.L.and is approved, listed, and bears
the U.L label (U.S.A. and Canada) for electric resistance boilers. For Canada, each vessel is registered in each
Province and the relative CRN number is attached to the boiler.
Dimensions, ratings, and product information may change to meet current market requirements and product
improvements. Therefore, use this information as a guide.
Refer to Table B4-1 as a quick reference guide to the boiler models and sizes provided.
Standard Equipment - Steam Boilers
Equipment described below is for the standard steam electric boilers offering:
A.
Model CR and S Boiler

1. Each boiler is designed and constructed in accordance with the A.S.M.E. Code; UL listed,
and are mounted on an integral steel frame. Fiberglass insulation (4" thickness) is
covered with a preformed, sectional steel painted jacket, factory installed.
2. Trim and Controls:
a. Manual Reset High Pressure Cutoff.
b. Probe Aux. Low Water Cutoff, MR.
c. Aux. Auto High Pressure Cutoff.
d. For S/CR-120 through 161:
1-Step (1) on/off pressure switch.
2-Step (2) on/off pressure switch.
e.
For Models S/CR 162 and greater:
B4-4
09-09
Electric Boilers
Section B4
Solid state electronic proportional pressure control with progressive step control with
adjustable span and inter-stage time delay.
3.
4.
5.
B.
f.
Primary Low Water Cutoff and On/Off Pump Controller.
g. Bottom and Water Column Blowdown Valves.
h. Feedwater Stop and Check Valves.
i.
A.S.M.E Pressure Relief Valve(s).
j.
Steam Pressure Gauge w/test cock.
k. Sight Gauge with drain and guards.
Model CR Boilers include an integral Feedwater Tank and Feedwater Pump Assembly
piped and wired.
Electric Equipment
a. Main Control Panel with panel door key lock.
b. Lugs for the primary power supply, top of panel ingress as standard.
c. Fuses for each contactor, 200,000 Amps interrupting capacity (AIC).
d. Contactors duty rated @ 500,000 cycles.
e. Pilot lights for "Control Power On", "High Pressure", "Low Water", and "Steps".
f.
67 watts per square inch (WSI) Incoloy 800 heating elements.
g. Control Circuit Step-down Transformer with primary and secondary fuses and
secondary control power switch.
h. Terminal strip for control wiring and external customer connections.
Vessel Inspection Openings:
S/CR120 to S/CR 162: Element Flange.
S/CR200 to S/CR302: 3 Half Coupling.
S361 and larger: 12" x 16" Manway.
Model HSB Boiler

1. Each boiler is designed and constructed in accordance with the A.S.M.E. Code; UL listed,
and are mounted on an integral steel frame. Fiberglass insulation (2" thickness) is covered
with a preformed, sectional steel painted jacket, factory installed.
a. Manual Reset High Pressure Cutoff.
b. Probe Aux. Low Water Cutoff, MR.
c. Aux. Auto High Pressure Cutoff.
d. Solid state electronic proportional pressure control with progressive step control with
e. Primary Low Water Cutoff and On/Off Pump Controller.
f.
Bottom and Water Column Blowdown Valves.
g. Feedwater Stop and Check Valves.
h. A.S.M.E Pressure Relief Valve(s).
i.
Steam Pressure Gauge w/test cock.
j.
Sight Gauge with drain and guards.
3. Electric Equipment
B4-5
09-09
Section B4
Electric Boilers
c.
d.
e.
f.
g.
4.
Fuses for each contactor, 200,000 Amps interrupting capacity (AIC).

Contactors duty rated @ 500,000 cycles.
Pilot lights for "Control Power On", "High Pressure", "Low Water", and "Steps".
75 watts per square inch (WSI) "Incoloy- 800" heating elements.
Control Circuit Step-down Transformer with primary and secondary fuses and
HSB-301 to HSB-302: 3" Half Coupling.
HSB-361 and larger: 12" x 16" Manway.
Standard Equipment - Water Boilers

Equipment described below is for the standard hot water electric boilers offering:
A.
Model WB Boiler
1. The Model WB boiler is designed and constructed in accordance with the A.S.M.E. Code;
UL listed, and are mounted on an integral steel frame. Fiberglass insulation (2" thickness)
is covered with a preformed, sectional steel painted jacket, factory installed.
a. Manual Reset High Temperature Cutoff.
b. Probe Low Water Cutoff, auto reset.
c. Aux. Auto High Temperature Cutoff.
d. For WB-120:
1-Step (1) on/off temperature switch.
3-Step (1) 3-stage electronic temperature control.
e.
3.
For Models WB 121 and above:

Solid state electronic proportional temperature control with progressive step control
with adjustable span and inter-stage time delay.
f.
Bottom drain valve.
g. A.S.M.E Pressure Relief Valve(s).
h. WB120: Separate Pressure and temperature gauge.
i.
WB-121 and above: Separate Pressure Gauge and Digital Temperature Readout.
Electric Equipment
e. Pilot lights for "Control Power On", "High Temperature", "Low Water", and "Steps".
f.
B4-6
09-09
Electric Boilers
Section B4
g.
4.
B.
Control Circuit Step-down Transformer with primary and secondary fuses and
WB-120 to WB-200: Element Flange.
WB-201 to WB-243: 3 Half Coupling.
WB-361 and larger: 12" x 16" Manway.
Model IWH Heater

1. The Model IWH water heater is designed and constructed in accordance with the A.S.M.E.
Code; UL listed, and are mounted on an integral steel frame. Fiberglass insulation (2"
thickness) is covered with a preformed, sectional steel painted jacket, factory installed.
a. Manual Reset High Temperature Cutoff.
b. Water Flow Switch - shipped loose.
c. Aux. Auto High Temperature Cutoff.
d. Stage Controls for 15 - 240 kW:
1)

For 270 kW and greater:
Solid state electronic proportional temperature control with progressive step control with
3.
4.
e. Bottom drain valve.

f.
A.S.M.E Pressure Relief Valve(s).
g. Combination Pressure and Temperature gauge - shipped loose.
Electric Equipment
e. Pilot lights for "Control Power On", "High Temperature", "Low Water", and "Steps".
f.
g. Control Circuit Step-down Transformer with primary and secondary fuses and
Element Flange.
Optional Equipment
For option details, contact the local authorized Cleaver-Brooks representative. In summary, here are the options
that can be provided with the boiler:
B4-7
09-09
Section B4
Electric Boilers
Output step enable/disable toggle switches.

Additional Pilot Lights.
Alarm relays for remote annunciation.
Alarm Horn with silence switch.
Safety Door Interlock.
Outdoor reset control.
Time Clock.
Ammeter.
Voltmeter.
Kilowatt hour meter.
Ground Fault Detection.
Pneumatic control interface (3-15 or 6 - 30 psig to 0 - 145 ohms.)
Load limiting module.
Auxiliary Low Water Cutoff.
Preheat Switch for elements.
Manual Disconnect Switches.
Shunt Trip for disconnect switches.
Main Power Door Interlock (standard with switchgear below 600 AMPS).
Blowdown Separators.
Water Softener.
Chemical Feed Systems.
SCR controls
Local/Remote control
BMS interface
Return water baffle
Conductivity control
Optional choices also available for nozzles, inspection hand holes, and valves.
B4-8
09-09
Electric Boilers
Section B4
Table B4-1. Standard product offering

Product Type
Boiler Model
Output (kW)
Element
Density (W/sq
in)
Water Content
(gallons)
Design
Pressure (psig)
Hot water boilers
WB
12 - 3360
75
16 - 500
160 , 200,
250
12 - 1944
67
16 - 595
15, 150, 200,

250
CR
12 - 563
67
16 - 115
15, 150, 200,

250
1, 2
HSB
1560 - 3375
75
180 - 790
15, 150, 200,

250
IWH
15 - 360
75
135 - 360*
160
Steam boilers
Instantaneous
Water Heaters
Notes
Notes: 1. Heating elements are of Incolloy-800 construction

2. Model CR identical to Model S but has integral condensate return tank and pump.
A. Water content not applicable. Flow rate in GPM is listed.

For layout purposes, the overall dimensions for the Electric Boilers are shown in Figures B4-1 through B4-5
including the various pipe connections sizes for supply and return water, drain, and steam supply.
Specific ratings of each model are noted in Tables B4-2 through B4-10. These tables provide the ampacity at
the various supply voltages, element ratings, and contactors employed in the standard models.
Altitude
Because the electric boiler does not require combustion air, installation of the boiler at any elevation is possible
without derating or providing special devices for altitude correction normally associated with fuel combustion.
Thus the ratings shown are for all elevations.
B4-9
09-09
Section B4
Electric Boilers
D
A
MODEL NO
DIMENSIONS (IN.)
CONNECTION SIZE (NPT)
WIDTH DEPTH HEIGHT INLET

SUPPLY RETURN DRAIN
APPROIXMATE
WEIGHTS (LBS.)
CLEARANCES
TOP
SIDES
REAR
SHIPPING OPERATING
WB-120
3/4
28
25
37
12
15
12
450
WB-121
3/4
28
25
37
12
15
12
500
580
630
WB-122
3/4
36
29
54
12
15
12
800
1005
WB-201
4*
4*
1-1/4
50
42
72
14
18
18
18
1400
2040
WB-202
4*
4*
1-1/4
46
38
66
14
18
18
18
1500
2140
WB-241
6*
6*
1-1/2
50
42
72
18
18
21
18
2200
3200
WB-242
6*
6*
1-1/2
50
42
72
18
18
21
18
2400
3400
WB-243
6*
6*
1-1/2
56
44
80
18
18
21
18
2800
3980
WB-361
6*
6*
1-1/2
62
54
72
20
24
24
24
3300
5260
WB-362
8*
8*
1-1/2
62
54
88
23
24
24
24
3600
6220
7280
WB-363
8*
8*
68
72
100
23
24
24
36
4200
WB-421A
10 *
10 *
68
72
86
24
24
30
36
5800
9300
WB-422A
10 *
10 *
68
72
100
24
24
30
36
6500
10500
NOTES:
Dimensional heights are for the boiler only. Control panel size varies based
on the number of steps and optional equipment.
A.These models normally supplied with 2 control cabinets for 2 power supplies.
*These are flange connections; 150# ANSI.
Figure B4-1. Model WB Dimensions

B4-10
09-09
Electric Boilers
Section B4
F
E
OUTLET
RELIEF
LWCO
ALWCO
LWCO
C
D
BLOWDOWN

MODEL
NO
DIMENSIONS (IN.)
CLEARANCES
BLOWDOWN
STEAM OUTLET*
FEED- WIDTH DEPTH HEIGHT LWCO
15 PSIG 150 PSIG 15 PSIG 150 PSIG WATER
A
B
C
D
TOP
SIDES
APPROIXMATE
WEIGHTS (LBS.)
SHIPPING OPERATING
S-120
3/4
3/4
1-1/2
1-1/4
1/2
28
25
37
20
12
18
600
675
S-161
3/4
3/4
1-1/4
1/2
28
29
54
34
12
18
750
880
S-162
3/4
3/4
1/2
28
29
54
34
12
18
800
930
S-200
3 flg
3/4
33
33
66
41
12
18
1150
1480
S-241
1-1/4
4 flg
3/4
50
42
72
41
12
18
1400
1900
S-242
1-1/4
4 flg
3/4
50
42
72
41
12
18
1600
2000
S-301
1-1/2
6 flg
3 flg
3/4
56
48
72
40
15
21
2100
3000
S-302
1-1/2
6 flg
3 flg
3/4
56
48
88
50
15
21
2200
3300
S-361
1-1/2
8 flg
4 flg
3/4
62
54
72
42
18
24
2900
4000
S-362
1-1/2
8 flg
4 flg
3/4
62
54
72
52
18
24
3200
4800
S-421
1-1/2
8 flg
4 flg
68
60
72
41
18
27
4150
5800
S-422
1-1/2
8 flg
4 flg
68
60
88
51
18
27
4500
6700
S-480
1-1/4
10 flg
6 flg
74
66
92
53
18
27
5450
8000
NOTES: Dimensional heights are for the boiler only. Control Panel size varies based on the number of steps and optional equipment.
* Steam Outlet is MPT connection unless otherwise noted.
Figure B4-2. Model S Dimensions

B4-11
09-09
Section B4
Electric Boilers
E
OUTLET
C
CONDENSATE
DRAIN
BLOWDOWN

MODEL
NO
BLOWDOWN
APPROIXMATE WEIGHTS
(LBS.)
DIMENSIONS (IN.)
STEAM OUTLET*
COND. OVER15 PSIG 150 PSIG 15 PSIG 150 PSIG RETURN FLOW
WIDTH
DEPTH HEIGHT LWCO
SHIPPING
OPERATING
CR-120
3/4
3/4
1-1/2
1-1/4
3/4
3/4
28
38
37
20
850
950
CR-161
3/4
3/4
1-1/4
28
41
54
28
1050
1200
CR-162
3/4
3/4
28
41
54
34
1150
1280
CR-200
3 flg
1-1/4
1-1/4
35
45
66
41
1650
2030
CR-241
1-1/4
4 flg
1-1/2
1-1/2
50
50
72
41
2000
2600
CR-242
1-1/4
4 flg
1-1/2
1-1/2
50
50
72
41
2200
2700
* Steam Nozzle connection is MPT unless noted otherwise
Figure B4-3. Model CR Dimensions
B4-12
09-09
Electric Boilers
Section B4
36
36
PRESSURE
CONTROLS
24
RELIEF VALVES
LWCO/ALWCO
SURFACE BLOWOFF
CHEMICAL FEED
LWCO/ALWCO
FEEDWATER
BLOWDOWN
CONNECTION SIZE (NPT)*

MODEL
NO
DIMENSIONS (IN.)
CLEARANCES
BLOWDOWN
STEAM OUTLET*
FEED- WIDTH DEPTH HEIGHT LWCO
15 PSIG 150 PSIG 15 PSIG 150 PSIG WATER
A
B
C
D
TOP
SIDES
APPROIXMATE
WEIGHTS (LBS.)
SHIPPING OPERATING
HSB-423
1-1/2
10
116
68
62
34
24
36
5700
HSB-424
1-1/2
10
132
68
62
34
24
36
6400
8000
9300
HSB-425
1-1/2
10
140
68
62
34
24
36
7100
10600
NOTES: Dimensional heights are for the boiler only. Control Panel size varies based on the number of steps and optional equipment.
* Steam Outlet is 150# ANSI Flange connection unless otherwise noted.
Figure B4-4. Model HSB Dimensions
B4-13
09-09
Section B4
Electric Boilers
RL*
D
typ
RR*
RELIEF VALVE
C
DRAIN
*MINIMUM CLEARANCE FOR MAINTENANCE OR ELEMENT REMOVAL
MODEL NO
DIMENSIONS (IN.)
WIDTH DEPTH HEIGHT INLET

SUPPLY RETURN DRAIN
IWH-611
3/4
APPROIXMATE
WEIGHTS (LBS.)
CLEARANCES
INLET
LEFT
RIGHT
RL
RR
30
18
34
8-1/2
20
12
36
250
295
FRONT SHIPPING OPERATING
IWH-811
3/4
30
18
34
9-1/2
36
36
36
450
525
IWH-812
3/4
42
26
26
9-1/2
36
36
36
450
525
IWH-822
3/4
64
22
26
9-1/2
36
36
36
500
630
IWH-022
3*
3*
3/4
64
26
30
10
36
36
36
600
810
NOTES:
Dimensional heights are for the boiler only. Control panel size varies based on the
number of steps and optional equipment.
*For flow rates above 240 gpm, specify 4" flanged connections.
Figure B4-5. Model IWH Dimensions
B4-14
09-09
Electric Boilers
Section B4
Table B4-2. Model WB Ratings 208V, 240V Suppplies
# of
CONTACTORS
NUMBER and kW oF
STEPS
kW
208/240V
208-240V
208V
240V
1@12
34
30
1@18
51
44
82
1@24
68
59
30
102
1@30
84
73
36
123
1@36
101
87
45
154
1@30,1@15
126
109
54
184
1@36,1@18
151
131
60
205
12
2@30
167
145
72
246
12
2@36
201
174
MODEL
Vessel
Capacity
(gallons)
Rated kW
MBTU/HR
Qty
WB-120
16
12
41
18
61
24
WB-121
WB-122
WB-201
16
25
78
ELEMENTS
3-PHASE AMPERES
90
307
15
2@36,1@18
251
217
108
368
18
3@36
301
261
126
430
21
3@36,1@18
351
304
144
491
24
4@36
401
347
162
553
27
4@36,1@18
451
391
180
614
30
10
5@36
501
434
198
676
33
11
5@36,1@18
551
477
216
737
36
12
6@36
601
521
234
798
39
13
6@36,1@18
651
564
252
860
42
14
7@36
701
607
270
921
45
15
7@36,1@18
751
651
288
983
48
16
8@36
801
694
324
1105
54
18
6@54
901
781
360
1228
60
20
4@54,4@36
1001
868
396
1350
66
22
6@54,2@36
1101
954
432
1474
72
24
8@54
1201
1041
B4-15
09-09
Section B4
Electric Boilers
Table B4-3. Model WB Ratings 380V, 415V Suppplies

MODEL
WB-120
WB-121
WB-122
WB-201
WB-202
WB-241
WB-242
Vessel
Capacity
(gallons)
16
16
25
78
78
122
122
Rated kW
MBTU/
HR
ELEMENTS
Qty
kW
# of
CONTACTORS
NUMBER and kW of
STEPS
380/415
208-240V
380V
415V
3-PHASE AMPERES
15
51
1@15
23
21
30
102
1@30
46
42
45
154
1@15, 1@30
68
63
60
205
12
2@30
91
83
75
256
15
1@15, 2@30
114
104
125
90
307
18
3@30
137
105
358
21
1@15, 3@30
160
146
120
409
24
4@30
182
167
135
461
27
1@15, 4@30
205
188
150
512
30
5@30
228
209
165
563
33
1@15, 5@30
251
230
180
614
36
6@30
273
250
195
665
39
1@15, 6@30
296
271
210
717
42
7@30
319
292
225
768
45
1@15, 7@30
342
313
240
819
48
8@30
365
334
270
921
54
7@30, 1@60
410
376
417
300
1024
60
10
6@30, 2@60
456
330
1126
66
11
5@30, 3@60
501
459
360
1228
72
12
4@30, 4@60
547
501
390
1331
78
13
3@30, 7@60
593
543
420
1433
84
14
2@30, 6@60
638
584
450
1535
90
15
1@30, 7@60
684
626
668
480
1638
96
16
8@60
729
510
1740
51
10
17
3@30, 7@60
775
710
540
1842
54
10
18
2@30, 8@60
820
751
570
1945
57
10
19
1@30, 9@60
866
793
600
2047
60
10
20
10@60
912
835
630
2150
63
10
21
3@30, 9@60
957
876
660
2252
66
10
22
2@30, 10@60
1003
918
690
2354
69
10
23
1@30, 11@60
1048
960
720
2457
72
10
24
12@60
1094
1002
750
2559
75
10
25
11@60, 1@90
1140
1043
780
2661
78
10
26
10@60, 2@90
1185
1085
810
2764
81
10
27
9@60, 3@90
1231
1127
840
2866
84
10
28
8@60, 4@90
1276
1169
870
2968
87
10
29
7@60, 5@90
1322
1210
900
3071
90
10
30
6@60, 6@90
1367
1252
930
3173
93
10
31
5@60, 7@90
1413
1294
960
3276
96
10
32
4@60, 8@90
1459
1336
B4-16
09-09
Electric Boilers
Section B4
Table B4-3. Model WB Ratings 380V, 415V Suppplies (Continued)

MODEL
WB-243
WB-362
WB-363
WB-421
Vessel
Capacity
(gallons)
142
315
370
425
ELEMENTS
# of
CONTACTORS
NUMBER and kW of
STEPS
3-PHASE AMPERES
Rated kW
MBTU/
HR
Qty
kW
380/415
208-240V
380V
990
3378
99
10
33
3@60, 9@90
1504
1377
1020
3480
102
10
34
2@60, 10@90
1550
1419
1050
3583
105
10
35
1@60, 11@90
1595
1461
1080
3685
108
10
36
12@90
1641
1503
415V
1110
3787
111
10
37
5@60, 9@90
1687
1544
1140
3890
114
10
38
4@60, 10@90
1732
1586
1170
3992
117
10
39
3@60, 11@90
1778
1628
1200
4094
120
10
40
2@60, 12@90
1823
1669
1230
4197
123
10
41
1@60, 13@90
1869
1711
1260
4299
126
10
42
14@90
1914
1753
1290
4401
129
10
43
5@60, 11@90
1960
1795
1320
4504
132
10
44
4@60, 12@90
2006
1836
1350
4606
135
10
45
3@60, 13@90
2051
1878
1380
4709
138
10
46
2@60, 14@90
2097
1920
1410
4811
141
10
47
1@60, 15@90
2142
1962
1440
4913
144
10
48
16@90
2188
2003
1470
5016
147
10
49
5@60, 13@90
2233
2045
1500
5118
150
10
50
4@60, 14@90
2279
2087
1530
5220
153
10
51
3@60, 15@90
2325
2141
1560
5323
156
10
52
2@60, 16@90
2370
2170
1590
5425
159
10
53
1@60, 17@90
2416
2212
1620
5527
162
10
54
18@90
2461
2254
1650
5630
165
10
55
17@90, 1@120
2507
2296
1680
5732
168
10
56
16@90, 2@120
2553
2337
1710
5835
171
10
57
15@90, 3@120
2598
2379
1740
5967
174
10
58
14@90, 4@120
2644
2421
1770
6039
177
10
59
13@90, 5@120
2689
2463
1800
6142
180
10
60
12@90, 6@120
2735
2504
1830
6244
183
10
61
11@90, 7@120
2780
2546
1860
6346
186
10
62
10@90, 8@120
2826
2588
1890
6449
189
10
63
9@90, 9@120
2872
2629
2671
1920
6551
192
10
64
8@90, 10@120
2917
1950
6653
195
10
65
7@90, 11@120
2963
2713
1980
6756
198
10
66
6@90,12@120
3008
2755
B4-17
09-09
Section B4
Electric Boilers
Table B4-3. Model WB Ratings 380V, 415V Suppplies (Continued)
MODEL
WB-422
Vessel
Capacity
(gallons)
500
ELEMENTS
# of
CONTACTORS
NUMBER and kW of
STEPS
3-PHASE AMPERES
Rated kW
MBTU/
HR
Qty
kW
380/415
208-240V
380V
2010
6858
201
10
67
5@90, 13@120
3054
2796
2040
6960
204
10
68
4@90, 14@120
3100
2838
415V
2070
7063
207
10
69
6@90, 15@120
3145
2880
2100
7165
210
10
70
2@90, 16@120
3191
2922
2130
7268
213
10
71
1@90, 17@120
3236
2963
2160
7370
216
10
72
18@120
3282
3005
2190
7472
219
10
73
23@90, 1@120
3327
3047
2220
7575
222
10
74
22@90, 2@120
3373
3089
2250
7677
225
10
75
21@90, 3@120
3419
3130
2280
7779
228
10
76
20@90, 4@120
3464
3172
2310
7882
231
10
77
19@90, 5@120
3510
3214
2340
7984
234
10
78
18@90, 6@120
3555
3256
2370
8086
237
10
79
17@90, 7@120
3601
3297
2400
8189
240
10
80
16@90, 8@120
3647
3339
2430
8291
243
10
81
15@90, 9@120
3692
3381
2460
8394
246
10
82
14@90, 10@120
3738
3422
2490
8496
249
10
83
13@90, 11@120
3783
3464
2520
8598
252
10
84
12@90, 12@120
3829
3506
B4-18
09-09
Electric Boilers
Section B4
Table B4-4. Model WB Ratings 480V, 600V Supplies

Model
Vessel
Capacity
(gallons)
WB-120
16
WB-121
16
WB-122
25
WB-201
78
WB-202
78
WB-241
122
WB-242
122
WB-243
WB-243
WB-361
142
142
235
ELEMENTS
Rated kW
MBTU/HR
# of
NUMBER and kW of
CONTACTORS
STEPS
3-PHASE AMPERES
Qty
kW
480/600V
480/600V
480V
600V
3
3
6
6
6
9
9
12
12
15
18
21
24
27
30
33
36
39
42
45
48
54
60
66
72
78
84
90
96
60
63
66
69
72
75
78
81
84
87
90
93
96
4
6
4
5
6
5
6
5
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
10
10
10
10
10
10
10
10
10
10
10
10
10
1 @ 12
1 @ 18
1 @ 24
1 @ 30
1 @ 36
1 @ 45
1 @ 54
2 @ 30
2 @ 36
2 @ 36, 1 @18
3 @ 36
3 @36, 1 @18
4 @ 36
3 @36, 1 @54
5 @ 36
5 @36, 1@18
6 @ 36
6 @36, 1 @18
7 @ 36
7 @36, 1 @18
8 @ 36
3 @72, 3 @36
2 @72, 6 @36
3 @72, 5 @36
4 @72, 4 @36
5 @72, 3 @36
6 @72, 2 @36
7 @72, 1 @36
8 @72
10 @ 60
3 @30, 9 @60
2 @30, 10 @60
1@30, 11 @60
12 @60
5 @90, 5 @60
6 @90, 4 @60
7 @90, 3 @60
8 @90, 2 @60
9 @90, 1 @60
10 @ 90
7 @90, 5 @60
8 @90, 4 @60
9 @90, 3 @60
15
22
30
37
44
55
66
73
87
109
131
152
174
196
212
239
261
282
304
326
347
391
434
477
521
564
607
651
694
723
759
795
831
868
904
940
976
1012
1048
1084
1120
1157
13
18
24
29
35
44
53
58
70
87
105
122
139
157
174
191
209
226
243
261
278
313
347
382
417
451
486
521
555
579
607
636
665
694
723
752
781
810
838
868
896
925
1193
954
1229
983
12
18
24
30
36
45
54
60
72
90
108
126
144
162
180
198
216
234
252
270
288
324
360
396
432
468
504
540
576
600
630
660
690
720
750
780
810
840
870
900
930
960
41
61
82
102
123
154
184
205
246
307
368
430
491
553
614
676
737
798
860
921
983
1105
1228
1350
1474
1597
1720
1842
1965
2047
2150
2252
2354
2457
2559
2661
2764
2866
2968
3071
3173
3276
990
3378
99
10
1
1
1
1
1
2
2
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
10
11
12
13
14
15
16
20
21
22
23
24
25
26
27
28
29
30
31
32
33
1020
3480
102
10
34
10 @90, 2 @60
11 @90, 1 @60
1050
3583
105
10
35
1265
1012
1080
3685
108
10
36
12 @ 90
1301
1041
1110
3787
111
10
37
9 @90, 5 @60
1337
1070
1140
3890
114
10
38
10 @90, 4 @60
1373
1099
11 @90, 3 @60
1170
3992
117
10
39
1409
1128
1200
4094
120
10
40
12 @90, 2 @60
1446
1157
1224
4176
102
12
34
10 @108, 2 @72
1474
1180
1260
4299
105
12
35
11 @108, 1 @72
1518
1214
1296
4422
108
12
36
12 @ 108
1561
1249
B4-19
09-09
Section B4
Electric Boilers
Table B4-4. Model WB Ratings 480V, 600V Supplies (Continued)
WB-362
WB-363
WB-421
WB-422
315
370
425
500
1332
4545
111
12
37
9 @108, 5 @72
1605
1284
1368
4668
114
12
38
10 @108, 4 @72
1648
1318
1404
4790
117
12
39
11 @108, 3 @72
1691
1353
12 @108, 2 @72
1440
4913
120
12
40
1735
1388
1476
5036
123
12
41
13 @108, 1 @72
1778
1422
1512
5159
126
12
42
14 @ 108
1821
1457
1548
5282
129
12
43
11 @108, 5 @72
1865
1492
1584
5405
132
12
44
12 @108, 4 @72
1908
1527
13 @108, 3 @72
1620
5527
135
12
45
1951
1561
1656
5650
138
12
46
14 @108, 2 @72
1995
1596
1692
5773
141
12
47
15 @108, 1 @72
2038
1631
1728
5896
144
12
48
16 @ 108
2081
1665
1764
6019
147
12
49
13 @108, 5 @ 72
2125
1700
14 @108, 4 @ 72
2168
1735
1800
6142
150
12
50
1836
6264
153
12
51
15 @108, 3 @ 72
2211
1769
1872
6387
156
12
52
16 @108, 2 @ 72
2255
1804
1908
6510
159
12
53
17 @108, 1 @ 72
2298
1839
1944
6633
162
12
54
18 @ 108
2342
1873
1980
6756
165
12
55
15 @108, 5 @ 72
2385
1908
16 @108, 4 @ 72
2428
1943
2016
6879
168
12
56
2052
7001
171
12
57
17 @108, 3 @ 72
2472
1977
2088
7124
174
12
58
18 @108, 2 @ 72
2515
2012
20 @ 108
2160
7370
180
12
60
2602
2081
2240
7643
168
13.3
56
16 @120, 4 @ 80
2698
2158
2320
7916
174
13.3
58
18 @ 120, 2 @ 80
2794
2236
2400
8189
180
13.3
60
20 @ 120
2891
2313
2480
8462
183
13.3
62
2 @160, 18 @120
2987
2390
2560
8735
192
13.3
64
4 @160, 16 @120
3083
2467
6 @160, 14 @120
2640
9008
198
13.3
66
3180
2544
2720
9281
204
13.3
68
8 @160, 12 @120
3276
2621
2800
9554
210
13.3
70
10 @160, 10 @120
3372
2698
2880
9827
216
13.3
72
12 @160, 8 @120
3469
2775
15 @160, 5 @120
3000
10236
225
13.3
75
3613
2891
3040
10372
228
13.3
76
16 @160, 4 @120
3661
2929
3120
10509
234
13.3
78
18 @160, 2 @120
3758
3006
3200
10645
240
13.3
80
20 @ 160
3854
3083
3280
11191
246
13.3
82
18 @160, 2 @200
3950
3160
13.3
84
4 @200, 16 @160
4047
3237
3360
11464
252
B4-20
09-09
Electric Boilers
Section B4
Table B4-5. Model S/CR Ratings 208V, 240V Supplies)
Model
S-120 or
CR-120
S-161 or
CR-161
S-162 or
CR-162
S-200 or
CR-200
S-241 or
CR-241
S-242 or
CR-242
Vessel
Capacity
(gallons)
23
23
48
62
62
Steam
Space
(gallons)
ASME
Rated kW (Steam lbs/
hr)
ELEMENTS
# of
NUMBER and kW of
3-PHASE AMPERES
CONTACTORS
STEPS
Qty
kW
208/240V
208/240V
208V
240V
12
42
1 @ 12
34
30
24
84
1 @ 24
68
59
36
126
1 @ 36
101
88
48
168
12
2 @ 24
134
116
60
210
6.7
1 @40, 1 @20
168
145
16
16
26
53
53
80
280
12
6.7
2 @ 40
223
193
100
350
15
6.7
2 @40, 1 @20
279
242
120
420
18
6.7
3 @ 40
334
290
140
490
21
6.7
3 @ 40, 1 @ 20
390
338
160
560
24
6.7
4 @ 40
445
386
180
630
27
6.7
4 @40, 1 @20
501
434
200
700
30
6.7
10
5 @ 40
556
482
220
770
33
6.7
11
5 @40, 1 @ 20
612
530
240
840
36
6.7
12
6 @ 40
667
578
260
910
39
6.7
13
6 @40, 1 @ 20
723
626
280
980
42
6.7
14
7 @ 40
778
675
300
1050
45
6.7
15
7 @ 40, 1 @ 20
834
723
320
1120
48
6.7
16
8 @ 40
889
771
340
1190
51
6.7
17
8 @ 40, 1 @ 20
945
819
360
1260
54
6.7
18
2 @ 60, 6 @ 40
1000
867
380
1330
57
6.7
19
3 @ 60, 5 @ 40
1056
915
400
1400
60
6.7
20
4 @ 60, 4 @ 40
1111
963
B4-21
09-09
Section B4
Electric Boilers
Table B4-6. Model S/CR Ratings 380V, 415V Supplies

Model
Vessel
Capacity
(gallons)
S/CR-161
23
S/CR-162
23
S/CR-200
48
S/CR-241
62
S/CR-242
62
S-301
110
S-362
S-421
210
S-422
270
S-480
360
Rating kW
15
30
45
60
75
90
105
120
135
150
165
180
210
240
270
300
330
360
390
420
450
480
510
540
570
600
630
660
690
720
750
780
810
840
870
900
930
960
990
1020
1050
1080
1110
1140
1170
1200
1230
1260
1290
1320
1350
1380
1410
1440
1470
1500
1530
1560
1590
1620
# of
No. of
Steam lb./hr
Elements Qty CONTACTORS
0
@ 212 F
@ kW
51
3@5
1
102
6@5
1
154
9@5
2
205
12 @ 5
2
256
15 @ 5
3
307
18 @ 5
3
358
21 @ 5
4
409
24 @ 5
4
461
27 @ 5
5
512
30 @ 5
5
563
33 @ 5
6
614
36 @ 5
6
717
21 @ 10
7
819
24 @ 10
8
921
27 @ 10
9
1024
30 @ 10
10
1126
33 @ 10
11
1228
36 @ 10
12
1331
39 @ 10
13
1433
42 @ 10
14
1535
45 @ 10
15
1638
48 @ 10
16
1740
51 @ 10
17
1842
54 @ 10
18
1945
57 @ 10
19
2047
60 @ 10
20
2150
63 @ 10
21
2252
66 @ 10
22
2354
69 @ 10
23
2457
72 @ 10
24
2559
75 @ 10
25
2661
78 @ 10
26
2764
81 @ 10
27
2866
84 @ 10
28
2968
87 @ 10
29
3071
90 @ 10
30
3173
93 @ 10
31
3276
96 @ 10
32
3378
99 @ 10
33
3480
102 @ 10
34
3583
105 @ 10
35
3685
10 8@ 10
36
3787
111 @ 10
37
3890
114 @ 10
38
3992
117 @ 10
39
4094
120 @ 10
40
4197
123 @ 10
41
4299
126 @ 10
42
4401
129 @ 10
43
4504
132 @ 10
44
4606
135 @ 10
45
4709
138 @ 10
46
4811
141 @ 10
47
4913
144 @ 10
48
5016
147 @ 10
49
5118
150 @ 10
50
5220
153 @ 10
51
5323
156 @ 10
52
5425
159 @ 10
53
5527
162 @ 10
54
B4-22
09-09
3-PHASE AMPERES
No. of Steps @ kW
1 @ 15
1@30
1@15, 1@30
2@30
1@15, 2@30
3@30
1@15, 3@30
4@30
1@15, 4@30
5@30
1@15, 5@30
6@30
7@30
8@30
7@30, 1@60
6@30, 2@60
5@30, 3@60
4@30, 4@60
3@30, 5@60
2@30, 6@60
1@30, 7@60
8@60
3@30, 7@60
2@30, 8@60
1@30, 9@60
10@60
3@30, 9@60
2@30, 10@60
1@30, 11@60
12@90
11@60, 1@90
10@60, 2@90
9@60, 3@90
8@60, 4@90
7@60, 5@90
6@60, 6@90
5@60, 7@90
4@60, 8@90
3@60, 9@90
2@60, 10@90
1@60, 11@90
12@90
5@60, 9@90
4@60, 10@90
3@60, 11@90
2@60, 12@90
1@60, 13@90
14@90
5@60, 11@90
4@60, 12@90
3@60, 13@90
2@60, 14@90
1@60, 15@90
16@90
5@60, 13@90
4@60, 14@90
3@60, 15@90
2@60, 16@90
1@60, 17@90
18@90
380V
415V
23
21
46
68
91
114
137
160
182
205
228
251
273
319
365
410
456
501
547
593
638
684
729
775
821
866
912
957
1003
1048
1094
1140
1185
1231
1276
1322
1367
1413
1459
1504
1550
1595
1641
1687
1732
1778
1823
1869
1914
1960
2006
2051
2097
2142
2188
2233
2279
2325
2370
2416
2461
42
63
83
104
125
146
167
188
209
230
250
292
334
376
417
459
501
543
584
626
668
710
751
793
835
876
918
960
1002
1043
1085
1127
1169
1210
1252
1294
1336
1377
1419
1461
1503
1544
1586
1628
1669
1711
1753
1795
1836
1878
1920
1962
2003
2045
2087
2129
2170
2212
2254
Electric Boilers
Section B4
Table B4-7. Model S/CR Ratings 480V Supplies

Model
S-120 or
CR-120
Vessel
Capacity
(gallons)
S-161 or
CR-161
23
S-162 or
CR-162
23
S-200 or
CR-200
S-241 or
CR-241
S-242 or
CR-242
S-301
S-302
S-361
48
62
62
110
140
150
Steam
Space
(gallons)
16
16
26
53
53
70
90
100
ASME
Rated kW (Steam lbs/
hr)
ELEMENTS
# of Contactors
NUMBER and kW of
STEPS
3-PHASE
AMPERES
Qty
kW
480V
480V
480V
12
42
1 @ 12
15
24
84
1 @ 24
29
36
126
1 @ 36
44
48
168
12
2 @ 24
58
60
210
6.7
1 @40, 1 @20
73
80
280
12
6.7
2 @ 40
97
100
350
15
6.7
2 @40, 1 @20
121
120
420
18
6.7
3 @ 40
145
3 @40, 1 @20
169
140
490
21
6.7
160
560
24
6.7
4 @ 40
193
180
630
27
6.7
4 @40, 1 @20
217
200
700
30
6.7
5 @ 40
241
220
770
33
6.7
5 @40, 1 @20
265
240
840
36
6.7
6 @ 40
289
6 @40, 1 @20
314
260
910
39
6.7
280
980
42
6.7
7 @ 40
338
300
1050
45
6.7
7 @40, 1 @20
362
8 @ 40
386
8 @40, 1 @20
410
320
1120
48
6.7
340
1190
51
6.7
360
1260
54
6.7
1 @80, 7 @40
434
380
1330
57
6.7
10
1@80,6@40,1@60
458
400
1400
60
6.7
10
2 @80, 6 @40
482
2@80,5@40,1@60
506
420
1470
63
6.7
10
440
1540
66
6.7
11
3 @80, 5 @40
530
460
1610
69
6.7
11
3@80,4@40,1@60
554
4 @80, 4 @40
578
480
1680
72
6.7
12
500
1750
75
6.7
13
4 @80, 3 @40, 1@60
603
520
1820
78
6.7
13
5 @80, 3 @40
627
540
1890
81
6.7
13
5 @80, 2 @40, 1@60
651
560
1960
84
6.7
14
6 @80, 2 @40
675
6 @80, 1 @40, 1@60
699
580
2030
87
6.7
14
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
7 @80, 3 @40
819
680
2380
102
6.7
17
700
2450
105
6.7
17
7 @80, 2 @40, 1@60
843
720
2520
108
6.7
18
8 @ 80, 2 @40
867
756
2646
63
12
21
9 @72, 3 @36
911
10 @72, 2 @36
954
792
2772
66
12
22
828
2898
69
12
23
11 @72, 1 @36
998
864
3024
72
12
24
12 @ 72
1041
B4-23
09-09
Section B4
Electric Boilers
Table B4-7. Model S/CR Ratings 480V Supplies (Continued)
S-362
S-421
S-422
S-480
200
210
270
360
130
140
180
235
900
3276
75
12
25
12 @72, 1 @36
1084
936
3402
78
12
26
13 @ 72
1128
972
3528
81
12
27
13 @72, 1 @36
1171
14 @ 72
1214
1008
3780
84
12
28
1044
3654
87
12
29
14 @72, 1 @36
1258
1080
3780
90
12
30
15 @ 72
1301
1116
3906
93
12
31
15 @72, 1 @36
1344
16 @ 72
1388
1152
4032
96
12
32
1188
4158
99
12
33
16 @72, 1 @36
1431
1224
4284
102
12
34
17 @ 72
1474
1260
4410
105
12
35
17 @72, 1 @36
1518
1296
4536
108
12
36
18 @ 72
1560
18 @ 72, 1 @36
1605
1648
1332
4662
111
12
37
1368
4788
114
12
38
19 @ 72
1404
4914
117
12
39
19 @ 72, 1 @36
1691
1440
5040
120
12
40
20 @ 72
1735
1476
5166
123
12
41
9 @108, 7 @72
1778
10 @108, 6 @72
1821
1512
5290
126
12
42
1548
5418
129
12
43
11 @108, 5 @72
1864
1584
5540
132
12
44
12 @108, 4 @72
1908
1620
5670
135
12
45
13 @108, 3 @72
1951
14 @108, 2 @72
1995
1656
5790
138
12
46
1692
5922
141
12
47
15 @108, 1 @72
2038
1728
6050
144
12
48
16 @ 108
2081
1764
6174
147
12
49
13 @108, 5 @72
2125
B4-24
09-09
Electric Boilers
Section B4
Table B4-8. Model S/CR Ratings 600V Supply
Model
S-120
Vessel
Capacity
(gallons)
Steam
Space
(gallons)
Rated kW
S-162
S-200
S-241
S-242
23
23
48
62
62
16
16
26
53
53
S-302
110
140
70
90
100
3-PHASE
AMPERES
Qty
kW
600 V
600 V
600 V
1 @ 19
19
6.3
38
131
6.3
1 @ 37
37
6.3
1 @37, 1 @19
54
1 @47, 1 @23
68
73
197
70
246
7.8
75
263
12
6.3
2 @ 37
94
328
12
7.8
2 @ 47
91
2 @47, 1 @23
113
117
410
15
7.8
141
492
18
7.8
3 @ 47
136
164
574
21
7.8
3 @47, 1 @23
158
188
656
24
7.8
4 @ 47
182
4 @47, 1 @23
204
211
738
27
7.8
234
820
30
7.8
5 @ 47
226
5 @47, 1 @23
249
258
902
33
7.8
281
984
36
7.8
6 @ 47
271
305
1066
39
7.8
6 @47, 1 @23
294
328
1148
42
7.8
7 @ 47
316
7.8
7 @47, 1 @23
340
352
1230
45
375
1313
48
7.8
8 @ 47
362
398
1395
51
7.8
7 @47, 1 @70
384
422
1477
54
7.8
1 @94, 7 @47
407
7.8
10
1 @94, 6 @47, 1@60
429
452
1559
57
469
1641
60
7.8
10
2 @94, 6 @47
492
1724
63
7.8
10
2 @94, 5 @47, 1@60
474
516
1805
66
7.8
11
3 @94, 5 @47
498
539
1889
69
7.8
11
3 @94, 4 @47, 1@60
520
4 @94, 4 @47
543
563
1969
72
7.8
12
586
2054
75
7.8
12
4 @94, 3 @47, 1@60
565
609
2133
78
7.8
13
5 @94, 3 @47
587
633
2218
81
7.8
13
5 @94, 2 @47, 1@60
610
6 @94, 2 @47
632
656
2297
84
7.8
14
672
2355
87
7.8
14
6 @94, 1 @47, 1@60
648
703
2461
90
7.8
15
7 @94, 1 @47
678
750
2625
48
15.6
16
6 @94, 4 @47
723
15.6
17
7 @94, 3 @47
768
8 @94, 2 @47
814
859
2789
51
2953
54
15.6
18
891
3117
57
15.6
19
9 @94, 1 @47
938
3281
60
15.6
20
10 @ 94
904
9 @94 3 @47
948
10 @94, 2 @47
994
844
150
NUMBER and kW of
STEPS
797
S-361
# of
CONTACTORS
66
445
S-301
ELEMENTS
19
56
S-161
ASME
(Steam lbs/
hr)
984
3445
63
15.6
21
1031
3609
66
15.6
22
B4-25
09-09
Section B4
Electric Boilers
Table B4-8. Model S/CR Ratings 600V Supply (Continued)
1078
3773
69
15.6
23
11 @94, 1 @47
1039
1125
3938
72
15.6
24
12 @ 94
1084
1172
4102
75
15.6
25
12 @94, 1 @47
1129
15.6
26
13 @ 94
1175
13 @94, 1 @47
1220
1265
1219
S-421
210
140
1266
4430
81
15.6
1313
4594
84
15.6
28
14 @ 94
1359
4758
87
15.6
29
14 @94, 1 @47
1310
1406
4922
90
15.6
30
15 @ 94
1355
1453*
5086
93
15.6
31
15 @94, 1 @47
1400
15.6
32
16 @ 94
1445
16 @94, 1 @47
1491
96
1547*
5414
99
15.6
1594*
5578
102
15.6
34
17 @ 94
1536
1641*
5742
105
15.6
35
17 @94, 1 @47
1581
15.6
36
18 @ 94
1627
15.6
N/A
17 @94, 3 @47
1671
1716
1734
235
5250
33
1688*
360
78
27
1500*
S-480
4266
5906
6070
108
111
1781
6234
114
15.6
58
18 @94, 2 @47
1828
6398
117
15.6
60
19 @94, 1 @47
1761
1875
6563
120
15.6
62
20 @ 94
1807
1922*
6727
123
15.6
64
9 @ 141, 7 @94
1852
10 @141, 6 @94
1897
1969*
6891
126
15.6
66
2016*
7055
129
15.6
68
11 @141, 5 @94
1943
2063*
7219
132
15.6
70
12 @141, 4 @94
1988
2109*
7383
135
15.6
72
13 @141, 3 @94
2032
2156*
7547
138
15.6
75
14 @141, 2 @94
2077
15.6
76
15 @141, 1 @94
2123
15.6
84
16 @ 141
2168
2203*
2250*
7711
7875
141
144
* High pressure only
B4-26
09-09
Electric Boilers
Section B4
Table B4-9. Model HSB Ratings 380V, 415V Supply

Model
Vessel
Capacity
(gallons)
Steam
Space
(gallons)
No. of
Steam lb./hr Elements
# of
Rating kW
@ 2120F Qty @ kW CONTACTORS
450
HSB-301
HSB-362
HSB-421
HSB-422
CSB-424
1535
45 @ 10
15
No. of Steps @ kW
1@30, 7@60
3-PHASE AMPERES
380V
415V
684
626
480
1638
48 @ 10
16
8@60
729
668
510
1740
51 @ 10
17
3@30, 7@60
775
710
540
1842
54 @ 10
18
2@30, 8@60
820
751
570
1945
57 @ 10
19
1@30, 9@60
866
793
600
2047
60 @ 10
20
10@60
912
835
630
2150
63 @ 10
21
3@30, 9@60
957
876
918
660
2252
66 @ 10
22
2@30, 10@60
1003
690
2354
69 @ 10
23
1@30, 11@60
1048
960
720
2457
72 @ 10
24
12@90
1094
1002
750
2559
75 @ 10
25
11@60, 1@90
1140
1043
780
2661
78 @ 10
26
10@60, 2@90
1185
1085
810
2764
81 @ 10
27
9@60, 3@90
1231
1127
840
2866
84 @ 10
28
8@60, 4@90
1276
1169
870
2968
87 @ 10
29
7@60, 5@90
1322
1210
900
3071
90 @ 10
30
6@60, 6@90
1367
1252
930
3173
93 @ 10
31
5@60, 7@90
1413
1294
960
3276
96 @ 10
32
4@60, 8@90
1459
1336
990
3378
99 @ 10
33
3@60, 9@90
1504
1377
1020
3480
102 @ 10
34
2@60, 10@90
1550
1419
1050
3583
105 @ 10
35
1@60, 11@90
1595
1461
1080
3685
108@ 10
36
12@90
1641
1503
1110
3787
111 @ 10
37
5@60, 9@90
1687
1544
1140
3890
114 @ 10
38
4@60, 10@90
1732
1586
1170
3992
117 @ 10
39
3@60, 11@90
1778
1628
1200
4094
120 @ 10
40
2@60, 12@90
1823
1669
1230
4197
123 @ 10
41
1@60, 13@90
1869
1711
1260
4299
126 @ 10
42
14@90
1914
1753
1290
4401
129 @ 10
43
5@60, 11@90
1960
1795
1320
4504
132 @ 10
44
4@60, 12@90
2006
1836
1350
4606
135 @ 10
45
3@60, 13@90
2051
1878
1380
4709
138 @ 10
46
2@60, 14@90
2097
1920
1410
4811
141 @ 10
47
1@60, 15@90
2142
1962
1440
4913
144 @ 10
48
16@90
2188
2003
1470
5016
147 @ 10
49
5@60, 13@90
2233
2045
1500
5118
150 @ 10
50
4@60, 14@90
2279
2087
1530
5220
153 @ 10
51
3@60, 15@90
2325
2129
1560
5323
156 @ 10
52
2@60, 16@90
2370
2170
1590
5425
159 @ 10
53
1@60, 17@90
2416
2212
1620
5527
162 @ 10
54
18@90
2461
2254
1650
5630
165 @ 10
55
5@60, 15@90
2507
2296
1680
5732
168 @ 10
56
4@60, 16@90
2553
2337
1710
5835
171 @ 10
57
3@60, 17@90
2598
2379
1740
5937
174 @ 10
58
2@60, 18@90
2644
2421
1770
6039
177 @ 10
59
1@60, 19@90
2689
2463
1800
6142
180 @ 10
60
20@90
2735
2504
B4-27
09-09
Section B4
Electric Boilers
Table B4-10. Model HSB Ratings 480V Supply

MODEL #
HSB-423
Vessel
Capacity
(gallons)
300
Steam Space
(gallons)
200
Rated kW
260
3-PHASE
AMPERES
117
13.3
39
7 @120, 9 @80
1879
120
13.3
40
8 @120, 8 @80
1927
1640
5740
123
13.3
41
9 @120, 7 @80
1975
1680
5880
126
13.3
42
10 @120, 6 @80
2025
11 @120, 5 @80
2072
1720
6020
129
13.3
43
1760
6160
132
13.3
44
12 @120, 4 @80
2120
13 @120, 3 @80
2168
2216
1800
6300
135
13.3
45
1840
6440
138
13.3
46
14 @120. 2 @80
1880
6580
141
13.3
47
15 @120, 1 @80
2264
1920
6720
144
13.3
48
16 @ 120
2313
1960
6860
147
13.3
49
1 @160, 15 @120
2361
13.3
50
2 @160. 14 @120
2409
13.3
51
3 @160. 13 @120
2457
4 @160, 12 @120
2505
2553
7000
7140
150
153
2080
7280
156
13.3
52
2120
7420
159
13.3
53
5 @160, 11 @120
2160
7560
162
13.3
54
6 @160. 10 @120
2602
2200
7700
165
13.3
55
7 @160. 9 @120
2650
2240
7840
168
13.3
56
8 @160, 8 @120
2698
13.3
57
9 @160, 7 @120
2746
10 @160, 6 @120
2794
7980
171
2320
8120
174
13.3
58
2360
8260
177
13.3
59
11 @160, 5 @120
2843
2400
8400
180
13.3
60
12 @160, 4 @120
2891
2440
8540
183
13.3
61
13 @160, 3 @120
2939
2480
8680
186
13.3
62
14 @160, 2 @120
2987
13.3
63
15 @160, 1 @120
3035
13.3
64
16 @ 160
3083
11 @160, 7 @120
3132
2560
320
No. of Steps @ kW
5460
2520
470
# of
CONTACTORS
5600
2280
HSB-425
kW
1560
2040
385
ELEMENTS
Qty
1600
2000
HSB-424
Steam lb./hr
@ 2120F
8820
8960
189
192
2600
9100
195
13.3
65
2640
9240
198
13.3
66
12 @160, 6 @120
3180
2680
9380
201
13.3
67
13 @160, 5 @120
3228
2720
9520
204
13.3
68
14 @160, 4 @120
3276
2760
9660
207
13.3
69
15 @160, 3 @120
3324
13.3
70
16 @160, 2 @120
3372
13.3
71
17 @160, 1 @120
3421
13.3
72
18 @ 160
3469
2800
2840
2880
9800
9940
10080
210
213
216
B4-28
09-09
Electric Boilers
Section B4
Table B4-11. Model HSB Ratings 600V Supply

MODEL #
Vessel
Capacity
(gallons)
Steam Space
(gallons)
Rated kW
1734
1781
1828
HSB-423
300
200
260
3-PHASE
AMPERES
6070
111
15.6
37
17 @94, 3 @47
1671
15.6
38
18 @94, 2 @47
1716
15.6
39
19 @94, 1 @47
1762
20 @ 94
1807
6234
6398
114
117
120
15.6
6727
123
15.6
41
9 @141, 7 @94
1852
1969
6891
126
15.6
42
10 @141, 6 @94
1897
15.6
43
11 @141, 5 @94
1943
12 @141, 4 @94
1988
7055
129
2063
7219
132
15.6
44
2109
7383
135
15.6
45
13 @141, 3 @94
2032
2156
7547
138
15.6
46
14 @141, 2 @94
2078
2203
7711
141
15.6
47
15 @141, 1 @94
2123
16 @ 141
2168
2250
7875
144
15.6
48
2297
8039
147
15.6
49
13 @141, 5 @94
2213
2344
8203
150
15.6
50
14 @141, 4 @94
2259
2391
8367
153
15.6
51
15 @141, 3 @94
2304
2438
8531
156
15.6
52
16 @141, 2 @94
2349
15.6
53
17 @141, 1 @94
2394
18 @ 141
2439
8695
159
2531
8859
162
15.6
54
2578
9023
165
15.6
55
15 @141, 5 @94
2484
2625
9188
168
15.6
56
16 @141, 4 @94
2529
15.6
57
17 @141, 3 @94
2575
15.6
58
18 @141, 2 @94
2620
19 @141, 1 @94
2665
9352
9516
171
174
9680
177
15.6
59
2813
9844
180
15.6
60
20 @ 141
2710
2859
10008
183
15.6
61
17 @141, 5 @94
2755
15.6
62
18 @141, 4 @94
2800
19 @141, 3 @94
2845
2891
2766
2906
320
No. of Steps @ kW
6563
2719
470
# of
CONTACTORS
1922
2672
HSB-425
kW
1875
2484
385
Qty
40
2016
HSB-424
ELEMENTS
Steam lb./
hr @ 2120F
10172
186
2953
10336
189
15.6
63
3000
10500
192
15.6
64
20 @141, 2 @94
3047
10664
195
15.6
65
21 @141, 1 @94
2936
3094
10828
198
15.6
66
22 @ 141
2981
3141
10992
201
15.6
67
19 @141, 5 @94
3027
20 @141, 4 @94
3072
3188
11156
204
15.6
68
3234
11320
207
15.6
69
21 @141, 3 @94
3116
3281
11484
210
15.6
70
22 @141, 2 @94
3161
3328
11648
213
15.6
71
23 @141, 1 @94
3207
15.6
72
24 @ 141
3252
3375
11813
216
B4-29
09-09
Section B4
Electric Boilers
Table B4-12. Model IWH Ratings 208V, 240V Supplies)
Model
Maximum
MBTU/Hr Rated kW
Flow (GPM) *
51
IWH-611
IWH-811
135
240
240
# of CONTACTORS
NUMBER and kW of
STEPS
3-PHASE AMPERES
Qty.
kW
208/240V
208/240V
208V
240V
1 @ 15
42
37
1 @ 30
84
73
1 @ 45
125
109
102
30
154
45
205
60
12
2 @ 30
167
145
1 @ 30, 1 @ 45
209
181
256
IWH-812
15
ELEMENTS
75
15
307
90
18
2 @ 45
251
217
358
105
21
1 @ 15, 3 @ 30
292
253
409
120
24
4 @ 30
334
290
* Maximum flow rate based on a maximum velocity of 1.5 fps (feet per second) through the heater.
Minimum flow rate should not be less than 10% of the maximum flow rate listed.

Model
IWH-611
Maximum
Flow
MBTU/Hr Rating kW
(GPM) *
Qty
kW
380/415V
380V
415V
30
15
1@15
23
21
30
30
1@30
46
42
36
30
10
1@30
46
42
135
IWH-621
IWH-811
IWH-812
IWH-822
IWH-022
240
240
240
360
Elements
# of CONTACTORS
No. of Steps @ kW
3-PHASE AMPERES
36
60
10
2@30
91
83
30
45
1@45
68
63
30
60
12
2@30
91
83
42
75
15
1@30, 1@45
114
104
42
90
18
3@30
137
125
42
105
21
2@30, 1@45
160
146
42
120
24
4 @ 30
182
167
64
150
15
10
3@30, 1@60
228
209
64
180
18
10
2@30, 2@60
273
250
64
210
21
10
1@30, 3@60
319
292
64
240
24
10
4@60
365
334
64
270
27
10
3@30, 3@60
410
376
64
300
30
10
10
2@30, 4@60
456
417
64
330
33
10
11
1@30, 5@60
501
459
64
360
36
10
12
6@60
547
501
B4-30
09-09
Electric Boilers
Section B4
Maximum
Model #
MBTU/Hr Rated kW
Flow (GPM) *
IWH-611
IWH-811
IWH-812
IWH-822
IWH-022
135
240
240
240
360
ELEMENTS
# of CONTACTORS
NUMBER and kW of
STEPS
3-PHASE AMPERES
Qty.
kW
208/240V
208/240V
208V
240V
51
15
1 @ 15
19
15
102
30
1 @ 30
37
29
154
45
1 @ 45
55
44
2 @ 30
73
58
1 @ 30, 1 @ 45
91
73
205
60
12
256
75
15
307
90
18
3 @ 30
109
87
358
105
21
2 @ 30, 1 @ 45
127
102
409
120
24
4 @ 30
145
116
3 @ 30, 1 @ 60
181
145
512
150
15
10
614
180
18
10
2 @ 30, 2 @ 60
217
174
1 @ 30, 3 @ 60
717
210
21
10
6
7
253
203
819
240
24
10
4 @ 60
290
232
921
270
27
10
3 @ 30, 3 @ 60
325
261
1024
300
30
10
10
2 @ 30, 4 @ 60
362
290
1126
330
33
10
11
1 @ 30, 5 @ 60
398
318
19
12
60 @ 60
434
347
1228
360
36
* Maximum flow rate based on a maximum velocity of 1.5 fps (feet per second) through the heater.
Minimum flow rate should not be less than 10% of the maximum flow rate listed.
PERFORMANCE DATA
Efficiency
Electric boilers are void of losses normally associated with fuel fired equipment such as stack loss, combustion
loss, excess air loss, etc. Therefore electric boilers are nearly 100% efficient at all operating points. For hot
water boilers, the only loss from 100% is the radiation loss from the vessel which is %. For steam units, in
addition to the radiation loss, blowdown losses should be factored in.
Emissions
Since electric boilers are void of fuel combustion, no emissions occur. Therefore, electric boilers are well suited
for installations that must meet stringent emissions requirements.
Noise Level
With not moving parts, the electric boiler is nearly noiseless and thus, is well suited for installations sensitive to
noise emissions from mechanical equipment. Installations such as hospitals, nursing homes, schools, research
laboratories, and the like are ideal for an electric boiler application.
Regardless of output from minimum to maximum, noise emissions are almost undetectable.
B4-31
09-09
Section B4
Electric Boilers
ENGINEERING DATA
Boiler Information - Hot Water
Cleaver-Brooks electric hot water boilers are designed for service in any closed hydronic system and can be
used to augment any hot water system. They can be put into operation as a single stand-alone unit with high
turndown or in multiple units for larger turndown and capacity.
C-B electric hot water boilers may be utilized in water heating systems with temperatures from 400 F (4.4 C)
to 2450 F (118.3 C); ideal for ground water source heat pump applications, etc. Because the WB is an
electric boiler, low water temperature (below the dewpoint) restrictions do not apply.
Variable temperature differentials can be designed to make use of changing outdoor conditions and thus, the
WB is not restrictive to a nominal 200 F (10 C) differential. The boiler is designed to withstand thermal
stresses with supply and return temperature differences of 1000 F (55 C) and greater. However, when the
elements are on, water flow through the boiler must be ensured and a flow switch to prove water flow is
established is recommended.
Flow Rates and Pressure Drops
To maintain rated capacity of the boiler, recommended flow rates should not be exceeded as the flow will
remove the heat beyond the capacity of the boiler. Table B4-11 can be used to determine the full boiler output
relative to system temperature drop and the maximum recommended system pump flow.
The pressure drop through the boiler is < 1 psig.
B4-32
09-09
Electric Boilers
Section B4
Table B4-15. Model WB Max Flow Ratings Sheet 1 of 2
Model #
WB-120
WB-121
WB-122
WB-201
WB-202
WB-241
WB-242
Rated kW
10
20
30
12
18
24
30
36
45
54
60
72
90
108
126
144
162
180
198
216
234
252
270
288
324
360
396
432
468
504
540
576
600
630
660
690
720
750
780
810
840
870
900
930
960
8.2
12.4
16.5
20.5
24.5
30.9
37
41
49.5
61.5
73.6
86
98
110.5
122.6
135.5
148
160
172
184.3
196
222
246.5
271
296
320
345
370
394
411
431
452
472
493
514
534
555
575
596
615
637
657
4.5
6.5
8
10.3
12.25
15.7
18.4
20.5
24.2
30.5
37
43
49.2
55.5
61.5
67.5
74
80
86
92.4
98.5
111
123
135.5
148
160.3
172.5
185
197
205.5
215.5
226
236
246.4
257
267
277.5
287.5
298
308
318.5
328.5
3
4.5
5.5
6.75
8.2
10.3
12.3
13.5
16.5
20.5
24.7
28.7
32.9
37
41
45
49.3
53.4
57.5
61.6
65.7
74
82.2
90.4
98.6
106.8
115
123.3
131.5
137
143.8
150.7
157.5
164.4
171.2
178.1
185
191.8
198.6
205.5
212.3
219.2
System Temperature Drop 0F

40
50
Maximum Flow Rate in GPM
2
1.75
3.2
2.6
4.1
3.2
5.1
4.1
6.2
4.9
7.7
6.3
9.2
7.4
10.3
8.2
12.3
9.8
15.4
12.3
18.5
14.8
21.6
17.3
24.6
19.7
27.7
22.2
30.8
24.6
33.9
27.1
37
29.6
40
32
43.1
34.5
46.2
37
49.3
39.5
55.5
44.4
61.6
49.3
67.8
54.2
74
59.2
80.1
64.1
86.3
69
92.5
74
98.6
79
102.7
82.2
107.9
86.3
113
90.4
118.2
94.5
123.3
98.6
128.4
102.7
133.6
106.8
138.7
110.9
143.8
115.1
150
119.2
154.1
123.3
159.2
127.4
164.4
131.5
60
70
80
1.5
2
2.75
3.4
4.1
5.1
6.1
6.8
8.2
10.3
12.3
14.4
16.5
18.5
20.5
22.6
24.6
26.7
28.8
30.8
32.9
37
41.1
45.2
49.3
53.4
57.5
61.6
65.7
68.5
71.9
75.3
78.8
82.2
85.6
89
92.5
95.9
99.3
102.7
106.2
109.6
1.25
1.75
2.3
3
3.5
4.4
5.3
5.8
7
8.8
10.6
12.3
14.1
15.9
17.6
19.4
21.1
22.9
24.6
26.4
28.2
31.7
35.2
38.7
42.3
45.8
49.3
52.8
56.4
58.7
61.6
64.6
67.5
70.5
73.4
76.3
79.2
82.2
85.1
88.1
91
93.9
1
1.6
2.1
2.6
3.1
3.9
4.6
5.1
6.1
7.7
9.2
10.8
12.3
13.7
15.4
16.9
18.5
20
21.6
23.2
24.6
27.7
30.8
33.9
37
40
43.2
46.2
49.3
51.4
53.9
56.5
59.1
61.6
64.2
66.8
69.3
71.9
74.5
77
79.6
82.2
B4-33
09-09
Section B4
Electric Boilers
Table B4-15. Model WB Max Flow Ratings Sheet 2 of 2
Model #
WB-243
WB-361
WB-362
WB-363
WB-421
WB-422
Rated kW
10
20
30
990
1020
1050
1080
1110
1140
1170
1200
1224
1260
1296
1332
1368
1404
1440
1476
1512
1548
1584
1620
1656
1692
1728
1764
1800
1836
1872
1908
1944
1980
2016
2052
2088
2160
2240
2320
2400
2480
2560
2640
2720
2800
2880
3000
3040
3120
3200
3280
3360
678
698
719
740
760
781
801
822
838
863
888
912
937
962
986
1011
1035
1060
1085
1109
1134
1159
1183
1208
1233
1257
1282
1307
1332
1356
1381
1405
1430
1480
1534
1589
1644
1699
1754
1808
1863
1918
1973
2055
2082
2137
2192
2247
2302
339
349
359.5
370
380
390.5
400.5
411
419
431.5
444
456
468.5
481
493
505.5
517.5
530
542.5
554.5
567
579.5
591.5
604
616.5
628.5
641
653.5
665.5
678
690.5
702.5
715
740
767
794.5
822
849.5
877
904
931.5
959
98.5
1027.5
1041
1068.5
1096
1123
1151
226
232.9
239.7
246.6
253.4
260.3
267.1
274
279.5
287.7
296
304.1
312.3
320.5
328.8
337
322.4
353.4
361.6
370
378
386.3
394.5
402.7
411
419.2
427.4
435.6
443.8
452
460.3
468.5
476.7
493.2
511.4
529.7
548
566.2
584.5
602.7
621
639.3
657.5
685
694
712.3
730.5
748.8
767.1
System Temperature Drop 0F

40
50
Maximum Flow Rate in GPM
169.5
135.6
174.6
139.7
179.8
143.8
184.9
150
190
152.1
195.2
156.2
200.3
160.3
205.5
164.4
209.6
167.7
215.7
172.6
221.9
177.5
228.1
182.5
234.2
187.4
240.4
192.3
246.6
197.3
252.7
202.2
258.9
207.1
265.1
212.1
271.2
217
277.4
221.9
283.6
226.8
289.7
231.8
295.9
236.7
302.2
241.6
308.2
246.6
314.4
251.5
320.5
256.4
326.7
261.4
332.9
266.3
339
271.2
345.2
276.2
240.6
281.1
357.5
286
369.9
295.9
383.6
306.8
397.3
317.8
411
328.8
424.6
339.7
438.3
350.7
452.1
361.6
465.7
372.6
479.5
383.6
493.1
394.5
513.7
411
520.5
416.4
534.2
427.4
547.9
438.4
561.6
449.3
575.3
460.3
B4-34
09-09
60
70
80
113
116.4
119.9
123.3
126.7
130.1
133.6
137
139.7
143.8
147.9
150.9
156.2
160.3
164.4
168.5
172.6
176.7
180.8
184.9
189
193.1
197.3
201.4
205.5
209.6
213.7
217.8
221.9
226
230.1
234.2
238.4
246.6
255.7
264.8
274
283.1
292.2
301.4
310.5
319.6
328.8
342.5
347
356.2
365.3
374.4
383.6
96.9
99.8
102.7
105.7
108.6
111.5
114.5
117.4
119.8
123.3
126.8
130.3
133.8
137.4
140.9
144.4
147.9
151.5
155
158.5
162
165.5
169.1
172.6
176.1
179.6
183.2
186.7
190.2
193.7
197.3
200.8
204.3
211.3
219.2
227
234.8
242.7
250.5
258.3
266.1
274
281.8
293.5
297.5
305.2
313.1
320.9
328.8
84.8
87.3
89.9
92.5
95
97.6
100.2
102.7
104.8
107.9
110.9
114
117.1
120.2
123.3
126.4
129.5
132.5
135.6
138.7
141.8
144.9
147.9
151
154.1
157.2
160.3
163.4
166.4
169.5
172.6
175.7
178.8
184.9
191.8
198.6
205.5
212.3
219.2
226
232.9
239.7
246.6
256.8
260.3
267.1
274
280.8
287.7
Electric Boilers
Section B4
System Operating Parameters

To prevent water flashing to steam within the boiler or system, hot water boilers must operate with proper over
pressure. System over pressure requirements are shown in Table B4 12.
While proper overpressure is required, a means to relieve excess pressure at or beyond the design pressure of
the boiler must be provided. As boiler water is heated, expansion occurs. And this expansion must be
accounted for either with an expansion tank (air filled) or with a bladder type tank. These devices permit the
water pressure to expand outside of the boiler and not impact the pressure vessel or pressure relieving device.
But, in accordance with Code, each boiler is equipped with an ASME approved safety relieving device should
pressure build-up occur.
Table B4-16. Model WB Minimum Over Pressure Requirements
Outlet Water Temperature 0 F (C)
Minimum System Pressure PSIG (Bar)
80 - 180 ( 27 - 82)
12 (0.83)
181 - 185 ( 83 - 85)
15 (1.03)
186 - 195 ( 86 - 91)
18 (1.24)
Rule of Thumb Calculations

The following formula can be used to size a hot water boiler:
kW = gph (gallons per hour) x delta T (as expressed in 0F) divided by 410
Or
kW = 1 lph (liter per hour) x delta T (as expressed in 0C) divided by 862.
Where:
kW is the boiler output rating.
lph (liters per hour ) or gph (gallons per hour) is the hot water flow rate.
"delta T" is the temperature rise of water.
As an example:
kW= gph x delta T/410
kW = 5000 x 20/410
kW = 100000/410
kW = 244
B4-35
09-09
Section B4
Electric Boilers
Boiler Information - Steam

Models CR, S, and HSB are designed for steam service and are built in accordance with the ASME Code for
either low pressure steam applications (less than 15 psig operation) or for high pressure steam applications
(above 15 psig).
For approximate conversion of pounds of steam to kW, the following can be used:
10 kW = 34 lbs. steam/hr = 1.02 boiler horsepower from and at 212 F.
It is important to know what the operating pressure will be and the feedwater makeup temperature, to properly
size the steam boiler. From Table B4-11, one can obtain the pound of steam value for the operating pressure
and corresponding feedwater makeup temperature. Based on this, the proper assumption can be made as to
the required kW size of the electric boiler.
For example: Steam load required of 2000 pounds per hour of steam at an operating pressure of 100 psig and
feedwater temperature of 170 degrees F. Referring to Table B4-13, we find the value of 0.3077 kW per pound
of steam. We multiply the required pounds of steam by this value (2000 x 0.3077) and obtain 615. The
required boiler would be 615 kW or the Model S-301-620, 150# design.
Table B4-17. kW per pound of steam
Feedwater
Temperature (0F)
50
70
100
120
150
170
200
212
227
0
0.3318
0.3259
0.3171
0.3112
0.3025
0.2966
0.2878
0.2857
0.2836
Boiler Operating Pressure (PSIG)

15
50
100
0.3359
0.3401
0.3429
0.3300
0.3343
0.3370
0.3212
0.3255
0.3283
0.3154
0.3196
0.3224
0.3066
0.3108
0.3136
0.3001
0.3050
0.3077
0.2919
0.2962
0.2978
0.2898
0.2941
0.2957
0.2877
0.2920
0.2936
150
0.3441
0.3382
0.3294
0.3236
0.3148
0.3089
0.3001
0.2980
0.2967
Water Treatment
Even though hot water systems are closed, some amount of make-up water (up to 10%) will be introduced,
usually due to pump seal leaks or other minimal leaks from valves etc., that go unnoticed. Therefore, proper
water chemistry of a hot water boiler is necessary for good operation and longevity, particularly to ensure that
free oxygen is removed to prevent waterside corrosion.
For steam boilers, proper blowdown (surface and bottom) is a required maintenance procedure. This water loss
and associated steam use or loss must be made up. Any make-up water should be properly treated prior to
introduction into the boiler via water softener, chemical feed, etc. Proper water chemistry in a steam boiler is
mandatory for effective operation and longevity.
See Table B4-14 for water quality requirements.
B4-36
09-09
Electric Boilers
Section B4
Table B4-18. Electric Boilers Required Water Quality Parameters
Parameter
Boiler Water Limit
pH
8.3 - 10.5
Iron
0.1 ppm
Alkalinity
<300 ppm
Chlorides
30 mg/liter
Oxyen
0.1 mg/liter
4500 umho/cm
Suspended Solids
300 ppm
Total Hardness
0 ppm as CaCO3

The boiler must be installed on a level non-combustible surface. If the surface is not level, piers or a raised pad
(slightly larger than the length and width of the boiler base dimensions) will make boiler leveling possible.
Installing the boiler on a raised pad or piers will make boiler drain connections more accessible and will keep
water from splashing onto the boiler when the boiler room floor is washed. NOTE: The pad or piers must be of
sufficient load bearing strength to safely support the operating weight of the boiler and any additional
equipment installed with it. Approximate operating weights are shown in Dimensions and Ratings.
Clearances
The boiler must be installed so that all components remain accessible, especially be free of side mounted
piping so the element flanges may be opened. Refer to Dimension Sheets Figure B4 1 through B4 - 5.
Hot Water Piping
Primary/Secondary Pumps are not necessary with the electric hot water boilers, although they can be used. As
its design is such that thermal shock is not a concern, some flow is required whenever the boiler elements are
on. Therefore, whether primary/secondary or system pump, an interlock such as a flow switch should be
employed to ensure that water flow is established before the boiler elements are allowed on.
Electrical
Voltage requirements for the electric boilers are as noted in the ratings sheets including the relative ampacity.
Switchgear above 600 amps will not be furnished by Cleaver-Brooks due to the overall size of the equipment
and NEC Code requirement for switchgear wiring. The larger switchgear wiring requirements exceed the UL
certification of the package boiler.
B4-37
09-09
Section B4
Electric Boilers
B4-38
09-09
Section B4
Electric Boiler Specifications
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heating Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trim and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B4-40
B4-40
B4-40
B4-41
B4-41
The following sample specifications are provided by Cleaver-Brooks to assist you in meeting your customers
B4-39
Section B4
PART 1 GENERAL
1.1
CAPACITIES
A. Boiler Capacity - Hot Water
1. The ____ gallon _____ capacity hot water boiler shall be
Cleaver-Brooks Model ___________ rated ____ kW at ____ V,
____ ph, ___ Hz, ____ MBtu/hr. Unit shall be suitable to
operate under the following conditions: system flow rate ____
gpm; outlet water temperature ____ F; return water
temperature ____F; system operating pressure ____ psig.
B. Boiler Capacity - Steam
1. The _____ gallon ______ capacity steam boiler shall be
Cleaver-Brooks Model ______________ rated _____ kW at
____ V, _____ ph, 60 Hz. Unit shall produce ______ lbs steam/
hr (from and at 212 F) at a nominal pressure of ____ psig.
C. Water Heater Capacity - Instantaneous
D. The horizontal circulation water heater shall be Cleaver-Brooks
Model IWH ___________ rated _____ kW at ____ V, ____ ph,
60 Hz.
PART 2 PRODUCTS
2.1
BOILER
A. The vessel shall be constructed in accordance with ASME Boiler
Code.
B. The vessel shall be designed for ____ psig.
C. The relief valve shall be per ASME Code, set at ____ psig.
D. The vessel shall be insulated with 2-inch fiber blanket insulation
having 1-1/2 PCF density.
E. The boiler shall be UL listed, and bear the Underwriters
Laboratories label.
F.
The boiler shall be of the packaged type, factory assembled, wired,
and tested.
G. The boiler shall be mounted on a full size structural steel base.
H. The boiler jacket shall be 18-gauge steel.
I.
The entire exterior shall be finished in light blue enamel paint.
J. The overall dimensions of the boiler shall be _____ inches long,
______ inches wide, and _____ inches high.
K. For CR Models, the boiler shall include built-in condensate receiver
and feed pump, with make-up valve mounted on common base with
boiler, factory wired and piped, and enclosed in boiler casing.
2.2
HEATING ELEMENTS
A. The heating elements shall be individually mounted, rod type, and
field replaceable with standard tools.
B. The heating watt density shall not exceed _______ (50 or 75) W/
sq-in.
C. The heating elements shall be _________ (copper or Incoloy)
sheathed.
B4-40
Section B4
PART 3 EXECUTION

2.3
TRIM AND CONTROLS

A. The units shall be complete with the following:
1. Main lugs for supply circuits.
2. Supplemental internal branch circuit fuses, current limiting,
rated at 200,000 amps interrupting capacity.
3. Fused 120 V control circuit transformer.
4. Magnetic contactors rated at 500,000 cycles.
5. Integral high temperature limit (hot water boilers).
6. High pressure limit (steam boilers).
7. Low water cutoff (float-type with gauge glass for steam) on all
models except IWH which is supplied with a flow switch.
8. Pressure-temperature gauge (hot water boilers).
9. Pressure gauge (steam boilers).
10. Pilot switch.
11. Pilot lights for power on, low water, high temperature or
pressure.
12. Relief valve.
13. Drain valve (hot water boilers).
14. Bottom and water column blowdown valves (steam boilers).
15. Feedwater stop and check valves (steam boilers).
16. All models except IWH shall be supplied with modulating step
controls to gradually apply the load in ____ steps.
17. All models except IWH shall be supplied with proportioning
temperature (hot water units) or pressure (steam units) control
to balance power input to match system demand.
18. Temperature control on IWH is one of the following methods
(select a. or b. or c. below).
a. Thermostats - The heating elements shall be staged by
control thermostats. (Standard for one and two step
heaters).
b. Sequencer - The heating elements shall be staged by a
time delay sequencer, to energize heating elements in
____ stages with an adjustable 1 to 15 second time delay
between stages. (Standard for 3 or 4 step heaters.)
c. Modulating Step Control - (Standard for heaters above 4
steps).
3.1
WARRANTY
A. The Cleaver-Brooks unit shall be warranted against defective
workmanship and materials for a period of one year from the date of
start- up or 18 months from shipment.
B4-41
Section B4
Notes
B4-42
Section B5
Model CFC ClearFire Condensing Boiler
Table of Contents
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-54
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-63
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-67
List of Figures
AluFer Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-3
Fireside access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-3
Premix Burner Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-4
Heat Flow and Component Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-5
Clearfire Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-7
Dimensional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-9
Competitive Condensation Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-12
Emissions Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-15 B5-17
Pressure Drop Curves U.S. and Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-21 B5-26
Condensate Piping Direct To Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-29
Optional Condensate Treatment Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-29
Condensate Piping for Multiple Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-30
Condensate Treatment Tank for Multiple Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-30
Gas Piping Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-31
Gas Header Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-32
Minimum Room Clearance Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-34
CFC Seismic mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-34
No primary loop with domestic water and 2-way divert valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-36
2-Pipe system, typical (reverse return) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-37
Zoning with zone valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-38
Two Boilers and Three Variable Temperature Zones (no primary loop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-39
Two-Pipe Primary/Secondary Piping with Domestic Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-40
Two-Pipe Primary/Secondary Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-41
No Primary Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-42
Domestic Water Heating, No Primary Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-43
Domestic Water with On/Off and 3-Way Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-44
FEATURES AND BENEFITS . . . . . .

PRODUCT OFFERING . . . . . . . . . .
DIMENSIONS AND RATINGS . . . . .
PERFORMANCE DATA . . . . . . . . .
ENGINEERING DATA . . . . . . . . . . .
STACK/BREECHING SIZE CRITERIA
CB FALCON CONTROLLER . . . . . .
SAMPLE SPECIFICATIONS . . . . . . .
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B5-1
09-09
Commercial Boilers
Model CFC
Piping Hybrid Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-45

Hybrid Boilers with Domestic Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-46
Domestic Water with 2 Boilers and 2 Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-47
Two Opening Outside Wall Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-49
Two Opening Ducted Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-50
One Opening Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-51
Two Opening Engineered Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-52
Direct Vent Combustion Piping Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-53
Optional Direct Vent Combustion Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-53
Horizontal Through the wall venting using inside air for combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-56
Horizontal Flue through- wall with direct vent combustion intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-57
Inside Air - Vertical Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-60
Vertical Stack with Direct Vent Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-61
Electrical Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-62
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-62
CB Falcon Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-65
List of Tables
U.S. Standard Dimensions Model CFC Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-10
Metric Dimensions Model CFC Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-11
Boiler Ratings (Sea Level to 2000 Feet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-12
Altitude Correction for Input Capacity at Various Altitude Levels (Natural Gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-13
Efficiency Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-13 B5-14
Noise Level (dBA) measured 3 feet in front of boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-18
Maximum Flow Rate Through ClearFire Boilers (US Flow Rates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-20
Maximum Flow Rate Through ClearFire Boilers (Metric Flow Rates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-20
Minimum Over Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-27
Boiler Safety Valve Information @ 60 PSIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-27
Boiler Safety Valve Information @ 30 PSIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-27
Water Chemistry Requirements in accordance with ABMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-28
Maximum Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-29
Minimum and Maximum Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-33
Minimum Required Gas Pressure Altitude Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-33
Stack design single boiler using room air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-58
Stack sizing using outside air for combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-59
Operating Conditions - Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-63
Operating Conditions - Display/Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-63
CB Falcon Burner Sequence (central heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-64
B5-2
09-09
Model CFC
Commercial Boilers
MODEL CFC FEATURES AND BENEFITS

Compact Firetube
Design
The Model CFC boiler is a single pass,

vertical down fired durable firetube
boiler. The internal extended-heating
surface tubes provide very high levels of
performance in a compact space,
offering over 10 square feet of heating
surface per boiler horsepower, providing
many years of trouble free performance.
Figure B5-1. AluFer Inserts
Advanced
Technology
Construction from ASME steel, 316Ti stainless steel tube sheets and 2.3" OD 316Ti
stainless steel tubes with AluFer tube inserts provides optimal heat transfer.
Advanced
Construction
The extended heating surface design provides the ideal solution for the demands of
a condensing boiler and helps to recover virtually all the latent heat of the flue gas.
Each tube consists of an outer stainless steel tube (waterside) and the AluFer
extended surface profile on the flue gas side.
High Efficiency
With the extended heating surface tubes the CFC boiler will provide fuel to water
efficiency of up to 99% at low fire and 97% at high fire with 80 degrees F return
water temperature.
Ease of Maintenance
The powder coated steel casing is designed for easy removal and re-assembly. As
shown in Figure B5-2, the burner is hinged and is provided with hydraulic pistons
for simple opening for service of the spark electrode, inspection of the burner
cylinder, tubes and tube sheet on Models CFC1000 and larger. (On the CFC500 and
750, the burner is hinged only). A front mounted service platform is provided for
easy access to the burner components and controls.
Figure B5-2. Fireside Access
ISO 9001:2001 certified manufacturing process ensures the highest degree of

manufacturing standards are always followed.
ASME Code construction ensures high quality design, safety, third party inspection,
and reliability, and is stamped accordingly.
Each unit is tested and certified in accordance with CSA International and the CSA
Label is affixed attesting to meeting the latest CSA requirements for packaged
heating boilers.
Premix Technology
The burner utilizes "Premix" technology to mix both gas fuel and combustion air prior
09-09
B5-3
Commercial Boilers
Model CFC
to entering the burner canister, with air "leading" during burner firing transitions.
Combined with a variable speed fan, this technology provides very low emission
levels, exceptionally safe operation, and nearly 100% combustion efficiency.
Full Modulation
To provide only the amount of heat required to the burner, the variable speed fan
provides modulated firing to reduce on/off cycling, excellent load tracking, and
reduced operating costs. The burner does not require mechanical linkage
connections between the fuel input valve and air control. Instead, the
microprocessor control positions the fan speed in accordance with system demand,
and this determines the fuel input without mechanical device positioning, that is,
linkage-less fuel/air ratio control. This eliminates linkage slippage, minimizes
burner maintenance, and provides control repeatability. This is shown schematically
in Figure B5-3.
Figure B5-3. Premix Burner Technology
Designed For
Heating
Applications
The pressure vessel is designed for 60 psig MAWP (Max. Allowable Working
Pressure) and is constructed of durable ASTM Grade Steel and Stainless Steel
materials. Figure B5-4 shows the counter flow heat exchanger design that gives
optimal heat transfer. The design also prevents hot spots, does not require a
minimum flow for thermal shock protection, and does not require a minimum return
water temperature. In fact, the design carries a 20-year "Thermal Shock" warranty.
Because of the design characteristics, the Model CFC is well suited for applications
utilizing indoor/outdoor reset controls, radiant floor heating, snow melt systems,
ground source heat pump systems and systems that utilize variable speed
circulating pumps. It may also be employed in standard hot water systems that
require higher heated water at colder outdoor temperatures but then require
minimum temperatures during warmer heating days, realizing fuel efficiency savings
over traditional hot water boilers.
While the design does not lend itself to the direct supply of potable water, a separate
storage tank with an internal heat exchanger can be employed as the
microprocessor control permits domestic water programming. Therefore, the Model
CFC can service both hydronic heating and domestic water source heating.
Dual Return
B5-4
The CFC features a second high temperature water return for enhanced system
installation flexibility.
09-09
Model CFC
Commercial Boilers
Combustion Fan and

Premix Gas Valve
Assembly
Burner
Head
Safety Relief Valve
Burner
Canister
Control
Panel
Hot Water
Outlet
Electrode
Ignition and
Flame Rod
Finned High
Efficiency AluFer
Tubes
High Temp.
Return
Low Temp.
Return
ASME Code
Pressure Vessel
Flue Gas
Outlet
Figure B5-4. Model CFC Heat Flow and Component Orientation
MODEL CFC PRODUCT OFFERING

Information in this section applies to condensing hot water boiler sizes ranging from
500,000 Btu input through 2,500,000 Btu input for operation on Natural Gas or
LP Gas only. Installation is for indoor use only.
The complete package has been tested and certified in accordance with CSA 4.9b
and ANSI Standard Z21.13b 2003 and is approved, listed, and bears the CSA label
(U.S.A. and Canada) for condensing hot water boilers on gas only.
Dimensions, ratings, and product information may change to meet current market
requirements and product improvements. Therefore, use this information as a guide.
09-09
B5-5
Commercial Boilers
Standard Equipment
Model CFC
Equipment described below is for the standard boiler offering:
1. The Boiler
A. Each boiler size is designed for a Maximum Allowable Working Pressure
(MAWP) of 60 psig (4.1 Bar), constructed in accordance with the ASME
Code Section IV and bear the "H" stamp.
B. The insulated boiler is mounted on a base and powder coated steel casing
provided.
C. A drain valve connection is provided at the front bottom for field piping of a
boiler drain valve, which can be furnished as an option.
2. Boiler Trim and Controls
The following items are furnished:
Probe Type Low Water Cutoff control, manual reset.
Excess Water Temperature Cutoff, manual reset.
NTC (negative temp. coefficient) sensor for hot water supply temperature.
NTC sensor for hot water return temperature.
ASME Safety Relief Valve set @ 60 psig. (4.1 Bar)
Combination Temperature/Pressure Gauge.
3. Burner Control
A. The CB Falcon is an integrated burner management and modulation control
with a touch-screen display/operator interface. Its functions include the
following:
Two (2) heating loops with PID load control
Electronic Ignition.
Flame Supervision.
Safety Shutdown with time-stamped display of lockout condition.
Variable speed control of the combustion fan.
Supervision of low and high gas pressure, air proving, stack back pressure, high limit, and
low water.
Real-time data trending.
Modbus communication capability
B5-6
09-09
Model CFC
Commercial Boilers
Falcon Controller
Transformer
Terminal Blocks
LWCO
Ignition Transformer
Power Supply
Fuses
Falcon Display/Interface
Demand Switch
Control Circuit
On/Off
Figure B5-5. ClearFire Control Panel

4. Forced Draft Burner
A. The burner is a "Pre-mix" design consisting of a unitized venturi, single body
dual safety gas valve, blower, and burner head.
B. Full modulation is accomplished with a variable speed fan for 5:1 turndown
ratio.
C. For near flameless combustion, the burner utilizes a Fecralloy-metal fiber
head.
D. Noise level at maximum firing is less than 70 dBA regardless of boiler size.
E. Operating on Natural Gas, NOx emissions will be less than 20 PPM
regardless of boiler size and the boiler is certified for California and Texas for
Low NOx emissions.
F. As an option, the burner is capable of direct vent combustion.
G. Ignition of the main flame is via direct spark, utilizing high voltage electrodes
and a separate electrode for flame supervision.
H. To ensure adequate combustion air is present prior to ignition, and to ensure
the fan is operating, a combustion air proving switch is furnished.
I. A High Air Pressure Switch is provided to ensure burner lockout if excessive
back pressure due to a blocked stack occurs.
J. For ease of maintenance and inspection, the burner is furnished with
hydraulic rods and easy opening lockdown nuts, which permit the burner to
swing up (except 500 and 750, which are hinged only). This provides full
access to the burner and electrodes, as well, to the tube sheet and tubes.
5. Burner Gas Train
The standard gas train is equipped in accordance with CSA/ANSI Standards, ASME
CSD-1, GE-GAP (Formerly IRI), and FM. Each burner gas train includes:
Low Gas Pressure Interlock, manual reset.
09-09
B5-7
Commercial Boilers
Optional Equipment
Model CFC
High Gas Pressure Interlock, manual reset.
ASME CSD-1 Test Cocks.
Downstream manual ball type shutoff cock.
Single body dual safety shutoff gas valve.
For option details, contact the local authorized Cleaver-Brooks representative. In

summary, here are some of the options that can be provided with the boiler:
Auxiliary Low Water Cutoff, probe type shipped loose for installation in the
system piping.
Condensate Treatment Assembly.
Condensate water trap with make-up connection.
Direct Vent Combustion Kit.
Safety Valve set @ 30 psig. (2 Bar)
Outdoor reset control.
Alarm Horn.
Relay for remote boiler on signal.
Interface terminals for remote lead lag control, control by others.
Controller option for communication device to computer interface for service/setup.

For layout purposes, the overall dimensions for the Model CFC are shown in Table
B5-1 (US Dimensions) and Table B5-2 (Metric Dimensions) including the various
pipe connection sizes for supply and return water, drain, and vent. The performance
ratings for the boiler are shown in Table B5-3.
Altitude
Relative to the ratings shown, installation of the boiler above 2000 feet elevation
will result in input capacity reduction. Please refer to Table B5-4 for input ratings of
the boiler at various elevations.
PERFORMANCE DATA
Efficiency
The Model CFC is a "full condensing" boiler realizing efficiency gain at variable
operating conditions. It is designed to extract the latent heat of condensation over a
greater range than other designs. This can be seen in Figure B5-7, which depicts
nominal stack temperatures of the boiler versus other designs. The nominal point of
condensation is approximately 132 F (55.5 C) and thus, with the Clearfire's lower
stack temperature, due to its more efficient heat transfer design, it captures the
latent heat of condensation over a broader range.
Fuel-to-Water efficiency is relative to specific operating conditions. Operating
efficiency will be greater when performance is in the "condensing" mode of operation
as noted above, yet, with its inherently greater heat transfer surfaces and superior
pre-mix burner, efficiency at "traditional" hot water conditions is outstanding. Table
B5-6 through Table B5-9 show the guaranteed efficiencies at various operating
conditions and firing rates for Natural Gas. It should be noted that the efficiency is
exceptional at high fire and low fire versus other designs where high efficiency is
realized only when in low fire or minimal firing rates and low temperature returns.
B5-8
09-09
Model CFC
Commercial Boilers
Figure B5-6. Model CFC Dimensional Views
09-09
B5-9
Commercial Boilers
Model CFC
Table B5-1. U.S. Standard Dimensions Model CFC Boiler
ITEM
A
B
C
D
E
F
G
H
J
K
L
M
N
O
P
Q
R
S
T
AA
Boiler Size
DIMENSIONS
Overall Height
Overall Width
Overall Depth
Width less casing
Gas Connection to Top of Casing
Gas Connection to floor
Side of Casing to Gas Connection
Boiler Centerline to Air Inlet
Floor to Top of Stack Connection
Centerline to Centerline of Stack Stub
Rear of Boiler to Centerline of Stack Stub
Front of Boiler to Rear of Casing
Control Panel Projection
Casing Height
Air Vent Line Projection
Floor to Centerline of Lower Return
Floor to Centerline of Upper Return
Floor to Centerline of Supply Connection
Floor to Centerline of Air Vent
Boiler Adjustment Foot Height
Height Above Boiler for Burner Service
500
750
1000
1500
1800
2500
71.8"
32.3"
48.8"
26.8"
8.1"
63.7"
2.3"
4.0"
18.6"
15.4"
5.4"
38.8"
4.1"
56.2"
2.2"
19.5"
28.2"
54.3"
59.9"
2.5"
14"
71.8"
32.3"
48.8"
26.8"
8.1"
63.7"
2.3"
4.0"
18.6"
15.4"
5.4"
38.8"
4.1"
56.2"
2.2"
19.5"
28.7"
54.3"
59.9"
2.5"
14"
75.7"
36.6"
62.6"
31.1"
9.5"
66.2"
4.3"
4.0"
18.1"
16.9"
7.5"
49.4"
4.1"
60.0"
2.2"
19.6"
30.5"
56.2"
62.3"
2.5"
14"
81.6"
43.7"
65.6"
38.2"
12.5"
69.1"
3.4"
4.9"
19.1"
21.0"
8.1"
49.5"
4.1"
65.4"
2.2"
20.7"
20.3"
57.1"
63.1"
2.5"
14"
81.6"
43.7"
65.6"
38.2"
10.2"
71.4"
5.2"
7.1"
19.1"
21.0"
8.1"
49.5"
4.1"
65.4"
2.2"
21.3"
32.3"
56.2"
63.1"
2.5"
14"
82.2"
50.8"
72.6"
45.3"
9.4"
72.8"
4.7"
7.1"
20.9"
28.1"
8.6"
56.5"
4.1"
65.4"
2.2"
22.4"
33.8"
56.2"
63.6"
2.5"
14"
CONNECTIONS
U
V
W
X
Y
Z
BB
CC
Water Supply/Return, 150# RF Flg

Boiler Air Vent, NPT
Electrical Conduit, left or right
Boiler Drain, NPT
Flue Gas Nominal OD, Left or Right option
Combustion Air Option
Gas Connection, NPT
Condensate Drain, FPT
Relief Valve @ 60 # Setting
Voltage Fan Motor, single phase
Voltage Control Circuit
B5-10
2-1/2"
2-1/2"
2-1/2"
3"
4"
5"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
1.6"
1.6"
1.6"
1.6"
1.6"
1.6"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
6"
6"
8"
10"
12"
12"
4"
4" OR 6" 4" OR 6"
6"
6"
6" OR 8"
1"
1"
1"
1-1/2"
1-1/2"
1-1/2"
3/4"
3/4"
3/4"
3/4"
3/4"
1"
1"
1"
1"
1"
1-1/4"
1-1/4"
115
115
115
115
115
115
115/1/60 115/1/60 115/1/60 115/1/60 115/1/60 115/1/60
09-09
Model CFC
Commercial Boilers
Table B5-2. Metric Dimensions Model CFC Boiler
ITEM
A
B
C
D
E
F
G
H
J
K
L
M
N
O
P
Q
R
S
T
AA
U
V
W
X
Y
Z
BB
CC
DIMENSIONS (mm)
Overall Height
Overall Width
Overall Depth
Width Less Casing
Gas Connection to Top of Casing
Gas Connection to Base
Side Of Casing to Gas Connection
Boiler Centerline to Air Inlet Centerline
Base to Top of Stack Connection
Centerline to Centerline of Stack Stub
Rear of Boiler to Centerline of Stack Stub
Front of Boiler to Rear of Casing
Control Panel Projection
Casing Height
Air Vent Line Projection from Rear of Casing
Base to Centerline of Lower Return
Base to Centerline of Upper Return
Base To Centerline of Supply Connection
Base To Centerline of Air Vent
Boiler Height Adjustment (Max.)
500
1845
820
1243
693
206
1639
64
101
405
391
136
982
106
1439
119
496
721
1383
1524
64
750
1845
820
1243
693
206
1639
59
101
405
391
137
982
106
1439
114
501
721
1383
1524
64
BOILER
1000
1935
930
1590
803
234
1701
109
101
405
434
188
1243
106
1529
125
507
737
1437
1586
64
CONNECTIONS (INCHES NPT)

Water Supply/Return, 150# RF Flg
2-1/2"
2-1/2"
2-1/2"
Boiler Air Vent, NPT
1-1/2"
1-1/2"
1-1/2"
Electrical Conduit, left or right
1.6"
1.6"
1.6"
Boiler Drain, NPT
1-1/2"
1-1/2"
1-1/2"
Flue Gas Nominal OD, Left or Right option
6"
6"
8"
Combustion Air Option
4"
4" OR 6" 4" OR 6"
Gas Connection, NPT
1"
1"
1"
Condensate Drain, FPT
3/4"
3/4"
3/4"
Relief Valve @ 60 # Setting
1"
1"
1"
09-09
SIZE
1500
2090
1110
1666
952
316
1774
87
124
430
534
207
1256
106
1659
120
536
786
1461
1611
64
1800
2090
1110
1666
983
256
1834
132
179
430
534
197
1256
106
1659
120
559
839
1446
1611
64
2500
2100
1290
1818
1163
230
1870
118
179
450
714
218
197
106
1649
107
584
874
1443
1631
64
3"
1-1/2"
1.6"
1-1/2"
10"
6"
1-1/2"
3/4"
1"
4"
1-1/2"
1.6"
1-1/2"
12"
6"
1-1/2"
3/4"
1-1/4"
5"
1-1/2"
1.6"
1-1/2"
12"
6" OR 8"
1-1/2"
1"
1-1/4"
B5-11
Commercial Boilers
Model CFC
Table B5-3. Model CFC Boiler Ratings (Sea Level to 2000 Feet)
RATINGS
MAXIMUM BTU/HR INPUT @ SEA LEVEL TO
2000
BTU/HR OUTPUT @ SEA LEVEL TO 2000 (NAT
GAS)
SHIPPING WEIGHT, LBS.
OPERATING WEIGHT, LBS.
INLET GAS PRESSURE REQUIRED -- LF/HF,
"W.C.
MAX. AMP DRAW FAN @ 115/1/60
AMP DRAW CONTROL CIRCUIT
Boiler Size
1000
1500
500
750
1800
2500
500,000
750,000
1,000,000
1,500,000
1,800,000
2,500,000
480,000
1,477
2,224
697,000
1,477
2,224
940,000
1,554
2,276
1,410,000
1,940
2,835
1,690,000
2,061
2,932
2,412,500
3,600
4,654
7.0/5.0
4.0
1.3
7.0/5.0
4.0
1.3
7.0/5.0
4.0
1.5
10.0/7.0
8.5
1.5
7.0/5.0
12.0
2.0
9.5/8.0
12.0
2.0
Table B5-4. Altitude Correction for Input Capacity at Various Altitude Levels (Natural Gas)
700' ASL
2000'
4500'
6000'
8000'
10000'
CFC 2500
2500
2500
2250
2025
1925
1730
CFC 1800
1800
1779
1530
1472
1413
1356
CFC 1500
1500
1500
1350
1296
1244
1194
CFC 1000
1000
1000
900
864
829
783
CFC 750
750
750
700
675
645
620
425
400
CFC 500
500
500
450
425
** Ratings assume 35% excess air, 80F combustion air.
Blower speed adjustments should be made to match performance accordingly.
Gas pressure corrections for altitude should be made per Boiler Book Table B5-19.
Competitor 1
Competitor 2
Clearfire
Figure B5-7. Competitive Condensation Analysis
B5-12
09-09
Model CFC
ClearFire
Efficiencies
Commercial Boilers
The Tables below depict the operating efficiencies of each size Model CFC boiler,
including radiation losses. As the Model CFC is a fully condensing boiler, maximum
efficiency is obtained when operating within the condensing mode, utilizing the latent
heat of condensation.
Table B5-5. CFC 500 ClearFire Efficiency

Return Water Temperature F0 (C)
%
Firing Rate
68
(20)
80
(27)
100
(38)
120
(49)
130
(55)
140
(60)
160
(72)
20
99
98.4
97
96.5
95
93
87.5
50
98.25
98.1
96
92.5
93
89
87.5
75
98
97
94
87.5
88
87.5
86.5
100
97.2
96
90.5
87.25
87
87
86

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

Firing Rate
%

68
80
105
120
130
140
160
20
(20)
99
(27)
99
(38)
98.5
(49)
97
(55)
95.5
(60)
94.5
(72)
88.5
50
99
99
97.5
93.5
92
90.5
87.9
75
98
97
93
89
88
87.5
86.5
100
97.2
97
91.5
88.50
87.5
87
86.50
09-09
B5-13
Commercial Boilers
Model CFC
Firing Rate
%

68
80
105
120
130
140
160
20
(20)
99
(27)
99
(38)
98
(49)
97
(55)
96.5
(60)
94
(72)
88
50
98.25
99
97
93
91.5
89.5
87
75
98
97
93
89
88
87.5
86.5
100
97.2
97
91
88
87.5
87
86.25

Firing Rate
%

68
80
105
120
130
140
160
20
(20)
99
(27)
99
(38)
98
(49)
97
(55)
95.5
(60)
93.7
(72)
88
50
98.25
99
97
93
91.5
89.5
87.5
75
98
97
93
89
88
87.5
86.5
100
97.2
96.5
91
88.25
87.5
87
86.25

Firing Rate
%

68
80
105
120
130
140
160
20
(20)
99
(27)
99
(38)
98
(49)
97
(55)
95.5
(60)
93.7
(72)
88
50
98.25
99
97
93
91.5
89.5
87.5
75
98
97
93
89
88
87.5
86.5
100
97.2
96.5
91
88.25
87.5
87
86.25
Emissions
The Model CFC Boiler has been tested by an independent testing lab for Low NOx
certification in California under the requirements of South Coast Air Quality
Management District (SCAQMD) Rule 1146. Meeting the requirements of SCAQMD
also qualifies the boiler for meeting the NOx requirements in the state of Texas.
By means of the Pre-mix burner, the Clearfire boiler provides environmentally
friendly emissions when firing natural gas; emission data are shown in Figure B5-8
through Figure B5-13.
B5-14
09-09
Model CFC
Commercial Boilers
Em issio n s CF C 500
* P M is le ss th a n 1
*S 0x re la tive to S u lp h u r in fu e l
Co m p lia n t to S CAQ M D Ru le 1146.2
20
19
18
17
16
17
15
14
12
*PM
PPM
CO
NOx
10
8
7
6
5
4
4
2
20
50
75
100
0
Fir in g Rate %
Figure B5-8. Emissions Data Clearfire Model CFC 500
Em issio n s CF C 750
* P M is le ss th a n 1
*S 0x re la tive to S u lp h u r in fu e l
C o m p lia n t to S CA Q M D R u le 1146.2
20
19
18
17
16
17
15
14
12
*PM
NOx
PPM
CO
10
8
7
6
5
4
4
2
20
50
75
100
0
Fir in g Rat e %
09-09
B5-15
Commercial Boilers
Model CFC
Emissions CFC1000
* PM is less than 1
*S0x relative to Sulphur in fuel
Compliant to SCAQMD Rule 1146.2
19
20
17
18
17
15
16
14
12
*PM
PPM
CO
NOx
10
8
6
6
5
4
2
20
50
75
100
0
Firing Rate %
Emissions CFC 1500

* PM is less than 1
19
20
17
18
16
13
14
12
*PM
NOx
PPM
CO
10
9
8
6
5
4
2
20
50
75
100
0
Firing Rate %
B5-16
09-09
Model CFC
Commercial Boilers
Em issions CFC 1800

* PM is le ss tha n 1
*S0x re la tive to Sulphur in fue l
Com plia nt to SCAQMD Rule 1146.2
16
14
14
14
13
13
12
10
*PM
PPM
CO
NOx
8
6
6
4
4
2
20
50
75
100
0
Fir ing Rate %
Emissions CFC 2500

* PM is less than 1
16
14
14
14
13
13
12
10
*PM
NOx
PPM
CO
8
6
6
4
4
2
20
50
75
100
0
Firing Rate %
09-09
B5-17
Commercial Boilers
Noise Level
Model CFC
The Model CFC is extremely quiet at all operating levels, does not require any sound
level modifications to provide ultra low noise levels, and is virtually vibration free.
Thus, it is very suitable in applications that demand low noise levels.
Table B5-11 shows the noise levels of the Clearfire at various firing rates.
CFC 500
CFC 750
CFC 1000
CFC 1500
CFC 1800
CFC 2500
20% Firing
39
41
43
40
45
45
60% Firing
48
51
57
50
56
57
100% Firing
60
62
66
64
66
68
Table B5-11. Noise Level (dBA) measured 3 feet in front of boiler
ENGINEERING DATA
Boiler Information
The Model CFC boiler is designed for service in any closed hydronic system and can
be used to augment any hot water system. It can be put into operation as a single
stand-alone unit with 5:1 turndown or in multiple units for larger turndown and
capacity.
Clearfire boilers may be utilized in water heating systems with temperatures from
40 F (4.4 C) to 195 F (90.5 C); ideal for ground water source heat pump
applications, etc. Because the Clearfire is a full condensing boiler, low water
temperature (below the dewpoint) restrictions do not apply. In fact, the lower the
return the better the fuel savings.
Variable temperature differentials can be designed to make use of changing outdoor
conditions and thus, the Clearfire is not restricted to a nominal 20 F (10 C)
differential. The boiler is designed to withstand thermal stresses with supply and
return temperature differences up to 100 F (55 C), without the use of a boilercirculating pump, blend pump or minimum water flow.
Note: The Clearfire does not require a minimum flow or continuous flow through it during operation.
However, the load imposed on the boiler must be considered when sizing the system flow so that
the flow does not exceed the capacity of the boiler or the demand.
Flow Rates and

Pressure Drops
To maintain rated capacity of the boiler, recommended flow rates should not be
exceeded as the flow will remove the heat beyond the capacity of the boiler. Table
B5-12 through Table B5-13 can be used to determine the full boiler output relative
to system temperature drop and the maximum recommended system pump flow.
Knowing the flow rate, the pressure drop through the boiler can be found in Figure
B5-14 through Figure B5-24.
System Operating
Parameters
To prevent water flashing to steam within the boiler or system, hot water boilers
must operate with proper over-pressure. System over-pressure requirements are
shown in Table B5-14.
Note: The ASME Code Section IV limits the maximum setting of the excess temperature control to
210 F (98.9 C) for boilers constructed with stainless steel. This is to ensure that water
temperature will not reach the boiling point (steaming) and therefore, so as not to exceed the
maximum limit of this control and in compliance with the Code, the operating limit of 195 F
(90.5 C) is set for normal boiler operation.
B5-18
09-09
Model CFC
Commercial Boilers
While proper overpressure is required, a means to relieve excess pressure at or
beyond the design pressure of the boiler must be provided. As boiler water is
heated, expansion occurs. And this expansion must be accounted for either with an
expansion tank (air filled) or with a bladder type tank. These devices permit the
water pressure to expand outside of the boiler and not impact the pressure vessel or
pressure relieving device. But, in accordance with Code, each boiler is equipped
with an ASME approved safety relieving device should pressure build-up occur (See
Table B5-15 and Table B5-16).
Air Venting
The elimination of entrained air is required. It is recommended that each unit be

piped to an expansion tank. If this is not possible, then an auto air vent should be
provided on the vent connection of the boiler. The caveat in using an auto vent is
that free oxygen can be introduced to the vesel as the boiler cools, or in some
instances the vent can become plugged.
09-09
B5-19
Commercial Boilers
Model CFC
Table B5-12. Maximum Flow Rate Through ClearFire Boilers (US Flow Rates)
System Temperature Drop 0 F
10
20
30
40
50
Boiler
Size
60
70
80
90
100
110
120
Flow Rate GPM
500
95
48
33
24
19
16
12
11
10.5
750
131
66
44
33
26
22
19
16
15
13
12
11
1000
176
88
59
44
35
29
25
22
20
18
16
15
1500
260
130
87
65
52
43
37
33
29
26
24
23
1800
351
176
117
88
70
59
50
44
39
35
32
30
2500
470
235
157
118
95
79
67
59
52
48
43
39
Recommended flow rates relative to temperature drop so as not to exceed boiler output.
Table B5-13. Maximum Flow Rate Through ClearFire Boilers (Metric Flow Rates)
System Temperature Drop 0 C
5
11
17
22
27
Boiler
Size
33
38
45
50
55
61
64
Flow Rate m3 /hr.
500
21.6
10.9
7.5
5.4
4.3
3.6
2.7
2.5
2.3
1.8
1.6
750
29.75
15
10
7.5
4.3
3.6
3.4
2.9
2.7
2.5
1000
40
20
14
10
4.5
3.6
3.4
1500
59
29.5
20
15
12
10
8.4
7.5
6.6
5.4
5.2
1800
80
40
27
20
16
13
11.3
10
7.3
6.8
2500
106.7
53.4
36.7
26.8
21.6
17.9
15.2
13.4
11.8
10.9
9.8
8.8
Recommended flow rates relative to temperature drop so as not to exceed boiler output.
B5-20
09-09
Model CFC
Commercial Boilers
Hyd rau lic Re sistan ce CF C 500

Pres sure PSI
1 .4
1 .2
1
0 .8
0 .6
0 .4
0 .2
131
70.4
66
61.6
57.2
52.8
48.4
44
39.6
35.2
30.8
26.4
22
17.6
13.2
8.8
Flow - GPM
Figure B5-14. Pressure Drop Curve ClearFire Boiler Size 500, U.S. Flow Rates.
H yd r a u lic R e s is ta n c e C FC 5 0 0
M e tr ic
Pr e s s u r e m b ar
30
25
20
15
10
5
0
0
10
11
12
13
14
15
16
Flo w m 3 /h
Figure B5-15. Pressure Drop Curve ClearFire Boiler Size 500, Metric Flow Rates.
09-09
B5-21
Commercial Boilers
Model CFC
Hydraulic Resistance CFC 750

Pressure PSI
1.4
1.2
1
0.8
0.6
0.4
0.2
13
1
66
57
.2
48
.4
39
.6
30
.8
22
.0
1
13
.2
Flow - GPM

Metric
Pressure mbar
30
25
20
15
10
5
0
0 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16
Flow m3/h
B5-22
09-09
Model CFC
Commercial Boilers
Hydraulic Resistance CFC 10 00

Pr e s s u r e - PSI
1.2
1
0.8
0.6
0.4
0.2
0
0
8.8
22
44
66
88
110
132
154
176
Flo w - GPM
H y d r a u lic R e s is t a n c e C FC 1 0 0 0
P re s s ure m ba r
80
70
60
50
40
30
20
10
0
0
10
15
20
25
30
35
40
Flo w m 3 /h
09-09
B5-23
Commercial Boilers
Model CFC
Hydraulic Re sistance CFC 1500

U.S. Standards
Pre ssure - PSI
2
1.8
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0
0
8.8 22
44
66
88 110 132 154 176 198 220 242 264

Flow - GPM

Metric
Pressure mbar
140
120
100
80
60
40
20
0
0
10
15
20
25
30
35
40
45
50
55
60
Flow m3/h
Figure B5-21. Pressure Drop Curve ClearFire Boiler Size 1500, Metric Flow Rate.
B5-24
09-09
Model CFC
Commercial Boilers

U.S. Standards
Pressure - PSI
1.8
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
352
330
308
286
264
242
220
198
176
154
132
110
88
66
44
22
8.8
Flow - GPM

M etric
Pressure mbar
120
100
80
60
40
20
0
0
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
Flow m3/h
09-09
B5-25
Commercial Boilers
Model CFC
Hydr aulic Re s is tance CFC 2500

U.S. Standar ds
Pr e s s ur e - PSI
1.8
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0
0
44
66
88
118
132
154
176
198
220 242
Flow - GPM
264
286
308
330
352
375
B5-26
09-09
395
420
474
Model CFC
Commercial Boilers
Table B5-14. Model CFC Minimum Over Pressure Requirements
Outllet Water Temperature 0 F (C)
Minimum System Pressure PSIG (Bar)
80 - 180 (27 - 82)
12 (0.83)
181 - 185 (83 - 85)
15 (1.03)
186 - 195 (86 - 91)
18 (1.24)
Table B5-15. Model CFC Boiler Safety Valve Information @ 60 PSIG

Boiler Size
Valve Connection
Valve Setting 60 psig
@ Boiler
No. Valves Req'd Outlet Size
Relief
Valve
Capacity (MBH)
500
3/4"
1"
1784
750
3/4"
1"
1784
1000
3/4"
1"
1784
1500
3/4"
1"
1784
1800
1"
1-1/4"
2788
2500
1"
1-1/4"
2788
Table B5-16. Model CFC Boiler Safety Valve Information @ 30 PSIG

Boiler Size
Valve Connection
Valve Setting 30 psig
@ Boiler
No. Valves Req'd Outlet Size
Relief
Valve
Capacity (MBH)
500
3/4"
1"
1054
750
3/4"
1"
1054
1000
3/4"
1"
1054
1500
1"
1-1/4"
1648
1800
1-1/2"
2"
3495
2500
1-1/2"
2"
3495
09-09
B5-27
Commercial Boilers
Water Treatment
Model CFC
Even though hot water systems are "closed", some amount of make-up water (up to
10%) will be introduced. This more often than not happens from seal leaks of
pumps, or other minimal leaks from valves etc., that go unnoticed. Therefore,
proper water chemistry of a hot water boiler is necessary for good operation and
longevity, particularly to ensure that free oxygen is removed to prevent waterside
corrosion (see Table B5-17).
Table B5-17. Model CFC Water Chemistry Requirements in accordance with ABMA
Condensation
Parameter
Limit
Glycol
40%
pH
8.0 - 9.5
Chloride
30 mg/liter
Oxyen
0.1 mg/liter
3500 umho/cm
Total Hardness
0 ppm as CaCO3
As the Model CFC boiler is a full condensing boiler, condensation will develop during
startup of a cold boiler or at any time when the return water temperature is below
the dew point or approximately 132 F (55.5 C).
The condensation collects in the lower portion of the boiler from the tube surfaces
and from the stack, and must be discharged to a drain. A Condensate trap must be
piped on the boiler and this must be field piped to either a drain or to the optional
Condensate treatment kit. Table B5-18 provides the amount of condensation that
will form when the boiler operates in the full condensing mode.
B5-28
09-09
Model CFC
Commercial Boilers
Table B5-18. Model CFC Maximum Condensation
500
Gallons Per Hour - GPH

(Liters Per Hour - L/H)
3.5 [
750
5 [18.9]
1000
7 [26.5]
1500
9 [34]
1800
12 [45]
2500
17
Boiler Size
Boiler Operating @ maximum in full condensing mode.
As prescribed by local codes, this condensate may be discharged directly to the

drain or treated using an optional treatment assembly. Figure B5-25 depicts piping
without the treatment assembly and Figure B5-26 shows the optional treatment
assembly. Note: One treatment kit may be used for up to four boilers as shown in
Figure B5-27 and Figure B5-28.
3
1
2
1. Removable front
2. Min. 6 water trap
3. Plastic drain pipe
Figure B5-25. Condensate Piping Direct To Drain

Drain trap
Neutralization tank
Condensate in
To drain
Float valve for makeup water
Neutralization media
Figure B5-26. Optional Condensate Treatment Assembly
09-09
B5-29
Commercial Boilers
Model CFC
Notice
If a treatment kit is utilized, clearance at the front of the boiler must be provided for
servicing the assembly and for periodically adding the neutralizing granules.
1/4" O.D. Make-up Water Supply

Condensate Drain Trap
Neutralization Tank
To Drain
Figure B5-27. Condensate Piping for Multiple Boilers
Model CFC Boiler

1" NPT Minimum Header Size
(Use PVC Pipe or other Nonferrous Material)
Condensate Drain Trap
Neutralization Tank
Neutralization Media
12" Minimum
To Drain
Figure B5-28. Condensate Treatment Tank for Multiple Boilers
B5-30
09-09
Model CFC
Gas Fuel
Connections
Commercial Boilers
The local Gas Company should be consulted for the requirements for installation
and inspection of gas supply piping. Installation of gas supply piping and venting
must be in accordance with all applicable engineering guidelines and regulatory
codes. All connections made to the boiler must be arranged so that all components
are accessible for inspection, cleaning, and maintenance.
A drip leg should be installed in the supply line before the connection to the boiler.
The drip leg should be at least as large as the gas piping connection on the boiler.
See Figure B5-29, and Figure B5-30 for piping suggestions.
Figure B5-29. Gas Piping Schematic

Consideration of volume and pressure requirements must be given when selecting
gas supply piping.
Connections to the burner gas train must include a union so that the burner may be
opened for inspection and maintenance.
09-09
B5-31
Commercial Boilers
Model CFC
A. Gas supply connection is at the rear of the boiler near the top. To permit
burner opening, gas piping must not traverse the top of the boiler.
B. Table B5-19 shows the gas pressure required at the inlet of the gas line.
Note: a pressure regulator is not furnished and if gas pressure exceeds 14"
W.C. a pressure regulator is recommended.
C. Table B5-20 shows the correction factors for gas pressure at elevations at
2000 feet and higher above sea level.
Figure B5-30. Gas Header Piping
B5-32
09-09
Model CFC
Commercial Boilers
Table B5-19. Model CFC Minimum and Maximum Gas Pressure
Boiler Size
Low Fire
Inches W.C.
High Fire
Inches W.C.
500-1000
1500
10
1800
2500
9.5
Maximum Pressure
Inches W.C.
14
Note: Pressure is measured at entrance to burner gas train or discharge of regulator.

A gas pressure regulator is not furnished as standard.
Table B5-20. Model CFC Minimum Required Gas Pressure Altitude Correction
Altitude in Feet
Correction Factor
Altitude in Feet
Correction Factor
1000
1.04
6000
1.25
2000
1.07
7000
1.3
3000
1.11
8000
1.35
4000
1.16
9000
1.4
5000
1.21
To obtain minimum required inlet pressure, select altitude of installation and multiply the pressure shown
in Table B5-19 by the correction factor corresponding to the altitude listed above.
Boiler Room
Information
The boiler must be installed on a level non-combustible surface. If the surface is not
level, piers or a raised pad, slightly larger than the length and width of the boiler
base dimensions, will make boiler leveling possible. Installing the boiler on a raised
pad or piers will make boiler drain connections more accessible and will keep water
from splashing onto the boiler whenever the boiler room floor is washed.
Note: The pad or piers must be of sufficient load bearing strength to safely support the operating
weight of the boiler and any additional equipment installed with it. Approximate operating
weights are shown in Dimensions and Ratings.
Leveling
Once the boiler is placed, it must be leveled side to side and front to back using the
supply and return nozzles for horizontal and vertical positions. If shims are required
to level the boiler, the weight of the boiler must be evenly distributed at all points of
support. The legs may also be used for leveling.
Clearances
The boiler must be installed so that all components remain accessible; ensure no
overhead obstructions so the burner may be opened. Refer to Figure B5-31.
09-09
B5-33
Commercial Boilers
Model CFC
DIM
Inches
Top Clearance
14
Side Clearance
20
Backway
20
Front
36
Between Boilers
Figure B5-31. Model CFC Minimum Room Clearance Dimensions

Seismic Legs
Seismic mounting details shown below.
Figure B5-32. CFC Seismic Mounting
B5-34
09-09
Model CFC
Hot Water Piping
Commercial Boilers
Primary/secondary pumps are not necessary with the Model CFC boiler. As its
design is such that no minimum flow is required, variable speed or on/off pumps
may be employed in the piping scheme.
Typical piping arrangements are shown in figures B5-33 through B5-45.
Note: These diagrams are generic and are not intended for use in a specific design without
consultation with your local Cleaver-Brooks sales representative
09-09
B5-35
Figure B5-33. No primary Loop with Domestic Water and 2-Way Divert Valve
Figure B5-34. 2 Pipe System, Typical (reverse-return)
Figure B5-35. Zoning with Zone Valves
Figure B5-36. Two Boilers and Three Variable Temperature Zones (No Primary Loop)
Figure B5-37. Two-Pipe Primary/Secondary Piping with Domestic Hot Water
Figure B5-38. Two-Pipe Primary/Secondary Piping
Figure B5-39. No Primary Loop
Figure B5-40. Domestic Water Heating, No Primary Loop
Figure B5-41. Domestic Water with On/Off and 3-Way Valves
Figure B5-42. Piping Hybrid Boilers
Figure B5-43. Hybrid Boilers with Domestic Water
Figure B5-44. Domestic Water with 2 Boilers and 2 Coils
Commercial Boilers
Boiler Room
Combustion and
Ventilation Air
Model CFC
The boiler(s) must be supplied with adequate quantities of uncontaminated air to
support proper combustion and equipment ventilation. Air shall be free of chlorides,
halogens, fluorocarbons, construction dust or other contaminants that are
detrimental to the burner/boiler. If these contaminants are present, we recommend
the use of direct vent combustion provided the outside air source is
uncontaminated.
Combustion air can be supplied by means of conventional venting, where
combustion air is drawn from the area immediately surrounding the boiler (boiler
room must be positive pressure), or with direct vent (direct vent combustion) where
air is drawn directly from the outside. All installations must comply with local
Codes and with NFPA 54 (the National Fuel Gas Code - NFGC) for the U.S. and for
Canada, CAN/CGA B 149.1 and B 149.2.
Note: A boiler room exhaust fan is not recommended as this type of device can cause a negative
pressure in the boiler room if using conventional air intake.
In accordance with NFPA54, the required volume of indoor air shall be determined
in accordance with the "Standard Method" or "Known Air Infiltration Rate Method.
Where the air infiltration rate is known to be less than 0.40 Air Changes per Hour,
the Known Air Infiltration Rate Method shall be use. (See Section 8.3 in the
NFPA54 Handbook for additional information.)
Combustion Air
Supply - Unconfined
Spaces (For U.S.
Installations Only)
A. All Air From Inside the Building - If additional combustion air is drawn from
inside the building (the mechanical equipment room does not receive air
from outside via louvers or vent openings and the boiler is not equipped with
direct vent combustion) and the boiler is located in a unconfined space, use
the following guidelines:
1. The mechanical equipment room must be provided with two permanent
openings linked directly with additional room (s) of sufficient volume so
that the combined volume of all spaces meet the criteria for an
unconfined space. Note: An "unconfined space" is defined as a space
whose volume is more than 50 cubic feet per 1,000 Btu per hour of
aggregate input rating of all appliances installed in that space.
2. Each opening must have a minimum free area of one square inch per
1,000 Btu per hour of the total input rating of all gas utilizing equipment
in the mechanical room.
3. One opening must terminate within twelve inches of the top, and one
opening must terminate within twelve inches of the bottom of the room.
4. Refer to the NFGC, Section 8.3 for additional information.
B5-48
09-09
Model CFC
Commercial Boilers
GAS
VENT
GAS
VENT
12" MINIMUM
FRESH AIR OPENING
INTERIOR WALL
CLEARFIRE
BOILER
WATER
HEATER
FRESH AIR OPENING
12" MINIMUM
Figure B5-45. Two Opening Outside Wall Method

B. All Air From Outdoors - If all combustion air will be received from outside the building (the mechanical
room equipment is linked with the outdoors), the following methods can be used:
1. Two Opening Method (Figure B5-45) - The mechanical equipment room
must be provided with two permanent openings, one terminating within
twelve inches from the top, and one opening terminating within twelve
inches of the bottom of the room.
2. The openings must be linked directly or by ducts with the outdoors.
3. Each opening must have a minimum free area of one square inch per
4,000 Btu per hour of total input rating of all equipment in the room,
when the opening is directly linked to the outdoors or through vertical
ducts.
4. The minimum free area required for horizontal ducts is one square inch
per 2,000 Btu per hour of total input rating of all the equipment in the
room.
09-09
B5-49
Commercial Boilers
Model CFC
GAS
VENT
GAS
VENT
12" MINIMUM
OUTLET AIR DUCT
INTERIOR WALL
EXTERIOR WALL
CLEARFIRE
BOILER
WATER
HEATER
FRESH AIR
INLET DUCT
12" MINIMUM
Figure B5-46. Two Opening Ducted Method

C. One Opening Method (Figure B5-47) - One permanent opening,
commencing within 12 inches of the top of the enclosure, shall be provided.
1. The equipment shall have clearances of at least 1 inch from the sides and
back and 6 inches from the front of the appliance.
2. The opening shall directly communicate with the outdoors and shall have
a minimum free area of 1 square inch per 3000 BTU's per hour of the
total input rating of all equipment located in the enclosure, and not less
than the sum of the areas of all vent connectors in the confined space.
3. Refer to the NFGC, Section 8.3 for additional information.
B5-50
09-09
Model CFC
Commercial Boilers
GAS
VENT
GAS
VENT
12" MINIMUM
FRESH AIR OPENING
EXTERIOR WALL
CLEARFIRE
BOILER
WATER
HEATER
Figure B5-47. One Opening Method

Unconfined Space/
Engineered Design
When determining boiler room air requirements for unconfined space, the size of the
room, airflow, and velocity of air must be reviewed as follows:
1. Size (area) and location of air supply openings in the boiler room.
recommended. Locate one at each end of the boiler room, preferably below
a height of 7 feet. This allows air to sweep the length of the boiler. See
Figure B5-48.
qualities and is subject to clogging with dirt and dust.
C. A vent fan in the boiler room is not recommended, as it could create a slight
vacuum under certain conditions and cause variations in the quantity of
combustion air. This can result in unsafe burner performance.
D. Under no condition should the total area of the air supply openings be less
than one square foot.
09-09
B5-51
Commercial Boilers
Model CFC
GAS
VENT
GAS
VENT
FRESH AIR OPENING
FRESH AIR OPENING

CLEARFIRE
BOILER
WATER
HEATER
EXTERIOR WALL
EXTERIOR WALL
Figure B5-48. Two Opening Engineered Method

Area in square feet = cfm/fpm
Where cfm = cubic feet per minute of air
Where fpm = feet per minute of air
2. Amount of Air Required (cfm).
A. Combustion Air = Rated bhp x 8 cfm.
B. Ventilation Air = Maximum bhp x 2 cfm.
C. Total air = 10 cfm per bhp (boiler horsepower up to 1000 feet elevation.
Add 3% more per 1000 feet of added elevation.
3. Acceptable air velocity in the Boiler Room (fpm).
A. From floor to 7 feet high = 250 fpm.
B. Above 7 feet above floor = 500 fpm.
Example: Determine the area of the boiler room air supply openings for (2) Clearfire
1800 boilers at 750 feet elevation. The air openings to be 5 feet above floor level.
(Size 1800 boiler is equivalent to 52 horsepower at full condensing)
B5-52
Air required: 52 x 2 = 104 bhp. From 2C above, 104 x 10 = 1,040 cfm.
Air Velocity: Up to 7 feet = 250 fpm from 3 above.
Area required: Area = cfm/fpm = 1,040/250 = 4.16 square feet total.
Area/Opening: 4.16/2 = 2.08 sq-ft/opening (2 required).
09-09
Model CFC
Commercial Boilers
Notice
Direct Vent
Combustion

If combustion air will be drawn directly from the outside by means of a duct
connected to the burner air intake, use the following as a guide:
1. Install combustion air vent (direct vent combustion) in accordance with the
boiler's Operating and Maintenance manual.
2. Provide for adequate ventilation of the boiler room or mechanical equipment
room.
3. In cold climates, and to mitigate potential freeze-up of the intake pipe, it is
highly recommended that a motorized sealed damper be used to prevent the
circulation of cold air through the boiler during non-operating hours.
4. Refer to Figure B5-49 for suggested piping of direct vent combustion
installations. Figure B5-50 shows the optional direct vent combustion kit
providing easy adaptation of the contractor supplied air duct to boiler
connection. Refer to Table B5-22 for sizing the direct vent combustion air pipe.
Flue Gas Vent (w/Screen)
36" Minimum
Air Intake (w/Screen)
24" Minimum
12" Minimum
Clearfire Boiler
Figure B5-49. Direct Vent Combustion Piping Options.

FAN/BLOWER
VENTURI
AIR SUPPLY LINE
Figure B5-50. Optional Direct Vent Combustion Kit
09-09
B5-53
Commercial Boilers
Model CFC
STACK/BREECHING SIZE CRITERIA

General
The Model CFC is a Category IV Boiler, according to ANSI Z21.13. This Code
defines a Category IV boiler as one that operates with a positive vent pressure and a
vent gas temperature that may produce condensation in the breeching and stack,
depending upon operating conditions. Consequently, the vent material must
conform to this category boiler rating. UL 17-38 certified material must be used.
Under certain conditions, PVC and CPVC may be utilized.
If PVC or CPVC is considered, the maximum outlet temperature of the water supply
from the boiler shall not exceed 120 F. Also, the primary consideration of PVC or
CPVC shall be the temperature limits of the material and local codes.
Proper installation of flue gas exhaust venting is critical to efficient and safe
operation of the Clearfire Boiler. The vent should be supported to maintain proper
vent passes through combustible roofs and walls.
flue gas connection; proper draft is critical to burner performance.
size the breeching and stack to limit flue gas pressure variation. Consideration of
the draft must be given whenever direct vent combustion is utilized and lengthy runs
of breeching are employed. Please note: The allowable pressure range for design of
the stack, breeching and if used, direct vent combustion pipe, is negative 0.25"
W.C. (- 62 Pa) to positive 0.25" W.C. (+62 Pa) for proper combustion and light offs.
Whenever two or more boilers are connected to a common breeching/stack, a draft
control system may be required to ensure proper draft.
Vent Termination
To avoid the possibility of property damage or personal injury, special attention to

the location of the vent termination must be considered.
1. Combustion gases can form a white vapor plume in the winter. The plume could
obstruct a window view if the termination is installed in close proximity to
windows.
2. Prevailing winds could cause freezing of Condensate and water/ice buildup on
building, plants, or roof.
3. The bottom of the vent termination and the air intake shall be located at least
12 inches above grade, including the normal snow line.
4. Non-insulated single-wall metal vent pipe shall not be used outside in cold
climates for venting combustion gases.
5. Through the wall vents for Category II and Category IV appliances shall not
terminate over public walkways or over an area where Condensate or vapor
could create a nuisance or hazard or could be detrimental to the operation of
other equipment.
6. To prevent accidental contact by people or pets, the vent termination shall be
guarded.
7. DO NOT terminate vent in window well, alcove, stairwell or other recessed area,
unless approved by local authority.
8. DO NOT terminate above any door, window, or gravity air intake as Condensate
can freeze causing ice formation.
B5-54
09-09
Model CFC
Commercial Boilers
9. Locate or guard vent to prevent Condensate from damaging exterior finishes.
Use a 2' x 2' rust resistant sheet metal backing plate against brick or masonry
surfaces.
10. Multiple direct stack installations require four feet clearance between the stack
caps, center to center.
U.S. Installations -
Refer to the latest edition of the National Fuel Gas Code/NFPA 54. Vent
termination requirements are:
1. Vent must terminate at least four feet below and four feet horizontally or one foot
above any door, window or gravity air inlet to the building.
2. The vent must be at least seven feet above grade when located adjacent to
public walkways.
3. Terminate vent at least three feet above any forced air inlet located within ten
feet.
4. Vent must terminate at least four feet horizontally, and in no case above or below
unless four feet horizontal distance is maintained, from electric meters, gas
meters, regulators, and relief equipment.
5. Terminate vent at least six feet from adjacent walls.
6. DO NOT terminate vent closer than five feet below roof overhang.
Canadian
Installations -
Refer to the latest edition of CAN/CSA-B149.1 and B149.2. Vent shall not
terminate:
1. Directly above a paved sidewalk or driveway which is located between two
single-family dwellings and serves both dwellings.
2. Less than 7 feet (2.31m) above a paved sidewalk or paved driveway located on
public property.
3. Within 6 feet (1.8m) of a mechanical air supply inlet to any building.
4. Above a meter/regulator assembly with 3 feet (900mm) horizontally of the
vertical centerline of the regulator.
5. Within 6 feet (1.8m) of any gas service regulator vent outlet.
6. Less than 1 foot (300mm) above grade level.
7. Within 3 feet (1m) of a window or door which can be opened in any building,
any non-mechanical air supply inlet to any building or to the combustion air inlet
of any other appliance.
8. Underneath a Verandah, porch, or deck unless:
A. The Verandah, porch, or deck is fully open on a minimum of two sides
beneath the floor.
B. The distance between the top of the vent termination and the underside of
the Verandah, porch, or deck is greater than one foot (300mm).
09-09
B5-55
Commercial Boilers
Horizontal Through
the Wall Venting
Model CFC
Venting configurations using inside air for combustion (See Figure B5-51)
These installations utilize the boiler-mounted blower to vent the combustion
products to the outside. Combustion air is obtained from inside the room and the
exhaust vent is installed horizontally through the wall to the exterior of the building.
Adequate combustion and ventilation air must be supplied to the boiler room in
accordance with the NFGC/NFPA 54 for the U.S. and in Canada, the latest edition
of CAN/CSA-B149.1 and.2 Installation Code for Gas Burning Appliances and
Equipment.
Inside Air
Combustion
Intake
Flue Gas Vent

(w/Screen)
12" Minimum + any

Snow Load
Figure B5-51. Horizontal Through the wall venting using inside air for combustion
The vent must be installed to prevent the potential accumulation of stack
condensate in the horizontal run of vent pipe. Therefore, it is recommended that:
1. The vent shall be installed with a slight downward slope of not more than 1/4"
per foot of horizontal run to the vent termination.
2. The vent must be insulated through the length of the horizontal run.
Note: For installations in cold/freezing climates, it is recommended that:
1. The vent shall be installed with a slight upward slope of not more than 1/4" per
foot of horizontal run to the vent termination. In this case, an approved
Condensate trap must be installed per applicable codes.
2. The vent must be insulated through the length of horizontal run.
The stack vent cap MUST be mounted on the exterior of the building. The stack
vent cap cannot be installed in a well or below grade. The stack vent cap must be
installed at least two feet above ground level and above normal snow levels.
Notice
The stainless steel direct vent cap must be furnished in accordance with AGA/CGA
requirements.
Refer to Table B5-21 for the recommended sizes of horizontal vent pipe.
B5-56
09-09
Model CFC
Commercial Boilers
Horizontal Through
the Wall Stack
Venting
Direct Vent Combustion. See Figure B5-52.
24" Minimum
18" Minimum
24" Minimum
Figure B5-52. Horizontal Flue through-wall with direct vent combustion intake
These installations utilize the boiler-mounted blower to take combustion air from the
outside and vent combustion by-products to the outside.
The direct vent combustion air vent cap is not considered in the overall length of the
venting system.
The stack vent must be installed to prevent the potential accumulation of
Condensate in the stack pipes. It is recommended that:
1. The vent shall be installed with a slight downward slope of not more than 1/4"
per foot of horizontal run to the stack termination.
2. The stack vent is to be insulated through the length of the horizontal run.
Note: For installations in freezing climates, it is recommended that:
1. The stack vent shall be installed with a slight upward slope of not more than 1/
4" per foot of horizontal run to the vent termination. In this case, an approved
Condensate trap must be installed per applicable codes.
2. The stack vent is to be insulated through the length of the horizontal run.
Note: For Horizontal Stack Vent Termination:
09-09
B5-57
Commercial Boilers
Model CFC
1. The stack vent cap must be mounted on the exterior of the building. The stack
vent cap cannot be installed in a well or below grade. The stack vent cap must
be installed at least one foot above ground level and above normal snow levels.
2. Multiple stack vent caps should be installed in the same horizontal plane with
three feet clearance from side of one stack cap to the side of the adjacent vent
cap.
3. Combustion air supplied from the outside must be free of particulate and
chemical contaminants. To avoid a blocked flue condition, keep all the vent
caps clear of snow, ice, leaves, debris, etc.
Note: Multiple direct stack vent caps must not be installed with one combustion air inlet directly above
a stack vent cap. This vertical spacing would allow the flue products from the stack vent to be
pulled into the combustion air intake installed above. This type of installation can cause nonwarrantable problems with components and poor operation of the unit due to the recirculation of
flue products.
Refer to Table B5-22 for recommended flue vent sizing when using Direct Vent
Combustion.
Table B5-21. STACK DESIGN SINGLE BOILER USING ROOM AIR
Boiler Size
Boiler Stack
Connection
Stack/Vent
Size
Maximum length of breeching or stack

(feet)*
6" Standard
6"
80
4" Option
4"
40
6" Standard
6"
80
8" Standard
8"
140
6" Option
6"
80
10" Option
10"
220
10" Standard
10"
140
8" Option
8"
90
12" Option
12"
250
12" Standard
12"
60
10" Option
10"
40
12" Standard
12"
110
CFC 500
CFC 750
CFC 1000
CFC 1500
CFC 1800
CFC 2500
* Each additional 90 elbow equals 5 equivalent feet of ductwork. Subtract from the
maximum or minimum length accordingly.
Maximum allowable pressure drop in flue vent ducting is 0.25" w.c.
B5-58
09-09
Model CFC
Commercial Boilers
Table B5-22. STACK SIZING USING OUTSIDE AIR FOR COMBUSTION
Boiler
Boiler Stack
Connection
Boiler Vent/ Maximum length of

Boiler Air
Intake Duct & Stack Size Flue Gas Vent in
Feet*
Connection
Maximum length of
Air Intake Duct in
Feet**
6" Standard
4"
6"
75
75
4" Option
4"
4"
40
40
6" Standard
4"
6"
40
40
8" Standard
6"
8"
60
60
6" Option
6"
6"
40
40
10" Option
6"
10"
70
70
10" Standard
6"
10"
40
40
8" Option
6"
8"
30
30
12" Option
6"
12"
45
45
12" Standard
6"
12"
30
30
10" Option
6"
10"
25
25
12" Standard
8"
12"
100
100
CFC 500
CFC750
CFC1000
CFC1500
CFC1800
CFC 2500
* Each additional 90 elbow equals 5 equivalent feet of ductwork. Subtract from the maximum or
minimum length accordingly.
** Increasing the diameter of the air intake will reduce the pressure drop and thereby allow longer total
vent lengths.
Maximum allowable pressure drop in combustion air intake duct is - 0.25" w.c.
09-09
B5-59
Commercial Boilers
Vertical Venting
Inside Combustion
Air
Model CFC
See Figure B5-53.

10'-0" or Less
24"
Minimum
24"
Minimum
ClearFire Boiler
Figure B5-53. Inside Air - Vertical Vent

As noted in Paragraph A above, these installations use air from within the boiler
room for combustion. The same recommendations apply as noted in Paragraph A
above and also, the recommendations on flue vent sizing according to Table B5-21.
B5-60
09-09
Model CFC
Vertical Venting
Direct Vent
Combustion
Commercial Boilers
See Figure B5-54.

36" Minimum
24"
Minimum
12"
Minimum
ClearFire Boiler
Figure B5-54. Vertical Stack with Direct Vent Combustion Air

As noted in Paragraph B above, these installations use air from outside the building
for combustion. The same recommendations apply as noted in B and also, the
recommendations on flue vent sizing according to Table B5-22.
ELECTRICAL
Voltage requirements for the Fan Motor are 208 - 240/1/60 (sizes 700-1800) and
120/1/60 (Sizes 500 and 2500). Control Circuit voltage is 120/1/60 for all boiler
sizes. Refer to Table B5-3 "Ratings" for ampacity requirements.
Refer to Figure B5-55 and Figure B5-56 for wiring connections and control
locations.
09-09
B5-61
Commercial Boilers
Model CFC
Figure B5-55. Electrical Connection Diagram
Air Inlet
Gas
Connection
Electrical
Low Voltage
(sensors)
Electrical
High Voltage
Hot Water Out

High Temp.
Return
Flue Gas
Vent Connection
Low Temp.
Return
Condensate
Drain
Alt. Flue Gas
Figure B5-56. CFC Connections
B5-62
09-09
Model CFC
Commercial Boilers
CB FALCON CONTROLLER
1. Control Description - The CB Falcon hydronic control is an integrated burner
management and modulation control with a touch-screen display/operator
interface.
2. Functionality - The controller is capable of the following functions:
Two (2) heating loops with PID load control.

Burner sequencing with safe start check, pre-purge, direct spark ignition,
and post purge.
Electronic ignition.
Flame Supervision.
Safety shutdown with time-stamped display of lockout condition.
Variable speed control of the combustion fan.
Supervision of low and high gas pressure, air proving, stack back pressure,
high limit, and low water.
Alarm output
Remote reset
First-out annunciator.
Real-time data trending.
(3) pump/auxiliary relay outputs.
Modbus communication capability.
Outdoor temperature reset.
Anti-short-cycling mode
Frost protection
Time-of-day (night setback) operation
Three levels of access to control configuration:
End-user
Installer/Service Engineer (password protected)
OEM Manufacturer (password protected)
Table B5-23. Operating Conditions - Controller
Temperature Range
Humidity
Operating
-4 F to 150 F (-20 C to 66 C)
Storage
-40 F to 150 F (-40 C to 66 C)
85% max. relative humidity, non-condensing
Table B5-24. Operating Conditions - Display/Interface

Temperature Range
Humidity
Operating
32 F to 122 F (0 C to 50 C)
Storage
-40 F to 150 F (-40 C to 66 C)

85% max. relative humidity
09-09
B5-63
Commercial Boilers
Model CFC
Table B5-25. CB Falcon burner sequence (Central Heat)

1. Heat request detected (CH demand)
2. CH pump switched on
3. Safe Start Check, dynamic ILK input test (if enabled), blower switched on
4. If ILK input and CAPS switch closed and purge rate fan speed achieved, begin 15
second prepurge
5. When purge complete, blower RPM changed to lightoff speed
6. Trial for Ignition - 4 seconds
7. Ignition and gas valve switched on
8. Ignition turned off at the end of direct ignition period; 5 sec. stabilization time
9. Release to modulation (Run)
10. At the end of CH heat request, burner is switched off and blower stays on for 15
sec. post purge period. Boiler enters standby mode.
3. Main Voltage Connection - 115V/single phase/60Hz

4. Local/Remote demand switch
5. Combustion Air Proving Switch - This input is used for proving airflow sufficient
for proper combustion throughout the burner run sequence.
6. High Air Pressure Switch - prevents boiler operation in the event of high stack
back pressure (blocked flue or condensate drain).
7. Gas Pressure Switch - Gas pressure switches for low gas pressure and high gas
pressure prevent the burner from being activated if either is open. Each switch
is a physical manual reset device, requiring physical depression of the reset
button if either switch is not closed prior to burner start or during burner
operation.
8. NTC (Negative Temperature Coefficient) Thermistor Inputs (10k @ 25 oC)
A. Flow Temperature (Outlet water temperature)
B. Return Temperature (Inlet water temperature)
C. Optional Domestic Water Temperature
D. Optional Outdoor Temperature
E. Optional Stack Temperature
F. Optional Header Temperature
9. System Configuration - CB Falcon configuration is grouped into the following
functional groups:
B5-64
System Identification and Access

Central Heat Configuration
Outdoor Reset Configuration
DHW - Domestic Hot Water Configuration
Modulation Configuration
Pump Configuration
Statistics Configuration
High Limits
Stack Limit
Other Limits
09-09
Anti-condensation Configuration
Frost Protection Configuration
Annunciation Configuration
Burner Control Interlocks
Burner Control Timings & Rates
Burner Control Ignition
Burner Control Flame Failure
System Configuration
Fan Configuration
Lead Lag Configuration
Model CFC
Commercial Boilers
10. CB Falcon Access - There are three levels of access to the CB Falcon controller:
End User Level - read or view parameters; change setpoints. No password

required.
Installer/Service Level - read all parameters; enables changing of most

parameters. This access level is used to configure the CB Falcon for a
particular installation, and is password-protected.
OEM Level - read/change all parameters; for factory configuration of boilerspecific parameters. Password-protected and restricted to CB or factory
authorized service personnel.
For additional information regarding service and setup of the burner controller, refer
to CB manual part no. 750-263.
FAN POWER (25 VDC)

FAN GND
PWM OUT
TACHOMETER
EGND
L2 FOR 120VAC OR
24VAC RETURN (OPTOS)
L1
{
{
PUMP C {
PUMP A
PUMP B
EX. IGNITION
MAIN VALVE
INTERLOCK
ALARM
LCI
ANNUN 1/IAS
ANNUN 2
ANNUN 5
ANNUN 6
J1
J1
J2
J4
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
7
6
5
4
3
2
1
J5
J9
1
2
3
4
5
6
7
DHW TEMP A
DHW TEMP RTN
DHW TEMP B
STACK TEMP A
STACK TEMP RTN
STACK TEMP B
REMOTE RESET
TOD
J10
1
2
3
4
5
6
7
8
PIM
POWER
J6
FLAME
ALARM
RESET
J7
J11
J3
LOCAL
MODBUS
A B C
MULTIPLE
APPLIANCE
CONTROLLER
J8
1
2
3
4
5
6
7
8
9
10
11
12
CB FALCON
HYDRONIC
CONTROL
FLAME
STRENGTH
ANNUN 3
ANNUN 4
12
11
10
9
8
7
6
5
4
3
2
1
GLOBAL
MODBUS
A B C
1
2
3
4
5
6
7
24 VAC
24 VAC RTN
INLET TEMP
INLET TEMP RTN
HEADER TEMP
HEADER TEMP RTN
OUTLET TEMP A
OUTLET TEMP RTN
OUTLET TEMP B
OUTDOOR TEMP
OUTDOOR TEMP RTN
+
+
4 TO 20 MA
0 - 10 VDC
MA /VDC RTN
AUX. (REMOTE) INPUT
FUTURE
SYSTEM DISPLAY
ENVIRACOM
D R C
BUILDING
AUTOMATION
SYSTEM
LOCAL DISPLAY
GLOBALMODBUS
LOCALMODBUS
Figure B5-57. CB Falcon pinout
09-09
B5-65
Commercial Boilers
B5-66
Model CFC
09-09
Section B5
ClearFire Model CFC
SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-68
REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-68
QUALITY ASSURANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-69
SUBMITTALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-69
SUBSTITUTIONS/MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-70
CERTIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-70
DELIVERY, STORAGE, AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-71
MANUFACTURERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-71
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-71
PERFORMANCE: BOILER SIZE AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-71
BOILER DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-73
BURNER DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-74
BOILER TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-75
BOILER CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-75
BOILER FLUE VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-76
MANUFACTURER'S FIELD SERVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-76
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-78
FIELD TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-78
START-UP, INSTRUCTION AND WARRANTY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-78
B5-67
03-08
Section B5
Commercial Boilers
PART 1 GENERAL
Cleaver Brooks Condensing Boiler Line

1.01
1.02
SCOPE
A. The work to be performed consists of providing all labor, equipment,
materials, etc. to furnish and install new factory assembled, lowpressure full condensing hot water boilers as described in the
specifications herein.
1. Division 15 Section "Chemical Water Treatment" for feedwater
treatment.
2.
Division 15 Section, "Breechings, Chimneys, and Stacks" for

connections to chimneys, and stacks.
3.
Division 15 Sections for control wiring for automatic

temperature control.
REFERENCES
A. Product Data: Include rated capacities; shipping, installed, and
operating weights; furnished specialties; and accessories for each
model indicated.
B. Shop Drawings: Detail equipment assemblies and indicate
dimensions, required clearances, and method of field assembly,
components, and location and size of each field connection.
C. Wiring Diagrams: Detail wiring for power, signal, and control
systems and differentiate between manufacturer-installed and fieldinstalled wiring.
D. Source Quality Control Tests and Inspection Reports: Indicate and
interpret test results for compliance with performance requirements
before shipping.
E. Field Test Reports: Indicate and interpret test results for compliance
with performance requirements.
F.
Maintenance Data: Include in the maintenance manuals specified in
Division 1. Include parts list, maintenance guide, and wiring
diagrams for each boiler.
G. Other:
1. ASME Section IV - Heating Boilers
2. ANSI Z21.13 - Gas Fired Low Pressure Boilers
3. NFPA 54/ANSI Z221.3 - National Fuel Code
4. FM - Factory Mutual
5. ASME CSD-1 - Controls and Safety Devices
6. XL-GAP (Formerly GE-GAP/IRI)
7. UL or CSA Standards for Gas Fired Boilers
8. UBC - Uniform Building Code
B5-68
03-08
Commercial Boilers
Section B5
9. UMC - Uniform Mechanical Code
10. NEC - National Electrical Code
1.03
QUALITY ASSURANCE
A. The equipment shall, as a minimum, be in strict compliance with
the requirements of this specification and shall be the
manufacturer's standard commercial product unless specified
otherwise. Additional equipment features, details, accessories,
appurtenances, etc. which are not specifically identified but which
are a part of the manufacturer's standard commercial product, shall
be included in the equipment being furnished.
B. The equipment shall be of the type, design, and size that the
manufacturer currently offers for commercial sale and appears in the
manufacturer's current catalogue. The equipment shall be new and
fabricated from new materials and shall be free from defects in
materials and workmanship
C. The equipment must fit within the allocated space, leaving ample
allowance for maintenance and cleaning, and must leave suitable
space for easy removal of all equipment appurtenances.
D. All units of the same classification shall be identical to the extent
necessary to ensure interchangeability of parts, assemblies,
accessories, and spare parts wherever possible.
E. To accept unit responsibility for the specified capacities, efficiencies,
and performance, the boiler manufacturer shall certify in writing that
the equipment being submitted shall perform as specified. The
boiler manufacturer shall be responsible for guarantying that the
boiler provides the performance as specified herein.
1.04
SUBMITTALS
A. The contractor shall submit, in a timely manner, all submittals for
approval by the engineer. Under no circumstances shall the
contractor install any materials until the engineer has made final
approval on the submittals.
B. The engineer shall review and stamp submittals. Work may proceed
and equipment released for fabrication after contractor receives
returned submittals stamped with "NO EXCEPTIONS TAKEN" or
"MAKE CORRECTIONS NOTED".
C. Shop Drawings - Shop drawings shall be submitted to the engineer
for approval and shall consist of:
1. General assembly drawing of the boiler including product
description, model number, dimensions, clearances, weights,
service sizes, etc.
3. Schematic wiring diagram of boiler control system of the
ladder-type showing all components, interlocks, etc.
Schematic wiring diagram shall clearly identify factory wiring
and field wiring by others.
4. Manufacturer's Warranties: Manufacturer's printed warranties,
as specified hereinafter, shall be submitted prior to final
acceptance by the engineer.
B5-69
03-08
Section B5
Commercial Boilers
5.
Manufacturer's Field Service: Manufacturer's printed field

service procedures and reports, as specified hereinafter, shall
be submitted prior to final acceptance by the engineer. Report
forms shall contain all information as required to do start-up
and testing as specified in the product section.
1.05
SUBSTITUTIONS/MODIFICATIONS
A. The bidder must submit in writing to the engineer any request for a
proposed deviation, omission, modification, or substitution to this
specification for evaluation no later than ten (10) days prior to the
bid date.
B. Technical data, drawings, product samples, and complete data
substantiating compliance of proposed substitution with these
specifications shall accompany a request for any substitution.
C. No materials shall be deemed acceptable if not in strict and full
compliance with these specifications.
D. All bidders must bid solely on the specified materials unless
acceptance by the engineer of a deviation, omission, modification,
or substitution is granted in writing to all bidders prior to the bid
date.
1.06
CERTIFICATIONS
A. Manufacturer's Certification: The boiler manufacturer shall certify
the following:
1. The products and systems furnished are in strict compliance
with the specifications.
2. The boiler, burner, and other associated mechanical and
electrical equipment have been properly coordinated and
integrated to provide a complete and operable boiler package.
3. ASME Certification.
4. ASME CSD-1 Certification.
5. CSA or UL Certification.
B. Contractor's Certification: The contractor shall certify the following:
1. The products and systems installed are in strict compliance
with the specifications.
C. Boiler Inspectors' Certification: All boiler inspections during
hydrostatic testing shall be performed by an authorized boiler
inspector who is certified by the National Board of Boiler and
Pressure Vessel Inspectors and shall be submitted in writing prior to
final acceptance by the engineer.
D. Operation and Maintenance Manuals: Manufacturer's printed
operation and maintenance manuals shall be submitted prior to
final acceptance by the engineer. Operation and maintenance
manuals shall contain shop drawings, product data, operating
instructions, cleaning procedures, replacement parts list,
maintenance and repair data, complete parts list, etc.
B5-70
03-08
Commercial Boilers
PART 2 PRODUCTS
Section B5
1.07

A. The contractor shall be responsible for the timely delivery of the
equipment to the jobsite. The contractor shall be responsible for
unloading and rigging of the equipment. The contractor shall be
responsible for protecting the equipment from the weather, humidity
and temperature conditions, dirt, dust, other contaminants, as well
as jobsite conditions during construction.
B. Equipment shall be unloaded, handled, and stored in accordance
with the manufacturer's handling and storage instructions.
C. Responsibility of making freight claims to be performed by
contractor or owner personnel.
2.01
MANUFACTURERS
A. Contractor shall furnish and install Cleaver Brooks Model CFC 700______ -60 natural gas (LP Gas) fired hot water boiler(s) with input
as scheduled on the drawings.
B. Alternate manufacturers complying with plans and specifications
must be submitted and approved by the engineer within 10 days
prior to bid date (Approval of alternate manufacturer does not imply
that performance, including warranties, efficiencies, etc. are waved,
only that alternate manufacters are acceptable).
2.02
GENERAL DESCRIPTION
A. Each unit shall be a Down-fired Firetube type complete with boiler
fittings and automatic controls. The boiler, with all piping and
wiring, shall be factory packaged. Each boiler shall be neatly
finished, thoroughly tested and properly packaged for shipping.
Boiler design and construction shall be in accordance with Section
IV of the ASME Code for hot water heating boilers with a maximum
working pressure of 60 PSIG. The boiler shall be CSA (formerly AGA/
CGA) certified as an indirect or direct vent boiler and comply with
ASME CSD-1 Code requirements.
2.03

A. The capacity of each unit shall be indicated on the drawing
schedule.
B. Exit flue gas temperature of the boiler shall not exceed ______ F
gross at maximum rated input and a hot water supply temperature
of ______ F and return temperature of _____ F. The boiler net
input shall not exceed ____________ BTU/Hr and the output not less
than _________ BTU/Hr with an overall fuel-to-water efficiency of
_______ % at high fire and ________% at low fire at above operating
temperatures.
C. Performance Criteria:
B5-71
03-08
Section B5
Commercial Boilers
Manufacturer:
CLEAVER-BROOKS
Model:
CFC____________
Horsepower:
_____________HP
Output:
_____________MBTU
Gas Input:
_____________MBTU
Design Pressure:
_____________PSIG
Operating Pressure:
_____________PSIG
_____________Sq. Ft. Fireside
Burner Turndown Ratio
5:1
Overall Efficiency (With a hot

water supply
_____________% at low fire
_____________% at low fir
___________% at High Fire
Temperature of ______ F and

return
Temperature of _____ F.
20 PPM (corrected to 3% O2)
10 PPM (corrected to 3% O2)
Electrical:
220V / 60H / 1P
Fan Motor:
_____HP Max
Noise level
70 dBA Max
Available Gas Supply Pressure
_____PSIG
Weight
Dry:_____
Flooded:_____
Seismic Zone:_____
Altitude:_____? ASL
Code Requirements:

CSD-1
CSA
STATE OF _____
FACTORY MUTUAL (FM)
XL-GAP - Formerly GE-GAP (IRI)
B5-72
03-08
Commercial Boilers
Section B5
A.
2.04
Noise Sound Levels: Based on ABMA test code for packaged boilers
measured @ 4 1/2 feet vertically above the bottom of the base and
3'0" horizontally in front of the end of the burner or front surface of
control cabinet. Sound levels dBA on the scale in reference to
0.0002 microbars.
BOILER DESIGN
A. Boiler shall be a compact, single-pass, vertical down-fired Firetube
type, with stainless steel tubes and tube sheets. The boiler pressure
vessel shall be completely insulated with a minimum of 2" of
insulation and shall be encased in an 18 gauge metal cabinet with
powder coated finish. To prevent installation damage, the casing
shall be packaged separately and shall ship loose for field
installation by the manufacturer's service representative.
B. The tubes shall be 316Ti Stainless Steel and shall be fitted with
Aluminum internal heat transfer fins creating no less than 10 square
feet of fireside heating surface per boiler horsepower.
C. The Vessel shall be mounted on a structural steel stand with exhaust
gasses collected in a polymer drain collection box complete with
drain fitting for draining condensation from the products of
combustion. As an option, a condensate neutralizing box complete
with limestone granules shall be shipped loose for field installation
by contractor. Note: A condensate trap assembly shall be furnished
if a condensate collection tray is not provided due to operating
conditions.
D. The top tubesheet shall be fully accessible by lifting the burner
assembly which shall come complete with lifting hinges and
pneumatic lifters. The boiler shall have a built in hinged platform
allowing the operator to access the tubesheet, burner, ignition
assembly and flame rod without the use of a ladder.
E. The vessel shall be fully insulated with a minimum of 2" of
insulation, guaranteeing external convection and radiation heat
losses to the boiler room from the boiler shall be less than 0.5% of
the rated input.
F.
The condensing capability shall allow the boiler to be operated
without the use of a 3-way valve for the boiler supply water
temperature reset. No minimum boiler return water temperature or
secondary pump or minimum flow rate shall be required.
G. Boiler shall be built to seismic zone ___ requirements and
manufacturer shall provide seismic calculations showing tie-down
requirements for bolt diameters. Bolts and tie-down shall be by
contractor.
H. Each boiler shall be constructed in accordance with the A.S.M.E.
Section IV Code and bear the "H" stamp and shall be manufactured
within an ISO 9001 Certified facility to ensure high quality
standards.
B5-73
03-08
Section B5
Commercial Boilers
I.
J.
K.
2.05
The boiler shall be designed for top rear water outlet and bottom
rear water inlet; the water inlet [return] shall be equipped with
internal baffling. Inlet connection size shall be _______ flanged.
Outlet connection size shall be _______ flanged. The maximum
pressure drop through the boiler shall not exceed 0.45 psi with a
20-degree differential and less than 0.05 psi with a 60-degree
differential.
A threaded air vent connection shall be furnished at the top rear of
the boiler for field piping to an expansion tank or for the addition of
an auto-vent valve when a bladder type expansion tank is utilized.
To drain the boiler, a bottom-threaded connection shall be provided
at the front of the boiler and field piped by the installing contractor
with a manual full size shutoff valve to drain.
BURNER DESIGN
A. General: Forced draft burner mounted in and integral with the boiler
hinged top door so when the door is opened the burner head,
furnace, tubesheet, and tubes are exposed. The burner door shall
utilize easy removable threaded handles, and the burner shall swing
upward on hydraulic piston arms, one on each side to provide open
support of the burner assembly.
B. A drop down hinged service platform shall be furnished to provide
service personnel an easy means of accessing the burner and
controls for service and maintenance. When out of use, this
platform shall fold up beneath the front service boiler panel.
C. The burner shall be of the Unitized Venturi, Gas Valve, Blower, and
burner head design. This pre-mix design shall utilize a variable
speed fan connected to a venturi to simultaneously modulate fuel
and air for a minimum a 5:1 turndown ratio. The venturi design
shall also act as a method for compensating for changes in
barometric pressure, temperature and humidity so the excess air
levels are not adversely affected by changes in atmospheric
conditions. External linkages, damper motor drives and single
speed fans shall not be acceptable.
D. Burner head shall be constructed of a Fecralloy-metal fiber for solid
body radiation of the burner flame. Combustion shall take place on
the surface of the burner mantle, which shall be constructed of a
woven fecralloy material creating a 360 degree low temperature
radiant flame.
E. Emissions: The boiler(s) burner shall be guaranteed to limit NOx
emissions to 20 PPM or less, as certified by an independent testing
lab. NOx emissions shall be at full operating conditions. Proof of
such certification shall be made available to the engineer and
purchaser. External flue gas recirculation shall not be accepted for
emission control.
F.
Gas Train - As a minimum, the gas train shall meet the
requirements of CSA and ASME CSD-1 and shall include:
1. Low Gas Pressure Interlock, manual reset.
2. High Gas Pressure Interlock, manual reset.
3. Upstream and downstream manual test cocks.
B5-74
03-08
Commercial Boilers
Section B5
G.
H.
4. Ball Type manual shutoff valve upstream of the main gas valve.
5. Unibody double safety gas valve assembly.
6. Gas Pressure Regulator
7. Union connection to permit burner servicing.
Combustion Air Proving Switch shall be furnished to ensure
sufficient combustion airflow is present for burner firing.
To ensure that proper draft is not blocked in the stack, the burner
shall include a High Air Pressure Switch sensing the outlet pressure
connection relative to stack back draft.
2.06
BOILER TRIM
A. Safety valve(s) shall be ASME Section IV approved side outlet type
mounted on the boiler water outlet. Size shall be in accordance with
code requirements and set to open at 60 psig.
B. Temperature and pressure gauge shall be mounted on the water
outlet.
C. Solid State Low water cut-off probe with manual reset and test
switch.
D. Outlet water supply sensing probe for operating water limit setpoint.
E. Return water-sensing probe for operating water limit setpoint.
2.07
BOILER CONTROLS
A. The Boiler shall include a Computerized Boiler Burner control which
shall be an integrated, solid state digital micro-processing
modulating device, complete with sequence indication, fault reset,
mode selection, and parameter set-point switches. It shall be
mounted at the front of the boiler panel for easy access and viewing.
B. Controller shall provide for both flame safeguard and boiler control
and shall perform the following functions:
1. Burner sequencing with safe start check, pre-purge, Electronic
direct spark ignition, and post purge. Flame rod to prove
combustion.
2. Flame Supervision - the control shall provide pre-purge and
post-purge and shall maintain a running history of operating
hours, number of cycles, and the most recent faults. The
control shall be connected to a touchscreen display module
that will retrieve this information.
3. Safety Shutdown with display of error.
4. Modulating control of the variable speed fan for fuel/air input
relative to load requirements.
5. High Limit temperature control.
6. Gas pressure supervision, high and low.
7. Combustion Air Proving Supervision.
8. High Air Pressure (back draft too high) Supervision.
9. Display of supply temperature and set-point temperature shall
be accessible via touchscreen. Output shall be continuous PID
via 4 -20 mA current.
B5-75
03-08
Section B5
Commercial Boilers
C.
D.
E.
F.
10. Controller shall have an option for communication device to a

laptop computer interface service and troubleshooting.
11. Include the programming of system circulating pump and
provide the programming of 2 heating loops.
All parameter input control set-points shall be factory downloaded
with jobsite conditions programmed at the time of initial jobsite
operation.
All controls to be panel mounted and so located on the boiler as to
provide ease of servicing the boiler without disturbing the controls
and also located to prevent possible damage by water according to
CSA requirements.
Electrical power supply shall be 220 volts, 60 Hertz, single phase
for the fan motor and 120 volts, 60 Hertz, single phase for the
control circuit.
When multiple boilers are utilized for a single installation, the boiler
manufacturer or its authorized representative shall provide a UL
listed sequencing control for up to 4 boilers. The control shall
include automatic rotation of lead boiler, and adjustable outdoor
reset schedule, 4-20 mA output to the boilers, digital display of
settings, and interface capabilities to an Energy Management
System. The control shall be provided with a NEMA 1 enclosure.
2.08
BOILER FLUE VENTING

A. The Boiler shall be CSA certified as an indirect or direct vent boiler.
Venting shall be accomplished with a catagory IV vent piping
installed in accordance with applicable national and local codes.
B. For direct venting, the boiler shall have the combustion air intake
supply ducted with PVC pipe from the outside. Vibration isolation
components are not required.
2.09
MANUFACTURER'S FIELD SERVICES

A. General: The boiler supplier's factory authorized service
organization shall be responsible for performance of inspections,
start up and testing of the package boiler, and accessory equipment
and materials furnished under this Section. A detailed written
record of the start up performance, including burner setting data
over the entire load range shall be furnished to the engineer before
final acceptance. All labor, equipment, and test apparatus shall be
furnished by the authorized service organization. All equipment
defects discovered by the tests shall be rectified either by the
service organization or boiler manufacturer.
B. Equipment inspection: Boiler representative to provide ___ hours of
jobsite assistance to inspect boilers and other equipment upon
arrival, verifying completeness of equipment supplied and potential
damages. All shipped loose components, such as casing, to be
mounted on boiler by boiler provider after contractor has set boiler
in building.
C. Pre start-up walk through: Boiler representative shall spend ___
hours at jobsite reviewing installation with mechanical contractor to
be conducted approximately 1 week prior to startup.
B5-76
03-08
Commercial Boilers
Section B5
D.
E.
Start-up shall be conducted by experienced and factory authorized

technician in the regular employment of the authorized service
organization, and shall include:
1. Demonstrate that boiler, burner, controls, and accessories
comply with requirements of this Section as proposed by the
boiler and accessories supplier. Pre-test all items prior to
scheduling the final testing that will be witnessed by the test
engineer.
2. Readings at different firing rates (20, 50, 75 and 100%) of
load for the modulating burner shall be taken with a written
report of the tests submitted to the engineer. The reports shall
include readings for each firing rate tested and include stack
temperatures, O2, CO, NOx, and overall boiler efficiency.
3. Auxiliary Equipment and Accessories: Observe and check all
valves, draft fans, electric motors and other accessories and
appurtenant equipment during the operational and capacity
tests for leakage, malfunctioning, defects, and non compliance
with referenced standards or overloading as applicable.
b. Set up fuel train and combustion air system
c. Set up operating set points
d. Check all safeties, including Flame safeguard, LWCO,
Airflow, Fuel pressures, High limits.
e. Set up and verify efficiencies at 20%, 50%, 75%, and
100%
f.
Set up and verify burner turndown.
Training to include all safety procedures, maintenance procedures,
control operations, and diagnostic procedures. Training to be
provided in a single ____ hour continuous session to accommodate
operator's availability on site.
2.10

A. Provide two (2) Operating and Maintenance manuals including cutaway views of boiler and burner, schematics including fuel trains,
general instructions for maintenance and inspections, complete
spare parts lists and trouble shooting procedures.
B. A wiring diagram corresponding to the boiler shall be affixed to the
boiler near the electrical panel.
2.11
WARRANTY DATA
A. The pressure vessel shall be guaranteed against thermal shock for
20 years when utilized in a closed loop hydronic heating system
with a temperature differential of 170 F or less. The boiler pressure
vessel shall be guaranteed accordingly without a minimum flow rate
or return water temperature requirement. The boiler shall not
require the use of flow switches or other devices to ensure minimum
flow.
B5-77
03-08
Section B5
Commercial Boilers
B.
C.
PART 3 EXECUTION
The pressure vessel, tubes and tube sheets (heat exchanger) shall
be guaranteed against flue gas corrosion and materials/
workmanship for a period of 10 years. The condensate collection
box shall be guaranteed for 20 years.
All parts not covered by the above warranties shall carry a 1 year
warranty from startup, or 18 months from shipment, whichever
occurs first. This shall include all electrical components and burner
components.
3.01
GENERAL
Installation shall be provided by the contractor in accordance with the requirements
of the codes specified hereinbefore. All of the contractor's work shall be performed
by experienced personnel previously engaged in boiler plant construction and shall
be under the supervision of a qualified installation supervisor.
3.02
INSTALLATION
A. Install equipment in strict compliance with manufacturer's
B. Install equipment in strict compliance with state and local codes
and applicable NFPA standards.
C. Maintain manufacturer's recommended clearances around sides and
over top of equipment.
D. Install components that were removed from equipment for shipping
purposes.
E. Install components that were furnished loose with equipment for
field installation.
F.
3.03
FIELD TESTING
A. The manufacturer's representative shall test all boiler and burner
interlocks, actuators, valves, controllers, gauges, thermometers,
pilot lights, switches, etc. Any malfunctioning component shall be
replaced.
B. All adjustments to boiler, burner, and boiler control system shall be
performed by the manufacturer's representative.
3.04

A. The manufacturer's representative shall provide start-up and
instruction of each new boiler, including burner and boiler control
system as specified herein. Start-up and instruction shall cover all
components assembled and furnished by the manufacturer whether
or not of his own manufacture.
B5-78
03-08
Section B6
CLEARFIRE MODEL CFH BOILERS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-5
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-13
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-20
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-22
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-37
LIST OF FIGURES
Figure B6-1
Figure B6-2
Figure B6-3
Figure B6-4
Figure B6-5
Figure B6-6
Figure B6-7
Figure B6-8
Tube Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-3

AluFer Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-3
Premix Burner Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-4
Burner maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-4
Model CFH Steam Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-5
CB Falcon Display/Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-9
CB Falcon pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-10
Burner Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-11
B6-1
03/08
Clearfire-H Boilers
Section B6
Figure B6-9 Model CFH burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure B6-10 Gas Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure B6-11 Model CFH electrical panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure B6-12 Model CFH Steam Boiler Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure B6-13 Boiler Room Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure B6-14 Model CFH Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure B6-15 Model CFH Lifting Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure B6-16 Inside Air - Two Opening Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure B6-17 Two Opening Ducted Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure B6-18 One Opening Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure B6-19 Engineered Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure B6-20 Direct Vent Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure B6-21 Air Inlet Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure B6-22 Typical gas header piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure B6-23 Example gas piping <1 psig supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B6-11
B6-12
B6-12
B6-14
B6-18
B6-19
B6-19
B6-24
B6-25
B6-26
B6-26
B6-28
B6-29
B6-35
B6-35
LIST OF TABLES
Table B6-1 Operating Conditions - CB Falcon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B6-2 CB Falcon burner sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B6-3 Steam Boiler Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B6-4 Steam Boiler Metric Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B6-5 Steam Boiler Connection Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B6-6 Steam Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B6-7 Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B6-8 Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B6-9 Gas Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B6-10 Boiler Room Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B6-11 Model CFH Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B6-12 Predicted Fuel-to-Steam Efficiencies-Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B6-13 Radiation and Convection Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B6-14 Natural Gas, Estimated Emission Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B6-15 Predicted sound levels at high fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B6-16 Boiler Feedwater Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B6-17 Boilers Required Water Quality Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B6-18 Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tables B6-19 B6-23 Gas line capacity - Schedule 40 metallic pipe . . . . . . . . . . . . . . . . . . . .
Tables B6-24 B6-31 Pipe sizing for multiple unit manifolds . . . . . . . . . . . . . . . . . . . . . . . . .
B6-2
03/08
B6-7
B6-8
B6-15
B6-16
B6-17
B6-17
B6-17
B6-18
B6-18
B6-18
B6-19
B6-20
B6-21
B6-21
B6-21
B6-22
B6-22
B6-23
B6-31
B6-36
Section B6
Clearfire-H Boilers

General
The ClearFire Model CFH is a single pass, horizontally fired durable firetube steam boiler.
Extended heating surface tubes provide a very high level of performance in a compact
package. An integral premix burner is provided for natural gas operation. As standard, the
Model CFH burner provides low emissions of <20 PPM NOx. Propane fuel is also available.
Advanced Technology
Heat is transferred through 3 OD carbon steel tubes with patented AluFer extended heating
surfaces. The AluFer tube design provides for optimum heat transfer and eliminates laminar
gas flow during minimum firing, providing optimized efficiency throughout the firing range
(see Figure B6-1 and Figure B6-2).
Figure B6-2. Tube Cross Section
Figure B6-1. AluFer Tubes

High Efficiency
With the AluFer extended heating surface tubes, the Model CFH steam boiler will provide
fuel-to-steam efficiency of up to 83% operating at 125 psig or 85% at 10 psig (85%
efficiency for high-pressure steam is available with an optional flue gas economizer package).
ISO 9001-2001 certification ensures the highest manufacturing standards.

ASME code construction ensures high quality design, safety, and reliability. Units are thirdparty inspected and are stamped to assure compliance.
Certification
Each unit is tested and certified in accordance with UL/cUL standards and the UL/cUL label is
affixed attesting to equipment meeting the latest UL requirements for packaged steam boilers.
Premix Technology
The ClearFire CFH burner utilizes Premix technology to mix both gas fuel and combustion air
prior to entering the burner canister, with fuel flow governed by the air flow during firing
transitions. Combined with a variable speed fan, this technology provides very low emission
levels, exceptionally safe operation, and nearly 100% combustion efficiency. An inlet air filter
is provided as standard to prevent airborne dust from entering the combustion canister.
Full Modulation
The variable speed fan modulates to provide only the amount of heat required to the boiler.
Full modulation reduces on/off cycling and provides excellent load tracking with reduced
operating costs. The burner does not require mechanical linkage connections between the fuel
input valve and air control. Instead, the microprocessor control adjusts the fan speed in
accordance with system demand, determining fuel input without mechanical device
B6-3
03/08
Clearfire-H Boilers
Section B6
positioning. This method of controlling the fuel-air ratio eliminates slippage due to linkages,
minimizes burner maintenance, and provides control repeatability. See Figure B6-3.

Ease of Maintenance
The burner is hinged and swings out to allow inspection or service of the burner canister,
tubes, and tube sheets (see Figure B6-4). A union connection provides easy disconnect from
the fuel train. All burner components are easily accessed for inspection and maintenance.
Figure B6-4. Burner maintenance
Designed for commercial

steam applications
Whether for heating or for steam process, the CFH packaged boiler is designed for 15 psig or
150 psig MAWP (Maximum Allowable Working Pressure) and is constructed of durable ASTM
grade steel materials. Figure B6-5 shows the component and connection locations.
B6-4
03/08
Section B6
Clearfire-H Boilers
Safety Relief Valve
Steam Outlet
Stack Outlet
Feedwater
Gas Train
Combustion Air
(Optional Direct Vent)
Chem. Feed
Blowdown
Aux. Low Water Cut-Off
High Limit Control

CB Falcon Display/
Operator Interface
Operating Limit Control

Low Water Cut-Off
Figure B6-5. Model CFH Steam Boiler
PRODUCT OFFERING
Information in this section applies to steam boiler sizes ranging from 10 horsepower
through 60 horsepower for operation on natural gas or LP gas only. Fuel oil operation
is not available for the model CFH. Standard installation is for indoor use with an
optional engineering design for outdoor applications.
The complete package has been tested and certified in accordance with UL/cUL.
Package is approved and listed and bears the appropriate UL/cUL package boiler
label.
Dimensions, ratings, and product information may change due to market
requirements or product enhancements. The information contained herein is a guide
for general purposes only.
Standard Equipment
The equipment listed below applies to the standard boiler package offering. Optional
items are available to meet specific projects when required.
B6-5
03/08
Clearfire-H Boilers
Section B6
A. The Boiler
A.Each boiler (pressure vessel) size is designed and built for a Maximum Allowable
Working Pressure (MAWP) of 15 psig in accordance with ASME Section IV
(bearing the H stamp) or 150 psig in accordance with ASME Section I (bearing
the S stamp).
B.The vessel is insulated with a 2 thick blanket and mounted on a base frame. A
powder-coated 18 gauge steel casing covers the insulation.
C.Vessel connections are furnished for:
Steam outlet
Bottom drain or blowoff
Surface blowoff
Chemical feed
Feedwater makeup
High water level overflow
D.For waterside inspection, handholes are provided.
E. Two lifting lugs are provided for rigging purposes.
F. The combustion exhaust is located at the top rear.
B. Boiler trim and controls
Water column with primary low water cutoff and pump control (probe type).
Water column gauge glass and gauge glass drain valve.
Water column drain valve.
Auxiliary low water cutoff (probe type), manual reset.
Operating limit pressure control, auto reset.
Excess steam pressure control, manual reset.
Pressure transmitter for burner on/off and modulation.
Steam pressure gauge.
ASME safety relief valve.
C. CB Falcon Control System

A.Control Description - The CB Falcon control is an integrated burner management
and modulation control with a touch-screen display/operator interface.
B.Functionality - The controller incorporates the following functions:
PID load control.

Burner sequencing with safe start check, pre-purge, direct spark ignition, and
post purge.
Flame Supervision.
Safety shutdown with time-stamped display of lockout condition - last 15
lockouts stored in memory.
Variable speed control of the combustion air fan.
B6-6
03/08
Section B6
Clearfire-H Boilers
and low water.
Alarm output
Remote enable & remote modulation or set point.
Diagnostics.
Real-time data trending (w/System Display).
Modbus communication.
End-user
Table B6-1. Operating Conditions - CB Falcon

Temperature Range
Humidity
Operating
32 F to 122 F (0 C to 50 C)
Storage
-40 F to 140 F (-40 C to 60 C)

B6-7
03/08
Clearfire-H Boilers
Section B6
Table B6-2. CB Falcon burner sequence

1. Heat request detected (Setpoint minus On Hysteresis); LCI limits and steam
demand detected (terminals J6 3 and J8 3).
2. The CH pump is switched on (relay contact closes).
3. After a system Safe Start Check, the Blower (combustion air fan) is started
4. After the ILK input is energized - 10 sec. allowed for IAS input (combustion air
proving) to energize - and the purge rate proving fan RPM is achieved, prepurge
time is started.
5. When 30 sec. purge time is complete, the fan RPM is changed to the lightoff
speed.
6. Trial for Ignition (4 sec).
7. The ignitor and the gas valve are energized.
8. The ignitor is turned off at the end of the direct burner ignition period.
9. The fan is kept at the lightoff rate during the stabilization time.
10.Release to modulation (Run).
11.At the end of the CH-heat request the burner is switched off and the fan stays on
until post purge is complete (15 sec.). Boiler enters standby mode.
C.Main Electrical Connection - 115V/single phase/60Hz

D.Demand switch - Local/Remote/Off.
E. Combustion Air Proving Switch
F. Gas Pressure Switch - Gas pressure switches for low gas pressure and high gas
operation. Monitored in Interlock (ILK) Circuit.
G.System Configuration - CB Falcon configuration is grouped into the following
functional groups:

Pump Configuration
High Limits
Stack Limit
Other Limits
Fan Configuration
H.CB Falcon Control Access - There are three levels of access to the CB Falcon
controller:

required.

OEM Level - read/change all parameters; for factory configuration of boiler-
B6-8
03/08
Section B6
Clearfire-H Boilers
specific parameters. Password-protected and restricted to CB or factory
For additional information regarding service and setup of the burner controller, refer to
CB manual part no. 750-222.
Figure B6-6. CB Falcon Display/Operator Interface
B6-9
03/08
Clearfire-H Boilers
Section B6
FALCON STEAM CONTROL

PLUG CONNECTORS
BLUE
UV
FAN POWER (25 VDC)

FAN GND
PWM OUT
TACHOMETER
WHITE
EGND
L2 FOR 120VAC OR
L1
{
{
PUMP C {
PUMP A
PUMP B
BLOWER/HSI
EX. IGNITION
MAIN VALVE
PILOT VALVE
INTERLOCK
ALARM
PRE IGN INTLK
LCI
ANNUN 1/IAS
ANNUN 2
ANNUN 5
ANNUN 6
ANNUN 7 HFS
ANNUN 8 LFS
J1
J2
J8
J4
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
7
6
5
4
3
2
1
STEAM
CONTROL
J5
POWER
J6
J10
1
2
3
4
5
6
7
8
J11
1
2
3
4
5
6
7
ALARM
J7
J3
LOCAL
MODBUS
A B C
MULTIPLE
APPLIANCE
CONTROLLER
J9
FLAME
RESET
GLOBAL
MODBUS
A B C
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
PIM
FLAME
STRENGTH
ANNUN 3
ANNUN 4
12
11
10
9
8
7
6
5
4
3
2
1
24 VAC
24 VAC RTNS
STAT
STEAM PRESSURE
1
SENSOR
4-20 mA
STACK TEMP A
STACK TEMP RTN
STACK TEMP B
REMOTE RESET
TOD
+
+
4 TO 20 MA
0 - 10 VDC
MA /VDC RTN
FUTURE
FUTURE
System Display
ECOM
D R C
Local Display
BUILDING
AUTOMATION
SYSTEM
GLOBALMODBUS
LOCALMODBUS
1
EXTERNALLY POWERED PRESSURE SENSOR (0-15 PSI OR 0-150 PSI).

D. Forced draft burner
A.The burner is a "Pre-mix" design consisting of a unitized venturi, single body dual
safety gas valve, blower, and burner head (canister).
B.Full modulation is accomplished with a variable speed fan for up to 5:1
turndown ratio on 40 horsepower boilers and larger (4:1 turndown on 30
horsepower and less).
C.For near flameless combustion, the burner utilizes a Fecralloy metal fiber head
(canister).
B6-10
03/08
Section B6
Clearfire-H Boilers
D.Noise level at maximum firing is less than 70 dBA regardless of boiler size.
E. When boiler is operating on natural gas, NOx emissions will be less than 20
PPM regardless of boiler size; certified for California and Texas low emissions
requirements.
F. As an option, the burner can utilize direct vent combustion air.
G.Ignition of the main flame is via direct spark, utilizing high voltage electrodes
H.To ensure adequate combustion air is present prior to ignition, and to ensure the
fan is operating, a combustion air proving switch is provided.
I. For ease of inspection and maintenance, the burner is hinged for easy swing
away from the boiler permitting full inspection of the burner components, front
tube sheet and furnace.
J. A flame observation port is located in the burner door.
Figure B6-8. ClearFire-H burner
Figure B6-9. Burner Components
E. Burner Gas Train

The standard gas train is equipped in accordance with UL 795, ASME, CSD-1, GEGAP (formerly IRI), and FM. Each burner gas train includes:
Low gas pressure interlock, manual reset

High gas pressure interlock, manual reset
ASME CSD-1 test cocks
Downstream manual ball type shutoff cock
Single body dual safety shutoff gas valve
Gas pressure regulator for maximum of 1 psig inlet pressure
B6-11
03/08
Clearfire-H Boilers
Section B6
Figure B6-10. Gas Train

F. Boiler control panel
A standard NEMA 1A type panel enclosure is located at the front top of the boiler.
This panel encloses the CB Falcon operating control, water level circuit boards,
transformers, electrical terminals, and fuses. 115/1/60 terminals are provided for
contractor connections.
Transformer
Fuses (Blower
Motor, Control Circuit)
LWCO & Pump Control
ALWCO Control
w/Reset
Blower Power
Cable
CB Falcon Controller
Power Supply
Terminal Block
Cable Harness
Blower Signal
Cable
Flame Rod Cable
Figure B6-11. Model CFH electrical panel
B6-12
03/08
Section B6
Optional Equipment
Clearfire-H Boilers
summary, here are some of the options that can be provided with the boiler package:
Bottom blowdown valves, shipped loose or mounted and piped

Surface blowoff valve, shipped loose or mounted and piped
Feedwater stop and check valves, shipped loose or mounted and piped
Surface blowoff skimmer tube
Steam stop valve
ASME hydro test of boiler piping
Integral economizer package (150 psig boiler only) complete with vertical
feedwater tank and make-up pump
Modbus communications
Alarm light package
Direct vent combustion air provision

For layout purposes, the overall dimensions for the Model CFH are shown in Figure
B6-12 and Tables B6-1 (U.S. dimensions) and B6-2 (metric). Connection sizes are
given in Table B6-3 and ratings of each boiler size are noted in Table B6-4. Additional
information is shown in the following tables and illustrations:
Table B6-5 Recommended steam nozzle sizes
Table B6-6 Minimum required gas pressure
Table B6-7 Safety valve outlet sizes
Table B6-8, Figure B6-13 Boiler room width
Figure B6-14 Lifting lug locations
Table B6-10, Figure B6-15 Boiler mounting piers
B6-13
03/08
Clearfire-H Boilers
Section B6
Figure B6-12. Model CFH Steam Boiler Dimensions
MM/NN
M
JJ
KK
LL
F
CC
T
X
GG
L
E
AA
B
K
Z
1
DD
Q
R
S
C
A
G
FF
BB
EE
HH
W
AA
1
4
DD
B6-14
03/08
(4)1/2 Holes
Section B6
Clearfire-H Boilers
Table B6-3. Model CFH Steam Boiler Dimensions
Boiler Horsepower
Dimension
10
15
20
25
30
40
50
60
Overall
86
86
87
87
91.5
104
110
110
Shell
54
54
56
56
58
66
68
68
Base Channel
56
56
58
58
60
68
70
70
Front Lagging Extension
18
18
18
18
18
23.5
23.5
23.5
Rear Lagging Extension
14
14
13
13
15.5
14.5
18.5
18.5
LENGTHS inches
Front Tubesheet to Steam Outlet
30
30
38
38
34
40
38
38
Front Tubesheet to Stack Outlet
61
61
62.5
62.5
66
74
77.5
77.5
Base End to Bolt Hole
Hole to Hole
48
48
50
50
52
60
62
62
Rear Base to Gas Train Inlet
34.25
34.25
35.5
35.5
34
44
43.25
43.25
Front Tubesheet to Combustion Air Inlet
10
13
14
14
Overall
43.5
43.5
47
47
56
56
60
60
Center to Lagging
17.5
17.5
19.5
19.5
23.5
23.5
26.5
26.5
33.5
WIDTHS inches
26
26
27.5
27.5
32.5
32.5
33.5
Base, Inside of Channel
30.5
30.5
34
34
42
42
48
48
Base Bolt Hole to Bolt Hole
33
33
36.5
36.5
44.5
44.5
50.5
50.5
Base, Outside of Channel
35
35
38.5
38.5
46.5
46.5
52.5
52.5
Boiler I.D.
30.5
30.5
34
34
42
42
48
48
HEIGHTS inches
Overall
54
54
57
57
65.5
65.5
69
69
Base to 150# Steam Outlet
47
47
50
50
58
58.5
64.5
64.5
47.5
47.5
50.5
50.5
58.5
59
65
65
Base to Stack Outlet
49
49
52
52
60.5
60.5
66.5
66.5
Base to Combustion Air Inlet
19
19
19
19
22
19.5
21.5
21.5
Front Door SwingA
JJ
31
31
32
32
39
39
46
46
Tube Removal, Rear
LL
41
41
41
41
41
49
49
49
CLEARANCES inches
MINIMUM BOILER ROOM LENGTH (INCHES) ALLOWING FOR DOOR SWING AND TUBE REMOVAL FROM:
Rear of Boiler
MM
126
126
129
129
138
154
163
163
Front of Boiler
NN
123
123
125
125
136.5
143.5
156.5
156.5
1010
1010
1250
1250
1850
2150
2700
2700
920
920
1150
1150
1710
1980
2510
2510
Approx. Dry Weight (150#)
2020
2020
2410
2410
3160
3700
5600
5600
2000
2000
2330
2330
2870
3400
5400
5400
WEIGHTS - LBS
Water Weight (150# Normal Level)
A. Front Door Swing clearance sufficient for front tube removal.
B6-15
03/08
Clearfire-H Boilers
Section B6
Table B6-4. Model CFH Steam Boiler Metric Dimensions
Boiler Horsepower
Dimension
10
15
20
25
30
40
50
60
LENGTHS mm
Overall
2184.4
2184.4
2209.8
2209.8
2324.1
2641.6
2794
2794
Shell
1371.6
1371.6
1422.4
1422.4
1473.2
1676.4
1727.2
1727.2
Base Channel
1422.4
1422.4
1473.2
1473.2
1524
1727.2
1778
1778
Front Lagging Extension
457.2
457.2
457.2
457.2
457.2
596.9
596.9
596.9
Rear Lagging Extension
355.6
355.6
330.2
330.2
393.7
368.3
469.9
469.9
Front Tubesheet to Steam Outlet
762
762
965.2
965.2
863.6
1016
965.2
965.2
Front Tubesheet to Stack Outlet
1549.4
1549.4
1587.5
1587.5
1676.4
1879.6
1968.5
1968.5
Base End to Bolt Hole
101.6
101.6
101.6
101.6
101.6
101.6
101.6
101.6
Hole to Hole
1219.2
1219.2
1270
1270
1320.8
1524
1574.8
1574.8
Rear Base to Gas Train Inlet
869.95
869.95
901.7
901.7
863.6
1117.6
1098.55
1098.55
Front Tubesheet to Combustion Air Inlet
228.6
228.6
228.6
228.6
254
330.2
355.6
355.6
Overall
1104.9
1104.9
1193.8
1193.8
1422.4
1422.4
1524
1524
Center to Lagging
444.5
444.5
495.3
495.3
596.9
596.9
673.1
673.1
WIDTHS mm
660.4
660.4
698.5
698.5
825.5
825.5
850.9
850.9
774.7
774.7
863.6
863.6
1066.8
1066.8
1219.2
1219.2
Base Bolt Hole to Bolt Hole
838.2
838.2
927.1
927.1
1130.3
1130.3
1282.7
1282.7
889
889
977.9
977.9
1181.1
1181.1
1333.5
1333.5
Boiler I.D.
774.7
774.7
863.6
863.6
1066.8
1066.8
1219.2
1219.2
Overall
1371.6
1371.6
1447.8
1447.8
1663.7
1663.7
1752.6
1752.6
1193.8
1193.8
1270
1270
1473.2
1485.9
1638.3
1638.3
1206.5
1206.5
1282.7
1282.7
1485.9
1498.6
1651
1651
Base to Stack Outlet
1244.6
1244.6
1320.8
1320.8
1536.7
1536.7
1689.1
1689.1
Base to Combustion Air Inlet
482.6
482.6
482.6
482.6
558.8
495.3
546.1
546.1
HEIGHTS mm
CLEARANCES mm
Front Door SwingA
JJ
787.4
787.4
812.8
812.8
990.6
990.6
1168.4
1168.4
Tube Removal, Rear
LL
1041.4
1041.4
1041.4
1041.4
1041.4
1244.6
1244.6
1244.6
MINIMUM BOILER ROOM LENGTH (mm) ALLOWING FOR DOOR SWING AND TUBE REMOVAL FROM:
Rear of Boiler
MM
3200.4
3200.4
3276.6
3276.6
3505.2
3911.6
4140.2
4140.2
Front of Boiler
NN
3124.2
3124.2
3175
3175
3467.1
3644.9
3975.1
3975.1
458.13
458.13
566.99
566.99
839.15
975.22
1224.7
1224.7
417.31
417.31
521.63
521.63
775.64
898.11
1138.5
1138.5
916.26
916.26
1093.2
1093.2
1433.4
1678.3
2540.1
2540.1
907.19
907.19
1056.9
1056.9
1301.8
1542.2
2449.4
2449.4
WEIGHTS - kg
A. Front Door Swing clearance sufficient for front tube removal.
B6-16
03/08
Section B6
Clearfire-H Boilers
Table B6-5. Model CFH Steam Boiler Connection Sizes
BOILER CONNECTIONS inches
10
15
20
25
30
40
50
60
Feedwater, Both Sides
AA
1-1/4
1-1/4
Steam Outlet (150# Only)
BB
1-1/2
1-1/2
Steam Outlet (15# Only)A
CC
Drain / Blowdown (Front)
DD
1-1/4
1-1/4
Surface Blowoff
EE
Stack O.D.
FF
10
10
Combustion Air Inlet
GG
Chemical Feed
HH
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1-1/4
1-1/4
1-1/2
1-1/2
Gas Train
A. Connections are 150# F.F. Flanged
Table B6-6. Model CFH Steam Ratings

Boiler H.P.
10
15
20
25
30
40
50
60
345
518
690
863
1,035
1,380
1,725
2,070
156.5
234.5
313
391
469.5
626
782
939
Output Btu/hr
334,750
502,125
669,500
836,875
Output Kcal/Hr
84,168
126,535
168,714
210,892
253,071
337428
421,785
506,142
97
145
194
243
291
388
485
582
2,363
Ratings
Rated Capacity - Steam (lbs. steam/hr
o
from & at 212 F.)
Rated Steam Capacity [kg/hr from and at
100 C]
Output KW
1,004,250 1,339,000 1,673,750 2,008,500
Approximate Fuel Consumption At Rated Capacity [ Input]

3
394
591
788
985
1,181
1,575
1,969
11.1
16.7
22.3
27.9
33.4
44.6
55.7
66.9
408
612
816
1,020
1,225
1,633
2,041
2,449
11.5
17.3
23.1
28.9
34.7
46.2
57.8
69.3
157
236
315
394
473
630
788
945
4.4
6.7
8.9
11.1
13.4
17.8
22.3
26.8
163
245
327
408
490
653
817
980
4.6
6.9
9.3
11.5
13.9
18.5
23.1
27.8
255
335
335
335
335
750
1,200
1,200
Blower Motor
3.3
8.5
13.5
13.5
Blower Motor Fuse
4.5
12
15
15
Control Circuit
1.7
1.7
1.7
1.9
1.9
1.9
2.4
Notes:
3
3
A. Input calculated at nominal 85% efficiency with Nat. Gas @ 1000 Btu/ft and Propane @ 2500 Btu/ft .
3
3
B. Input calculated at nominal 82% efficiency with Nat. Gas @ 1000 Btu/ft and Propane @ 2500 Btu/ft .
C. For altitudes above 1000 Feet, contact your local Cleaver-Brooks authorized representative for capacity rating.
D. Fan motor is variable speed, DC Brushless Type.
2.4

3

3

3

3

3

3
Power Requirements - 60 Hz (Single Phase, 115 VAC)

Blower Motor Size (Watts)
C,D
Minimum Ampacity
Table B6-7. Model CFH Recommended Steam Nozzle Size

OPERATING PRESSURE
PSIG
15
30
40
50
75
100
125
NOTES:
1. Steam nozzle sizes given
10
4
2
2
1.5
1.5
1.5
1.5
15
4
2
2
1.5
1.5
1.5
1.5
20
4
2
2
2
2
1.5
1.5
BOILER HP
25
30
4
4
2.5
2.5
2.5
2.5
2
2.5
2
2
2
2
2
2
40
6
3
3
2.5
2.5
2
2
50
6
4
3
3
3
3
3
60
6
4
4
3
3
3
3
in inches.
B6-17
03/08
Clearfire-H Boilers
Section B6
Table B6-8. Model CFH Steam Boiler Safety Valve Outlet Size
VALVE SETTING
15 PSIG STEAM
150 PSIG STEAM
BOILER HP
NO. OF VALVES OUTLET SIZE NO. OF VALVES OUTLET SIZE

REQ'D
(IN.)
REQ'D
(IN.)
10
15
20
25
30
40
50
60
1
1
1
1
1
1
1
1
1-1/2
1-1/2
1-1/2
2
2
2-1/2
2-1/2
2
1
1
1
1
1
1
1
1
3/4
3/4
3/4
1
1
1
1-1/4
1-1/4
NOTE: Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on

availability.
Table B6-9. Model CFH Gas Pressure Requirements

Boiler HP
Inlet pipe
size
(inches)
Gas valve
size
(inches)
10
15
20
25
30
40
50
60
1
1
1
1
1.25
1.25
1.5
1.5
0.5
0.75
0.75
1
1
1.25
1.25
1.25
Minimum pressure required

at gas train connection
Low Fire
High Fire
7.2" w.c.
7.3" w.c.
7.5" w.c.
7.7" w.c.
8.5" w.c.
11.0" w.c.
10.0" w.c.
10.0" w.c.
5.2"
5.3"
5.5"
5.7"
6.8"
8.0"
7.0"
8.0"
Max.
pressure
inches
w.c.
w.c.
w.c.
w.c.
w.c.
w.c.
w.c.
w.c.
w.c.
28
Note: For altitudes above 700 feet, contact your local Cleaver-Brooks representative.
Figure B6-13. Boiler Room Width

Table B6-10. Boiler Room Width (Typical
Layout) Model CFH
BOILER HP
10-15
20-25
30-40
50-60
DIM.
"A"1
62
64
69
70
DIM.
"B"2
80
83
92
96
NOTES:
1. Recommended minimum distance between boiler and
wall. Dimension A allows for a clear 36 inch aisle
between the water column on the boiler and the wall. If
space permits, this aisle should be widened.
2. Recommended minimum distance between boilers.
Dimension B between boilers allows for a clear aisle of
36 inches. If space permits, this aisle should be widened.
B6-18
03/08
Section B6
Clearfire-H Boilers
Figure B6-14. Model CFH Lifting Lugs
Table B6-11. Model CFH Boiler Mounting Piers

BOILER
HP
10-15
20-25
30
40
50-60
A
4
4
4
4
4
B
6
6
6
6
6

C
D
E
26.75
38.75
2.25
30.25
42.25
2.25
38.25
50.25
2.25
38.25
50.25
2.25
44.25
56.25
2.25
F
30.5
34
42
42
48
G
56
58
60
68
70
NOTE:
4" high mounting piers recommended for use beneath the boiler base frame. The use of these piers
provides increased inspection accessibility to the boiler and added height for washing down the area
beneath the boiler.
Figure B6-15. Model CFH Mounting Piers
B6-19
03/08
Clearfire-H Boilers
Section B6
PERFORMANCE DATA
Table B6-10 shows predicted fuel-to-steam efficiencies for the Model CFH.
Cleaver-Brooks offers an industry leading fuel-to-steam efficiency guarantee for Model
CFH boilers. The guarantee is based on the numbers shown in the tables and on the
conditions listed below (the efficiency percent number is only meaningful if the
specific conditions of the efficiency calculations are clearly stated in the
specification).
Cleaver-Brooks will guarantee that, at the time of initial start-up, the boiler will
achieve fuel-to-steam efficiency as shown for 25%, 50%, 75% and 100% firing. If
the boiler fails to achieve the corresponding efficiency guarantee as published,
Cleaver-Brooks will rebate, to the final owner, five thousand dollars ($5,000.00) for
every full efficiency point (1.0%) that the actual efficiency is below the guaranteed
level. The specified boiler efficiency is based on the following conditions:
Natural Gas
Carbon, % by weight = 69.98
Hydrogen, % by weight = 22.31
Sulfur, % by weight = 0.0
Heating Value, Btu/lb = 21,830
Efficiencies are based on ambient air temperature of 80o F (27 C), relative
humidity of 30%, and 15% excess air in the exhaust gas stream.
Efficiencies are based on the manufacturer's published radiation and convection
losses; see Table B6-11.
Nominal feedwater temperature of 1900 F (88 C) or greater.
Table B6-12. Model CFH Boilers: Predicted Fuel-to-Steam Efficiencies-Natural Gas

BHP
10
15
20
25
30
40
50
60

% OF LOAD
25%
50%
75%
100%
84.8
85.5
85.4
85.2
84.6
85.0
84.7
84.3
84.7
85.2
85.0
84.7
84.6
85.0
84.6
84.2
84.8
85.3
85.2
85.0
84.7
85.3
85.1
84.8
84.8
85.5
85.4
85.2
84.8
85.3
85.2
84.9
B6-20
03/08

% OF LOAD
25%
50%
75%
100%
82.0
82.8
82.9
83.0
81.8
82.3
82.2
82.1
81.9
82.5
82.5
82.4
81.8
82.3
82.2
82.0
82.0
82.6
82.7
82.7
81.9
82.6
82.6
82.6
82.0
82.8
82.9
83.0
82.0
82.6
82.7
82.6
Section B6
Clearfire-H Boilers
Table B6-13. Model CFH Radiation and Convection Losses
BHP
10# Operating Pressure
25%
50%
75%
100%
25%
50%
75%
100%
10
1.6
0.7
0.5
0.4
1.9
1.0
0.7
0.5
15
1.6
0.7
0.5
0.4
1.9
1.0
0.7
0.5
20
1.6
0.7
0.5
0.4
1.9
1.0
0.7
0.5
25
1.6
0.7
0.5
0.4
1.9
1.0
0.7
0.5
30
1.6
0.7
0.5
0.4
1.9
1.0
0.7
0.5
40
1.6
0.7
0.5
0.4
1.9
1.0
0.7
0.5
50
1.6
0.7
0.5
0.4
1.9
1.0
0.7
0.5
60
1.6
0.7
0.5
0.4
1.9
1.0
0.7
0.5
The emission data included in Table B6-12 consists of typical controlled emission
levels of the Model CFH boiler. Because of the premix burner technology, the standard
burner provided with the CFH package provides low emissions as standard without
the need for external or special devices.
Table B6-13 shows predicted sound levels at high fire.
Table B6-14. Model CFH Boilers: Natural Gas, Estimated
Emission Levels
POLLUTANT
UNITS
ppm*
50
CO
lb/MMBtu
0.04
ppm*
20
NOx
lb/MMBtu
0.024
ppm*
1
SOx
lb/MMBtu
0.001
ppm*
10
HC/VOC
lb/MMBtu
0.004
ppm*
PM
lb/MMBtu
0.01
* ppm levels are given on a dry volume basis and corrected to 3% oxygen
(15% excess air)
Table B6-15. Model CFH Boilers: Predicted

sound levels at high fire
BHP
Sound Level - dBA*
10
60
15
65
20
60
25
66
30
62
40
68
50
67
60
69
*At 1 m from front of boiler and 4.5 ft height
B6-21
03/08
Clearfire-H Boilers
Section B6
ENGINEERING DATA
The following engineering information is provided for the Model CFH steam boiler.
Additional information may be obtained from your local Cleaver-Brooks
representative.
Feedwater
combination of condensate return and raw make-up or in some instances, 100% raw
make-up. Proper treatment of make-up water is essential to the longevity and
performance of the boiler. Table B6-14 shows the rate of make-up required and Table
B6-15 shows the water quality guidelines.
Table B6-16. Model CFH Boiler Feedwater Flow Rates
BHP
10
15
20
25
30
40
50
60
Gallons/Hour
41
62
83
103
124
165
207
248
Table B6-17. Model CFH Boilers Required Water Quality Parameters

Parameter
pH
Iron
Oxyen
Suspended Solids
Total Hardness
Blowdown
Boiler Water Limit

8.3 - 10.5
0.1 ppm
0.1 mg/liter
2000 mmho/cm
300 ppm
0 ppm as CaCO3
As steam is produced, unwanted solids are left behind in the water and become
concentrated within the vessel. If these constituents are allowed to adhere to the heat
transfer surfaces they will impede the flow of energy. Their removal requires proper
blowdown - either bottom, surface, or both. Table B6-16 shows the recommended
blowdown tank requirements for bottom blowdown. The surface blowdown
requirement is relative to the water quality and to the level of TDS control desired by
the water treatment specialist. Local codes will dictate the manner of treating
blowdown affluent.
recommendations of the National Board of Boiler and Pressure Vessel Inspectors. The
National Board's recommendations base the size of the blowdown tank on the
B6-22
03/08
Section B6
Clearfire-H Boilers
Table B6-18. Model CFH Blowdown Tank Sizing Information

BOILER HP
WATER (GAL)
10
11
15
11
20
13
25
13
30
16
40
19
50
22
60
22
NOTE: Quantity of water removed from boiler by lowering normal

water line 2".
Stack/Breeching
Criteria
General - The ClearFire Model CFH is a Category III Boiler according to ANSI Z21.13.
This code defines a Category III boiler as one that operates with a positive vent
pressure and a vent gas temperature that is non-condensing. Therefore the stack
must be a positive pressure design.
operation of the boiler. The vent should be designed with proper supports and
stack connection as proper draft is critical to safe and efficient burner performance.
size the breeching and stack to limit flue gas pressure variations. Consideration of the
draft must be given whenever direct combustion air ducting is utilized and lengthy
runs of breeching are employed. Please note: The allowable pressure range for design
of the stack and breeching is negative 0.25" w.c. (-62 Pa) to a positive 0.25" w.c.
(+62 Pa) for proper light offs and combustion. NOTE: This pressure range does not
pertain to the boiler room; that is, the boiler room must be neutral or slightly positive,
never negative when using air from the boiler room for combustion.
Whenever two or more CFH boilers are connected to a common breeching/stack, a
mechanical draft control system may be required to ensure proper draft at all times.
Cleaver-Brooks recommends individual stacks for multiple boiler installations.
Combustion Air - The burner must be supplied with adequate volume of
uncontaminated air to support proper combustion and equipment ventilation. Air
B6-23
03/08
Clearfire-H Boilers
Section B6
method, all installations must comply with NFPA54 (the National Fuel Gas Code NFGC) for U.S. installations and CAN/CSA B149.1 and B149.2 for Canadian
installations.
Note: A boiler room exhaust fan is not recommended as this type of device can cause
a negative pressure in the boiler room if using conventional air intake.
In accordance with NFPA 54, the required volume of indoor air shall be determined
in accordance with the "Standard Method" or "Known Air Infiltration Rate Method".
Where air infiltration rate is known to be less than 0.40 Air Changes per Hour, the
Known Air Infiltration Rate Method shall be used. (See the NFPA Handbook for
additional information).
Unconfined Spaces
All Air From Inside the Building - If combustion air is drawn from inside the building
(the mechanical equipment room does not receive air from outside via louvers or vent
openings and the boiler is not equipped with direct vent) and the boiler is located in
an unconfined space, use the following guidelines:
The mechanical equipment room must be provided with two permanent openings
linked directly with additional room(s) of sufficient volume so that the combined
volume of all spaces meets the criteria for an unconfined space. Note: An "unconfined
space" is defined as a space whose volume is more than 50 cubic feet per 1,000 Btu
per hour of aggregate input rating of all appliances installed in that space.
Each opening must have a minimum free area of one square inch per 1,000 Btu per
hour of the total input rating of all gas utilizing equipment in the mechanical room.
One opening must terminate within twelve inches of the top, and one opening must
terminate within twelve inches from the bottom of the room.
See Figure B6-16; refer to the NFGC for additional information.
Figure B6-16. Inside Air - Two Opening Method
GAS
VENT
12" MINIMUM
FRESH AIR OPENING
INTERIOR WALL
CLEARFIRE
BOILER
FRESH AIR OPENING
12" MINIMUM
B6-24
03/08
Section B6
Clearfire-H Boilers
All Air From Outdoors - If all combustion air will be received from outside the
building (the mechanical room is linked with the outdoors), the following methods
can be used:
Two Opening Method (Figure B6-17) - The mechanical equipment room must be
provided with two permanent openings, one terminating within twelve inches from
the top, and one opening terminating within twelve inches from the bottom of the
room.
A. The opening must be linked directly or by ducts with the outdoors.
B. Each opening must have a minimum free area of one square inch per 4,000 Btu
per hour of total input rating of all equipment in the room, when the opening is
directly linked to the outdoors or through vertical ducts.
C. The minimum free area required for horizontal ducts is one square inch per 2,000
Btu per hour of total input rating of all the equipment in the room.
GAS
VENT
12" MINIMUM
OUTLET AIR DUCT
INTERIOR WALL
EXTERIOR WALL
CLEARFIRE
BOILER
FRESH AIR
INLET DUCT
12" MINIMUM
One Opening Method (Figure B6-18) - One permanent opening, commencing within
12 inches of the top of the room shall be provided.
A. The equipment shall have clearances of at least 1 inch from the sides and back
and 6 inches from the front of the appliance.
B. The opening shall directly communicate with the outdoors and shall have a
minimum free area of 1 square inch per 3000 Btu's per hour of the total input rating
of all equipment located in the enclosure, and not less than the sum of the areas of
all vent connectors in the unconfined space.
C. Refer to the NFGC for additional information.
B6-25
03/08
Clearfire-H Boilers
Section B6
GAS
VENT
12" MINIMUM
FRESH AIR OPENING
EXTERIOR WALL
CLEARFIRE
BOILER
Unconfined Spaces
Engineered Design - When determining boiler room air requirements for an
unconfined space the "Engineered Design" method may be used. Following this
method, consideration must be given to the size of the room, airflow and velocity of
air as follows:
of 7 feet. This allows air to sweep the length of the boiler (see Figure B6-19).
Figure B6-19. Engineered Method
GAS
VENT
FRESH AIR OPENING
FRESH AIR OPENING
EXTERIOR WALL
CLEARFIRE
BOILER
EXTERIOR WALL
B6-26
03/08
Section B6
Clearfire-H Boilers
subject to clogging with dirt and dust.
square foot.
Determine the area of the boiler room air supply openings for (2) 60 horsepower
Model CFH boilers at 750 feet elevation. The air openings will be 5 feet above the
floor level.
Total boiler horsepower (bhp): 60 x 2 = 120 bhp
Area required: From the formula in E above, 1200cfm/250fpm = 4.8 square feet
total.
Area/Opening: 4.8 divided by 2 = 2.4 ft2 per opening (2 required).
Notice
Direct Combustion Air - If combustion air will be drawn directly from the outside
(sometimes referred to as "sealed combustion") by means of a duct connected directly
to the burner air intake, use the following guidelines:
1. Install combustion air duct in accordance with local codes and the boiler
operating and maintenance manual.
room.
3. Duct material can be PVC or metallic vent material. It should be air tight to
prevent in leakage of air during operation.
B6-27
03/08
Clearfire-H Boilers
Section B6
4. Maximum pressure drop for the duct shall not exceed 0.25" w.c. negative. If this
pressure drop is exceeded a larger size duct is recommended.
5. Multiple boilers may be connected to a single duct with take-offs to each boiler.
6. If the duct will run horizontally to an outside wall, it is recommended that the
duct have a slight downward slope away from the burner intake to prevent
collected moisture from draining into the burner connection.
7. If the outside air is dust-laden or the installation is near a heavily traveled
roadway, it is recommended that an air filter be installed to prevent intake of
contaminants that could accumulate on the burner canister.
Figure B6-20. Direct Vent Combustion
B6-28
03/08
Section B6
Clearfire-H Boilers
Fan/Blower
Casing Support
Attachment
Venturi
Gasket
Adapter Flange
Flexible Connection
Direct Vent Connection
Figure B6-21. Air Inlet Extension kit for Direct Vent combustion
Gas Piping
General - The ClearFire Model CFH gas fired steam boilers are full modulating input
units that require appropriate gas supply pressure and volume for proper operation
and long burner life. The gas requirements specified in this section must be satisfied
to ensure efficient and stable combustion. Installation must follow these guidelines
and of the local authorities that have installation jurisdiction.
Gas Train Components - CFH boilers are equipped with a gas train that meets the
requirements of UL/cUL and ASME CSD-1, and also the requirements of FM and GEGAP (formerly IRI). The gas train and its components have been designed and tested
to operate for the highest combustion efficiency for the CFH units. Major components
are as noted in the current product specifications and O & M manual.
Gas Pressure Requirements - For proper and safe operation, each Model CFH boiler
requires a stable gas pressure input. The pressure requirements are listed in the O &
M and current specifications and added here for reference purposes.
The minimum inlet supply pressure must be as noted in Table B6-7 when firing the
boiler at low fire and high fire. Actual gas pressure should be measured when the
burner is firing using a manometer at the upstream test port connection on the main
gas valve. For a multiple unit installation, gas pressure should be set for a single unit
first, then the remaining units should be staged on to ensure that gas pressure droop
is not more than 1" w.c. and never below the required pressure. Fluctuating gas
pressure readings could be indicative of a faulty supply regulator or improper gas train
size to the boiler.
Gas Piping - CFH units are standardly equipped with a gas pressure regulator. If
upstream pressure exceeds 1 psig, an additional upstream regulator must be installed
along with a pressure relief valve. Note: Gas connection is at the left side of the boiler,
left hand side as you face the front of the boiler.
For buildings or boiler rooms with gas supply pressure exceeding 28" w.c. a "full lockup" type regulator is recommended along with proper overpressure protection (e.g.
relief valve). In addition to the regulator, a plug type or "butterball type" gas shutoff
cock should be installed upstream of the regulator for use as a service valve. This is
also required to provide positive shutoff and isolate the unit during gas piping tests.
any dirt, weld slag, or debris can deposit in the drip leg rather than into the boiler gas
train. The bottom of the drip leg should removable without disassembling any gas
piping. The connected piping to the boiler should be supported from pipe supports
and not supported by the boiler gas train or the bottom of the drip leg.
B6-29
03/08
Clearfire-H Boilers
Section B6
Before starting the unit(s) all piping must be cleaned of all debris to prevent its'
entrance into the boiler gas train. Piping should be tested as noted in NFPA 54 and
the boiler must be isolated during any tests.
After initial startup, the inlet screen to the gas valve should be checked and cleaned
for any debris buildup
Gas Supply Pipe Sizing - For proper operation of a single unit or a multiple unit
installation, we recommend that the gas pipe sizing be sized to allow no more than
0.3" w.c. pressure drop from the source (gas header or utility meter) to the final unit
location. The gas supplier (utility) should be consulted to confirm that sufficient
volume and normal pressure are provided to the building at the discharge side of the
gas meter or supply pipe.
For installations of new boilers into an existing building, gas pressure should be
measured with a manometer to ensure sufficient pressure is available. A survey of all
connected "gas using devices" should be made. If appliances other than the boiler or
boilers are connected to the gas supply line, then a determination must be made of
how much flow volume (cfh = cubic feet per hour) will be demanded at one time and
the pressure drop requirement when all appliances are firing.
piping. Total equivalent length should be calculated from the utility meter or source to
the final unit connection. As a minimum guideline, gas piping Tables B6-17 through
B6-20 should be used. The data in these tables is from the NFPA 54 source book,
2006 edition.
To verify the input of each device that is connected to the gas piping, obtain the btu/
hr input and divide this input by the calorific value of the gas that will be utilized. For
instance, a 40 HP unit with 1,613,253 btu/hr input divided by a gas calorific value
of 1060 will result in a cfh flow of 1,522. The single boiler is approximately 20 feet
from the gas supply header source. And with a measured gas supply pressure of 10"
w.c. we find from Table 17 that a supply pipe size of 2" should be used as a
minimum.
B6-30
03/08
Section B6
Clearfire-H Boilers
Pipe Size
Nominal
1"
1-1/4"
1-1/2"
2"
2-1/2"
Actual I.D.
1.049
1.380"
1.610"
2.067"
2.469"
Length in feet
**Maximum Capacity in Cubic Feet of Gas per
514
1,060
1,580
3,050
4,860
10
363
726
1,090
2,090
3,340
20
284
583
873
1,680
2,680
30
243
499
747
1,440
2,290
40
215
442
662
1,280
2,030
50
195
400
600
1,160
1,840
60
179
368
552
1,060
1,690
70
167
343
514
989
1,580
80
157
322
482
928
1,480
90
148
304
455
877
1,400
100
131
269
403
777
1,240
125
119
244
366
704
1,120
150
109
209
336
648
1,030
175
102
185
313
602
960
200
**Fuel: Natural Gas
3"
3.068"
Hour (cfh)
8,580
5,900
4,740
4,050
3,590
3,260
3,000
2,790
2,610
2,470
2,190
1,980
1,820
1,700
4"
4.026"
17,500
12,000
9,660
8,290
7,330
6,640
6,110
5,680
5,330
5,040
4,460
4,050
3,720
3,460

Pipe Size
1-1/4"
1-1/2"
2"
2-1/2"
3"
1.380"
1.610"
2.067"
2.469"
3.068"
678
1,390
2,090
4,020
6,400
11,300
10
466
957
1,430
2,760
4,400
7,780
20
374
768
1,150
2,220
3,530
6,250
30
320
657
985
1,900
3,020
5,350
40
284
583
873
1,680
2,680
4,740
50
257
528
791
1,520
2,430
4,290
60
237
486
728
1,400
2,230
3,950
70
220
452
677
1,300
2,080
3,670
80
207
424
635
1,220
1,950
3,450
90
195
400
600
1,160
1,840
3,260
100
173
355
532
1,020
1,630
2,890
125
157
322
482
928
1,480
2,610
150
144
296
443
854
1,360
2,410
175
134
275
412
794
1,270
2,240
200
**Fuel: Natural Gas
Nominal
Actual I.D.
Length in feet
1"
1.049"
4"
4.026"
23,100
15,900
12,700
10,900
9,600
8,760
8,050
7,490
7,030
6,640
5,890
5,330
4,910
4,560
B6-31
03/08
Clearfire-H Boilers
Section B6
Pipe Size
Nominal
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
4"
Actual I.D.
Length in
feet
0.622
0.824
1.049"
1.380"
1.610"
2.067"
2.469"
3.068"
4.026"
10
1,510
3,040
5,560
11,400
17,100
32,900
52,500
92,800
189,000
20
1,070
2,150
3,930
8,070
12,100
23,300
57,100
65,600
134,000
30
869
1,760
3,210
6,590
9,880
19,000
30,300
53,600
109,000
40
753
1,520
2,780
5,710
8,550
16,500
26,300
46,400
94,700
50
673
1,360
2,490
5,110
7,650
14,700
23,500
41,500
84,700
60
615
1,240
2,270
4,660
6,980
13,500
21,400
37,900
77,300
70
569
1,150
2,100
4,320
6,470
12,500
19,900
35,100
71,600
80
532
1,080
1,970
4,040
6,050
11,700
18,600
32,800
67,000
90
502
1,010
1,850
3,810
5,700
11,000
17,500
30,900
63,100
100
462
954
1,710
3,510
5,260
10,100
16,100
28,500
58,200
125
414
836
1,530
3,140
4,700
9,060
14,400
25,500
52,100
150
372
751
1,370
2,820
4,220
8,130
13,000
22,900
46,700
175
344
695
1,270
2,601
3,910
7,530
12,000
21,200
43,300
200
318
642
1,170
2,410
3,610
6,960
11,100
19,600
40,000
500
192
401
717
1,470
2,210
4,250
6,770
12,000
24,400
1000
132
275
493
1,010
1,520
2,920
4,650
8,220
16,800
1500
106
221
396
812
1,220
2,340
3,740
6,600
13,500
**Fuel: Natural Gas

B6-32
03/08
Section B6
Clearfire-H Boilers
Pipe Size
Nominal
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
4"
Actual I.D.
Length in
feet
0.622
0.824
1.049"
1.380"
1.610"
2.067"
2.469"
3.068"
4.026"
10
2,350
4,920
9,270
19,000
28,500
54,900
87,500
155,000
316,000
20
1,620
3,380
6,370
13,100
19,600
37,700
60,100
106,000
217,000
30
1,300
2,720
5,110
10,500
15,700
30,300
48,300
85,400
174,000
40
1,110
2,320
4,380
8,990
13,500
25,900
41,300
75,100
149,000
50
985
2,060
3,880
7,970
11,900
23,000
36,600
64,800
132,000
60
892
1,870
3,520
7,220
10,300
20,300
33,200
58,700
120,000
70
821
1,720
3,230
6,640
9,950
19,200
30,500
54,000
110,000
80
764
1,600
3,010
6,180
9,260
17,800
28,400
50,200
102,000
90
717
1,500
2,820
5,800
8,680
16,700
26,700
47,100
96,100
100
677
1,420
2,670
5,470
8,200
15,800
25,200
44,500
90,300
125
600
1,250
2,360
4,850
7,270
14,000
22,300
39,500
80,500
150
544
1,140
2,140
4,400
6,590
12,700
20,200
35,700
72,900
175
500
1,050
1,970
4,040
6,060
11,700
18,600
32,900
67,100
200
465
973
1,830
3,760
5,640
10,900
17,300
30,600
62,400
500
283
593
1,120
2,290
3,430
6,610
10,300
18,600
38,000
1000
195
407
897
1,380
2,360
4,550
7,240
12,000
26,100
1500
156
327
616
1,270
1,900
3,650
5,820
10,300
21,000
**Fuel: Natural Gas

B6-33
03/08
Clearfire-H Boilers
Section B6
Pipe Size
Nominal
Actual
I.D.
Length
in feet
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
4"
0.622
0.824
1.049"
1.380"
1.610"
2.067"
2.469"
3.068"
4.026"
10
3,190
6,430
11,800
24,200
36,200
69,700
111,000
196,000
401,000
20
2,250
4,550
8,320
17,100
25,600
49,300
78,600
139,000
283,000
30
1,840
3,720
6,790
14,000
20,900
40,300
64,200
113,000
231,000
40
1,590
3,220
5,880
12,100
18,100
34,900
55,600
98,200
200,000
50
1,430
2,880
5,260
10,800
16,200
31,200
49,700
87,900
179,000
60
1,300
2,630
4,800
9,860
14,800
28,500
45,400
80,200
164,000
70
1,200
2,430
4,450
9,130
13,700
26,400
42,000
74,300
151,000
80
1,150
2,330
4,260
8,540
12,800
24,700
39,300
69,500
142,000
90
1,060
2,150
3,920
8,050
12,100
23,200
37,000
65,500
134,000
100
979
1,980
3,620
7,430
11,100
21,400
34,200
60,400
123,000
125
876
1,770
3,240
6,640
9,950
19,200
30,600
54,000
110,000
150
786
1,590
2,910
5,960
8,940
17,200
27,400
48,500
98,900
175
728
1,470
2,690
5,520
8,270
15,900
25,400
44,900
91,600
200
673
1,360
2,490
5,100
7,650
14,700
23,500
41,500
84,700
500
384
802
1,510
3,100
4,650
8,950
14,300
25,200
51,500
1000
264
551
1,040
2,130
3,200
6,150
9,810
17,300
35,400
1500
212
443
834
1,710
2,570
4,940
7,880
13,900
28,400
**Fuel: Natural Gas

B6-34
03/08
Section B6
Clearfire-H Boilers
Figure B6-23. Example gas piping <1 psig supply
B6-35
03/08
Clearfire-H Boilers
Section B6
Gas Header - For multiple unit installations, a single common gas header with
individual takeoffs for each boiler is recommended (See Figure B6-22). Boiler gas
manifold piping should be sized based on the volume requirements and lengths
between boilers and the fuel main header. Tables B6-22 through B6-29 indicate the
proper sizing for multiple units of equal size, placed on the factory standard center
with the noted take off size. For installations with a mixed sized use, determine the
flow of each unit and total the input. With the total input, determine length of run
from the source and determine what size header will be needed for the flow of all
units firing. Pipe sizes are based on Table B6-18 with boiler gas line take-off at 20
feet from the header. If pipe runs are greater or if gas pressure is different, refer to the
Tables for pipe sizing.
Pipe sizing for multiple unit manifolds

Table B6-24. CFH 10 HP Boilers
# of
Units
Pipe Size
To Boiler
Header
Pipe Size
1-1/4"
1-1/4"
1-1/4"
1-1/4"
1-1/4"
1-1/4"
2"
2"
# of
Units
Pipe Size
To Boiler
Header
Pipe Size

# of
Units
Pipe Size
To Boiler
Header
Pipe Size
1-1/2"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
2"
2-1/2"
2-1/2"
# of
Units
Pipe Size
To Boiler
Header
Pipe Size
1-1/4"
1-1/4"
1-1/4"
1-1/4"
1-1/4"
2"
2"
2-1/2"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
2"
2-1/2"
3"
2"
2"
2"
2"
2"
2-1/2"
3"
3"
# of
Units
Pipe Size
To Boiler
Header
Pipe Size

# of
Units
Pipe Size
To Boiler
Header
Pipe Size

# of
Units
Pipe Size
To Boiler
Header
Pipe Size
2"
2"
2"
2"
2"
2-1/2"
3"
4"
2"
2"
2"
2"
2"
3"
3"
4"
# of
Units
Pipe Size
To Boiler
Header
Pipe Size
B6-36
03/08
2-1/2"
2-1/2"
2-1/2"
2-1/2"
2-1/2"
3"
4"
4"
Section B6
Clearfire-H Boilers
SPECIFICATIONS
MODEL CFH PRODUCT SPECIFICATIONS
1.0 GENERAL BOILER DESIGN
A. The boiler shall be a Cleaver-Brooks Model CFH 700, single pass horizontal
commercial Firetube design or approved equal. It shall be mounted on a heavyduty steel frame with premix forced draft burner and burner controls as a complete
package from one manufacturer.
B. Approvals - The complete package including the burner shall be Underwriters
Laboratories, Inc. listed and the official UL/cUL label shall be affixed to the
package attesting to its certification.
C. As a preassembled package, the standard boiler shall be factory fire tested.
D. The complete package as shipped, shall be ready for connections to water, fuel,
blowdown, and exhaust venting. Certain items may be shipped loose to prevent
their damage such as the safety valves and gauges.
E. The specified boiler shall have an output rating of _____ horsepower when fired
with Natural Gas [LP Gas] with a gas supply pressure of ____" w.c. Power supply
to the boiler shall be 115/1/60. Design pressure shall be [15#] [150#] steam.
Operating characteristics shall be [___] psig steam. Steam boilers shall be
supplied with ____ degrees F make-up water @ ____%.
F. Performance: Shall be as specified in Paragraph 5.
1.1 BOILER SHELL
A. The boiler shell must be constructed in accordance with the ASME Code, either
Section I for high-pressure steam or Section IV for low-pressure steam. The vessel
must be subjected to the required inspections of the Code conducted by an
independent third party inspector. A signed inspection sheet shall be provided to
the purchaser and the appropriate ASME symbol shall be affixed or stamped onto
the boiler.
1.Two lifting eyes shall be furnished and located on the top centerline of the vessel
for lifting or rigging purposes.
2.Furnace and front furnace tube sheet access/inspection shall be provided via a
swing away burner housing attached to the front head on a right hand hinge
assembly.
3.Rear tube sheet access shall be available via a removable exhaust outlet
assembly.
4.Each carbon steel boiler tube shall utilize the AluFer heat transfer design
technology for high efficiency and reduction in overall size of the vessel and shall
be a minimum of 0.105 tube wall thickness.
5.To facilitate waterside inspection, 3 hand holes shall be provided.
6.An observation port for flame inspection shall be provided in the front burner
door.
B6-37
03/08
Clearfire-H Boilers
Section B6
7.Boiler insulation shall consist of 2-inch fiberglass blanket, which shall be
covered with a powder coated sheet metal jacket. This jacket and insulation
design shall permit field removal and reattachment if necessary for inspection,
etc.
8.The entire boiler and base frame shall be factory painted.
9.Tube cleaning and inspection shall be provided from either end.
10.Exhaust vent shall be located at the rear of the boiler and shall be a slip
connection. Stack support shall be by means other than the boiler connection.
1.2 BOILER SHELL TAPPINGS/OPENINGS
A. The following boiler vessel tappings/openings shall be furnished:
1.Steam supply, to be located on the top centerline, NPT connection for highpressure steam and flanged connection for low-pressure steam with 3" and
greater connection.
2.Bottom blowdown at the front bottom of the boiler.
3.Feedwater Make-up - located on the right hand side and left hand of the shell
when facing the front of the boiler.
4.Surface blowoff on the top centerline of the boiler including a collector tube.
5.Chemical Feed.
6.High Water Level Overflow Drain to discharge water in the boiler if water level
reaches an unacceptable level.
2.0 STEAM BOILER TRIM (All piping and devices per ASME CSD-1)
A. Water Column
1.A water column shall be piped on the right hand side of the boiler [when facing
the burner] complete with gauge glass and water column blowdown valve.
a. Feedwater Pump control - shall be integral with the water column via probe control
device and electronics for on/off pump operation.
b. Low Water cutoff - shall be integral with the water column via probe control device
and solid state electronics mounted and wired in the control panel.
B. An Auxiliary Low Water Cutoff shall be provided. It shall be located on the top
centerline of the boiler using an internal probe and of the manual reset design.
C. For safety steam pressure lockout a high limit pressure control, manual reset shall
be provided. The device shall be mercury free.
D. For normal operation an operating limit pressure control, auto reset shall be
provided to start and stop the burner on demand requirements and demand
satisfied. The device shall be mercury free.
E. To provide steam demand tracking a steam pressure transmitter shall be provide
that provides an input signal for burner positioning in accordance to steam
demand.
B6-38
03/08
Section B6
Clearfire-H Boilers
F. A 3" Steam Pressure Gauge shall be piped onto the trim piping, including an
inspectors test cock.
G. In accordance with the A.S.M.E. Code an approved A.S.M.E. rated and stamped
safety valve shall be provided and set at [15#] or [150#].
3.0 BURNER AND BURNER CONTROLS
A. Mode of Operation - To minimize short cycling and provide highest efficiency the
burner for the specified boiler shall be of the electronic modulation with a
turndown ratio of 5:1 for Natural Gas for sizes of 30 horsepower and greater, and
4:1 for sizes below 30 horsepower. On/off or low/high burner operation shall not
be accepted.
B. The burner shall be enclosed in a NEMA 1 type enclosure. A lift off panel shall be
provided to gain access to the burner and controls.
C. Design - The burner design shall be of the linkage-less premix technology wherein
the fuel and air are mixed in the fan housing assembly prior to entering the burner
canister. Separately driven linkage or servo motor driven fuel and air valves shall
not be permitted.
1.Fan housing shall utilize non-sparking material and shall be approved for premix
operation.
2.The fan shall be driven by a variable speed motor which shall react to output
demand requirements via the demand control Motor shall be a high efficiency
DC Brushless type. Continuous speed synchronous motors will not be
acceptable.
D. Ignition of the fuel shall be of the direct spark design; separate pilot gas train is
not required. Dual ignition electrodes shall used for the spark generated from the
panel mounted ignition transformer.
E. Combustion shall take place on the surface of the burner canister. The canister
shall be constructed of Fecralloy material and stainless steel and shall be
warranted for five years against failure from defects or poor workmanship.
F. Air Filter - shall be fitted to the intake air venturi to filter the incoming air supply
when using boiler room air. The air filter shall be designed to be easily cleaned
and re-used.
G. Fuel - The burner shall be designed for operation with natural gas or LP gas. Gas
Train, shall be located at the front of the burner and along the left side of the boiler.
In accordance with UL/cUL and ASME CSD-1, the following components shall be
furnished:
1.Single body dual solenoid safety shutoff valve and incorporate the following:
a. The valve shall be a 1:1 ratio valve with an integral trim regulator and operate in
relation to the fan speed. An air sensing line shall be connected from the air inlet venturi
[mounted to the fan motor] and to the gas valve for control of gas input.
b. As fan speed increases a negative pressure will be applied to the valve, allowing the
valve to open further, permitting more fuel to flow into the venturi for mixing. As fan
speed is reduced, fuel input shall be reduced accordingly. Air shall always lead fuel from
low to high or high to low.
B6-39
03/08
Clearfire-H Boilers
Section B6
2.Manual fuel shutoff valve - shall be located downstream of the gas valve and
used for CSD-1 leak testing.
3.Gas Pressure Interlocks - one shall be provided for sensing high gas pressure and
one provided to sense low gas pressure. Each control shall be of the manual
reset type.
4.Gas Pressure Regulator - shall be provided upstream of the gas valve to provide
regulated pressure to the gas train from the gas supply. This regulator shall be
suitable for a maximum of 1 psig gas pressure. If gas pressure exceeds 1 psig,
a gas pressure relief valve shall be furnished and upstream pressure regulator
that is of the full lockup type.
5.Manual Shutoff Valves - shall be provided upstream of the gas regulator to
manually close off the gas supply when servicing the gas train or isolating the
boiler. A shutoff valve shall be provided at the burner for tightness checking of
the gas valve.
6.Combustion Air Proving Switch shall be provided to prove, prior to modulation
that the fan is operating properly.
7.A High Air Pressure Switch (Blocked Flue) shall be mounted and wired to
prevent burner operation if excessive back pressure in the flue is sensed. This
switch shall require a manual reset.
H. Flame Safety
1.Flame sensing shall be accomplished with a flame rod mounted in the burner
mounting plate, designed for easy removal for inspection or replacement.
2.Flame supervision shall be performed by the CB Falcon control.
4.0 BOILER CONTROL - The boiler shall include the CB Falcon boiler-burner control
system which is an integrated, microprocessor-based primary safety and steam
boiler control, complete with status indication, lockout messaging and reset,
control mode selection, and configurable parameter settings. The system shall
include a Touchscreen Display Interface. The display shall be mounted at the front
of the boiler panel for convenient access and viewing.
A. Controller shall provide for both flame safeguard and boiler control and shall
perform the following functions:
Burner sequencing with safe start check, pre-purge, electronic direct spark ignition,
run, and post purge.
Flame Supervision by flame rod; includes test locations for flame signal
measurement.
The control shall maintain a running history of operating hours, number of cycles,
and the most recent 15 lockouts and alerts. The control shall be connected to a
touchscreen display interface that will allow retrieval of this information.
Safety Shutdown with display of lockout condition.
Modulating PI control of the variable speed fan via PWM output for fuel/air input to
match load requirements.
Gas pressure supervision, high and low.
Combustion Air Proving Supervision.
Boiler status, supply temperature, and set-point temperature shall be displayed at all
B6-40
03/08
Section B6
Clearfire-H Boilers
times by the touchscreen display.

Controller shall have Modbus communication.
PID Load control for heating application and domestic water. Includes priorization for
demand and rate limiting.
High Limit control of boiler outlet temperature.
Anti-short cycling control.
Remote Modulation or Remote Set Point control
B. All parameter settings shall be factory configured for the specific boiler model.
Installer/Service level parameters can be configured at installation to suit job site
conditions.
C. Control shall include sensors for supply and return water sensing.
D. Electrical power supply shall be 120 volts, 60 cycle, single phase for the
combustion air fan and boiler control circuit.
E. When multiple boilers are to be installed together, the Boiler Control shall have an
option for sequencing control via Modbus network and shall provide staging for up
to 8 boilers. The control shall include automatic rotation of lead boiler, an
adjustable outdoor reset schedule, multiple setback schedules, domestic hot water
priority, and a digital display. The control shall force each boiler to low fire, before
allowing any boiler to operate at high fire. When all boilers are running, they will
then be modulated in unison. The control shall be supplied by the boiler supplier,
in order to ensure proper integration with the boiler controls.
F. The touchscreen Display/Interface shall provide the following:
Burner Control status

Firing Rate Control, auto and manual
Lockout condition and reset
Alert and Hold Messages
Heating Set Point adjustment
Heating Time-of-Day (setback) Set Point adjustment
First out annunciation and system status and diagnostics
Control Temperatures
Installation Setup
G. The control shall have the following capabilities/options:

Outdoor Reset control and sensor
Lead/lag configuration
System Pump control of up to three pumps
High Stack Temperature Limit
Frost protection
Time-of-Day (setback/dual set point)
Remote Reset
H. Control Panel - A NEMA 1A type enclosure is furnished and located at the front of
the boiler above the burner to house the following components. Surface mounted
devices are located on the right hand side of the panel.
CB Falcon controller.
B6-41
03/08
Clearfire-H Boilers
Section B6
Falcon touchscreen display/operator interface
Boiler Control Circuit On/Off switch.
Local/Remote demand switch.
Provide terminals for control interface wiring, customer connections, and

connections for incoming power.
Install solid state circuit boards for water level controls.
Selectable Options:
_____Alarm Light Package to provide indication of Low Water, Flame Failure,
Load Demand, Fuel Valve On, including a horn with silence switch for alarm
conditions.
5.0 PERFORMANCE
The proposed Boiler shall provide the following operating performance targets for
Natural Gas:
A. Efficiency - Fuel to Steam Efficiency shall be guaranteed at 85% for 15# Steam
Design. For 150# steam operating at 125#, the guaranteed Fuel to Steam
Efficiency shall be 83% and 85% with an optional flue gas economizer. Efficiency
rating shall account for radiation and convection losses.
B. Emissions - NOx emissions shall be less than 20 PPM corrected to 3% O2 and
less than 10 PPM CO over the operating range of the burner turndown. If
emissions exceed this level, the boiler manufacturer shall correct at their expense
until this level is achieved on a repeatable basis.
C. Noise - Sound level shall not exceed 70 dBA at high fire when measured 3 feet in
front of the burner.
D. Radiation losses shall be less than 0.5% of the rated input at maximum firing.
E. Steam quality shall be 99.5% at maximum firing regardless of operating pressure.
6.0 WARRANTY
The package boiler shall be warranted for a period of one year from date of start-up or
18 months from shipment whichever shall occur first.
7.0 OPTIONAL ECONOMIZER PACKAGE
For application with 150# Design Model CFH, an economizer package shall be
factory installed and piped to increase operating efficiency to 85%. The factory
installed package shall include an economizer coil located in the rear of the boiler,
integral to the stack outlet with integral make-up water supply and outlet piping. A
vertical stainless steel feedwater tank complete with a continuous running pump shall
be provided with integral piping. This piping shall include the feedwater make-up
stop valve, check valve, and on/off electric make up valve. The make-up valve shall
be factory wired to the on/off pump control. Feedwater piping shall include by-pass
piping so that water circulates through the economizer at all times.
B6-42
03/08
Section B7
CLEARFIRE MODEL CFV BOILERS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-6
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-13
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-18
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-20
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-36
LIST OF FIGURES
Tube Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-3
AluFer Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-3
Premix Burner Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-4
Burner maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-4
CFV connections and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-5
CB Falcon Display/Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-9
CB Falcon pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-10
CFV Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-11
B7-1
01/09
Model CFV Boilers
Section B7
Gas Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-12

CFV electrical panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-12
Model CFV Steam Boiler Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-14
Inside Air - Two Opening Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-23
Two Opening Ducted Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-24
One Opening Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-24
Engineered Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-25
Direct Vent Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-27
Direct Vent Combustion kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-27
Typical gas header piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-30
Example gas piping <1 psig supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-30
LIST OF TABLES
Operating Conditions - CB Falcon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-7
CB Falcon burner sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-8
Model CFV Steam Boiler Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-15
Model CFV Steam Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-16
Model CFV Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-16
Model CFV Gas Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-16
Model CFV Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-17
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-17
Predicted Fuel-to-Steam Efficiencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-18
Radiation and Convection Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-19
Model CFV Boilers: Natural Gas, Estimated Emission Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-20
Predicted sound levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-20
Feedwater flow rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-21
Model CFV Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-21
Model CFV Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-22
Gas line capacity - Schedule 40 metallic pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-31
Pipe sizing for multiple unit manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-35
B7-2
01/09
Section B7
Model CFV Boilers

General
The ClearFire Model CFV is a single pass, horizontally fired durable firetube steam boiler.
Extended heating surface tubes provide a very high level of performance in a compact
package. An integral premix burner is provided for natural gas operation. As standard, the
Model CFV burner provides low emissions of <20 PPM NOx. Propane fuel is also available.
Advanced Technology
Heat is transferred through 3 OD carbon steel tubes with patented AluFer extended heating
surfaces. The AluFer tube design provides for optimum heat transfer and eliminates laminar
gas flow during minimum firing, providing optimized efficiency throughout the firing range
(see Figure B7-1 and Figure B7-2).
Figure B7-2. Tube Cross Section

Figure B7-1. AluFer Tubes
High Efficiency
With the AluFer extended heating surface tubes, the Model CFV steam boiler will provide
fuel-to-steam efficiency of up to 81% operating at 125 psig.
ISO 9001-2001 certification ensures the highest manufacturing standards.

ASME code construction ensures high quality design, safety, and reliability. Units are thirdparty inspected and are stamped to assure compliance.
Certification
Each unit is tested and certified in accordance with UL/cUL standards and the UL/cUL label is
affixed attesting to equipment meeting the latest UL requirements for packaged steam boilers.
Premix Technology
The ClearFire CFV burner utilizes Premix technology to mix both gas fuel and combustion air
prior to entering the burner canister, with fuel flow governed by the air flow during firing
transitions. Combined with a variable speed fan, this technology provides very low emission
levels, exceptionally safe operation, and nearly 100% combustion efficiency. An inlet air filter
is provided as standard to prevent airborne dust from entering the combustion canister.
Full Modulation
The variable speed fan modulates to provide only the amount of heat required to the boiler.
Full modulation reduces on/off cycling and provides excellent load tracking with reduced
operating costs. The burner does not require mechanical linkage connections between the fuel
input valve and air control. Instead, the microprocessor control adjusts the fan speed in
accordance with system demand, determining fuel input without mechanical device
positioning. This method of controlling the fuel-air ratio eliminates slippage due to linkages,
B7-3
01/09
Model CFV Boilers
Section B7
minimizes burner maintenance, and provides control repeatability. See Figure B7-3.

Ease of Maintenance
The blower is easily removed to allow inspection or service of the burner canister, tubes, and
tube sheets (see Figure B7-4). A union connection provides easy disconnect from the fuel
train. All burner components are easily accessed for inspection and maintenance.
Figure B7-4. Burner maintenance
B7-4
01/09
Section B7
Designed for commercial
steam applications
Model CFV Boilers

The CFV packaged boiler is designed for 150 psig MAWP (Maximum Allowable Working
Pressure) and is constructed of durable ASTM grade steel materials. Figure B7-5 shows the
component and connection locations.
Figure B7-5. CFV connections and controls
B7-5
01/09
Model CFV Boilers
Section B7
PRODUCT OFFERING
Information in this section applies to steam boiler sizes ranging from 10 horsepower
through 60 horsepower for operation on natural gas or LP gas only. Fuel oil operation
is not available for the model CFV. Standard installation is for indoor use with an
optional engineering design for outdoor applications.
The complete package has been tested and certified in accordance with UL/cUL.
Package is approved and listed and bears the appropriate UL/cUL package boiler
label.
Dimensions, ratings, and product information may change due to market
requirements or product enhancements. The information contained herein is a guide
for general purposes only.
Standard Equipment
The equipment listed below applies to the standard boiler package offering. Optional
items are available to meet specific projects when required.
1. The Boiler
A.Each boiler (pressure vessel) size is designed and built for a Maximum Allowable
Working Pressure (MAWP) of 150 psig in accordance with ASME Section I
(bearing the S stamp).
B.The vessel is insulated with a 2 thick blanket and mounted on a base frame. A
powder-coated 18 gauge steel casing covers the insulation.
C.Vessel connections are furnished for:
Steam outlet
Bottom drain or blowoff
Surface blowoff
Chemical feed
Feedwater makeup
High water level overflow
D.For waterside inspection, handholes are provided.
E. Two lifting lugs are provided on the top of the boiler for rigging purposes.
F. The combustion exhaust is located at the top rear.
2. Boiler trim and controls
Water column with primary low water cutoff and pump control (probe type).
Water column gauge glass and gauge glass drain valve.
Water column drain valve.
Auxiliary low water cutoff (probe type), manual reset.
Operating limit pressure control, auto reset.
Excess steam pressure control, manual reset.
Pressure transmitter for burner on/off and modulation.
ASME safety relief valve.
B7-6
01/09
Section B7
Model CFV Boilers

3. CB Falcon Control System
A.Control Description - The CB Falcon control is an integrated burner management
and modulation control with a touch-screen display/operator interface.
B.Functionality - The controller incorporates the following functions:
PID load control.

Burner sequencing with safe start check, pre-purge, direct spark ignition, and
post purge.
Flame Supervision.
Safety shutdown with time-stamped display of lockout condition - last 15
lockouts stored in memory.
Variable speed control of the combustion air fan.
and low water.
Alarm output
Remote enable & remote modulation or set point.
Diagnostics.
Real-time data trending (w/System Display).
Modbus communication.
End-user
Table B7-1. Operating Conditions - CB Falcon

Temperature Range
Humidity
Operating
32 F to 122 F (0 C to 50 C)
Storage
-40 F to 140 F (-40 C to 60 C)

B7-7
01/09
Model CFV Boilers
Section B7
Table B7-2. CB Falcon burner sequence

1. Heat request detected (Setpoint minus On Hysteresis); LCI limits and steam
demand detected (terminals J6 3 and J8 3).
2. The CH pump is switched on (relay contact closes).
3. After a system Safe Start Check, the Blower (combustion air fan) is started
4. After the ILK input is energized - 10 sec. allowed for IAS input (combustion air
proving) to energize - and the purge rate proving fan RPM is achieved, prepurge
time is started.
5. When 30 sec. purge time is complete, the fan RPM is changed to the lightoff
speed.
6. Trial for Ignition (4 sec).
7. The ignitor and the gas valve are energized.
8. The ignitor is turned off at the end of the direct burner ignition period.
9. The fan is kept at the lightoff rate during the stabilization time.
10.Release to modulation (Run).
11.At the end of the CH-heat request the burner is switched off and the fan stays on
until post purge is complete (15 sec.). Boiler enters standby mode.
C.Main Electrical Connection - 115V/single phase/60Hz

D.Demand switch - Local/Remote/Off.
E. Combustion Air Proving Switch
F. Gas Pressure Switch - Gas pressure switches for low gas pressure and high gas
operation. Monitored in Interlock (ILK) Circuit.
G.System Configuration - CB Falcon configuration is grouped into the following
functional groups:

Pump Configuration
High Limits
Stack Limit
Other Limits
Fan Configuration
H.CB Falcon Control Access - There are three levels of access to the CB Falcon
controller:

required.

OEM Level - read/change all parameters; for factory configuration of boiler-
B7-8
01/09
Section B7
Model CFV Boilers

specific parameters. Password-protected and restricted to CB or factory
For additional information regarding service and setup of the burner controller, refer to
CB manual part no. 750-269.
Figure B7-6. CB Falcon Display/Operator Interface
B7-9
01/09
Model CFV Boilers
Section B7
FALCON STEAM CONTROL

PLUG CONNECTORS
BLUE
UV
FAN POWER (25 VDC)

FAN GND
PWM OUT
TACHOMETER
WHITE
EGND
L2 FOR 120VAC OR
L1
{
{
PUMP C {
PUMP A
PUMP B
BLOWER/HSI
EX. IGNITION
MAIN VALVE
PILOT VALVE
INTERLOCK
ALARM
PRE IGN INTLK
LCI
ANNUN 1/IAS
ANNUN 2
ANNUN 5
ANNUN 6
ANNUN 7 HFS
ANNUN 8 LFS
J1
J2
J8
J4
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
7
6
5
4
3
2
1
STEAM
CONTROL
J5
POWER
J6
J10
1
2
3
4
5
6
7
8
J11
1
2
3
4
5
6
7
ALARM
J7
J3
LOCAL
MODBUS
A B C
MULTIPLE
APPLIANCE
CONTROLLER
J9
FLAME
RESET
GLOBAL
MODBUS
A B C
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
PIM
FLAME
STRENGTH
ANNUN 3
ANNUN 4
12
11
10
9
8
7
6
5
4
3
2
1
24 VAC
24 VAC RTNS
STAT
STEAM PRESSURE
1
SENSOR
4-20 mA
STACK TEMP A
STACK TEMP RTN
STACK TEMP B
REMOTE RESET
TOD
+
+
4 TO 20 MA
0 - 10 VDC
MA /VDC RTN
FUTURE
FUTURE
System Display
ECOM
D R C
Local Display
BUILDING
AUTOMATION
SYSTEM
GLOBALMODBUS
LOCALMODBUS
1
EXTERNALLY POWERED PRESSURE SENSOR (0-15 PSI OR 0-150 PSI).
4. Forced draft burner

A.The burner is a "Pre-mix" design consisting of a unitized venturi, single body dual
safety gas valve, blower, and burner head (canister).
B7-10
01/09
Section B7
Model CFV Boilers

B.Full modulation is accomplished with a variable speed fan for up to 5:1
turndown ratio on 40 horsepower boilers and larger (4:1 turndown on 30
horsepower and less).
C.For near flameless combustion, the burner utilizes a Fecralloy metal fiber head
(canister).
D.Noise level at maximum firing is less than 70 dBA regardless of boiler size.
E. When boiler is operating on natural gas, NOx emissions will be less than 20
PPM regardless of boiler size; certified for California and Texas low emissions
requirements.
F. As an option, the burner can utilize direct vent combustion air.
G.Ignition of the main flame is via direct spark, utilizing high voltage electrodes
H.To ensure adequate combustion air is present prior to ignition, and to ensure the
fan is operating, a combustion air proving switch is provided.
I. For ease of inspection and maintenance, the blower is hinged for easy swing
away from the boiler permitting full inspection of the burner components, front
tube sheet and furnace.
J. A flame observation port is located at the top of the boiler.
Figure B7-8. CFV Burner

5. Burner Gas Train
The standard gas train is equipped in accordance with UL 795, ASME, CSD-1, GEGAP (formerly IRI), and FM. Each burner gas train includes:
Low gas pressure interlock, manual reset

High gas pressure interlock, manual reset
ASME CSD-1 test cocks
Downstream manual ball type shutoff cock
Single body dual safety shutoff gas valve
Gas pressure regulator for maximum of 1 psig inlet pressure
B7-11
01/09
Model CFV Boilers
Section B7
Manual SOV
Test Cocks
Gas Valve
Manual SOV
Regulator
LGPS
HGPS
Figure B7-9. Gas Train
6. Boiler control panel

A standard NEMA 1A type panel enclosure is mounted on the side of the boiler. This
panel encloses the CB Falcon control, water level circuit boards, terminals, fuse
blocks, and ignition transformer. 115/1/60 terminals are provided for contractor
connections.
Optional
Alarm/Annunciation
Fuse Block
Terminal Block
Falcon Display
& Operator Interface
Transformer
CB Falcon
Controller
Power Supply
ALWCO
Reset
Power
On/Off
Demand
Switch
Optional
Aux. Switch
LWCO and
Pump Control
ALWCO
Control
Figure B7-10. CFV electrical panel

Optional Equipment

summary, here are some of the options that can be provided with the boiler package:
Bottom blowdown valves, shipped loose or mounted and piped
B7-12
01/09
Section B7
Model CFV Boilers
Surface blowoff valve, shipped loose or mounted and piped

Feedwater stop and check valves, shipped loose or mounted and piped
Surface blowoff skimmer tube
Steam stop valve
ASME hydro test of boiler piping
Alarm light package
Direct vent combustion air provision

For layout purposes, the overall dimensions for the Model CFV are shown in Figure
B7-11 and Table B7-3. Connection sizes are given in Table B7-3 and ratings of each
boiler size are noted in Table B7-4. Additional information is shown in the following
Table B7-5 Recommended steam nozzle sizes
Table B7-6 Minimum required gas pressure
Table B7-7 Safety valve outlet sizes
Table B7-8 Boiler room width
Table B7-9, Figure B7-14 Lifting lug locations
Table B7-10, Figure B7-15 Boiler mounting piers
B7-13
01/09
Model CFV Boilers
Section B7
Figure B7-11. Model CFV Steam Boiler Dimensions
B7-14
01/09
Section B7
Model CFV Boilers

Table B7-3. Model CFV Steam Boiler Dimensions
Boiler Horsepower
Dimension
10
15
20
25
30
40
50
60
LENGTHS
Overall
50
50
55
55
68
68
75
75
Centerline to Boiler Front
25
25
29
29
35
35
37.5
37.5
Centerline to Boiler Rear
25
25
26
26
33
33
37.5
37.5
Centerline to Stack Outlet

Centerline to Combustion Air
Inlet
Boiler I.D.
22.5
22.5
24.5
24.5
30.5
30.5
34.5
34.5
27
27
34
34
42
42
51
51
WIDTHS
Overall
32
32
39
39
47
47
56
56
26
26
28
28
36
36
46
46
14
14
16
16
24
24
34
34
Centerline to Gas Inlet
26
26
26
26
26
33
33
33
HEIGHTS
Overall
84
90
84
90
86.5
92.5
99
105
Vessel
73
77
73
79
72
78
81
87
Top of Boiler Clearance
24
24
24
24
24
36
36
36
Floor to Gas Inlet
77
83
77
83
78.5
88.5
89.25
95.25
Floor to Air Inlet
77
83
77
83
78.5
87.5
88.25
94.25
Floor to Feedwater Inlet
30
30
27
27
29.5
29.5
34.5
34.5
Floor to Drain/Blowdown
15.5
15.5
15
15
17
17
20
20
Floor to Stack Outlet
8.5
8.5
8.5
8.5
11
11
4.25
4.25
4.25
5.25
5.25
5.25
6.5
6.5
7.25
7.25
11.4
11.5
14
14
17.5
17.5
19.75
19.75
1-1/4
BOILER CONNECTIONS
Horizontal Centerline to Gas
Inlet
Horizontal Centerline to Steam
Outlet
Vertical Centerline to Steam
Outlet
Feedwater
AA
1-1/4
Steam Outlet
BB
1-1/2
1-1/2
1-1/2
1-1/2
Gas Inlet
CC
1-1/4
1-1/4
1-1/2
1-1/2
Surface Blowoff
DD
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
Drain / Blowdown
EE
1-1/4
1-1/4
Stack O.D.
FF
10
10
Combustion Air InletA
GG
WEIGHTS - LBS
Water Weight (Normal)
710
815
1195
1365
1795
2050
2715
3090
Approx. Dry Weight
2000
2120
2540
2780
3690
4030
5280
5740
B7-15
01/09
Model CFV Boilers
Section B7
Table B7-4. Model CFV Steam Ratings

Boiler H.P.
10
15
20
25
30
40
50
60
Ratings
Rated Capacity - Steam
345
518
690
863
1,035
1,380
1,725
2,070
1,339
1,674
2,008
258
312
388
1,653
2,066
2,479
750
1,200
1,200
Output (1000 Btu/hr)

335
502
669
837
1,004
Fireside Heating Surface
84
103
128
159
208
(sq.ft.)
Approximate Fuel Consumption At Rated Capacity
Natural Gas Input (cfh) 413
620
826
1,033
1,240
150# SteamA
Power Requirements (Single Phase, 115 VAC)
60Hz
Blower Motor Size
335
335
335
335
335
(Watts)B
Notes:
A. Input calculated at nominal 81% efficiency for 1000 Btu gas content
B. For altitudes above 700 ft, contact your local Cleaver Brooks authorized representative for verification of blower
motor size.
Table B7-5. Model CFV Recommended Steam Nozzle Size

OPERATING PRESSURE
PSIG
75
100
125
10
1.5
1.5
1.5
15
1.5
1.5
1.5
20
2
1.5
1.5
BOILER HP
25
30
2
2
2
2
2
2
40
2.5
2
2
50
3
3
3
NOTES:
B7-16
01/09
60
3
3
3
Section B7
Model CFV Boilers
Table B7-6. Model CFV Gas Pressure Requirements

Boiler HP
Inlet pipe
size
(inches)
10
15
20
25
30
40
50
60
1
1
1
1
1.25
1.25
1.5
1.5
Table B7-7. Model CFV Steam Boiler

Safety Valve Outlet Size
Minimum pressure required

at gas train connection
Low Fire
High Fire
7.2" w.c.
7.3" w.c.
7.5" w.c.
7.7" w.c.
8.5" w.c.
11.0" w.c.
10.0" w.c.
10.0" w.c.
Max.
pressure
inches
w.c.
5.2" w.c.
5.3" w.c.
5.5" w.c.
5.7" w.c.
6.8" w.c.
8.0" w.c.
7.0" w.c.
8.0" w.c.
BOILER HP
10
15
20
25
30
40
50
60
28
VALVE SETTING
150 PSIG STEAM
OUTLET
NO. OF
VALVES SIZE (IN.)
REQ'D
1
3/4
1
3/4
1
3/4
1
1
1
1
1
1
1
1-1/4
1
1-1/4
NOTE: Valve manufacturers are Kunkle,

Consolidated or Conbraco, depending on
availability.
Table B7-8. Clearances
BOILER HP
DIM. "A"
DIM. "B"
10-15
40
62
20-25
44
63
30-40
48
71
50-60
52
80
NOTES:
1. Recommended Minimum Distance Between Boiler and Wall. Dimension "A" allows for a clear 24" aisle between the
water column on the boiler and the wall. If space permits, this aisle should be widened.
2. Recommended Minimum Distance Between Boilers. Dimension "B" between boilers allows for a clear aisle of 24". If
space permits, this aisle should be widened.
3. Clearance above boiler 36.
24 MIN.
A
24 MIN.
24 MIN.
36 MIN.
B7-17
01/09
Model CFV Boilers
Section B7
PERFORMANCE DATA
Table B7-9 shows predicted fuel-to-steam efficiencies for the Model CFV.
Cleaver-Brooks offers an industry leading fuel-to-steam efficiency guarantee for Model
CFV boilers. The guarantee is based on the numbers shown in the tables and on the
conditions listed below (the efficiency percent number is only meaningful if the
specific conditions of the efficiency calculations are clearly stated in the
specification).
Cleaver-Brooks will guarantee that, at the time of initial start-up, the boiler will
achieve fuel-to-steam efficiency as shown for 25%, 50%, 75% and 100% firing. If
the boiler fails to achieve the corresponding efficiency guarantee as published,
Cleaver-Brooks will rebate, to the final owner, five thousand dollars ($5,000.00) for
every full efficiency point (1.0%) that the actual efficiency is below the guaranteed
level. The specified boiler efficiency is based on the following conditions:
Natural Gas
Carbon, % by weight = 69.98
Hydrogen, % by weight = 22.31
Sulfur, % by weight = 0.0
Heating Value, Btu/lb = 21,830
Efficiencies are based on ambient air temperature of 80o F (27 C), relative
humidity of 30%, and 15% excess air in the exhaust gas stream.
Efficiencies are based on the manufacturer's published radiation and convection
losses; see Table B7-10.
Nominal feedwater temperature of 1900 F (88 C) or greater.
Table B7-9. Predicted Fuel-to-Steam Efficiencies
BHP
10
15
20
25
30
40
50
60

% OF LOAD
25%
50%
75%
100%
81.8
82.3
82.2
82.1
81.7
82.2
82.0
81.8
81.5
81.6
81.2
80.7
81.6
81.9
81.6
81.2
81.8
82.3
82.2
82.0
81.8
82.4
82.3
82.2
81.4
81.6
81.1
80.6
81.6
81.9
81.6
81.3
B7-18
01/09
Section B7
Model CFV Boilers

Table B7-10. Model CFV Radiation and Convection Losses
BHP

25%
50%
75%
100%
10
1.9
1.0
0.7
0.5
15
1.9
1.0
0.7
0.5
20
1.9
1.0
0.7
0.5
25
1.9
1.0
0.7
0.5
30
1.9
1.0
0.7
0.5
40
1.9
1.0
0.7
0.5
50
1.9
1.0
0.7
0.5
60
1.9
1.0
0.7
0.5
The emission data included in Table B7-11 consists of typical controlled emission
levels of the Model CFV boiler. Because of the premix burner technology, the standard
burner provided with the CFV package provides low emissions as standard without
the need for external or special devices.
Table B7-12 shows predicted sound levels at high fire.
Table B7-11. Model CFV Boilers: Natural Gas, Estimated Emission Levels
POLLUTANT
CO
NOx
SOx
HC/VOC5
PM
UNITS
ppmA
lb/MMBtu
ppmA
lb/MMBtu
ppmA
lb/MMBtu
ppmA
lb/MMBtu
ppmA
lb/MMBtu
50
0.04
20
0.024
1
0.001
10
0.004
0.01
A. ppm levels are given on a dry volume

basis and corrected to 3% oxygen (15%
excess air)
B7-19
01/09
Model CFV Boilers
Section B7
Table B7-12. Predicted sound levels
BHP
10
15
20
25
30
40
50
60
Sound Level-dbA
60
65
60
66
62
68
67
69
Sound levels are measured 3 feet from the front of the panel at an elevation of 5 feet
from the floor.
ENGINEERING DATA
The following engineering information is provided for the Model CFV steam boiler.
Additional information may be obtained from your local Cleaver-Brooks
representative.
Feedwater
combination of condensate return and raw make-up or in some instances, 100% raw
make-up. Proper treatment of make-up water is essential to the longevity and
performance of the boiler. Table B7-13 shows the rate of make-up required and Table
B7-14 shows the water quality guidelines.
Table B7-13. Feedwater flow rates
BHP
10
15
20
25
30
40
50
60
Gallons/Hour
41
62
83
103
124
165
207
248
Feedwater flow is at maxumin firing rate, 212F steaming capacity
Table B7-14. Model CFV Water Quality

Constituent
Hardness
Iron
pH
Suspended Solids
Level
1.0 ppm max.
0.1 ppm max.
8.3 - 10.5
300 ppm max.
B7-20
01/09
Section B7
Blowdown
Model CFV Boilers

As steam is produced, unwanted solids are left behind in the water and become
concentrated within the vessel. If these constituents are allowed to adhere to the heat
transfer surfaces they will impede the flow of energy. Their removal requires proper
blowdown - either bottom, surface, or both. Table B7-15 shows the recommended
blowdown tank requirements for bottom blowdown. The surface blowdown
requirement is relative to the water quality and to the level of TDS control desired by
the water treatment specialist. Local codes will dictate the manner of treating
blowdown affluent.
recommendations of the National Board of Boiler and Pressure Vessel Inspectors. The
National Board's recommendations base the size of the blowdown tank on the
Table B7-15. Model CFV Blowdown Tank Sizing Information

BOILER HP
10
15
20
25
30
40
50
60
WATER (GAL)
3
3
6
6
8
8
12
12

Stack/Breeching
Criteria
General - The ClearFire Model CFV is a Category III Boiler according to ANSI Z21.13.
This code defines a Category III boiler as one that operates with a positive vent
pressure and a vent gas temperature that is non-condensing. Therefore the stack
must be a positive pressure design.
operation of the boiler. The vent should be designed with proper supports and
stack connection as proper draft is critical to safe and efficient burner performance.
size the breeching and stack to limit flue gas pressure variations. Consideration of the
draft must be given whenever direct combustion air ducting is utilized and lengthy
runs of breeching are employed. Please note: The allowable pressure range for design
of the stack and breeching is negative 0.25" w.c. (-62 Pa) to a positive 0.25" w.c.
(+62 Pa) for proper light offs and combustion. NOTE: This pressure range does not
pertain to the boiler room; that is, the boiler room must be neutral or slightly positive,
never negative when using air from the boiler room for combustion.
Whenever two or more CFV boilers are connected to a common breeching/stack, a
B7-21
01/09
Model CFV Boilers
Section B7
mechanical draft control system may be required to ensure proper draft at all times.
Cleaver-Brooks recommends individual stacks for multiple boiler installations.
Combustion Air - The burner must be supplied with adequate volume of
uncontaminated air to support proper combustion and equipment ventilation. Air
method, all installations must comply with NFPA54 (the National Fuel Gas Code NFGC) for U.S. installations and CAN/CSA B149.1 and B149.2 for Canadian
installations.
Note: A boiler room exhaust fan is not recommended as this type of device can cause
a negative pressure in the boiler room if using conventional air intake.
In accordance with NFPA 54, the required volume of indoor air shall be determined
in accordance with the "Standard Method" or "Known Air Infiltration Rate Method".
Where air infiltration rate is known to be less than 0.40 Air Changes per Hour, the
Known Air Infiltration Rate Method shall be used. (See the NFPA Handbook for
additional information).
Unconfined Spaces
All Air From Inside the Building - If combustion air is drawn from inside the building
(the mechanical equipment room does not receive air from outside via louvers or vent
openings and the boiler is not equipped with direct vent) and the boiler is located in
an unconfined space, use the following guidelines:
The mechanical equipment room must be provided with two permanent openings
linked directly with additional room(s) of sufficient volume so that the combined
volume of all spaces meets the criteria for an unconfined space. Note: An "unconfined
space" is defined as a space whose volume is more than 50 cubic feet per 1,000 Btu
per hour of aggregate input rating of all appliances installed in that space.
Each opening must have a minimum free area of one square inch per 1,000 Btu per
hour of the total input rating of all gas utilizing equipment in the mechanical room.
One opening must terminate within twelve inches of the top, and one opening must
terminate within twelve inches from the bottom of the room.
See Figure B7-12; refer to the NFGC for additional information.
B7-22
01/09
Section B7
Model CFV Boilers

Figure B7-12. Inside Air - Two Opening Method
GAS
VENT
12" MINIMUM
FRESH AIR OPENING
INTERIOR WALL
FRESH AIR OPENING
12" MINIMUM
All Air From Outdoors - If all combustion air will be received from outside the
building (the mechanical room is linked with the outdoors), the following methods
can be used:
Two Opening Method (Figure B7-13) - The mechanical equipment room must be
provided with two permanent openings, one terminating within twelve inches from
the top, and one opening terminating within twelve inches from the bottom of the
room.
A. The opening must be linked directly or by ducts with the outdoors.
B. Each opening must have a minimum free area of one square inch per 4,000 Btu
per hour of total input rating of all equipment in the room, when the opening is
directly linked to the outdoors or through vertical ducts.
C. The minimum free area required for horizontal ducts is one square inch per 2,000
Btu per hour of total input rating of all the equipment in the room.
B7-23
01/09
Model CFV Boilers
Section B7
GAS
VENT
12" MINIMUM
OUTLET AIR DUCT
INTERIOR WALL
EXTERIOR WALL
FRESH AIR
INLET DUCT
12" MINIMUM
One Opening Method (Figure B7-14) - One permanent opening, commencing within
12 inches of the top of the room shall be provided.
A. The equipment shall have clearances of at least 1 inch from the sides and back
and 6 inches from the front of the appliance.
B. The opening shall directly communicate with the outdoors and shall have a
minimum free area of 1 square inch per 3000 Btu's per hour of the total input rating
of all equipment located in the enclosure, and not less than the sum of the areas of
all vent connectors in the unconfined space.
C. Refer to the NFGC for additional information.
GAS
VENT
12" MINIMUM
FRESH AIR OPENING
EXTERIOR WALL
B7-24
01/09
Section B7
Model CFV Boilers

Unconfined Spaces
Engineered Design - When determining boiler room air requirements for an
unconfined space the "Engineered Design" method may be used. Following this
method, consideration must be given to the size of the room, airflow and velocity of
air as follows:
of 7 feet. This allows air to sweep the length of the boiler (see Figure B7-15).
Figure B7-15. Engineered Method
GAS
VENT
FRESH AIR OPENING
FRESH AIR OPENING
EXTERIOR WALL
EXTERIOR WALL
subject to clogging with dirt and dust.
square foot.
B7-25
01/09
Model CFV Boilers
Section B7

Determine the area of the boiler room air supply openings for (2) 60 horsepower
Model CFV boilers at 750 feet elevation. The air openings will be 5 feet above the
floor level.
Total boiler horsepower (bhp): 60 x 2 = 120 bhp
Area required: From the formula in E above, 1200cfm/250fpm = 4.8 square feet
total.
Area/Opening: 4.8 divided by 2 = 2.4 ft2 per opening (2 required).
Notice
Direct Combustion Air - If combustion air will be drawn directly from the outside
(direct vent combustion, sometimes called "sealed combustion") by means of a duct
connected directly to the burner air intake, use the following guidelines:
1. Install combustion air duct in accordance with local codes and the boiler
operating and maintenance manual.
room.
3. Duct material can be PVC or metallic vent material. It should be air tight to
prevent in leakage of air during operation.
4. Maximum pressure drop for the duct shall not exceed 0.25" w.c. negative. If this
pressure drop is exceeded a larger size duct is recommended.
5. Multiple boilers may be connected to a single duct with take-offs to each boiler.
6. If the duct will run horizontally to an outside wall, it is recommended that the
duct have a slight downward slope away from the burner intake to prevent
collected moisture from draining into the burner connection.
7. If the outside air is dust-laden or the installation is near a heavily traveled
roadway, it is recommended that an air filter be installed to prevent intake of
contaminants that could accumulate on the burner canister.
B7-26
01/09
Section B7
Model CFV Boilers

Figure B7-16. Direct Vent Combustion
Fan/Blower
Casing Support
Attachment
Venturi
Gasket
Adapter Flange
Flexible Connection
Direct Vent Connection
Figure B7-17. Direct Vent Combustion kit

Gas Piping
General - The ClearFire Model CFV gas fired steam boilers are full modulating input
units that require appropriate gas supply pressure and volume for proper operation
and long burner life. The gas requirements specified in this section must be satisfied
to ensure efficient and stable combustion. Installation must follow these guidelines
and of the local authorities that have installation jurisdiction.
Gas Train Components - CFV boilers are equipped with a gas train that meets the
requirements of UL/cUL and ASME CSD-1, and also the requirements of FM and GEGAP (formerly IRI). The gas train and its components have been designed and tested
to operate for the highest combustion efficiency for the CFV units. Major components
are as noted in the current product specifications and O & M manual.
Gas Pressure Requirements - For proper and safe operation, each Model CFV boiler
requires a stable gas pressure input. The pressure requirements are listed in the O&M
B7-27
01/09
Model CFV Boilers
Section B7
manual and current specifications and are added here (Table B7-6) for reference
purposes.
The minimum inlet supply pressure must be as noted in Table B7-6 when firing the
boiler at low fire and high fire. Actual gas pressure should be measured when the
burner is firing using a manometer at the upstream test port connection on the main
gas valve. For a multiple unit installation, gas pressure should be set for a single unit
first, then the remaining units should be staged on to ensure that gas pressure droop
is not more than 1" w.c. and never below the required pressure. Fluctuating gas
pressure readings could be indicative of a faulty supply regulator or improper gas train
size to the boiler.
Gas Piping - CFV units are standardly equipped with a gas pressure regulator. If
upstream pressure exceeds 1 psig, an additional upstream regulator must be installed
along with a pressure relief valve. Note: Gas connection is at the left side of the boiler,
left hand side as you face the front of the boiler.
For buildings or boiler rooms with gas supply pressure exceeding 28" w.c. a "full lockup" type regulator is recommended along with proper overpressure protection (e.g.
relief valve). In addition to the regulator, a plug type or "butterball type" gas shutoff
cock should be installed upstream of the regulator for use as a service valve. This is
also required to provide positive shutoff and isolate the unit during gas piping tests.
any dirt, weld slag, or debris can deposit in the drip leg rather than into the boiler gas
train. The bottom of the drip leg should be removable without disassembling any gas
piping. The connected piping to the boiler should be supported from pipe supports
and not supported by the boiler gas train or the bottom of the drip leg.
Before starting the unit(s) all piping must be cleaned of all debris to prevent its'
entrance into the boiler gas train. Piping should be tested as noted in NFPA 54 and
the boiler must be isolated during any tests.
After initial startup, the inlet screen to the gas valve should be checked and cleaned
for any debris buildup
Gas Supply Pipe Sizing - For proper operation of a single unit or a multiple unit
installation, we recommend that the gas pipe sizing be sized to allow no more than
0.3" w.c. pressure drop from the source (gas header or utility meter) to the final unit
location. The gas supplier (utility) should be consulted to confirm that sufficient
volume and normal pressure are provided to the building at the discharge side of the
gas meter or supply pipe.
For installations of new boilers into an existing building, gas pressure should be
measured with a manometer to ensure sufficient pressure is available. A survey of all
connected "gas using devices" should be made. If appliances other than the boiler or
boilers are connected to the gas supply line, then a determination must be made of
how much flow volume (CFV = cubic feet per hour) will be demanded at one time
and the pressure drop requirement when all appliances are firing.
B7-28
01/09
Section B7
Model CFV Boilers

piping. Total equivalent length should be calculated from the utility meter or source to
the final unit connection. As a minimum guideline, gas piping Tables B7-16 through
B7-21 should be used. The data in these tables is from the NFPA 54 source book,
2006 edition.
To verify the input of each device that is connected to the gas piping, obtain the btu/
hr input and divide this input by the calorific value of the gas that will be utilized. For
instance, a 40 HP unit with 1,613,253 btu/hr input divided by a gas calorific value
of 1060 will result in a CFV flow of 1,522. The single boiler is approximately 20 feet
from the gas supply header source. And with a measured gas supply pressure of 10"
w.c. we find from Table 16 that a supply pipe size of 2" should be used as a
minimum.
B7-29
01/09
Model CFV Boilers
Section B7
MODEL CFV
MODEL CFV
MODEL CFV
Figure B7-23. Example gas piping <1 psig supply
B7-30
01/09
MODEL CFV
Section B7
Model CFV Boilers

Pipe Size
Nominal
1"
1-1/4"
1-1/2"
2"
Actual I.D.
1.049
1.380"
1.610"
2.067"
Length in feet
**Maximum Capacity in Cubic Feet
514
1,060
1,580
3,050
10
363
726
1,090
2,090
20
284
583
873
1,680
30
243
499
747
1,440
40
215
442
662
1,280
50
195
400
600
1,160
60
179
368
552
1,060
70
167
343
514
989
80
157
322
482
928
90
148
304
455
877
100
131
269
403
777
125
119
244
366
704
150
109
209
336
648
175
102
185
313
602
200
**Fuel: Natural Gas
2-1/2"
3"
4"
2.469"
3.068"
4.026"
of Gas per Hour (CFV)
4,860
8,580
17,500
3,340
5,900
12,000
2,680
4,740
9,660
2,290
4,050
8,290
2,030
3,590
7,330
1,840
3,260
6,640
1,690
3,000
6,110
1,580
2,790
5,680
1,480
2,610
5,330
1,400
2,470
5,040
1,240
2,190
4,460
1,120
1,980
4,050
1,030
1,820
3,720
960
1,700
3,460

Pipe Size
1-1/4"
1-1/2"
2"
2-1/2"
3"
4"
1.380"
1.610"
2.067"
2.469"
3.068"
4.026"
**Maximum Capacity in Cubic Feet of Gas per Hour (CFV)
678
1,390
2,090
4,020
6,400
11,300
23,100
10
466
957
1,430
2,760
4,400
7,780
15,900
20
374
768
1,150
2,220
3,530
6,250
12,700
30
320
657
985
1,900
3,020
5,350
10,900
40
284
583
873
1,680
2,680
4,740
9,600
50
257
528
791
1,520
2,430
4,290
8,760
60
237
486
728
1,400
2,230
3,950
8,050
70
220
452
677
1,300
2,080
3,670
7,490
80
207
424
635
1,220
1,950
3,450
7,030
90
195
400
600
1,160
1,840
3,260
6,640
100
173
355
532
1,020
1,630
2,890
5,890
125
157
322
482
928
1,480
2,610
5,330
150
144
296
443
854
1,360
2,410
4,910
175
134
275
412
794
1,270
2,240
4,560
200
**Fuel: Natural Gas
Nominal
Actual I.D.
Length in feet
1"
1.049"
B7-31
01/09
Model CFV Boilers
Section B7
Pipe Size
Nominal
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
4"
Actual I.D.
Length in
feet
0.622
0.824
1.049"
1.380"
1.610"
2.067"
2.469"
3.068"
4.026"
10
1,510
3,040
5,560
11,400
17,100
32,900
52,500
92,800
189,000
20
1,070
2,150
3,930
8,070
12,100
23,300
57,100
65,600
134,000
30
869
1,760
3,210
6,590
9,880
19,000
30,300
53,600
109,000
40
753
1,520
2,780
5,710
8,550
16,500
26,300
46,400
94,700
50
673
1,360
2,490
5,110
7,650
14,700
23,500
41,500
84,700
60
615
1,240
2,270
4,660
6,980
13,500
21,400
37,900
77,300
70
569
1,150
2,100
4,320
6,470
12,500
19,900
35,100
71,600
80
532
1,080
1,970
4,040
6,050
11,700
18,600
32,800
67,000
90
502
1,010
1,850
3,810
5,700
11,000
17,500
30,900
63,100
100
462
954
1,710
3,510
5,260
10,100
16,100
28,500
58,200
125
414
836
1,530
3,140
4,700
9,060
14,400
25,500
52,100
150
372
751
1,370
2,820
4,220
8,130
13,000
22,900
46,700
175
344
695
1,270
2,601
3,910
7,530
12,000
21,200
43,300
200
318
642
1,170
2,410
3,610
6,960
11,100
19,600
40,000
500
192
401
717
1,470
2,210
4,250
6,770
12,000
24,400
1000
132
275
493
1,010
1,520
2,920
4,650
8,220
16,800
1500
106
221
396
812
1,220
2,340
3,740
6,600
13,500
**Fuel: Natural Gas

B7-32
01/09
Section B7
Model CFV Boilers

Pipe Size
Nominal
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
4"
Actual I.D.
Length in
feet
0.622
0.824
1.049"
1.380"
1.610"
2.067"
2.469"
3.068"
4.026"
10
2,350
4,920
9,270
19,000
28,500
54,900
87,500
155,000
316,000
20
1,620
3,380
6,370
13,100
19,600
37,700
60,100
106,000
217,000
30
1,300
2,720
5,110
10,500
15,700
30,300
48,300
85,400
174,000
40
1,110
2,320
4,380
8,990
13,500
25,900
41,300
75,100
149,000
50
985
2,060
3,880
7,970
11,900
23,000
36,600
64,800
132,000
60
892
1,870
3,520
7,220
10,300
20,300
33,200
58,700
120,000
70
821
1,720
3,230
6,640
9,950
19,200
30,500
54,000
110,000
80
764
1,600
3,010
6,180
9,260
17,800
28,400
50,200
102,000
90
717
1,500
2,820
5,800
8,680
16,700
26,700
47,100
96,100
100
677
1,420
2,670
5,470
8,200
15,800
25,200
44,500
90,300
125
600
1,250
2,360
4,850
7,270
14,000
22,300
39,500
80,500
150
544
1,140
2,140
4,400
6,590
12,700
20,200
35,700
72,900
175
500
1,050
1,970
4,040
6,060
11,700
18,600
32,900
67,100
200
465
973
1,830
3,760
5,640
10,900
17,300
30,600
62,400
500
283
593
1,120
2,290
3,430
6,610
10,300
18,600
38,000
1000
195
407
897
1,380
2,360
4,550
7,240
12,000
26,100
1500
156
327
616
1,270
1,900
3,650
5,820
10,300
21,000
**Fuel: Natural Gas

B7-33
01/09
Model CFV Boilers
Section B7
Pipe Size
Nominal
Actual
I.D.
Length
in feet
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
4"
0.622
0.824
1.049"
1.380"
1.610"
2.067"
2.469"
3.068"
4.026"
10
3,190
6,430
11,800
24,200
36,200
69,700
111,000
196,000
401,000
20
2,250
4,550
8,320
17,100
25,600
49,300
78,600
139,000
283,000
30
1,840
3,720
6,790
14,000
20,900
40,300
64,200
113,000
231,000
40
1,590
3,220
5,880
12,100
18,100
34,900
55,600
98,200
200,000
50
1,430
2,880
5,260
10,800
16,200
31,200
49,700
87,900
179,000
60
1,300
2,630
4,800
9,860
14,800
28,500
45,400
80,200
164,000
70
1,200
2,430
4,450
9,130
13,700
26,400
42,000
74,300
151,000
80
1,150
2,330
4,260
8,540
12,800
24,700
39,300
69,500
142,000
90
1,060
2,150
3,920
8,050
12,100
23,200
37,000
65,500
134,000
100
979
1,980
3,620
7,430
11,100
21,400
34,200
60,400
123,000
125
876
1,770
3,240
6,640
9,950
19,200
30,600
54,000
110,000
150
786
1,590
2,910
5,960
8,940
17,200
27,400
48,500
98,900
175
728
1,470
2,690
5,520
8,270
15,900
25,400
44,900
91,600
200
673
1,360
2,490
5,100
7,650
14,700
23,500
41,500
84,700
500
384
802
1,510
3,100
4,650
8,950
14,300
25,200
51,500
1000
264
551
1,040
2,130
3,200
6,150
9,810
17,300
35,400
1500
212
443
834
1,710
2,570
4,940
7,880
13,900
28,400
**Fuel: Natural Gas

B7-34
01/09
Section B7
Model CFV Boilers

Gas Header - For multiple unit installations, a single common gas header is
recommended with individual takeoffs for each boiler (See Figure B7-22). Boiler gas
manifold piping should be sized based on volume requirements and lengths between
each boiler and the fuel main header. Tables B7-22 through B7-29 indicate the
proper sizing for multiple units of equal size, placed on the factory standard center
with the indicated take off size. For installations with a mixed sized use, determine
the flow of each unit and total the input. With the total input, determine length of run
from the source and determine what size header will be needed for the flow of all
units firing. Pipe sizes are based on Table B7-16 with boiler gas line take-off at 20
feet from the header. If pipe runs are greater or if gas pressure is different, refer to the
Tables for pipe sizing.
Pipe sizing for multiple unit manifolds

Table B7-22. CFV 10 HP Boilers
# of
Units
Pipe Size
To Boiler
Header
Pipe Size
1-1/4"
1-1/4"
1-1/4"
1-1/4"
1-1/4"
1-1/4"
2"
2"
# of
Units
Pipe Size
To Boiler
Header
Pipe Size

# of
Units
Pipe Size
To Boiler
Header
Pipe Size
1-1/2"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
2"
2-1/2"
2-1/2"
1-1/4"
1-1/4"
1-1/4"
1-1/4"
1-1/4"
2"
2"
2-1/2"
# of
Units
Pipe Size
To Boiler
Header
Pipe Size
1-1/2"
1-1/2"
1-1/2"
1-1/2"
1-1/2"
2"
2-1/2"
3"
2"
2"
2"
2"
2"
2-1/2"
3"
3"
# of
Units
Pipe Size
To Boiler
Header
Pipe Size

# of
Units
Pipe Size
To Boiler
Header
Pipe Size

# of
Units
Pipe Size
To Boiler
Header
Pipe Size
2"
2"
2"
2"
2"
2-1/2"
3"
4"
2"
2"
2"
2"
2"
3"
3"
4"
# of
Units
Pipe Size
To Boiler
Header
Pipe Size
2-1/2"
2-1/2"
2-1/2"
2-1/2"
2-1/2"
3"
4"
4"
B7-35
01/09
Model CFV Boilers
Section B7
SPECIFICATIONS
MODEL CFV PRODUCT SPECIFICATIONS
1.0 GENERAL BOILER DESIGN
A. The boiler shall be a Cleaver-Brooks Model CFV 700, single pass vertical
commercial Firetube design or approved equal. It shall be mounted on a heavyduty steel frame with premix forced draft burner and burner controls as a complete
package from one manufacturer.
B. Approvals - The complete package including the burner shall be Underwriters
Laboratories, Inc. listed and the official UL/cUL label shall be affixed to the
package attesting to its certification.
C. As a preassembled package, the standard boiler shall be factory fire tested.
D. The complete package as shipped, shall be ready for connections to water, fuel,
blowdown, and exhaust venting. Certain items may be shipped loose to prevent
their damage such as the safety valves and gauges.
E. The specified boiler shall have an output rating of _____ horsepower when fired
with Natural Gas [LP Gas] with a gas supply pressure of ____" w.c. Power supply
to the boiler shall be 115/1/60. Design pressure shall be 150# steam. Operating
characteristics shall be [___] psig steam. Steam boilers shall be supplied with
____ degrees F make-up water @ ____%.
F. Performance: shall be as specified in Paragraph 5 below.
1.1 BOILER SHELL
A. The boiler shell must be constructed in accordance with the ASME Code, either
Section I for high-pressure steam or Section IV for low-pressure steam. The vessel
must be subjected to the required inspections of the Code conducted by an
independent third party inspector. A signed inspection sheet shall be provided to
the purchaser and the appropriate ASME symbol shall be affixed or stamped onto
the boiler.
1.Boiler shall be mounted on base rails suitable for transporting by fork lift.
2.Burner housing shall be removable or hinge-mounted (50-60 HP) to allow tube
inspection.
3.Each carbon steel boiler tube shall utilize the AluFer heat transfer design
technology for high efficiency and reduction in overall size of the vessel and shall
be a minimum of 0.105 tube wall thickness.
4.To facilitate waterside inspection, 3 hand holes shall be provided.
5.An observation port for flame inspection shall be provided.
6.Boiler insulation shall consist of 2-inch fiberglass blanket, which shall be
covered with a powder coated sheet metal jacket. This jacket and insulation
design shall permit field removal and reattachment if necessary for inspection,
etc.
7.The entire boiler and base frame shall be factory painted.
B7-36
01/09
Section B7
Model CFV Boilers

8.Exhaust vent shall be located at the rear of the boiler and shall be a slip
connection. Stack support shall be by means other than the boiler connection.
1.2 BOILER SHELL TAPPINGS/OPENINGS
A. The following boiler vessel tappings/openings shall be furnished:
1.Steam supply by NPT connection for high-pressure steam.
2.Bottom blowdown.
3.Feedwater Make-up.
4.Surface blowoff.
5.Chemical Feed.
6.High Water Level Overflow Drain to discharge water in the boiler if water level
reaches an unacceptable level.
2.0 STEAM BOILER TRIM (All piping and devices per ASME CSD-1)
A. Water Column
1.A water column shall be furnished complete with gauge glass and water column
blowdown valve.
a. Feedwater Pump control - shall be integral with the water column via probe control
device and electronics for on/off pump operation.
b. Low Water cutoff - shall be integral with the water column via probe control device
and solid state electronics mounted and wired in the control panel.
B. An Auxiliary Low Water Cutoff shall be provided. It shall be located on the top
centerline of the boiler using an internal probe and of the manual reset design.
C. For safety steam pressure lockout a high limit pressure control, manual reset shall
be provided. The device shall be mercury free.
D. To provide steam demand tracking a steam pressure transmitter shall be provided
that provides an input signal for burner positioning in accordance to steam
demand.
E. A 3" Steam Pressure Gauge shall be piped onto the trim piping, including an
inspectors test cock.
F. In accordance with the A.S.M.E. Code an approved A.S.M.E. rated and stamped
safety valve shall be provided and set at 150#.
3.0 BURNER AND BURNER CONTROLS
A. Mode of Operation - To minimize short cycling and provide highest efficiency the
burner for the specified boiler shall be of the electronic modulation with a
turndown ratio of 5:1 for Natural Gas for sizes of 30 horsepower and greater, and
4:1 for sizes below 30 horsepower. On/off or low/high burner operation shall not
be accepted.
B. The burner shall be enclosed in a NEMA 1 type enclosure. A lift off top cover shall
be provided to gain access to the burner and controls.
B7-37
01/09
Model CFV Boilers
Section B7
C. Design - The burner design shall be of the linkage-less premix technology wherein
the fuel and air are mixed in the fan housing assembly prior to entering the burner
canister. Separately driven linkage or servo motor driven fuel and air valves shall
not be permitted.
1.Fan housing shall utilize non-sparking material and shall be approved for premix
operation.
2.The fan shall be driven by a variable speed motor which shall react to output
demand requirements via the demand control Motor shall be a high efficiency
DC Brushless type. Continuous speed synchronous motors will not be
acceptable.
D. Ignition of the fuel shall be of the direct spark design; separate pilot gas train is
not required. Dual ignition electrodes shall used for the spark generated from the
panel mounted ignition transformer.
E. Combustion shall take place on the surface of the burner canister. The canister
shall be constructed of Fecralloy material and stainless steel and shall be
warranted for five years against failure from defects or poor workmanship.
F. Air Filter - shall be fitted to the intake air venturi to filter the incoming air supply
when using boiler room air. The air filter shall be designed to be easily cleaned
and re-used.
G. Fuel - The burner shall be designed for operation with natural gas or LP gas. Gas
Train, shall be located at the front of the burner and along the left side of the boiler.
In accordance with UL/cUL and ASME CSD-1, the following components shall be
furnished:
1.Single body dual solenoid safety shutoff valve incorporating the following:
a. The valve shall be a 1:1 ratio valve with an integral trim regulator and shall operate
in relation to the fan speed. An air sensing line shall be connected from the air inlet
venturi (mounted to the fan motor) and to the gas valve for control of gas input.
b. As fan speed increases a negative pressure will be applied to the valve, allowing the
valve to open further, permitting more fuel to flow into the venturi for mixing. As fan
speed is reduced, fuel input shall be reduced accordingly. Air shall always lead fuel from
low to high or high to low.
2.Manual fuel shutoff valve - shall be located downstream of the gas valve and
used for CSD-1 leak testing.
3.Gas Pressure Interlocks - one shall be provided for sensing high gas pressure and
one provided to sense low gas pressure. Each control shall be of the manual
reset type.
4.Gas Pressure Regulator - shall be provided upstream of the gas valve to provide
regulated pressure to the gas train from the gas supply. This regulator shall be
suitable for a maximum of 1 psig gas pressure. If gas pressure exceeds 1 psig,
a gas pressure relief valve shall be furnished and upstream pressure regulator
that is of the full lockup type.
5.Manual Shutoff Valves - shall be provided upstream of the gas regulator to
manually close off the gas supply when servicing the gas train or isolating the
B7-38
01/09
Section B7
Model CFV Boilers

boiler. A shutoff valve shall be provided at the burner for tightness checking of
the gas valve.
6.Combustion Air Proving Switch shall be provided to prove, prior to modulation
that the fan is operating properly.
H. Flame Safety
1.Flame sensing shall be accomplished with a flame rod and mounted in the
burner mounting plate, designed for easy removal for inspection or replacement.
4.0 BOILER CONTROL - The boiler shall include the CB Falcon boiler-burner control
system which is an integrated, microprocessor-based primary safety and steam
boiler control, complete with status indication, lockout messaging and reset,
control mode selection, and configurable parameter settings. The system shall
include a Touchscreen Display Interface. The display shall be mounted at the front
of the boiler panel for convenient access and viewing.
A. Controller shall provide for both flame safeguard and boiler control and shall
perform the following functions:
Burner sequencing with safe start check, pre-purge, electronic direct spark ignition,
run, and post purge.
Flame Supervision by flame rod; includes test locations for flame signal
measurement.
The control shall maintain a running history of operating hours, number of cycles,
and the most recent 15 lockouts and alerts. The control shall be connected to a
touchscreen display interface that will allow retrieval of this information.
Safety Shutdown with display of lockout condition.
Modulating PI control of the variable speed fan via PWM output for fuel/air input to
match load requirements.
Gas pressure supervision, high and low.
Combustion Air Proving Supervision.
Boiler status, supply temperature, and set-point temperature shall be displayed at all
times by the touchscreen display.
Controller shall have Modbus communication.
PID Load control for heating application and domestic water. Includes priorization for
demand and rate limiting.
High Limit control of boiler outlet temperature.
Anti-short cycling control.
Remote Modulation or Remote Set Point control
B. All parameter settings shall be factory configured for the specific boiler model.
Installer/Service level parameters can be configured at installation to suit job site
conditions.
C. Control shall include sensors for supply and return water sensing.
D. Electrical power supply shall be 120 volts, 60 cycle, single phase for the
combustion air fan and boiler control circuit.
E. When multiple boilers are to be installed together, the Boiler Control shall have an
option for sequencing control via Modbus network and shall provide staging for up
to 8 boilers. The control shall include automatic rotation of lead boiler, an
adjustable outdoor reset schedule, multiple setback schedules, domestic hot water
B7-39
01/09
Model CFV Boilers
Section B7
priority, and a digital display. The control shall force each boiler to low fire, before
allowing any boiler to operate at high fire. When all boilers are running, they will
then be modulated in unison. The control shall be supplied by the boiler supplier,
in order to ensure proper integration with the boiler controls.
F. The touchscreen Display/Interface shall provide the following:
Burner Control status

Firing Rate Control, auto and manual
Lockout condition and reset
Alert and Hold Messages
Heating Set Point adjustment
Heating Time-of-Day (setback) Set Point adjustment
First out annunciation and system status and diagnostics
Control Temperatures
Installation Setup
G. The control shall have the following capabilities/options:

Outdoor Reset control and sensor
Lead/lag configuration
System Pump control of up to three pumps
High Stack Temperature Limit
Frost protection
Time-of-Day (setback/dual set point)
Remote Reset
H. Control Panel - A NEMA 1A type enclosure is furnished and located at the front of
the boiler above the burner to house the following components. Surface mounted
devices are located on the right hand side of the panel.
CB Falcon controller.
Falcon touchscreen display/operator interface
Boiler Control Circuit On/Off switch.
Local/Remote demand switch.
Provide terminals for control interface wiring, customer connections, and

connections for incoming power.
Install solid state circuit boards for water level controls.
Selectable Options:
_____Alarm Light Package to provide indication of Low Water, Flame Failure,
Load Demand, Fuel Valve On, including a horn with silence switch for alarm
conditions.
5.0 PERFORMANCE
The proposed Boiler shall provide the following operating performance targets for
Natural Gas:
A. Efficiency - For 150# steam operating at 125#, the guaranteed Fuel to Steam
Efficiency shall be 81%. Efficiency rating shall account for radiation and
convection losses.
B7-40
01/09
Section B7
Model CFV Boilers

B. Emissions - NOx emissions shall be less than 20 PPM corrected to 3% O2 and
less than 10 PPM CO over the operating range of the burner turndown. If
emissions exceed this level, the boiler manufacturer shall correct at their expense
until this level is achieved on a repeatable basis.
C. Radiation losses shall be less than 0.5% of the rated input at maximum firing.
D. Steam quality shall be 99.5% at maximum firing regardless of operating pressure.
6.0 WARRANTY
The package boiler shall be warranted for a period of one year from date of start-up or
18 months from shipment whichever shall occur first.
B7-41
01/09
Model CFV Boilers
Section B7
B7-42
01/09
Section B8
Electrode Boilers
Model CEJS Steam
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . .
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . .
....
....
....
....
....
....
....
....
....
....
.....
.....
.....
.....
.....
....
....
....
....
....
....
....
....
....
....
. . . . B8-3
. . . . B8-3
. . . . B8-6
. . . . B8-6
. . . . B8-9
TABLES
Table B8-1 Model CEJS Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8-4
Table B8-2 Electrode Boilers Required Water Quality Parameters . . . . . . . . . . . . . . . . . . . . . . . . . B8-7
Table B8-3 CEJS Minimum Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8-7
B8-1
09-09
Section B8
Electrode Boilers
This section contains information on the complete line of Cleaver-Brooks electrode boilers with megawatt output
ratings from 2 to 65 MW.
B8-2
09-09
Electrode Boilers
Section B8

In applications where electric power is more economically available than fossil fuels,
or where fossil fuel combustion and the handling of combustion by-products are
unacceptable, electric boilers offer a viable alternative.
Economical
Installation
Fuel lines, storage and handling equipment, economizers, stacks, and emission
control equipment are not required, saving on capital expenditures.
Lower Operating
Cost
Simple to operate and maintain - automatic controls reduce personnel requirements.

No complex pollution or combustion control equipment to operate or maintain. No
heating surfaces.
Emissions
Because there is no combustion, electrode boilers are 100% emission free. This is
beneficial in meeting total emissions of the project site or in areas where fuel
combustion emissions are not tolerated.
Quiet Operation
Elimination of combustion noise and minimal moving parts result in extremely quiet
operation - very beneficial in applications such as hospitals, nursing homes, and
schools.
High Efficiency
With minimum radiation losses and without the losses associated with combustion
equipment the electric boiler will provide nearly 100% efficiency at all operating
points.
Ease of Maintenance
The absence of high maintenance combustion equipment and the use of solid state
control devices reduce the complexity and number of moving parts.
The absence of fuel residue greatly simplifies boiler cleaning.
Pressure vessel components are not subjected to thermal stresses induced by high
temperature differentials or cycling encountered with fossil fuel combustion.
All CEJS boilers are designed to ASME Boiler and Pressure Vessel Code and are
certified and registered pressure vessels.
Design Features
The CEJS electrodes are vertically mounted around the inside of the pressure vessel,
enabling the boiler to produce maximum amounts of steam in a minimum amount
of floor space.
The CEJS operates at voltages from 4.16 to 25 kV with up to 99.9% efficiency.
Models are available to produce steam in capacities to 270,000 pounds per hour.
Pressure ratings range from 100 psig to 500 psig.
PRODUCT OFFERING
Cleaver-Brooks electrode boilers are available in sizes ranging from 2 to 65 MW
with operating pressures from 100 psig to 500 psig. Input power is by direct
connection to a 4.16 to 25 kV supply.
Dimensions, ratings, and product information may change to meet current market
requirements and product improvements. Therefore, use this information only as a
guide.
Refer to Table B8-1 as a quick reference guide to the boiler models and sizes
provided.
B8-3
09-09
Section B8
Electrode Boilers
Table B8-1. Model CEJS Product Offering
Model No.
CEJS 400
CEJS 600
CEJS 900
CEJS 1200
CEJS 1800
CEJS 2400
CEJS 3000
CEJS 3600
CEJS 4200
6.9 kV
11 kV
13.2 kV
20 kV
25 kV
lbs/hr @125 PSI
6,700
11,100
13,500
16,800
17,800
lbs/hr @250 PSI
6,400
10,500
12,800
16,000
16,900
Max Megawatts
2.0
3.3
4.0
5.0
5.3
Vessel OD (in.)
72"
72"
72"
96"
108"
# of Electrodes
lbs/hr @125 PSI
10,100
16,800
20,200
25,200
26,900
lbs/hr @250 PSI
9,600
16,000
19,200
23,900
25,600
Max Megawatts
3.0
5.0
6.0
7.5
8.0
Vessel OD (in.)
72"
72"
72"
96"
108"
# of Electrodes
lbs/hr @125 PSI
15,100
25,200
30,300
37,800
40,300
lbs/hr @250 PSI
14,300
23,900
28,800
35,900
38,300
Max Megawatts
4.5
7.5
9.0
11.3
12.0
Vessel OD (in.)
72"
72"
72"
96"
108"
# of Electrodes
lbs/hr @125 PSI
20,200
33,600
40,400
50,400
53,800
lbs/hr @250 PSI
19,200
31,900
38,400
47,900
51,100
Max Megawatts
6.0
10.0
12.0
15.0
16.0
Vessel OD (in.)
84"
72"
72"
96"
108"
# of Electrodes
lbs/hr @125 PSI
30,200
50,400
60,600
75,600
80,600
lbs/hr @250 PSI
28,700
47,900
57,600
71,800
76,600
Max Megawatts
9.0
15.0
18.0
22.5
24.0
Vessel OD (in.)
84"
84"
84"
108"
120"
# of Electrodes
lbs/hr @125 PSI
40,300
67,200
80,800
100,800
107,500
lbs/hr @250 PSI
38,300
63,800
76,800
95,800
102,100
Max Megawatts
12.0
20.0
24.0
30.0
32.0
Vessel OD (in.)
96"
84"
96"
108"
120"
# of Electrodes
lbs/hr @125 PSI
50,400
84,000
101,000
126,000
134,400
lbs/hr @250 PSI
47,900
79,800
96,000
119,700
127,700
Max Megawatts
15.0
25.0
30.0
37.5
40.0
Vessel OD (in.)
96"
96"
96"
120"
120"
# of Electrodes
lbs/hr @125 PSI
60,500
100,800
121,200
151,200
161,300
lbs/hr @250 PSI
57,500
95,800
115,100
143,600
153,200
Max Megawatts
18.0
30.0
36.0
45.0
48.0
Vessel OD (in.)
108"
96"
108"
120"
120"
# of Electrodes
lbs/hr @125 PSI
70,600
117,600
141,400
176,400
188,200
lbs/hr @250 PSI
67,100
111,700
134,300
167,600
178,800
Max Megawatts
21.0
35.0
42.0
52.5
56.0
Vessel OD (in.)
108"
108"
108"
120"
120"
# of Electrodes
N/A
N/A
lbs/hr @125 PSI

lbs/hr @250 PSI
CEJS 5000
Max Megawatts
N/A
140,100
168,300
133,100
159,900
41.7
50.0
Vessel OD (in.)
108"
120"
# of Electrodes
B8-4
09-09
Electrode Boilers
Standard Equipment
Section B8
Equipment described below is for the standard steam electrode boilers offering:
A.
Model CEJS Boiler

1. Each boiler is designed and constructed in accordance with the
ASME Code and is mounted on an integral steel frame.
a. Water column with 4-20mA transmitter and gauge glass;
transmitter signal opens and closes the feedwater valve
according to boiler water level.
b. High Water and High High Water limit probes.
c. Air vent.
d. Bottom and water column blowdown valves.
e. Surface blowdown.
f.
Feedwater piping with regulating valve, check valve, and
gate valve.
g. ASME pressure relief valves.
h. Boiler steam pressure gauge & transmitter.
i.
System steam pressure gauge & transmitter.
j.
Conductivity control system with sample cooler.
3. Pre-assembled centrifugal circulation pump with water-cooled
mechanical seal.
4. Electric Equipment
a. High voltage supply - customer connected three-phase,
four-wire, Y connected configuration.
b. Medium voltage supply - powers the control panel,
circulating pump, hydraulic pump, and (optional)
chemical feed pump.
c. PLC with 10 color touch screen oversees automatic
functioning of the following:
High pressure limit circuit
High and low water limit circuits
Alarm circuits
High voltage feedback
Conductivity controller
Load and pressure control
Standby control
Circulating pump
Hydraulic system
d.
5.
Electrodes (three, six, or nine depending on boiler size) comprising upper and lower electrode assemblies installed
through vessel and connected to electrode box and target
plates; used to establish a current path to nozzle stock
and to counter electrodes.
e. Attached pre-wired control panel on most models.
Hydraulics:
a. Positioning of the control sleeve is accomplished by a
hydraulic system consisting of hydraulic pump, lift tower,
B8-5
09-09
Section B8
Electrode Boilers
6.
Optional Equipment
and hydraulic cylinder.

Boiler Control System
a. PLC-based control system with touchscreen HMI.
b. Main control panel with panel door key lock.
c. PID controls for steam pressure and water level.
d. Real-time trending and bar graph display of process
variable, setpoint, and control output.
e. Automatic or manual operation.
f.
On-screen fault annunciation with diagnostics and alarm
history
For option details, contact the local authorized Cleaver-Brooks representative.

Below are some options that can be provided with the boiler:
Chemical feed pump.

Standby heater.
Three-valve bypass for feed system.
PERFORMANCE DATA
Efficiency
Whereas fuel-fired equipment is susceptible to efficiency losses such as stack loss,

combustion loss, excess air loss, etc., electrode boilers by contrast are nearly 100%
efficient at all operating levels.
Emissions
Electrode boilers do not use fuel combustion, and so produce no emissions.

Therefore, electrode boilers are well suited for installations that must meet stringent
emissions requirements.
Noise Level
The electrode boiler is nearly noiseless and thus is well suited for installations
sensitive to noise emissions from mechanical equipment. Installations such as
hospitals, nursing homes, schools, research laboratories, and the like are ideal for
an electrode boiler application.
ENGINEERING DATA
Water Treatment
Proper blowdown is a required maintenance procedure. Any water lost in the

procedure must be made up. Make-up water should be properly treated prior to
introduction into the boiler via water softener, chemical feed, etc. Proper water
chemistry in a steam boiler is mandatory for effective operation and longevity.
See Table B8-2 for Model CEJS water quality requirements.
B8-6
09-09
Electrode Boilers
Section B8
Table B8-2. Electrode Boilers Required Water Quality Parameters
Parameter
Boiler Water Limit
pH
8.5 - 9.5
Iron
O2.0 ppm
Alkalinity
0 - 750 ppm
Oxygen
0.005 ppm
Conductivity
3500 mmho/cm
Hardness
Makeup water 0 - 0.5 ppm (preferably 0);

Boiler water 0 ppm
See below for Model CEJS minimum clearances.
Clearances
Table B8-3. CEJS Minimum Clearances

Model
Number
Minimum Clearances
A
CEJS-200
60
30
CEJS-400
60
36
CEJS-600
60
36
CEJS-900
60
48
CEJS-1200
60
48
CEJS-1800
60
48
CEJS-2400
60
48
CEJS-3000
60
55
CEJS-3600
60
55
CEJS-4200
60
70
CEJS-5000
60
70
B8-7
09-09
Section B8
Electrode Boilers
B8-8
09-09
Electrode Boilers
Section B8
ELECTRODE STEAM BOILER MODEL CEJS
SPECIFICATION
Provide High Voltage Electrode Steam Boiler for operation on ____KV __PH, 4 wire,
__HZ. Boiler rating shall be ___PSI and shall be designed for operation at ___PSI
steam pressure, __MW capacity.
1.0
Design
The boiler design shall consist of a pressure vessel having a central column from
which water, under pressure, is forced through nozzles toward the several electrodes
which surround the column. Steam is generated from the surface of the several
streams of water by heat generated as the electrical current flows from the electrode
to the central column and through the stream of excess water as it falls from the
electrode to a grounded "counter electrode" on its way back to the bottom of the
boiler.
All streams of water originating in the central column shall be identical in shape
based on pressure maintained in the central column therefore avoiding steam and
interference droop causing splashing and potential electrical short leading to
shutdown.
There shall be upper an level man-way(s) allowing a visual initial adjustment of
stream shape by varying the speed of the boiler pump (see 2.1.4) to establish
suitable pressure in the central column for internal distance based on voltage
spacing.
Regulation of the boiler output shall be accomplished by a movable load regulating
shield which prevents part or all of the nozzle streams from coming into contact
with the boiler electrodes. The position of the load regulating shield will be regulated
by the boiler controls to maintain the desired steam pressure or to prevent the boiler
from drawing more than the desired kilowatts when the steam requirements exceed
the boiler capacity. The boiler electrodes shall be located entirely in the boiler
steam space so that stopping of the boiler pump will cause the boiler to shut down.
Regulation of the boiler capacity shall be from 100% to 0% without the necessity of
interrupting the high voltage supply.
2.0
The Boiler Component Parts
2.0.1
Boiler Shell
The boiler shall be a single shell, vertical type. The shell shall be constructed and
stamped in accordance with the ASME Boiler & Pressure Vessel Code, and shall
carry a National Board Pressure Vessel Registration Nameplate.
The shell design (and stamped) pressure rating shall be ___PSI for operation at
___PSI.
A man-way 355mm x 457mm (14" x 18") shall be provided for access to the boiler
interior for internal inspection and repair/replacement of internal parts. A second
man-way 305mm x 380mm (12" x 16") shall be provided at the upper level for
B8-9
07-09
Section B8
Electrode Boilers
inspection of the jets. No other access is required for inspection or service. All
boiler connections over 50mm (2) pipe size shall be flanged.
2.0.2
The Central Column and Nozzle Stock Plates
The central column and nozzle stock, through which water is conducted to the
stream nozzles, is fabricated from mild steel and supported from the top of the
boiler.
For optimum water stream shape, each nozzle has a conical collector cone leading
to a round pipe with a cross insertion forming straightening vanes. This design
produces a sharply defined water stream from each nozzle.
The stream nozzles are inserted into bolted, removable plates to allow replacement
or cleaning without removal of the nozzle stock from the boiler. Nozzle rows shall
be horizontally slanted for smooth progressive interception and capacity control.
The pump shall deliver its full output to the nozzle stock at all times and maintain a
constant static head inside the nozzle stock to assure that at no time during boiler
operation will any stream nozzle have less than 15 of liquid static head supply
pressure.
2.0.3
Electrode Boxes and Target Plates
Electrode boxes have 3 closed sides terminating in rounded edges.

Target Plates are removable and reversible with round bars facing the jet streams
for smooth contact and no splashing. Water then flows smoothly in the formed
grooves to a collection at the bottom of the box.
The bottom of the box is solid steel with machined holes with cross insertion to
form the steams of water toward the counter electrode.
2.0.4
Counter Electrodes
Counter electrodes shall be made of solid steel plate with machined holes matching
the holes in the bottom of the electrode box for smooth flow in order to avoid
splashing. Solid welded bracket for attaching to boiler shell.
2.0.5
Insulators and Power Rods
Each electrode box is supported by the high voltage power rod. Power rods
insulating tubes shall be quartz 25KV class.
Insulators shall be 25KV class high grade aluminum, 9 skirts for long tracking path,
coated, for maximum protection and reliability.
The internal insulator shall be protected by stainless steel steam throttling shield
and rated for 750PPM alkalinity.
The external insulator shall be identical 25KV class coated insulator in order to offer
maximum protection against deposits on skirts due to air contaminants in boiler
room atmosphere.
2.0.6
The Load Regulating Shield 0-100%
The load regulating shield shall be concentric with the central column and will be
supported by a yoke and rod extending through the top of the boiler to the load
B8-10
07-09
Electrode Boilers
Section B8
regulating mechanisms. The upper rim of the load regulating shield shall
incorporate a stainless steel "knife" edge to intercept the flow from the water nozzles
in a manner which will minimize the disturbance to the nozzle streams which are
above the shield. This sharp edge shall be able to split the capacity of a stream for
maximum accuracy in capacity control and without loss of quality or excessive
splashing. A shield position Indicator shall be included in the control system.
Boiler will be furnished with a hydraulic cylinder, pump and control system to
control shield position according to demand between 0% and 100%.
2.0.7
Boiler Circulating Pump(s) on separate skid
The boiler circulating pump(s) shall be a centrifugal type rated for continuous duty
at the boiler operating pressure and temperature and shall be selected for low NPSH
and to deliver the flow and head required for proper operation of the boiler. The
pump shall be coupled to the boiler with suitable piping spools, flanges and a
manually set butterfly valve.
The pump shall incorporate a single mechanical seal with water cooling. Pump
motors shall be sized for maximum pump horsepower requirements and to be
standard shaft, T.E.F.C., foot mounted, and readily available. The pump will be beltdriven or VSD driven, allowing for a simple initial adjustment to maintain a steady
pressure in the central column and therefore of the shape of the parallel water jets.
2.0.8
Standby Heater
The boiler will be supplied with an immersion type flanged heating element
assembly rated at _____V, ___Ph, ___Hz for use in maintaining the boiler at desired
pressure when the boiler is not being used to generate steam. The standby heater
shall be controlled by two pressure set points and by the "Standby-Run".
2.0.9
Steam Water Preheater
A steam injection preheater has been provided for quicker heating of the cold
boiler water after a shut-down. It will bring the boiler to stand-by condition by
using an outside source of steam to heat the water and generate steam in the
isolated boiler. This procedure is manually controlled by a hand valve.
2.1
Boiler Control System
2.1.1
Pressure and Load Controls and associated Control Panel
The boiler control system shall incorporate processor pressure control and ampere
load control in the primary control system in a manner which will permit the boiler
to maintain the desired steam pressure so long as the steam demand does not
exceed the desired maximum KW limit and at such times as the demand exceeds
the rating, to regulate the boiler output to the desired maximum. The maximum
allowable KW rating will be adjustable by the operator to ratings of 100% maximum
to 5% minimum. The boiler will regulate the output from 0% to 100% as required
by the pressure control. Boiler will utilize "split" streams to attain step-less control
that is linear over entire output range of the boiler. Stable regulation shall be
possible from 100% output down to zero load. Controls shall be provided so
electrodes are energized before water is supplied to electrodes. Boiler shall always
start at zero load.
B8-11
07-09
Section B8
Electrode Boilers
2.1.2
Standby-Run Control
The boiler shall incorporate a Standby-Run control which, when in "Standby", will
manually override the Pressure and Load controls to cause the Load Regulating
Shield to go to the "no output" position and simultaneously energize the Standby
Heater control circuit and de-energize the conductivity control and surface blowdown. When the Standby-Run Control is returned to "Run", the boiler will resume
normal operation starting at 0 load. This operation can also be remotely
controlled.
2.1.3
Limit Controls
The boiler shall be equipped with limit controls to shut down the boiler in event of
occurrence of any of the following conditions: (1) excess pressure; (2) low water;
(3) high water; (4) sudden pressure drop in system supply line. Limit controls
(optional or supplied by others) such as supervisory relays for over-current, ground
fault, or phase imbalance (supplied by others) may be connected into the limit
control circuit.
2.1.4
Water Level Controls
The boiler water level control will be a proportional type regulator which will adjust
the position of a valve in the feed-water supply line to maintain the flow of feedwater to match the rate of steam generation. If a single dedicated suitable feedwater pump is used, the control valve could be replaced by a variable speed control
on the pump motor.
2.1.5
Conductivity Control and Sample Cooler Assembly
Conductivity of the water being circulated to the boiler electrodes will be controlled
by an indicating type conductivity controller which will have separately adjustable
high and low set points. On actuation of the "high" set point, automatic boiler bleed
(surface blow-down) will begin and a light will indicate that bleed is in process.
Low conductivity" closes a PLC contact and may be used to signal a chemical feed
pump to start. Chemical feed pump is optional or supplied by others. It is not
furnished as part of this boiler.
A Sample Cooler assembly shall be supplied, including the sample cooler,
connections for the boiler water, connections for the cooling water, valves,
conductivity measuring cell, and manual sampling valve.
2.2
Boiler Trim
The boiler will be supplied with the following trim items:

2.2.1
Pressure Control Piping
Pressure gauges will indicate steam pressure in the boiler shell and in the user's
steam header. Gauge ranges shall be approximately 2 times the operating pressure.
The Gauges and Pressure Controllers will be mounted on the boiler at eye level, prepiped and pre-wired.
2.2.2
Water gauge glass
B8-12
07-09
Electrode Boilers
Section B8
Water gauge glass complete with drain valve will be provided.
2.2.3
Water Column
A water column will be provided and will be suitable for mounting of the water
gauge glass, gauge cocks, the water level controller and the high and low water
cutoffs. A water column drain valve will be provided. A separate control is provided
for the Low-Low water level protection.
2.2.4
Feed-water Valves
Boiler feed-water line will be equipped with shut off valve and check valve between
the boiler and the feed-water regulating valve of 2.2.4. or pump
2.2.5
Blow-down Valves
Boiler blow-off line will be fitted with one quick and one slow opening valve. Valves
shall be "Y" pattern rated for boiler blow-off service.
2.2.6
Steam Valve
Boiler steam outlet valve are optional such as a stop and check.
2.2.7
Back Pressure Regulating Valve
A pneumatic back pressure regulating valve will be provided and will be adjusted to
throttle or close when the boiler steam pressure drops below the operating pressure
range. Valve and controller will be pneumatic type. This Valve will protect the
boiler against a sudden drop in system pressure. Timing shall be adjusted for quick
closing and slow opening.
2.2.8
Safety Valves
The boiler will have a minimum of two safety valves which shall be ASME rated and
stamped. Aggregate capacity of the safety valves at their set pressure will not be
less than 110% of the boiler rating in kilograms of steam per hour. Boiler rated
output will be taken as 3.5lbs of steam per KW. (1.59 kg of steam per KW).
2.2.9
Bleed Valves (for conductivity control)
The boiler bleed (surface blow-down) valve shall be a needle type valve with
calibrated stem, optional adder for boiler. This valve shall be set to control the bleed
rate. On-Off control of the bleed will be by means of a separate valve, air operated.
2.3
Insulation and Casing
The boiler will be insulated with 2" of glass fiber insulation secured to the boiler to
prevent sagging. Insulation rings are provided on the boiler pressure vessel.
Insulation is covered by 18GA Aluminum sheets.
2.4
Top Cage
The boiler high voltage terminals will be enclosed in a preferably full height heavy
screen enclosure with Kirk key interlock on access opening to prevent entrance
B8-13
07-09
Section B8
Electrode Boilers
unless the boiler supply switch-gear is open. Kirk interlock shall be supplied by
others.
2.5
Control Panel
Power required to Control Panel is ___V, 3Ph, __Hz, incorporating a ___A

disconnect switch.
All electrical controls, relays, pump and shield drive starters and associated push
buttons, lights, ammeters, and other components of the boiler control system will
be attached to the boiler before shipment and pre-wired with a 2 door NEMA 12
dust proof panel. Power and Control sections are separate, each with front access.
The H.V. switch-gear (by others) should include CTs and PTs to be connected (by
others) to the Control Panel (see 2.6). In addition to their use for the boiler control
logic, the information on V, A, KW is available in the PLC. KW value can be sent to
a building system if desired.
3.0
Boiler Assembly and installation
The boiler will be shipped in two containers or on a flat bed truck in main sections,
and will require field erection and assembly and completion of electrical and piping
connections. The boiler manufacturers representative will supply labor for the
assembly and start-up of the boiler. The representatives will reassemble under
supervision the internal components of the boiler which were disassembled (Power
Rods, Insulators and Boxes) before shipping in order to protect them in transit.
Containers should be opened at the site. This is an opportunity to train local
personnel. Boiler access is through the lower level manhole.
Insulated boiler is provided with lifting lugs for handling vertically or horizontally.
Labor, material and equipment required for setting of the boiler and electrical and
piping work is not included in this proposal.
4.0 Electrical Supply System
The boiler will require a 3 phase, 4 wire supply circuit derived from a distribution or
a transformer with a wye connected secondary and having the transformer neutral
grounded at the transformer and extended by means of a full size insulated
conductor to the boiler neutral lug. The boiler shell and casing must also be
grounded to the building ground system. The motors specified for the boiler
circulating pump and shield control and stand-by heater will be ____V, 3 Ph,
___Hz., unless otherwise specified. The boiler control circuits will be 120V, 1
phase, ___Hz.
4.1 High Voltage Switchgear
High voltage switchgear for the boiler supply circuit is not included as a part of the
boiler proposal. The boiler supply circuit switchgear shall be air or vacuum or SF6
circuit breaker rated for the boiler voltage and ampere load and should be equipped
with protective relays as required to open the switchgear in event of phase
unbalance or loss of a phase, over-current and under-voltage, and ground current.
The switchgear may also be such that it can be made to open by the boiler high
pressure limit control for safety shutdown. Instrumentation should include an
ammeter and an ammeter switch for monitoring of phase amperages. The breaker
B8-14
07-09
Electrode Boilers
Section B8
shall be equipped with a Kirk key interlock which shall be keyed to match the
access door of the boiler high voltage terminal compartment described in par. 2.5.
It will be the Purchaser's responsibility to advise the supplier of the switchgear of the
need to coordinate the keying system with A.E.P. Thermal Inc. Provide CTs and
PTs for connection to boiler control circuit in boiler panel (2.6). The switchgear
shall incorporate a disconnect switch or equivalent means to provide a visible break
in the power supply circuit to the boiler.
5.0
Feedwater Treatment
No feed-water treatment equipment is included in this proposal. The necessary

feed-water treatment is not detailed in this typical specification.
The water hardness, required conductivity in the boiler shell, water pH, and
alkalinity play a key role in the proper functioning of the boiler. See Electrode Boilers
Required Water Quality Parameters table.
Boiler will operate at up to 3500 mho conductivity for reduced blow-down and
750PPM alkalinity with superior insulators.
B8-15
07-09
Section C
Industrial Watertube Boilers
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Flue Gas Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
Optional Equipment (Partial Listing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9
EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-34
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-36
Steam Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-36
Lower Drum (Mud Drum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-37
Drum Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-39
Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-39
Drum Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-40
Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-40
Convection Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-40
Casing and Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-42
Structural Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-43
Burner/Controls Information (Models A, BR, CN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-43
Flame Safeguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-44
Burner/Controls Information (Model CT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-44
C-1
09-09
Section C
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-50
Breeching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-50
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-59
Steam Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-59
Hot Water Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-73
ILLUSTRATIONS
Figure C-1. Model D Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-18

Figure C-2. Models DL and DLD Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-20
Figure C-3. Model DLDH Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-22
Figure C-4. Model DFE Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-24
Figure C-5. Model DW Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-26
Figure C-6. Model DLW Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-28
Figure C-7. General A Burner Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-30
Figure C-8. General BR Burner Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-31
Figure C-9. General CN Burner Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-32
Figure C-10. General CT Burner Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-33
Figure C-11. Drum Internals and Steam Purifiers for 1, 3, and 7 ppm Solids . . . . . . . . . . . . . . . . . . . . . . . . C-38
Figure C-12. Drum Internals and Separator for 99.5% Dry Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-38
Figure C-13. D Series Boiler Tube Cut-Away . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-39
Figure C-14. Tubes with Membrane design for Inner furnace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-41
Figure C-15. .D Series Boiler Enclosure Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-41
Figure C-16. Series Skid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-43
Figure C-17. Support Drum in Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-43
Figure C-18. Forced FGR System, Industrial Watertube Boiler (A, BR, CB Burners) . . . . . . . . . . . . . . . . . C-47
Figure C-19. Induced FGR System, Industrial Watertube Boiler (CT Burner) . . . . . . . . . . . . . . . . . . . . . . . C-51
Figure C-20. Pier Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-52
Figure C-21. Right Hand Boiler Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-52
Figure C-22. Left Hand Boiler Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-52
Figure C-23. RH and LH Boiler Arrangement With Separate Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-53
Figure C-24. LH and RH Boiler Arrangement With Common Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-53
Figure C-25. Two-Boiler Arrangement With Separate Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-54
Figure C-26. Breeching,; Top Outlet Transition Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-55
Figure C-27. Breeching; Gas Outlet Transition (Direct-to-Stack) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-56
Figure C-28. Breeching; Gas Outlet Transition (Connection to horizontal breeching) . . . . . . . . . . . . . . . . . C-57
TABLES
Table C-1. Industrial Watertube Steam Boiler Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
Table C-2. Standard Trim (Model D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10
Table C-3. Standard Trim (Models DL and DLD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-11
Table C-4. Standard Trim (Model DLDH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12
Table C-5. Standard Trim (Model DFE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13
Table C-6. 300 psig Steel Trim (Model D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-14
Table C-7. 300 psig Steel Trim (Models DL and DLD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-15
Table C-8. 300 psig Steel Trim (Model DLDH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-16
Table C-9. 300 psig Steel Trim (Model DFE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-17
C-2
09-09
Section C
Table C-10. Industrial Watertube Emission Data - Natural Gas (A, BR, CN Burners) . . . . . . . . . . . . . . . . . C-34
Table C-11. Industrial Watertube Emission Data -No. 2 Oil (A, BR, CN Burners) . . . . . . . . . . . . . . . . . . . C-34
Table C-12. Industrial Watertube Emission Data - Heavy Oils (A, BR, CN Burners) . . . . . . . . . . . . . . . . . C-34
Table C-13. Industrial Watertube Emission Data - Natural Gas (CT Burner) . . . . . . . . . . . . . . . . . . . . . . . . C-35
Table C-14. Industrial Watertube Emission Data - No. 2 Oil (CT Burner) . . . . . . . . . . . . . . . . . . . . . . . . . . C-35
Table C-15. Industrial Watertube Emission Data - Heavy Oils (CT Burner) . . . . . . . . . . . . . . . . . . . . . . . . C-35
Table C-16. Heating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-36
Table C-17. Maximum Heat Output (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-37
Table C-18. Maximum Heat Output (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-37
Table C-19. Burner Data (Model A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-45
Table C-20. Burner Data (Model BR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-45
Table C-21. Burner Data (Model CN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-45
Table C-22. Standard Offering (A, BR, and CN Burners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-46
Table C-23. Burner Data (Model CT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-48
Table C-24. Standard Offering (Model CT Burner). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-49
Table C-25. Industrial Watertube Boiler Stack Size Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-58
This section contains information on the Cleaver-Brooks D Series Industrial Watertube Boiler product line. The D
Series is named after its design. Tubes are assembled between the steam drum and mud drum forming the furnace in the
shape of a D, which provides maximum circulation and high steam quality. The D Series consists of five Models: D,
DL, DLD, DLDH and DFE. The models differ according to the size of their steam and mud drums, the height and
width of the boiler, and capacities.
Cleaver-Brooks Industrial Watertube Boilers range from 10,000 to 150,000 lbs/hr steam. Design pressure to 1000 psig.
Super heat temperature to 750 F. High temperature hot water boilers range from 13.4 MMBtu/hr to 62.5 MMBtu/hr
output. Model designations for the high temperature hot water boilers are DW and DLW.
C-3
09-09
Section C

The following features and benefits apply to Cleaver-Brooks Industrial Watertube Boiler
Products.
Boilers
Six Furnace Wall Cooling:
Ensures minimal refractory maintenance and extends boiler life.
Ensures proper circulation with tiles to protect furnace floor tubes to.
Tangent Tube Design, 2" Tubes on 2" Centers
Provides greater uniform heat transfer.
Minimizes thermal stress with non-welded water-cooled, heating surfaces.
Provides cooler furnace temperature minimizing the formation of thermallyproduced NOx emissions.
Membrane Inner Furnace Wall, 2" Tubes on 4" Centers:
Eliminates by-pass of furnace gases into the convection section.
Minimizes both CO and NOx emissions.
Rear Furnace Wall:
Maximizes heat transfer area and minimizes refractory maintenance with 80%
wall coverage with tubes m.
Allows stressless pressure vessel/tube expansion because of floating rear wall

with positive end wall seals.
Convection Section Design:
Enables easy tube removal with wide and narrow spacing between rows of
tubes.
Eliminates abrasion of tubes from sootblower action by locating sootblower

nozzle within the wide space area of tubes.
Maximizes heat transfer with even distribution of flue gases through the
utilization of vertical baffles.
Patented Drum Internals:
Eliminates, in many applications, the need for expensive two-or-three-element

feedwater control systems through use of Cleaver-Brooks patented system of
baffles to ensure stable water levels under dynamic load conditions.
10 Gauge Double Casing:
Provides static zone to prevent flue gas entrapment and acid-corroding of the
casing.
Allows higher furnace pressures required to minimize NOx formations when

utilizing flue gas recirculation technologies.
Rugged and suitable for outdoor installation.
C-4
09-09
Section C
Heavy Base Frame:
Burners
Permits easy lifting, jacking, or skidding during initial installation.
Allows placement of piers, facilitating visual underside inspections and

simplifying general housekeeping.
Provides maximum support for boiler vessel.
High Turndown Capability:
Reduces burner cycling.
Reduces fuel costs.
Is available for gas, oil or combination.
Integral Forced Draft Fan:
Eliminates need for special ducting or breeching.
Creates smaller overall package and an integral part of the burner windbox.
Reduces motor horsepower requirements.
Assures proper sizing for combustion air requirements.
Steam or Air Atomazation:
Provides clean, efficient firing of oil fuels.
Provides low steam consumption.
Provides packaged air compressor with air atomized burners.
Patented Fuel Oil Controller:
Consolidates function of four valves.
Eliminates need for up to 35 separate pipe fittings.
Provides ease of maintenance and operation.
Furnished completely piped and assembled.
Low NOx Capability:
Controls
Guaranteed NOx levels to 10 ppm available.
Provides ease of operation and installation.
Meets or exceeds EPA air quality regulations.
Microprocessor-Based Flame Safeguard System:
Provides diagnostic capability with alpha-numeric display.
Is UL, FM, IRI, and CSA approved.
Retains last fault/lockout condition with non-volatile memory (refer to Boiler

Controls, Section 8 for more information on optional flame safeguard systems).
Full Modulation Combustion Controls System:
Features single-point positioning for safety, simplicity, reliability, and ease of

start-up.
Maintains pressure or temperature setpoint automatically.

C-5
09-09
Section C
Features built-in low-fire hold.
Enables single switch quick changeover from gas firing to oil firing.
Cleaver-Brooks Water Column:
Comes with five probes for high and low water alarm conditions (audio-visual
alarm provided in boiler control panel) and dual redundant low water cutoffs.
Complete Controls Package Includes:
All controls piped and wired.
Custom control systems (optional).
All wiring conforms to NEC and industry standards.
Atomizing Air Compressor (Optional):
Flue Gas
Recirculation
Pre-piped (A and BR Burner) or mounted in a convenient console (CN Burner).
Automatically-controlled and interlocked through flame safeguard system.
Integrated Boiler/Burner/FGR Control Package
Satisfies FM/IRI requirements.
Assures high fuel-to-steam efficiency (no loss in efficiency over standard

package).
Offers synchronized FGR operation with boiler modulation.
Ensurer simplified control and safe and reliable operation with single-pointpositioning of fuel, air and FGR.
Is engineered specifically for CB Boilers.
Assures reliable, trouble-free operation with integrated safety controls.
Patented Dual Canister Burner Housing Design (Model A Burner) - Extended

Burner Drawer (Model BR & Model CN Burners):
Guarantees NOx emission control on natural gas and #2 oil-utilizing forced FGR
system configuration.
Improves CO performance.
Maintains flame stability and combustion control.
Assure complete mixing of flame and recirculating flue gases for excellent NOx
and CO control.
Proven Venturi-Type Burner Design
CT Burner venturi design allows for low NOx emissions through utilization of
induced FGR.
Mechanical Linkage Assembly
Minimizes complex controls.
Allows for single-point-positioning to synchronize fuel, air and FGR flow rates.
Manual Shutoff Valve:
Allows for isolation of FGR system during maintenance periods while allowing
boiler to operate and maintain load.
C-6
09-09
Section C
PRODUCT OFFERING
Cleaver-Brooks Industrial Watertube Boilers range from 10,000 to 150,000 lbs/hr steam.
Design pressure to 1000 psig. Super heat temperature to 750 F.
High temperature hot water boilers range from 13.4 to 62.5 MMBtu/hr output.
Table C-1. Industrial
Watertube Steam Boiler
Models
Standard Equipment
A
MODEL NO.
MAX OUT
LBS/HR
(STEAM)
Table C-1 shows Models D, DL, DLD, DLDH and DFE steam boilers and the associated
outputs.
An FGR system can be purchased with a new boiler or retrofit.
1. Included with each standard packaged unit are the following materials and
equipment:
Inner and outer 10-gauge casing.
Packaged burner assembly.
26.8
Electric single-point positioning full modulating combustion controls.
52
37.41
Forced draft fan and motor drive.
60
43.92
Sootblowers for heavy oil firing.
68
50.22
240 psig trim package.
76
57.17
Membrane inner furnace wall.
86
65.12
IRI requirements.
94
72.62
52
45.47
60
53.31
68
61.47
76
70.3
86
79.91
94
26
16
34
21.4
42
DL
2. Each burner is furnished with a standard Cleaver-Brooks electric positioning

combustion control system designed to operate in conjunction with the burner and
fuel control valves provided.
The system includes the following major components:
Master pressure control.
87.41
Limiting pressure control.
68
60.15
Electric drive motor.
76
68.87
Control shaft and linkages.
86
78.14
Gas control valve (for gas or combination burners).
94
85.54
Fuel oil controller (for oil or combination burners).
60
63.4
Forced draft fan control.
68
76.3
76
85.6
86
97
94
106.2
102
115.6
110
124.9
118
134.1
85
81.3
98
101.5
110
111.5
121
121.6
132
151.7
DLD
DLDH
DFE
A. DLDH with Economizer.
The combustion control system is mounted on the unit at the plant and is shipped as a
completely integrated system.
3. The boiler is built in accordance with the following requirements:
American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel

Code, Section I, Power Boilers.
American Boiler Manufacturers Association (ABMA) Manual of Industry

Standards.
National Fire Protection Association (NFPA), 8501 Prevention of Furnace

Explosions in Fuel Oil and Natural Gas-Fired Single Burner Boiler Furnaces.
Steel Structures Painting Council (SSPC), Surface Preparation SP-l.
National Electric Code (NEC)
National Electrical Manufacturers Association (NEMA).

C-7
09-09
Section C
Insurance Requirements: Safety equipment and combustion controls described above,
which are Cleaver-Brooks standard, can be modified to meet Factory Mutual, Military, or
other requirements.
Industrial Risk Insurers: Equipment is furnished in compliance with published
requirements of the Industrial Risk Insurers as given in the latest IRI information Single
Burner Boiler Furnaces.
Table C-2 , through Table C-5 show boiler trim packages included with standard design
pressure of 260 psig.
Table C-6 through Table C-9 show boiler trim installed at 300 psig design pressure.
Optional Equipment
(Partial Listing)
The following options are available:

Boiler Options
Design pressure up to 1000 psig.
Superheaters.
Hinged manway covers in steam drum.
Clean out ports in front and rear convection wall.
Multiple 12" x 24" convection side access doors.
Warm up coil in lower drum.
Platforms and ladders.
Various steam quality drum internals.
Special blowdown valves.
Weatherproofing.
Wash drains.
Rear furnace access door.
Burner/Control Options
Special motors (TEFC, high efficiency, etc.).
NEMA enclosures.
Special combustion control systems: Single-point, parallel positioning, full

metering, cross-limited systems.
Cleaver-Brooks oxygen trim system.
Plant master, lead-lag, day-night controls, etc.
Feed water control systems (one, two, or three element).
Special burner packages.
Special insurance or code requirements.
Fuel Options
Low fire fuel change-over.
Special gas train sizes.
Gas strainer.
Special fuel shut-off values.
Special oil pump sets.
C-8
09-09
Section C
Alternate fuel firing.
For information on the following options please refer to the referenced section:
Economizers (selected for specific job site conditions), Section G.
Optional Controls, Section D.

The following illustrations Figure C-1 thru Figure C-8) show dimensions for the
Industrial Watertube Product offering.
Figure C-1. Model D Dimensions
Figure C-2. Model DL and DLD Dimensions
Figure C-3. Model DLDH Dimensions
Figure C-4. Model DFE Dimensions
Figure C-5. Model DW Dimensions
Figure C-6. Model DLW Dimensions
Figure C-7. General A Burner Dimensions
Figure C-8. General BR Burner Dimensions
Figure C-9. General CN Burner Dimensions
Figure C-11. General CT Burner Dimensions
FGR sytems for Industrial Watertube boiler applications are custom engineered to meet
specific application requirements. Specific information regarding dimensions, ratings,
and performance data will be provided on a job-by-job basis. Contact your local
Cleaver-Brooks authorized representative for assistance.
C-9
09-09
Section C
Table C-2. Standard Trim (Model D)

VALVES
SERVICE
QUANTITY
MODEL D
MFG.
TYPE
26
34-42
52-76
86
94
VALVE SIZES
Safety
Code
Kunkle
252
Code
Code
Code
Code
Code
Feed Stop
Velan
S-2054B
1-1/2
1-1/2
Feed Stop
Velan
F-2054B
2-1/2
2-1/2
Feed Check
Lunk.
624
1-1/2
1-1/2
2-1/2
2-1/2
1 Set
Edw.
848-849
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
Air Vent
Velan
S-2074B
1/2
1/2
1/2
1/2
1/2
Continuous Blowdown
Velan
S-2074B
Soot Blower Control
Velan
S-2054B
Soot Blower Drain
Velan
S-2074B
3/4
3/4
3/4
3/4
3/4
Soot Blower Drain
Velan
S-2074B
3/4
3/4
Drum Blow-off Tandem
FEEDWATER REGULATOR ASSEMBLY

Feedwater Regulator
Fisher
667 EZ
1-1/2
Regulator By-pass (Throttle)
Velan
S-2074B
1-1/4
1-1/4
1-1/2
Regulator By-pass (Shut-off)
Velan
S-2074B
1-1/2
1-1/2
Velan
S-2074B
2-1/2
2-1/2
Liquid Level Control (Shut-off)
Velan
S-2054B
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
Control Drain
Velan
S-2054B
3/8
3/8
3/8
3/8
3/8
WATER COLUMN ASSEMBLY

Water Column
C-B
Steel
Water Gauge
Rel.
404-RS
3/4
3/4
3/4
3/4
3/4
Gauge Cocks
Rel.
GC-451
3/4
3/4
3/4
3/4
3/4
Column Drain
Velan
S-2054B
3/4
3/4
3/4
3/4
3/4
Gauge Drain
Velan
S-2054B
3/8
3/8
3/8
3/8
3/8
Hi-Low Alarm
Warr.
Probe
Low Water Cut-off
Warr.
Probe
Note: Valve manufacturers listed are for reference only. Actual manufacturer may vary.
C-10
09-09
Section C
Table C-3. Standard Trim (Models DL and DLD)

VALVES
SERVICE
MODELS DL & DLD
QUANTITY
MFG
TYPE
52
60
68
76
86
94
VALVE SIZES
Safety
Code
Kunkle
252
Code
Code
Code
Code
Code
Code
Feed Stop
Velan
S-2054B
Feed Stop
Velan
F-2054B
2-1/2
2-1/2
2-1/2
2-1/2
Feed Check
Lunk.
624
2-1/2
2-1/2
2-1/2
2-1/2
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
Velan
S-2074B
1/2
1/2
1/2
1/2
1/2
1/2
Continuous Blowdown
Velan
S-2074B
Soot Blower Control
Velan
S-2054B
Soot Blower Drain
Velan
S-2074B
3/4
3/4
3/4
3/4
3/4
3/4
Soot Blower Drain
Velan
S-2074B
3/4
3/4
3/4

Feedwater Regulator
Fisher
667 EZ
1-1/2
1-1/2
Velan
S-2074B
1-1/2
1-1/2
Velan
S-2074B
Velan
S-2074B
2-1/2
2-1/2
2-1/2
2-1/2
Velan
S-2054B
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
Control Drain
Velan
S-2054B
3/8
3/8
3/8
3/8
3/8
3/8

Water Column
C-B
Steel
Water Gauge
Rel.
404-RS
3/4
3/4
3/4
3/4
3/4
3/4
Gauge Cocks
Rel.
GC-451
3/4
3/4
3/4
3/4
3/4
3/4
Column Drain
Velan
S-2054B
3/4
3/4
3/4
3/4
3/4
3/4
Gauge Drain
Velan
S-2054B
3/8
3/8
3/8
3/8
3/8
3/8
Hi-Low Alarm
Warr.
Probe
Low Water Cut-off
Warr.
Probe
C-11
09-09
Section C
Table C-4. Standard Trim (Model DLDH)

VALVES
SERVICE
QTY
MODEL DLDH
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
Velan
S-2054B
Feed Stop
Velan
F-2054B
2-1/2
2-1/2
Feed Check
Lunk.
624
2-1/2
2-1/2
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
Velan
S-2074B
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
Continuous Blowdown
Velan
S-2074B
1-1/2
1-1/2
1-1/2
1-1/2
Soot Blower Control
Velan
S-2054B
Soot Blower Drain
Velan
S-2074B
3/4
3/4
3/4
3/4
3/4
3/4
3/4
3/4
Soot Blower Drain
Velan
S-2074B
3/4
3/4
3/4
3/4
3/4
3/4
3/4
3/4

Feedwater Regulator
Fisher
667 EZ
Velan
S-2074B
2-1/2
2-1/2
2-1/2
2-1/2
Velan
S-2074B
Velan
S-2074B
2-1/2
2-1/2
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
Velan
S-2054B
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8

Water Column
C-B
Steel
Water Gauge
Rel.
404-RS
3/4
3/4
3/4
3/4
3/4
3/4
3/4
3/4
Gauge Cocks
Rel.
GC-451
3/4
3/4
3/4
3/4
3/4
3/4
3/4
3/4
Column Drain
Velan
S-2054B
3/4
3/4
3/4
3/4
3/4
3/4
3/4
3/4
Gauge Drain
Velan
S-2054B
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
Hi-Low Alarm
Warr.
Probe
Low Water Cut-off
Warr.
Probe
C-12
09-09
Section C
Table C-5. Standard Trim (Model DFE)

VALVES
SERVICE
MODEL DFE
QTY
MFG
TYPE
85
98
110
121
132
VALVE SIZES
Safety
Code
Kunkle
252
Code
Code
Code
Code
Code
Feed Stop
Velan
S-2054B
Feed Stop
Velan
F-2054B
Feed Check
Lunk.
624
1 Set
Edw.
848-849
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
Air Vent
Velan
S-2074B
1/2
1/2
1/2
1/2
1/2
Continuous Blowdown
Velan
S-2074B
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
Soot Blower Control
Velan
S-2054B
Soot Blower Drain
Velan
S-2074B
3/4
3/4
3/4
3/4
3/4
Soot Blower Drain
Velan
S-2074B
3/4
3/4
3/4
3/4
3/4

Feedwater Regulator
Fisher
667 EZ
Velan
S-2074B
2-1/2
2-1/2
2-1/2
Velan
S-2074B
Velan
S-2074B
Velan
S-2054B
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
Control Drain
Velan
S-2054B
3/8
3/8
3/8
3/8
3/8

Water Column
C-B
Steel
Water Gauge
Rel.
404-RS
3/4
3/4
3/4
3/4
3/4
Gauge Cocks
Rel.
GC-451
3/4
3/4
3/4
3/4
3/4
Column Drain
Velan
S-2054B
3/4
3/4
3/4
3/4
3/4
Gauge Drain
Velan
S-2054B
3/8
3/8
3/8
3/8
3/8
Hi-Low Alarm
Warr.
Probe
Low Water Cut-off
Warr.
Probe
C-13
09-09
Section C
Table C-6. 300 psig Steel Trim (Model D)

VALVES
SERVICE
QTY
BOILER MODEL - D
MFG
TYPE
26
34-42
52-76
86
94
VALVE SIZES
Safety
Code
Kunkle
300
Code
Code
Code
Code
Code
Feed Stop
Velan
S-2054B
1-1/2
1-1/2
Feed Stop
Velan
F-1064C
2-1/2
2-1/2
Feed Check
Edw.
838
1-1/2
1-1/2
Feed Check
Lunk.
3072-C
2-1/2
2-1/2
1 Set
Edw.
848-849
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
Air Vent
Velan
S-2074B
1/2
1/2
1/2
1/2
1/2
Continuous Blowdown
Velan
S-2074B
Soot Blower Control
Velan
S-2054B
Soot Blower Drain
Velan
S-2074B
3/4
3/4
3/4
3/4
3/4
Soot Blower Drain
Velan
S-2074B
3/4
3/4

Feedwater Regulator
Fisher
667 EZ
1-1/2
Velan
S-2074B
1-1/4
1-1/4
1-1/2
Velan
S-2054B
1-1/2
1-1/2
Velan
F-1064C
2-1/2
2-1/2
Velan
S-2054B
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
Control Drain
Velan
S-2054B
3/8
3/8
3/8
3/8
3/8

Water Column
C-B
Steel
Water Gauge
Rel.
404-RS
3/4
3/4
3/4
3/4
3/4
Gauge Cocks
Rel.
GC-451
3/4
3/4
3/4
3/4
3/4
Column Drain
Velan
S-2054B
3/4
3/4
3/4
3/4
3/4
Gauge Drain
Velan
S-2054B
3/8
3/8
3/8
3/8
3/8
Hi-Low Alarm
Warr.
Probe
Low Water Cut-off
Warr.
Probe
C-14
09-09
Section C
Table C-7. 300 psig Steel Trim (Models DL and DLD)

VALVES
SERVICE
QTY
BOILER MODELS - DL AND DLD

MFG
TYPE
52
60
68
76
86
94
VALVE SIZES
Safety
Code
Kunkle
300
Code
Code
Code
Code
Code
Code
Feed Stop
Velan
S-2054B
Feed Stop
Velan
F-1064C
2-1/2
2-1/2
2-1/2
2-1/2
Feed Check
Edw.
838
Feed Check
Lunk.
3072-C
2-1/2
2-1/2
2-1/2
2-1/2
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
Velan
S-2074B
1/2
1/2
1/2
1/2
1/2
1/2
Continuous Blowdown
Velan
S-2074B
Soot Blower Control
Velan
S-2054B
Soot Blower Drain
Velan
S-2074B
3/4
3/4
3/4
3/4
3/4
3/4
Soot Blower Drain
Velan
S-2074B
3/4
3/4
3/4

Feedwater Regulator
Fisher
667 EZ
1-1/2
1-1/2
Velan
S-2074B
1-1/2
1-1/2
Velan
S-2054B
Velan
F-1064C
2-1/2
2-1/2
2-1/2
2-1/2
Velan
S-2054B
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
Control Drain
Velan
S-2054B
3/8
3/8
3/8
3/8
3/8
3/8

Water Column
C-B
Steel
Water Gauge
Rel.
404-RS
3/4
3/4
3/4
3/4
3/4
3/4
Gauge Cocks
Rel.
GC-451
3/4
3/4
3/4
3/4
3/4
3/4
Column Drain
Velan
S-2054B
3/4
3/4
3/4
3/4
3/4
3/4
Gauge Drain
Velan
S-2054B
3/8
3/8
3/8
3/8
3/8
3/8
Hi-Low Alarm
Warr.
Probe
Low Water Cut-off
Warr.
Probe
C-15
09-09
Section C
Table C-8. 300 psig Steel Trim (Model DLDH)

VALVES
SERVICE
QTY
BOILER MODEL - DLDH

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
Velan
S-2054B
Feed Stop
Velan
F-1064C
2-1/2
2-1/2
Feed Check
Edw.
838
Feed Check
Lunk.
3072-C
2-1/2
2-1/2
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
Velan
S-2074B
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
Continuous Blowdown
Velan
S-2074B
Soot Blower Control
Velan
S-2054B
Soot Blower Drain
Velan
S-2074B
3/4
3/4
3/4
3/4
3/4
3/4
3/4
3/4
Soot Blower Drain
Velan
S-2074B
3/4
3/4
3/4
3/4
3/4
3/4
3/4
3/4

Feedwater Regulator
Fisher
667 EZ
Velan
S-2074B
2-1/2
2-1/2
2-1/2
2-1/2
Velan
S-2054B
Velan
F-1064C
2-1/2
2-1/2
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
Velan
S-2054B
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8

Water Column
C-B
Steel
Water Gauge
Rel.
404-RS
3/4
3/4
3/4
3/4
3/4
3/4
3/4
3/4
Gauge Cocks
Rel.
GC-451
3/4
3/4
3/4
3/4
3/4
3/4
3/4
3/4
Column Drain
Velan
S-2054B
3/4
3/4
3/4
3/4
3/4
3/4
3/4
3/4
Gauge Drain
Velan
S-2054B
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
Hi-Low Alarm
Warr.
Probe
Low Water Cut-off
Warr.
Probe
C-16
09-09
Section C
Table C-9. 300 psig Steel Trim (Model DFE)

VALVES
SERVICE
MODEL DFE
QTY
MFG
TYPE
85
98
110
121
132
VALVE SIZES
Safety
Code
Kunkle
300
Code
Code
Code
Code
Code
Feed Stop
Velan
S-2054B
Feed Stop
Velan
F-2064C
Feed Check
Edw.
838
Feed Check
Lunk.
307-C
1 Set
Edw.
848-849
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
Air Vent
Velan
S-2074B
1/2
1/2
1/2
1/2
1/2
Continuous Blowdown
Velan
S-2074B
Soot Blower Control
Velan
S-2054B
Soot Blower Drain
Velan
S-2074B
3/4
3/4
3/4
3/4
3/4
Soot Blower Drain
Velan
S-2074B
3/4
3/4
3/4
3/4
3/4

Feedwater Regulator
Fisher
667 EZ
Velan
S-2074B
2-1/2
2-1/2
2-1/2
Velan
S-2074B
Velan
F-1064C
Velan
S-2054B
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
Control Drain
Velan
S-2054B
3/8
3/8
3/8
3/8
3/8

Water Column
C-B
Steel
Water Gauge
Rel.
404-RS
3/4
3/4
3/4
3/4
3/4
Gauge Cocks
Rel.
GC-451
3/4
3/4
3/4
3/4
3/4
Column Drain
Velan
S-2054B
3/4
3/4
3/4
3/4
3/4
Gauge Drain
Velan
S-2054B
3/8
3/8
3/8
3/8
3/8
Hi-Low Alarm
Warr.
Probe
Low Water Cut-off
Warr.
Probe
C-17
09-09
Section C
Figure C-1. Model D Dimensions - Sheet 1 of 2

C-18
09-09
Section C
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
12.5
14
18.5
19.875
20
22
23
23
25.875
91
91
91
91
85
85
85
85
80.5
74
74
74
74
74
74
74
74
74
E. Front to CL Gas Outlet

F. Skid to CL Gas Outlet
G. Skid to CL of Sootblower
FlangeA
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
(2) 48
(2) 60
(2) 76
(2) 94
(2) 108
(3) 82
(3) 92
(3) 104
(3) 114
M. No. of Piers/CL to CL spacing

N. 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, 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 OutletC
(1) Feedwater Inlet
2.5
2.5
2.5
Code
Code
Code
Code
Code
Code
Code
Code
Code
(2) Water Column
(2) Level Control
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
1.25
1.25
1.25
1.25
1.25
1.25
1.25
1.25
1.25
(2) Safety
ValvesC
(1) Blowdown (Surface)

Sootblower (if
applicable)A
(1) Chemical Feed

(1) Vent
(1) Blowdown (Mud drum)
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-19
09-09
Section C
Figure C-2. Models DL and DLD Dimensions - Sheet 1 of 2

C-20
09-09
Section C
DL MODELS
52
60
68
DLD MODELS
76
86
94
68
76
86
94
DIMENSIONS (IN.)
208
237
266
295
331.25
360.25
266
295
331.25
360.25
238
267
296
325
361.5
390.25
296
325
361.5
390.25
30
33
36
42
42
42
36
42
42
42
66
66
66
75
75
84
66
75
75
84
19.875
21.5
23
26
26
25.875
23
26
26
25.875
105
105
105
100.5
100.5
96
105
100.5
100.5
96
FlangeA
84
84
84
84
84
84
84
84
84
84
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
36
36
36
36
36
36
42
42
42
42
24
24
24
24
24
24
24
24
24
24
M. No. of Piers/CL to CL
spacing
(2) 94
(2) 108
(3) 82
(3) 92
(3) 104
(3) 114
(3)82
(3) 92
(3) 104
(3) 114
N. Burner
Refer to Figures C-7 thru C-10 for Dimensions

WEIGHTS (LBS)
Weight, DryB
62700
68200
77550
83600
91300
96800
78900
85000
93000
98600
78700
86200
96990
105220
115600
131300
98700
107000
117700
133700
Weight, FloodedB
83430
91610
103090
111830
122900
137200
107500
117800
129700
144200

10
10
10
(1) Feedwater Inlet
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
Code
Code
Code
Code
Code
Code
Code
(2) Safety
ValvesC

Sootblower (if
applicable)A
(3) Code (3) Code (3) Code
(2) Water Column
(2) Level Control
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
1.25
1.25
1.25
1.25
1.25
1.25
1.25
1.25
1.25
1.25
(1) Chemical Feed

(1) Vent
NOTES:
1. 12 x 16 manhole in each end of upper and lower drum. All tubes are 2 OD.
2. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension
prints.
A. Boiler Models DL and DLD, 76 thru 94, may use sootblowers on front and rear. All others may use one sootblower.
C. Steam outlet number and size of safety valves are based on 150 psig operating pressure. Steam outlet and safety valve sizes may vary
with pressure increase and actual steam outlet. For sizes with different operating pressure, and/or non-return valves, contact your local
Figure C-2. Models DL and DLD Dimensions - Sheet 2 of 2
C-21
09-09
Section C
Figure C-3. Model DLDH Dimensions - Sheet 1 of 2
C-22
09-09
Section C
MODEL DLDH
60
68
76
86
94
102
110
118
DIMENSIONS (IN.)
237
266
295
331.25
360.25
389.25
418.25
447.25
267
296
325
361.5
390.25
419.25
448.25
477.25
36
36
40
42
45
50
55
55
66
82
82
89
90
90
90
90
23
23
25
26
24.375
30
32.5
32.5
107
99
99
95.5
95
95
95
95
67.5
67.5
67.5
67.5
67.5
67.5
67.5
67.5
40
40
40
40
40
40
40
40

FlangeA

187
187
187
187
187
187
187
187
J. Overall Width
144
144
144
144
144
144
144
144
42
42
42
42
42
42
42
42
30
30
30
30
30
30
30
30
(3) 54
(3) 82
(4) 62
(4) 70
(4) 76
(4) 87
(4) 96
(4) 105

N. Burner

WEIGHTS (LBS)
Weight, DryB
83500
93503
101247
108106
111666
119611
127596
135581
105400
118027
127801
138079
144330
154966
178337
176318
Weight, FloodedB
112100
125997
135925
147813
155051
166674
165642
190000

10
10
10
10
12
12
(1) Feedwater Inlet
(3) Code
(3) Code
(3) Code
(3) Code
(3) Code
(3) Code
(3) Code
(3) Code
(2) Safety
ValvesC

Sootblower (if
applicable)A
1.5
1.5
1.5
1.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
(2) Water Column
(2) Level Control
2.5
2.5
(1) Chemical Feed
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
1.25
1.25
1.25
1.25
1.5
1.5
1.5
1.5
(1) Vent
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-23
09-09
Section C
Figure C-4. Model DFE Dimensions - Sheet 1 of 2

C-24
09-09
Section C
MODEL DFE
85
98
110
121
132
DIMENSIONS (IN.)
327
374.75
418.25
457.75
498
357
404.75
448.25
487.75
528
40
45
50
55
60
90
90
90
90
90
25
27.5
30
32.5
35
95
95
95
95
95
G. Skid to CL of Sootblower FlangeA
67.5
67.5
67.5
67.5
67.5
113.5
113.5
113.5
113.5
113.5
200.25
200.25
200.25
200.25
200.25
J. Overall Width
151.375
151.375
151.375
151.375
151.375
48 I.D.
48 I.D.
48 I.D.
48 I.D.
48 I.D.
30 O.D.
30 O.D
30 O.D
30 O.D
30 O.D
(4) 72
(4) 88
(4) 104
(4) 104
(4) 120

N. Burner

WEIGHTS (LBS)
117,250
130,750
143,350
154,750
166,350
154,300
170,400
188,050
204,100
220,450
Weight, FloodedB
163,450
184,400
203,800
221,400
239,350
Weight,
DryB

10
10
10
12
12
(1) Feedwater Inlet
(2) Safety ValvesC
Code
Code
Code
Code
Code
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
(2) Level Control
0.5
0.5
0.5
0.5
0.5
1.5
1.5
1.5
1.5
1.5
(1) Main Steam
OutletC
(1) Chemical Feed

(1) Vent
NOTES:
2. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed
for construction by certified dimension prints.
A. Boiler Model DFE 85 thru 132, may use two sootblowers on front and rear.
C. Steam outlet number and size of safety valves are based on a 150 psig operating pressure.
Steam outlet and safety valve sizes may vary with pressure increase and actual steam outlet. For
sizes with different operating pressure, and/or non-return valves, contact your local Cleaver-Brooks
Figure C-4. Model DFE Dimensions - Sheet 2 of 2

C-25
09-09
Section C
Figure C-5. Model DW Dimensions - Sheet 1 of 2
C-26
09-09
Section C
MODEL DW
26
34
42
52
60
68
76
86
94
DIMENSIONS (IN.)
113
142
171
207
236
265
294
330.5
359.5
144
173
202
238
267
296
325
361.5
390.25
15
18
27
30
30
33
36
36
42
54
54
54
54
66
66
66
66
75
125
14
18.5
19.875
20
22
23
23
25.875
91
91
91
91
85
85
85
85
80.5
74
74
74
74
74
74
74
74
74
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
(2) 48
(2) 60
(2) 76
(2) 94
(2) 108
(3) 82
(3) 92
(3) 104
(3) 114
H. Shipping Height (.375)
L. No. of Piers/CL to CL spacing

M. Burner

WEIGHTS (LBS)
Weight, DryB
35200
40700
45870
52580
57970
66330
72490
79640
85250
Weight, FloodedB
44400
52540
60340
70340
78380
89380
98200
108630
116865

-
(2) Safety/ Relief ValvesC
Code
Code
Code
Code
Code
Code
Code
Code
Code
(2) Water Column
(1) Vent
1.25
1.25
1.25
1.25
1.25
1.25
1.25
1.25
1.25
(1) Water Inlet/OutletC
(1) Blowdown (lower drum)
NOTES:
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. Contact your local Cleaver-Brooks authorized representative for job-specific information.
Figure C-5 Model DW Dimensions - Sheet 2 of 2
C-27
09-09
Section C
Figure C-6. Model DLW Dimensions - Sheet 1 of 2

C-28
09-09
Section C
MODEL DLW
52
60
68
76
86
94
DIMENSIONS (IN.)
207
236
265
294
330.5
359.5
238
267
296
325
361.5
390.25
30
33
36
42
42
42
66
66
66
75
75
84
19.875
21.5
23
26
26
25.875
105
105
105
100.5
100.5
96
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
(2) 94
(2) 108
(3) 82
(3) 92
(3) 104
(3) 114
L. No. of Piers/CL to CL spacing

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

-
(2) Safety/ Relief ValvesC
Code
Code
Code
Code
Code
Code
(2) Water Column
(1) Vent
1.25
1.25
1.25
1.25
1.25
1.25
(1) Water Inlet/OutletC
(1) Blowdown (lower drum)
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 temperatures and pressures. Contact your local Cleaver-Brooks authorized representative for job-specific information.
Figure C-6. Model DLW Dimensions - Sheet 2 of 2
C-29
09-09
Section C
STANDARD
BURNER
MODEL
66
60
67
24-1/4
54
70
115-1/8
52-1/8
21-3/4
33
Figure C-7. General A Burner Dimensions
C-30
09-09
Section C
STANDARD
BURNER
MODEL
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:
1. Fuel train shipped loose and not included in above weights.
2. Weight includes forced draft fan and drive.
Figure C-8. General BR Burner Dimensions
C-31
09-09
Section C
BURNER
MODEL
STANDARD
A
CN1
56-3/4
60-1/2
80-1/4
30-1/4
52
65
140-1/2
37-1/4
21-1/2
37-1/2
CN2
58-3/4
60-1/2
80-1/4
30-1/4
52
65
140-1/2
37-1/4
21-1/2
37-1/2
CN3
58-3/4
60-1/2
80-1/4
30-1/4
52
65
140-1/2
37-1/4
21-1/2
37-1/2
CN4
58-3/4
60-1/2
80-1/4
30-1/4
52
65
140-1/2
37-1/4
21-1/2
37-1/2
CN5
61-1/4
60-1/2
80-1/4
30-1/4
52
65
140-1/2
37-1/4
21-1/2
37-1/2
CN7
65-1/4
60-1/2
82
30-1/4
52
65
142
40-3/4
21-7/8
37-1/2
CN8
71-3/4
60-1/2
82
30-1/4
52
65
142
40-3/4
21-7/8
37-1/2
Figure C-9. General CN Burner Dimensions
C-32
09-09
Section C
BURNER
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-33
09-09
Section C
EMISSIONS
The emission data included in this section consists of uncontrolled and controlled levels of nitrogen
oxides (NOX) and carbon monoxide (CO) for Cleaver-Brooks D, DL, DLD, DLDH and DFE
Industrial Watertube Boilers equipped with Cleaver-Brooks Model A, BR, CN or CT burners. The
following tables include typical emission levels. Because individual boiler performance can vary,
contact your local Cleaver-Brooks authorized representative for specific levels of performance
for your application. Emission data for natural gas, No. 2 oil, and No. 6 oil are presented in Table C10 through Table C-15.
Cleaver-Brooks Industrial Watertube Boilers are available with a standard burner package or optional
flue gas recirculation (FGR) package.
The Cleaver-Brooks FGR packages are integrated boiler/burner/control packages designed
specifically for Cleaver- Brooks boilers.
Table C-10. Industrial Watertube Emission Data - Natural Gas (A, BR, CN Burners)
TYPICAL UNCONTROLLED EMISSIONS
TYPICAL EMISSIONS CONTROLLED W/FGR
< 65,000 pph
< 65,000 pph
ppm
200
200
lb/MMBtu
.146
.146
ppm
110
40
lb/MMBtu
.13
.05
POLLUTANT
CO
NOx
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 Burners)
< 65,000 pph
< 65,000 pph
ppm
200
200
lb/MMBtu
.155
.155
ppm
185
130
lb/MMBtu
.25
.17
POLLUTANT
CO
NOx
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)
POLLUTANT
< 65,000 pph
CO
NOx
ppm
200
lb/MMBtu
.158
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 expressed written consent of Cleaver-Brooks Division of Aqua-Chem, Inc. All information is based on 3% O2.
C-34
09-09
Section C
Table C-13. Industrial Watertube Emission Data - Natural Gas (CT Burner)
POLLUTANT
CO
NOx
<85,000 pph
86,000-105,000 pph
106,000-150,000 pph
15,000-150,000 pph
ppm
200
200
200
200
lb/MMBtu
.15
.15
.15
.15
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
CO
NOx
86,000-105,000 pph 106,000-150,000 pph
15,000-150,000 pph
ppm
200
200
200
200
lb/MMBtu
.155
.155
.155
.155
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)
15,000-150,000 pph
15,000-150,000 pph
ppm
200
200
lb/MMBtu
.158
.158
ppm
380
260
lb/MMBtu
.51
.35
POLLUTANT
CO
NOx
NOTES:
1. NOx Emissions from heavy oil are dependent upon fuel bound nitrogen content of oil. Emission levels indicated assume a fuel bound nitrogen content of.4% by weight.
C-35
09-09
Section C
ENGINEERING DATA
The following engineering data will
assist in selecting and specifying
Cleaver-Brooks Industrial Watertube
Boilers.
Table C-16 shows heating surfaces
for the IWT Boilers.Table C-17 and
Table C-18show temperature and
pressure information for selection of
high temperature hot water boilers.
Steam Drum
Model D and DL boilers have 36" ID

steam drums, constructed of SA-515
Grade-70 steel plate. Models DLD
and DLDH boilers have 42" ID steam
drums; the DFE has a 48 Drum constructed of SA- 515 Grade-70 steel
plate. All drums are of welded construction in strict conformance with
the ASME Power Boiler Code. All
drums are stress-relieved, and welded
seams are radiographed and hydrostatically tested at
1-1/2 times design pressure. The
drum incorporates elliptical heads
with 12" x 16" manholes on each end,
and is wholly supported by the tubes,
so no extra supporting steel is
required. All tubes are expanded into
the drums.
The steam drum has the following
external connections:
Table C-16. Heating Surface

CONV
HEATING
SURFACE
(SQ-FT)
FURNACE
HEATING
SURFACE
(PROJ)
(SQ-FT)
TOTAL
HEATING
SURFACE
(SQ-FT)
FURNACE
VOLUME
(CU-FT)
26
1120
241
1361
317
34
1517
302
1819
425
42
1911
369
2280
527
52
2407
449
2856
654
60
2806
511
3317
754
68
3206
580
3786
855
76
3595
634
4229
951
86
4087
726
4313
1081
94
4470
793
5263
1184
52
2912
518
3430
903
60
3393
593
3986
1048
68
3870
676
4546
1194
76
4346
751
5097
1328
86
4947
848
5795
1510
94
5418
923
6341
1654
68
3774
673
4447
1188
76
4248
747
4995
1321
86
4825
842
5667
1502
94
5284
919
6203
1645
MODEL NO.
DL
DLD
One main steam outlet, flanged.
60
4000
650
4650
1111
Two 12" x 16" manways.
68
4564
737
5301
1261
One feedwater inlet.
76
5126
818
5944
1411
86
5806
923
6729
1599
Two or three safety valve flanged

connections (as required).
DLDH
94
6368
1004
7372
1750
One blowdown connection,

screwed.
102
6930
1089
8019
1900
110
7495
1172
8667
2050
One soot blower connection,

screwed.
118
8056
1253
9309
2200
85
5707
923
6663
1750
Two water column connections,

screwed.
98
6622
1063
7685
2024
110
7461
1187
8648
2274
121
8223
1305
9528
2501
132
9000
1416
10416
2733
DFE
Two feedwater regulator

connections, screwed.
One chemical feed connection,
screwed.
Two lifting Lugs.
C-36
09-09
Section C
Table C-17. Maximum Heat Output
(Hot Water)
HOT WATER GENERATORS
MODEL NO.
DW
Table C-18. Maximum Heat Output (Steam)
MAX OUT
MM
BTU/HR
STEAM BOILER
MODEL NO.
13.4
34
17.9
42
22.5
26
16
52
28.2
34
21.4
60
32.7
42
26.8
68
37.5
52
37.41
76
41.7
60
43.92
86
47.5
68
50.22
94
51.9
76
57.17
52
33.8
86
65.12
60
39.3
94
72.62
68
44.8
52
45.47
76
50.3
60
53.31
86
57.1
68
61.47
94
62.5
76
70.3
86
79.91
94
87.41
68
60.15
76
68.87
86
78.14
94
85.54
60
63.4
68
76.3
76
85.6
86
97
94
106.2
102
115.6
110
124.9
118
134.1
85
81.3
98
101.5
110
111.5
121
121.6
132
151.7
DLW
DL
The steam drum is fitted with an internal feed pipe,

chemical feed pipe, and blowdown piping. Water
level control baffling is installed to ensure that all
steam released from the generating tubes is released
behind the baffles and not through the water level.
Standard patented drum internals consist of steam
separators or dryers that are installed to ensure the
steam leaving the drum will contain not more than
1/2 of 1 percent moisture when boiler water
concentrations are maintained in accordance with
ABMA recommendations. Special drum internals
for more stringent moisture content are available.
See Table C-11 and Table C-12 for illustration of
drum internals.
Lower Drum (Mud
Drum)
MAX OUTA
MMBTU/HR
(STEAM)
26
The lower drum is 24" OD of SA-53 Grade-B

seamless pipe, and is of fusion-welded construction,
or 30" OD of SA-515, Grade-70, welded plate
(DLDH and DFE boiler). The lower drum is stress
relieved,
seams
are
radiographed,
and
hydrostatically tested at 1-1/2 times design pressure.
The drum incorporates two 12" x 16" manways one at each end - and required blow-drum
connections.
DLD
DLDH
DFE
A. DLDH with economizer.
Internally, the drum has a blowdown guide baffle to

ensure effective blowdown of the lower drum
without disturbing water circulation in the unit. The
drum is supported by the structural steel frame
C-37
09-09
Section C
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-38
09-09
MEMBRANE
Section C
Figure C-13. D Series Boiler Tube Cut-Away

(skid) and has welded guide lugs that fit into the base frame, permitting expansion of the
drum within the skid, thereby eliminating potential expansion stresses.
Drum Enclosure
The steam drum is shop-insulated with mineral wool block and enclosed in a welded 10gauge steel casing. All drum heads are shop-insulated and enclosed in a 10-gauge steel
casing. No further insulation is required in the field.
Furnace
The furnace (combustion chamber) employs 2" OD, SA-178A electric resistance welded
tubes, arranged for maximum coverage of all six furnace walls. In a D type watertube
boiler, the furnace tubes generate more than half of the steam produced by the boiler,
although the furnace represents only about 15% of the reported surface. Due to the high
heat absorption rates present in the furnace, D tubes are placed in a tangent spacing
arrangement to provide as much water-cooled surface as possible. With the exception of
the inner furnace wall, which is membrane construction, extended metallic surfaces are
not used. See Table C-13.
All tubes in the furnace are accessible for mechanical tube cleaners. No headers are
employed in the boiler, and all tubes terminate in the upper and lower drums. Both floor
and roof tubes are designed with adequate pitch to ensure drainage and proper
circulation without swedging ends of tubes.
The six-wall furnace cooling is arranged as follows:
Front wall - Tubes closely spaced around burner.
Tangent outer side wall - 2" tubes spaced on 2" centers.
Membrane sealed inner wall - 2" tubes spaced on 4" centers.
Tangent floor - 2" tubes spaced on 2" centers.
Tangent roof - 2" tubes spaced on 2" centers.
Rear wall - Triple row of tubes.
Furnace exit - Double row of screen tubes.
Access: Access to furnace is through burner opening in front wall or optional rear access
C-39
09-09
Section C
door.
Observation: Two air-cooled observation ports, with Pyrex eye shields, provided in rear
wall.
Air Pressure Test: Inner seal-welded 10-gauge casing, subjected to an air pressure test of
8" WC. It is considered tight if air pressure drop does not exceed 2" WC in 5 minutes.
Flue Gas Outlet: One flanged rectangular flue gas outlet, sized for desired flue gas
velocity and arranged for field welding, will be provided. Top gas outlet is also available
on the D, DL and DLD models
Convection Tubes
Definition
The convection section, or boiler section, of a D type boiler are those tubes to which
heat is transmitted mainly by convection from the products of combustion.
Tubes
The convection section consists of 2" OD, wall tubes. The tubes are SA-178 electric
resistance-welded construction in accordance with ASME standards.
Tube Arrangement
The tubes are arranged with longitudinal rows of tubes in alternate wide and narrow
spacing to ensure proper and effective arrangement of soot-blowing equipment. This
arrangement also allows removal of any tube without the necessity of removing adjacent
tubes. All tubes in the boiler section are expanded into the upper and lower drums. No
swaged or finned tubes are used in the convection section, thereby allowing heating
surface to be reported based on actual tube surface, not extended metal surfaces or fins.
Baffling
The convection bank is designed to eliminate the need for longitudinal baffles. A vertical
steel deflector baffle is placed immediately in front of the flue gas outlet connection in
order to prevent any short-circuiting of flue gas at the outlet. The boiler incorporates
vertical baffles located to maintain gas velocities and transfer rates.(Figure C-14).
Soot Blowers
On heavy oil fired units, soot blowers are installed to provide the operator with a means
of cleaning the boiler while it is in operation. The soot blower element is installed on the
outside row of tubes, and blows an approximate 180 arc using steam piped from the
steam drum. Where the length of the convection bank requires a blower in excess of 20
feet, two soot blowers are provided - one entering from the rear of the unit and one from
the front.
Soot blower bearings are of the welded-type, which eliminates problems of misalignment
associated with bolted bearings. The soot blower is a valve-in-head type and arranged for
manual operation by means of a chain. Purging air is piped to the soot blower from the
burner windbox to provide continuous cleaning of the inside of the element, and to
prevent combustion gases from leaking back to the valve mechanism in the soot blower
head. On boilers without sootblowers, wall boxes and bearing are provided.
Internal Cleaning
The internal surfaces of all tubes, both convection and furnace types, can be
mechanically cleaned using either electric or pneumatic driven tube cleaners. Acid
C-40
09-09
Section C
Inner furnace wall
Outer furnace and

convection wall
with membrane
design.
Membrane Design
The inner furnace wall separating the furnace from the

convection section incorporates welded extended
surfaces on each side of the tube. After the tubes are
installed the adjacent surface fins are seal-welded
forming a gas tight membrane inner wall. Membrane
construction for the outer furnace wall and the outer
convection wall is available as an option.
Figure C-14. Tubes with Membrane design for Inner furnace.
2-1/2 BLOCK (LOW DENSITY)
Figure C-15. .D Series Boiler Enclosure Construction

C-41
09-09
Section C
cleaning procedures are also available.
Tube Removal
The use of the alternate wide-and-narrow spacing of boiler tube rows makes it possible to
remove and replace individual tubes in the convection section without the necessity of
cutting and removing adjacent tubes. In other staggered convection bank designs, it is
often necessary to remove many good tubes in order to provide physical clearance to
remove a damaged tube.
Casing and
Insulation
Design
The unit is enclosed by a double panel casing, with that portion of the casing exposed to
the products of combustion completely seal-welded to form an air and gas tight
enclosure. The outer casing panels are skip-welded and are suitable for indoor
installation (seal-welded for outdoor optional).
The casing is supported off the structural steel frame and is not welded or attached to
tubing, thereby ensuring free expansion of pressure parts within the casing enclosure.
Casing and Wall Design
Construction of the boiler enclosure is as follows (Figure C-15):
1. Front Wall - Furnace Area:
3", 4-way interlocking tile.
4" Hi-temperature block insulation.
10-gauge inner seal welded casing.
2-1/2 low density block insulation.
1/4 burner front plate.
2. Rear Wall:
3", 4-way interlocking tile.
4" Hi-temperature block insulation.
2-1/2 low density block insulation,
1/4 outer casing.
3. Convection Section and Furnace Side Wall and Roof:
4-3/8 low-density mineral wool block.
10-gauge outer steel casing.
4. Casing Finish:
Painted with high-temperature enamel paint prior to shipment.
Furnace Floor
Furnace floor tubes are covered with 1-1/2 square edge tile.
Structural Frame
Models D, DL, DLD, DLDH and DFE boilers (see Figure C-16 and Figure C-17) are
supported by a heavy structural steel frame skid assembly. The skid assembly consists of
two 14" wide flange beams running parallel to the drum. The beams are attached by
means of heavy steel plates that form the saddle and support for the lower drum. The skid
C-42
09-09
Section C
assembly also incorporates 10 ga. floor plate of the boiler beneath the furnace area and
convection section. The skid assembly is fabricated as a complete structure prior to
assembly of the unit. This method of support, using saddle plates and guide lugs, permits
the lower drum to ride in the saddle plates, thus permitting expansion of the pressure
parts in the structural frame and casing enclosure of the boiler. Stops are provided during
assembly to limit movement of the drum within the expected expansion limits.
To facilitate lifting and handling of the boiler, lifting lugs are welded to the upper drum.
In addition, the main beams of the skid are coped and reinforced to provide space
beneath the end of the beam for jacking of the unit as required during installation. Holes
are provided in the main beams for use by riggers to drag or lift the unit by its base
frame.
Burner/Controls
Information (Models
A, BR, CN)
Each application requires burner selection based on boiler and overall project
requirements. Table C-19, Table C-20, and Table C-21 show the standard CleaverBrooks burners and associated inputs and fuel requirements. Once the boiler has been
selected, the burner is matched based on the input requirements for the boiler. Table C22 shows the standard offering for each burner package.
The burner assembly is attached to the front wall of the boiler with all components
readily accessible for inspection and maintenance.
The oil burner is either low pressure air or steam atomized ignited by gas pilot. The main
gas burner is also ignited by a gas pilot.
The gas burner is designed for a 8:1 turndown when supplied with 10 psig gas pressure,
turndown on oil is 6:1 when supplied with 125 psig oil pressure.
Figure C-16. Series Skid Assembly
Figure C-17. Support Drum in Skid

C-43
09-09
Section C
The burner operates with full modulation through single point positioning controls. A
switch is provided to permit changeover from automatic, fully-modulated firing, to
continuous firing at any desired rate between minimum and maximum. Control
safeguards assure that the burner always returns to the minimum firing position for
ignition.
For air-atomized oil-fired boilers (air atomazation is optional), filtered primary air for
atomizing the fuel oil is provided independent of the combustion air by a motor-driven
air compressor. The fuel oil pump may be mounted near the boiler, or at a remote
location.
For burning heavy oil, the burner is equipped with a combination steam-electric heater,
each controlled by a thermostat. Both heaters are installed in a single compact shell, and
are mounted, piped, and wired on the burner.
The thermostatic controls are set to cut out the electric heater when steam is available. A
metering valve permits circulation of hot oil to the burner at all times. An automatic
purge pump system back-purges the burner drawer oil piping and nozzle upon shut-down
and returns any unburned oil to the storage tank.
The FGR system used with the A, BR and CN burner and controls, is shown in Figure C18.
Flame Safeguard
The burner is equipped with a fully automatic flame safeguard system to ensure prepurge, proper light-off, shutdown on flame failure, and post-purge on shutdown. The
system is designed to meet FM, IRI, and CSA requirements.
The control system includes safety interlocks to shut down the system in the event of any
of the following, as required for the fuel or fuels being fired:
Burner/Controls
Information (Model
CT)
Flame failure.
High steam pressure.
Low drum water level.
Low atomizing steam pressure (oil or combination gas/oil burners).
Low fuel oil pressure (oil or combination gas/oil burners).
Low fuel oil temperature (oil or combination gas/oil burners).
High fuel oil temperature (oil or combination gas/oil burners, IRI only).
Low or high fuel gas pressure.
Forced draft fan failure.
Each application requires burner selection based on boiler and overall project
requirements. Table C-23 shows the Model CT burner selections and the associated
inputs and fuel requirements. Burner selection is based upon input requirements for the
boiler. Table C-24 shows standard non FGR offerings for the Model CT burner
equipment package.
The burner assembly is seal-welded to the front wall of the boiler, with all comp-onents
readily accessible for inspection and maintenance. The windbox is not insulated for
ambient combustion air, and is fabricated of ASTM A-36 plate, complete with structural
framing, support legs, access door, and splitter vanes and baffles for equalizing air flow
distribution to the burner.
A forced draft fan of centrifugal-type construction, arrangement four, with downblast
discharge provides combustion air for the burner system. The fan is mounted directly on
top of the windbox for applications up to 80,000 pph of steam (may be less than 80,000
lbs/hr with certain FGR conditions). In applications exceeding 80,000 pph of steam, the
C-44
09-09
Section C
Table C-19. Burner Data (Model A)
GAS PRESSURE (INCHES H2O)
4 GAS LINE
W/4 MAXON VALVES
4 GAS LINE
W/4 GC VALVES
OIL
PRESSURE
(PSIG)
BURNER
MODEL
MAX
INPUT
(MBTU)
HP
(OIL)A
HP
(GAS)
FM
IRI
FM
IRI
A-1
13.8
10
10
10.5
12.3
8.9
9.1
100
A-2
16.9
15
10
15.7
18.4
13.3
13.6
100
A-3
16.6
15
10
15.0
17.6
12.6
13.0
100
A-4
18.6
15
10
18.8
22.0
15.9
16.3
100
A-5
19.7
20
15
21.0
24.7
17.7
18.2
100
A-6
22.2
25
20
26.1
30.7
22.0
22.5
100
A-7
22.9
25
20
27.8
32.7
23.4
24.0
100
A-8
26.5
30
25
36.8
43.3
31.0
31.8
100
A. Air compressor for atomizing air belt driven from FD fan motor. 25 CFM required.
Table C-20. Burner Data (Model BR)

GAS PRESSURE (INCHES H2O)
MAX
INPUT
(MBTU)
HP
(OIL)A
HP
(GAS)
BR-1
31.0
15
BR-2
36.0
BR-3
BR-4
BURNER
MODEL
4 GAS LINE W/4

GC VALVES
4 GAS LINE W/4

MAXON VALVES
6 GAS LINE W/4

MAXON VALVES
OIL
PRESSURE
(PSIG)
FM
IRI
FM
IRI
FM
IRI
15
45.8
56.6
36.4
38.3
26.3
28.0
100
20
20
60.7
74.9
48.4
50.8
34.9
37.1
100
40.2
25
25
75.1
92.5
60.0
63.0
43.3
46.1
100
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
MAXON VALVES
6 GAS LINE W/4

MAXON VALVES
OIL
PRESSURE
(PSIG)
BURNER
MODEL
MAXIMUM
INPUT
(MBTU)
HP
(OIL)A
HP
(GAS)
FM
IRI
FM
IRI
CN-1
46.5
20
20
61.5
65.4
39.6
43.3
100
CN-2
49.8
30
30
70.3
74.8
45.5
49.7
100
CN-3
63.5
40
40
108.8
115.5
70.4
76.9
100
CN-4
66.0
50
50
117.0
124.2
75.9
82.9
100
CN-5
77.1
60
60
134.6
142.8
87.8
95.8
125
CN-7
75.0
60
60
148.9
157.8
97.6
106.4
125
CN-8
81.3
75
75
113.8
123.9
125
NOTES:
1. All horsepower requirements shown are for altitudes up to 1500 feet above sea level.
A. CN Burner (if air-atomized) has separate 15 hp motor to drive atomizing air compressor. 70 cfm required.
C-45
09-09
Section C
Table C-22. Standard Offering (A, BR, and CN Burners)

BURNER MODEL
AND SIZE
A
1-8
BR
1-4
STANDARD EQUIPMENT
CN
1-8
FORCED DRAFT FAN
Fan driven by open drip-proof motor.
Damper at FD fan outlet.
Type of damper:
X
a. Rotary (as used on Firetube Boiler Product Line).
b. Characterized Quadrant (Rotary), NOT a Butterfly Type Damper.
Combustion air-proving switch (CAPS) mounted and wired.

ATOMIZING MEDIUM
Type of air compressor drive (if air-atomized):

X
C-B low pressure air or steam-atomized.
a. Belt driven from FD fan motor.
b. Motor driven module mounted on burner.
c. Motor driven module mounted in CN console, remote from burner (field piping and wiring required).
Atomizing air proving switch (AAPS) mounted and wired on compressor.

CONTROLS & ELECTRICAL
Cleaver-Brooks standard electric positioning controls.
C-B 100 flame safeguard control with lead sulfide scanner.
10
Controls remote from control enclosure have NEMA 1 housing.
11
Control enclosure: controls are mounted in NEMA 1A panel, mounted on burner.
12
NEMA 12 panel, mounted on burner.
13
NEMA 1A compartment of CN console for Model CN-100 thru CN-600 (oil fired).
14
NEMA 1A panel mounted on burner for Model CN-700 (gas-fired only).
15
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
Fuses and starters for FD fan motor, air compressor motor and fuel oil heater all mounted and wired on burner.
17
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
Electric current characteristics 230-460V/3-phase/60Hz.
19
Control circuit transformer mounted and wired on burner.
22
Turndown ratio of burner - 6:1 for oil firing, 8:1 for gas firing.
MISCELLANEOUS:
FUEL
24
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-46
09-09
Section C
Figure C-18. Forced FGR System, Industrial Watertube Boiler (A, BR, CN Burners)
forced draft fan is mounted remote from the windbox. The combustion air fan is
supplied with a variable inlet vane-type damper, inlet screen, and silencer to reduce fan
noise to 85 dBA at a distance of three (3) feet from the fan. The combustion air fan
utilizes a 240V or 480V, 3-phase, 60 Hz, electric motor drive. Special voltages and
frequencies
are
available.
The gas burner is of multi-spud injector-type design, utilizing fuel staging within the
flame envelope for reduction in thermal NOx formation. The burner is designed to
provide 10:1 turndown on natural gas when supplied with constant 15 psig gas pressure
at the inlet to the gas pressure regulator.
The oil burner is of the low-pressure, steam-atomizing type, and is designed to provide
8:1 turndown when supplied with constant 175 psig oil pressure at the inlet to the fuel oil
train.
Both the gas and oil burners utilize a spark-ignited, gas-pilot ignition system.
The burner operates with full modulation through single-point-positioning controls. A
switch is provided to permit changeover from automatic, fully modulated firing, to
continuous firing at any desired rate between minimum and maximum. Control
safeguards assure that the burner always returns to the minimum firing position for
ignition.
In forced FGR applications, the FGR fan can be mounted on the boiler as shown in
Figure C-18, mounted on a separate pedestal, or mounted on the floor.
Boiler Room
Information
Figure C-19 shows the recommended pier arrangement for industrial watertube boilers.
Figure C-20, through Figure C-24 show different boiler and stack arrangements for
industrial watertube boilers.
C-47
09-09
Section C
Figure C-19. Induced FGR System, Industrial Watertube Boiler (CT Burner)
C-48
09-09
Section C
Table C-23. Burner

Table 1: Data (Model CT)
NATURAL GAS FIRING
HEAT INPUT
NO. 2 FUEL OIL FIRING

HEAT INPUT
MMBTU/HR
MMBTU/HR
15
20
19
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
NOMINAL LOAD
REFERENCE
LB/HR
FD FAN MOTOR
HP
CT-1
15,000
CT-2
BURNER MODEL
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.
C-49
09-09
Section C
Table C-24. Standard Table

Offering
1: (Model CT Burner).
BURNER MODEL AND SIZE
CT
1-20
STANDARD EQUIPMENT ON CT BURNER
CT
21-27
FORCED DRAFT FAN

1
Fan driven by open drip proof motor.
Damper at FD fan inlet.
FD Fan Location:
a. On windbox.
b. Remote from burner.
Combustion air proving switch (CAPS) mounted and wired.
3
X
ATOMIZING MEDIA (OIL-FIRED UNITS)

5
Steam atomization standard.

CONTROLS & ELECTRICAL
Cleaver-Brooks standard electric positioning controls.

X
Cleaver-Brooks parallel positioning controls.
C-B 100 flame safeguard control with lead sulfide scanner.
Controls remote from control enclosure have NEMA 1 housing.
10
NEMA 12 panel, mounted on boiler.
11
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
Electric current characteristics 230-460V, 3-phase, 60-Hz.
14
Control circuit transformer mounted and wired on burner.

FUEL
15
Gas pilot for all fuel series.
NOTE: Standard equipment listed here is included only with burner model indicated by an X.
C-50
09-09
Section C
Breeching
If more than one boiler is connected to a common stack or breeching, an outlet damper
and damper regulator is required unless otherwise noted.
Refer to Figure C-25 through Figure C-27 for breeching transition dimensions, and to
Table C-25 for stack size selection.
C-51
09-09
Section C
Figure C-19. Pier Arrangement
Figure C-20. Right Hand Boiler Arrangement
Figure C-21. Left Hand Boiler Arrangement
C-52
09-09
Section C
Figure C-22. RH and LH Boiler Arrangement With Separate Stacks
Figure C-23. LH and RH Boiler Arrangement With Common Stack

C-53
09-09
Section C
Figure C-24. Two-Boiler Arrangement With Separate Stacks
C-54
09-09
Section C
DIMENSIONS IN INCHES
BOILER MODEL
A
26
34
42
52
60
68
76
86
94
15
18
27
30
30
33
36
36
42
36
36
36
36
39
39
39
39
42
86-3/4
86-3/4
86-3/4
86-3/4
98-3/4
98-3/4
98-3/4
98-3/4
107-3/4
DL
52
60
68
76
86
94
30
33
36
42
42
42
39
39
39
39
42
42
86-3/4
98-3/4
98-3/4
107-3/4
107-3/4
116-3/4
NOTES:
1. Dimensions vary per stack size and velocity.
2. Must be shipped loose for field installation.
3. For DLD-DLDH, contact your local Cleaver-Brooks authorized representative.
Figure C-25. Breeching,; Top Outlet Transition Piece
C-55
09-09
Section C
BOILER MODEL
A
26
34
42
52
60
68
76
86
94
54
54
54
54
66
66
66
66
75
15
18
27
30
30
33
36
36
42
36
36
36
36
36
36
36
36
36
DL
68
76
86
94
66
75
75
84
36
42
42
42
36
36
36
36
NOTES
1. Dimensions vary per stack size and velocities.
Figure C-26. Breeching; Gas Outlet Transition (Direct-to-Stack)
C-56
09-09
Section C
BOILER MODEL
A
26
34
42
52
60
68
76
86
94
54
54
54
54
66
66
66
66
75
15
18
27
30
30
33
36
36
42
36
36
36
36
39
39
39
39
42
35
35-1/2
35-1/2
35-1/2
41-1/2
41-1/2
41-1/2
41-1/2
46
24
24
24
24
25-1/2
25-1/2
25-1/2
25-1/2
27
DL
52
60
68
76
86
94
66
66
66
75
75
84
30
33
36
42
42
42
39
39
39
39
42
42
41-1/2
41-1/2
41-1/2
46
46
50-1/2
25-1/2
25-1/2
25-1/2
25-1/2
27
27
NOTES:
1. Dimensions vary per stack size and velocity.
Figure C-27. Breeching; Gas Outlet Transition (Connection to horizontal breeching)
C-57
09-09
Section C
Table C-25. Industrial Watertube

Boiler
Stack Size Selection Chart
Table
1:
FLUE GAS FLOW TO
STACK
LBS/HR
MINIMUM
MAXIMUM
12,910
15,510
21,210
24,410
32,010
36,010
43,010
50,010
57,010
66,010
75,010
84,010
94,010
104,010
115,010
126,010
137,510
150,010
162,510
178,010
192,010
206,010
221,010
237,010
255,010
271,010
15,500
21,200
24,400
32,000
36,000
43,000
50,000
57,000
66,000
75,000
84,000
94,000
104,000
115,000
126,000
137,500
150,000
162,500
178,000
192,000
206,000
221,000
237,000
255,000
271,000
287,000
STACK
DIAMETER
IN.*
FLUE GAS VELOCITY

FPM AT 560 F
GAS TEMP
FREE AREA
SQ-FT
24
28
30
34
36
39
42
45
48
51
54
57
60
63
66
69
72
75
78
81
84
87
90
93
96
99
MINIMUM
MAXIMUM
1840
1620
1920
1710
1995
1860
1920
1940
1945
1990
2020
2030
2050
2060
2080
2085
2090
2100
2100
2130
2140
2145
2150
2155
2170
2180
2200
2200
2200
2240
2245
2220
2225
2220
2250
2260
2260
2270
2270
2270
2270
2270
2270
2270
2300
2300
2300
2300
2310
2310
2310
2310
3.012
4.125
4.747
6.121
6.874
8.296
9.621
11.045
12.566
14.186
15.904
17.720
19.635
21.647
23.758
25.967
28.274
30.680
33.183
35.785
38.484
41.282
44.179
47.173
50.265
53.456
ELEVATION
FT
MULTIPLICATI
ON
FACTOR
0- 500
501-1000
1001-1500
1501-2000
2001-2500
2501-3000
3001-3500
3501-4000
4501-4500
4501-5000
5001-5500
5501-6000
6001-6500
6501-7000
1.0
1.025
1.05
1.07
1.085
1.105
1.12
1.15
1.17
1.19
1.22
1.24
1.26
1.28
* Dimensions vary per stack size and flue gas velocities.

If boiler is more than 500 feet above sea level, multiply the actual gas flow to stack by factor given and select the stack diameter that 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)
STACK DIAMETER
IN.
24
27
30
33
36
39
42
3/16
PLATE
1/4
PLATE
1305
1460
1632
1787
1959
2113
2268
1749
1956
2187
2394
2623
2830
3037
WEIGHT (LBS)
STACK DIAMETER
IN.
45
48
51
54
57
60
63
The stack weights shown include the base ring, clean-out door, and connection for breeching.
C-58
09-09
3/16
PLATE
1/4
PLATE
2439
2593
2765
2940
3080
3220
3400
3267
3474
3705
3910
4140
4350
4570
Section C
(Steam Boiler Specification)
Shop-Assembled Steam Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-60
General Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-60
Packaged Watertube Boiler(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-61
Design Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-61
Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-61
Boiler and Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-62
Boiler Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-63
Sootblower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-65
Boiler and Trim Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-65
Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-66
Economizer (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-67
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-67
Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-69
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-70
Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-70
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-71
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-71
Field Quality Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-71
Demonstrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-71
needs and application. A separate specification is provided for steam boiler packages and high temperature hot water packages.
C-59
Industrial Watertube Steam Boiler Specifications

PART 1 GENERAL
1.1
Section C
SHOP-ASSEMBLED STEAM BOILER
This specification shall govern the construction features, materials, fabrication, inspection, and
preparation for shipment of packaged-type, shop-assembled, watertube steam generating
equipment with burner assembly, all necessary appurtenances, controls and auxiliary equipment
mounted to the maximum practical extent, as an integral unit on a steel base so as to make a
complete self-contained assembly.
1.2
C-60
GENERAL REQUIREMENTS
A. Proposal
1. Complete description, drawings, and material specifications
and performance shall accompany each proposal.
B. Standards and Codes
1. The following regulatory codes and standards, publication issue
in effect at date of invitation for bids, form a part of this
specification. All applicable components shall be designed and
constructed in accordance with these codes with additions or
modifications as required by this specification.
a. American Society of Mechanical Engineers (ASME) Boiler
and Pressure Vessel Code, Section I, Power Boilers.
b. American Boiler Manufacturers Association (ABMA)
Manual of Industry Standards.
c. Underwriters Laboratories (UL), UL 795 CommercialIndustrial Gas-Fired Heating Equipment.
d. National Fire Protection Association (NFPA), 8501
Prevention of Furnace Explosions in Fuel Oil and Natural
Gas-Fired Single Burner Boiler Furnaces.
e. Steel Structures Painting Council (SSPC), Surface
Preparation SP-l.
f.
g. National Electrical Manufacturers Association (NEMA).
2. All equipment shall comply with the state, provincial or
municipal laws and regulations governing the location where
the equipment is to be installed.
C. Documentation Requirements
1. Dimension drawing with dry and flooded weights, major
component identification, and service connection location and
size.
2. Electrical drawings including elementary ladder logic and field
component interconnection diagram. Fuel train schematics.
3. Two (2) copies of certified ASME Manufacturers Data Reports
on the pressure vessel.
4. Operating and maintenance manuals.
5. Recommended spare parts list.
D. Design Requirements
1. Design continuous capacity: _____ lb/hr.
2. Design pressure: _____ psig.
3. Operating pressure: _____ psig.
Section C
E.
F.
G.
PART 2 PRODUCTS
2.1
4. Final steam temperature: _____ F.

5. Steam quality (solids): _____ ppm.
6. Feedwater temperature: _____ F.
7. Elevation above sea level: _____ ft.
8. Electrical characteristics: _____ Volts, _____ phase, ____ Hz.
9. Primary fuel: _____, Supply pressure ______.
10. Standby fuel _____, Supply pressure ______.
11. Insurance requirements _____.
Manufacturer
1. Subject to compliance with requirements, provide watertube
boiler manufactured by Cleaver-Brooks, Division of AquaChem, Inc.
1. Fuel-to-steam efficiency at above capacity is ____% when firing
oil and ____% when firing gas.
Heating Surface
1. The unit will have the following heating surface:
a. Boiler heating surface: _____ sq-ft.
b. Water wall projected surface: _____ sq-ft.
c. Total heating surface: _____ sq-ft.
d. Furnace volume: _____ cu-ft.
PACKAGED WATERTUBE BOILER(S)
Boilers shall be factory-assembled, packaged, and mounted on heavy steel base frame, complete
with integral forced draft burner, burner controls, boiler trim, and refractory. Boilers shall be
assembled and wired so that only water, steam, fuel, blowdown, electrical, and vent connections
are required.
2.2
DESIGN PRESSURE
The pressure vessel shall have a design pressure of 260 psig in accordance with ASME Power
Boiler Construction Code, Section 1, and the laws of the state or province in which the equipment
is to be installed. The boiler shall be registered with the National Board of Boiler and Pressure
Vessel Inspectors (Provincial Boiler Inspection Agency in Canada), and with the specific state or
provincial boiler inspection department.
2.3
DRUMS
A. The boiler shall have one upper steam drum and one lower mud
drum extending the full length of the boiler setting. Each drum head
shall have a 12" x 16" manhole opening with cover, yoke, and
gasket. Furnish one operating set of gaskets and two complete spare
sets. Drums shall be X-rayed and stress relieved as required, and
under the inspection of the Hartford Steam Boiler Inspection and
Insurance Company.
1. Steam Drum - The unit shall incorporate a steam drum of SA515 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,
C-61
B.
2.4
C-62
Section C
and hydrostatically tested at 1-1/2 times the design pressure.

a. The steam drum shall be fitted with an internal feed pipe,
chemical feed pipe, and the blowdown pipe. Water level
control baffling is to be installed to ensure that all steam
released from the generating tubes is released behind the
baffles and not through the water level. Drum internals
shall consist of steam separators or dryers, which are
installed to ensure that the steam leaving the drum
contains not more than 1/2 of 1% moisture when boiler
water concentrations are maintained in accordance with
ABMA recommendations.
2. Lower Drum - The lower drum shall be of fusion-welded
construction and will be stress-relieved, seams radiographed,
and hydrostatically tested at 1-1/2 times the design pressure.
The lower drum shall be fitted with an internal blowdown guide
baffle to ensure effective blowdown of the lower drum
disturbance to the water circulation in the unit.
Drum Connections
1. Provide the following openings in the drums for piping
connections, all flanges shall be raised face and drilled 300
psig ANSI.
a. Steam outlet: _____ One (1) flanged.
b. Safety valves: _____ as required by ASME.
c. Sootblower: _____ One (1) 2" screwed.
d. Water Column: _____ Two (2) 1" screwed.
e. Feedwater Regulator: _____ Two (2) 1" screwed.
f.
Top Vent: _____ One (1) 1" screwed.
g. Continuous Blowdown: _____ One (1) 1" screwed.
h. Chemical Feed: _____ One (1) 1/2 screwed.
i.
Feedwater: _____ One (1) 2" screwed.
j.
Blowdown: _____ One (1) 1-1/4 screwed.
2. All openings shall be properly protected from damage and
weather during shipment.
BOILER AND FURNACE

A. Furnace
1. The furnace shall employ six-wall cooling with the following:
a. Front wall tubes closely spaced around the burner.
b. Membrane inner furnace wall.
c. Tangent floor, roof, and outer furnace wall.
d. Triple row of rear wall tubes.
e. Double row of screen tubes at furnace exit.
2. All tubes shall terminate in the upper and lower drums. No
headers are to be used, and all heating surface in the furnace is
based on actual projected tube surface and membrane surface.
All tubes shall be cleanable by mechanical tube cleaners. All
tubes to be expanded into upper and lower drums.
Section C

B.
C.
D.
2.5
Boiler Section
1. The boiler convection section shall consist of 2" OD tubes SA
178A Grade A arranged in line with longitudinal rows of tubes
arranged on wide and narrow spacing to ensure proper and
effective arrangement of sootblowing equipment. This
arrangement shall also permit removal of any tube without the
necessity of removing adjacent tubes.
Tube Material
1. All tubes in the unit for boiler and furnace shall be 2" OD, of
SA-178, Grade A, electric resistance welded construction in
accordance with ASME Code.
Superheater (Optional)
1. A bare tube, completely drainable superheater shall be
furnished as an integral part of the boiler. All superheater
elements and headers shall be of suitable carbon and alloy
steel material of a thickness required for temperature and
pressure prevailing under maximum load conditions. The
superheater shall be equipped with a weld end superheater
outlet connection and safety valve nozzle, drain, vent,
thermometer, and thermocouple connections as required by the
design. Safety valve, drain valve, vent valve, and thermometer
shall be included. (A steam sampling connection shall be
provided by the owner in the connecting steam line).
Superheater outlet header is equipped with a connection for the
customers automatic start-up and shut-down vent valve size.
Piping contractor or others shall furnish and install an
automatic controlled vent valve when superheater is subjected
to low load conditions.
2. All super heater tube material subject to radiant furnace heat
shall be constructed of alloy steel suitable for the temperatures
involved.
BOILER ENCLOSURE
A. Casing
1. The boiler shall be enclosed with Cleaver-Brooks standard
double panel casing with the portion of the casing exposed to
the products of combustion completely seal welded to form an
air and gas tight enclosure. The outer casing panels shall also
be welded.
2. The casing is to be supported off the structural steel frame and
shall not be welded or attached to tubing, thereby ensuring free
expansion of pressure parts within the casing enclosure.
B. Arrangement of Casing
1. Construction of the boiler casing enclosure shall be as follows
a. Front Wall - Furnace Area
1) 3", 4-way interlocking tile.
2) 4" high-temperature block insulation.
3) 10-gauge inner seal welded casing.
4) 2-1/2 low density block insulation.
C-63
C.
D.
E.
F.
G.
H.
I.
J.
C-64
Section C
5) 1/4 burner front plate.

6) 2.5.2.2 Rear Wall - Furnace Area
7) 3", 4-way interlocking tile.
8) 4" high-temperature block insulation.
10) 2-1/2 low-density block insulation.
b. Convection Section - Furnace
2) 4-3/8 low-density mineral wool block.
Furnace Floor
1. Furnace floor tubes shall be covered with 1-1/2 square edge
tile.
Drum Enclosure
1.
The steam drum shall be shop-insulated with mineral wool
block and enclosed in a welded 10-gauge casing. All drum
heads will be shop-insulated and enclosed in a 10-gauge
casing. No further insulation in the field shall be required.
Access
1. Access to the furnace shall be through the burner opening in
the front wall, and through a separate refractory lined door on
the rear wall.
Observation
1. Two (2) air-cooled observation ports, with Pyrex eye shields,
shall be provided in the rear wall.
Air Pressure Test
1. The inner seal welded 10-gauge casing shall be subject to an
air pressure test of 8" WC, and shall be considered
satisfactorily tight if the air pressure drop does not exceed 2"
WC in five (5) minutes.
Baffling
1. The convection section shall contain vertical baffles of 10gauge steel to direct the flow of flue gases. The baffles shall not
require removal for tube replacement.
Insulation
1. The setting and insulation shall be so designed to ensure that a
maximum average casing surface temperature of 130F is not
exceeded under full load firing with an ambient air temperature
of 80F and with a surface air velocity of two feet per second
when burner is at maximum output. The manufacturer shall
guarantee the design against overheating, warping, or burning
of the casing.
2. Pressure Connection
a. Provide a sensing location in furnace, free of turbulence
from flame, for draft control sample connection.
Painting
1. The surfaces shall be prepared per SSPC SP-l specifications
Section C

and finished with rust resistant primer and a high-quality, hightemperature finish coat of enamel paint.
2.6
SOOTBLOWER
A. Provide, at a minimum, wall box(es) and bearings for boiler being
fired on natural gas and No. 2 oil. When heavy oil is specified,
provide the following:
1. Sootblowers shall be steam operated, valve-in-head type, and
shall be furnished complete with wall sleeves, clamps,
hangers, supports, operating chains, and other appurtenances
required for a complete installation.
2. Blower elements shall be so arranged that all parts of the
heating surfaces shall be cleaned of any soot deposits when
rotated by manual or automatic means.
3. Elements shall be of such length, diameter, and total nozzle
area that, for the operating pressure involved, there will be no
significant difference in the cleaning effect between the nozzle
nearest the inlet and those farthest from the inlet of the
element.
4. Sootblower piping shall include a valve, chain-operated from
the floor, in addition to an auxiliary steam-stop valve, and drain
connection.
5. Sootblowers shall be fitted with scavenging air ports, and shall
be connected by tubing to the draft fan in a manner to provide
sufficient air, for continuous scavenging of the blowers.
2.7
BOILER AND TRIM ACCESSORIES

A. Each unit shall be provided with the following trim (and quantity),
which shall be designed for a minimum of 240 psig.
1. Steam Pressure Gauge (1).
2. Safety Valves, Consolidated/Kunkle (ASME Code).
3. Feedwater Regulator, Fisher 2500 (1).
4. Feedwater Regulator By-Pass, Velan S254B (1).
5. Feedwater Regulator Shutoff, Velan S274B (2).
6. Water Column, Cleaver-Brooks (1).
7. Water Gauge, Reliance 404-RS (1).
8. Feedwater Regulator Drain, Velan S274B (1).
9. Gauge Cocks, Reliance No. GC-451 (3).
10. Column Drain, Velan S274B (1).
11. Gauge Drain, Velan S274B (1).
12. Hi-Low Alarm, Warrick Probe (1).
13. Low Water Cutoff, Warrick Probe (2).
14. Feed Stop, Velan S254B (1).
15. Feed Check, Lunkenheimer 624 (1).
16. Drum Blowdown Valve, Edwards No. 848-849 (1 Set).
17. Air Vent, Velan S274B (1).
18. Continuous Blowdown, Velan/Vogt S2054B (1).
C-65
B.
2.8
C-66
Section C
19. Chemical Feed Stop, Edwards No. 848 (1).

20. Chemical Feed Check, Edwards No. 838 (1).
21. Auxiliary Low-Water Cutoff, Float Magnetrol #249 (1).
22. Sootblower Shutoff, Velan S254B (1 when required).
23. Sootblower Drain, Velan S274B (1 when required).
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.
BURNER
A. Provide the unit with a forced-draft, register-type burner, arranged to
burn natural gas complete with gas electric ignition and observation
port. The burner shall be of a type that can be readily converted to
oil in the future. The windbox shall be ruggedly constructed and of a
proven design which will assure an even supply of air to all
quadrants of the burner register. The burner shall be a standard
product of the boiler manufacturer specifically designed for the
boiler.
B. Forced Draft Fan
1. The assembly shall be attached to the windbox in such a way
that will allow easy access for maintenance. An inlet screen
shall be provided, and the air volume shall be regulated by inlet
vanes. The fan shall develop sufficient static pressure to ensure
proper distribution of air over the entire turndown range of the
burner.
C. Operating and Safety Controls
1. The unit shall be provided with a full complement of operating
and safety controls, consisting of not less than the following
items and features, which shall be shop assembled:
a. Automatic gas-electric ignition system for gas operation.
2. Underwriters Laboratories listed and Factory Mutual approved
microprocessor burner programming and safety controller to
automatically provide proper cycling for pre-combustion purge,
ignition, start, stop, post-combustion purge and safety
shutdown, for use on gas firing and oil firing. This controller
shall be a standard product of the boiler manufacturer.
3. Electronic type flame failure protection as part of the program
controller to provide safety shutdown on failure of either the
main flame or the pilot flame, with manual reset, flame failure
and high temperature alarm, all on either oil or gas-firing.
4. Separate high-pressure safety cutoff for steam and low-fire hold
pressure control.
5. Separate auxiliary low-water safety cutoff for water level with
momentary bypass pushbutton for blowdown function.
6. Blower damper to automatically proportion combustion air to
firing rate.
7. Air flow safety switch.
Section C

8.
D.
E.
F.
2.9
The following gas valve trains shall be mounted on the burner

windbox. All electrical devices shall be prewired to terminals
within a burner mounted box. The gas train will be made from
Schedule 40 pipe. Sizes 4" and above shall be with butt-weld
fittings.
9. The pilot gas train shall conform to NFPA-8501 and be of the
interruptible type consisting of two (2) pilot gas solenoid
valves, one (1) pilot vent valve, one (1) manual shutoff valve,
and a gas pressure regulator.
10. The main gas train shall conform to NFPA-8501 and consist of
two (2) main gas valves with one valve having an overtravel
protection interlock, a flow control valve, a gas pressure
regulator, one (1) vent valve, one (1) manual gas shutoff valve,
high and low gas pressure limit protection, and main gas valve
leak-test provisions.
The oil burner shall be of the steam-atomizing type for fullyautomatic operation. Low pressure air-atomazation is available as an
option. Air-atomizing burners shall be supplied with a selflubricating 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.
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.
All controls for the boiler shall be enclosed in a suitable cabinet,
with hinged door and lock, containing all necessary relays, magnetic
starters, contactors, terminal blocks, fuse blocks, fuses,
transformers, switches, rheostats, and colored indicating lights. All
instruments on the panel front shall be identified by nameplate. An
alarm horn shall be provided on the panel to indicate flame failure
and low water level. All wire terminations shall be numbered in
accordance with the applicable wiring diagram. All wiring shall
conform with the National Electric Code.
1. Electronic continuity tests shall be provided on all circuits to
ensure minimal start-up time.
ECONOMIZER (OPTIONAL)
Refer to Economizer, Section G, for specification.
2.10
CONTROLS
A. Feedwater Control Valve
1. Provide a single element pneumatic system consisting of a
steam drum water level sensing device that controls a
diaphragm-operated control valve. The control valve shall be a
C-67
B.
C.
D.
E.
F.
C-68
Section C
tight shut-off with air-to-open type. Provide means to control

set point and proportional band.
Feedwater - Two-Element Control (Optional)
1. The feedwater system shall be of the two-element control type.
Drum level shall be maintained by integrating both steam flow
and water level signals to control final drum level. A master
controller, steam flow element (orifice plate), pressure
transducers and drum level transducers shall be included.
Feedwater - Three-Element Control (Optional)
1. The feedwater system shall be of the three-element control
type. Drum level shall be maintained by integrating steam flow,
water level and feedwater flow signals to control final drum
level. A master controller, steam flow and water flow elements
(orifice plates), pressure transducers and drum level transducer
shall be included.
Combustion Control - Single-Point
1. Provide a full modulating single-point electronic combustion
control package consisting of the following:
a. Master controller shall maintain steam pressure at boiler
outlet within 3% of set point.
b. The control shall be capable of handling load swings from
a steady state condition to an increase or decrease in load
equal to 20% of the maximum rated capacity of the boiler.
c. Provide a single jackshaft to regulate the flow of air and
fuel(s) to the burner. The jackshaft shall be driven from an
electric drive in response to the master steam pressure
controller. Provide characterizable fuel and air cams for
the optimizing of combustion fuel-to-air ratio throughout
the firing range.
Combustion Control - Parallel Positioning (Optional)
1. Provide a combustion control system that uses the concept of
controlling the fuel and air flows through separate actuators.
Provide a controller for boiler master, air flow controller, and
fuel flow controller. If a multiple-boiler application, include a
plant master controller.
2. The combustion control system shall be configured to interface
to a stand-alone burner management system. This interface
shall include interlocks for purge and low fire release.
Combustion control - Full Metering (Optional)
1. Provide a single-fuel-fired combustion control system that uses
the concept of parallel metering of fuel(s) and air with crosslimiting. For multiple boiler applications, include a plant master
single-loop controller in addition to a boiler-master, fuel flow
controller(s), and an air flow controller.
2. The combustion control system shall be configured to interface
to a stand-alone burner management system. This interface
shall include interlocks for purge and low-fire release.
3. Steam header pressure shall be controlled to within one
percent of set point without excessive hunting or overshooting.
Section C

G.
H.
I.
J.
K.
L.
Monitoring and Recording (Optional)

1. The following items shall be recorded. Measuring devices such
as orifice plate and transmitters shall also be included:
a. Steam flow.
b. Water flow.
c. Steam pressure.
d. Stack temperature.
e. Economizer outlet stack temperature.
f.
Feedwater temperature at economizer inlet.
g. Fuel water temperature at economizer outlet.
h. Fuel Flow.
i.
Drum Level.
j.
Percent Oxygen.
Multi-point indicator shall be provided for:
a. Furnace pressure.
b. Windbox pressure.
c. Boiler outlet.
A multi-point annunciator shall be provided for the following as
applicable:
a. Flame failure.
b. High-low gas pressure.
c. High-low oil pressure.
d. High-low oil temperature.
e. Low atomizing media.
f.
Combustion air.
g. Main and pilot failure.
h. Drum level, High-low.
i.
High steam pressure.
The annunciator shall include alarm horn, silence and test switch.
Forced Flue Gas Recirculation - (Optional)
Induced Flue Gas Recirculation (Optional)
Refer to FGR specifications.
PART 3 EXECUTION
3.1
GUARANTEE
1. Steam will contain not more than 1/2 of 1% moisture when
boiler water concentrations are maintained in accordance with
ABMA recommendations.
2. The boiler manufacturer shall guarantee the steam generating
capacity and thermal efficiency as stated herein, while the unit
is being fired with the primary fuel at the specified operating
conditions.
C-69

3.
4.
C-70
Section C
Performance and efficiency tests shall be conducted

immediately after completion of start-up. The manufacturer
must have a representative in attendance at the time the test is
conducted.
All equipment is to be guaranteed against defective design,
workmanship, or material for one year from the date of initial
operation, not to exceed eighteen (18) months from shipment.
3.2
TESTING
A. A shop hydrostatic test shall be performed at 1-1/2 times the design
pressure under the inspection of the Hartford Steam Boiler
Inspection and Insurance Company.
B. The boiler casing shall be subjected to a shop internal air test at a
minimum pressure of 8" WC, and held for five minutes without
dropping 2" WC to ensure that no leaks are present. Any detected
leaks shall be corrected.
C. Provide electronic continuity tests on all circuits to ensure minimal
start-up time.
3.3
EXAMINATION
Section C

Examine and verify size, location, and condition of concrete pads upon which boilers
are to be installed. Do not proceed with installation until unsatisfactory conditions
have been corrected.
3.4
INSTALLATION
A. General
1. Install boilers in accordance with manufacturers installation
instructions, requirements of state, provincial and local code,
and requirements of the local utility company. Maintain
manufacturers recommended clearances around and over
boilers.
B. Support
1. Install boilers on 15" high concrete pads. Pads to be located
under each boiler drum saddle.
C. Erection
1.
Assemble boiler trim shipped loose or unassembled for
shipment purposes. Follow manufacturers installation
instructions.
D. Gas Piping
1. Connect gas piping to boiler, full size of boiler gas train inlet,
and provide union with sufficient clearance for burner removal
and service.
E. Oil Piping
1. Connect oil piping to boiler, full size of inlet to burner, and
provide shutoff valve and union with sufficient clearance for
burner removal and service.
F.
Steam and Condensate Piping
1. Connect supply, return, and blowdown boiler tappings as
indicated, with shutoff valve and union, or flange, at each
connection.
G. Breeching
1. Connect breeching to boiler outlet, full size of outlet.
3.5
CLEANING
Flush and clean boilers, upon completion of installation, in accordance with manufacturers
instructions.
3.6
FIELD QUALITY CONTROL

A. Hydrostatically test assembled boiler and piping in accordance with
applicable sections of ASME Boiler and Pressure Vessel Code.
B. A representative of the National Board of Boiler and Pressure Vessel
Inspectors (or Provincial Boiler Inspection Agency in Canada) shall
inspect boiler installation, piping connections, and observe
hydrostatic testing and for certification of completed boiler units.
3.7
DEMONSTRATIONS
A. Services
1. After testing and inspection is complete, provide the services of
an authorized factory service representative to perform start-up
C-71
B.
C.
D.
C-72
Section C
and operation demonstration services.

Start-Up
1. Perform services in accordance with manufacturers written
start-up instructions. Test controls and demonstrate compliance
with requirements. Replace or repair damaged or
malfunctioning controls and equipment.
Maintenance and Operation Training
1. As part of the maintenance and operating instructions, review
data in operating and maintenance manual, including
preventative maintenance schedule and procedures, and
procedures for obtaining repair parts and technical assistance.
Demonstrate all phases of operation including start-up and
shut-down. Schedule training with Owner, and provide at least
7-day notice to Architect/Engineer.
Factory-trained authorized service and parts representative shall be
located within 4 hours of boiler plant.
Section C
(Hot Water Generator Specifications)
Shop-Assembled Watertube Hot Water Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-74
General Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-74
Packaged Watertube Generator(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-75
Design Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-75
Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-75
Boiler and Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-76
Boiler Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-76
Sootblower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-78
Generator and Trim Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-78
Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-78
Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-80
Instrumentation and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-80
Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-81
Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-81
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-81
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-82
Field Quality Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-82
Demonstrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-82
needs and application. A separate specification is provided for steam boiler packages and high temperature hot water packages.
C-73
09-09
Section C
PART 1 GENERAL
Industrial Watertube Hot Water Generator Specifications

1.1
SHOP-ASSEMBLED WATERTUBE HOT WATER GENERATOR
This specification shall govern the construction features, materials, fabrication, inspection,
and preparation for shipment of packaged-type, shop-assembled, watertube hot water generating equipment with burner assembly, all necessary appurtenances, controls, and auxiliary equipment mounted to the maximum practical extent, as an integral unit on a steel
base so as to make a complete self-contained assembly.
1.2
GENERAL REQUIREMENTS
A. Proposal
1. Complete description, drawings, and material specifications
and performance shall accompany each proposal.
B. Standards and Codes
1. The following regulatory codes and standards, publication
issue in effect at date of invitation for bids form a part of this
specification. All applicable components shall be designed and
constructed in accordance with these codes with additions or
modifications as required by this specification.
a.
American Society of Mechanical Engineers (ASME) Boiler
and Pressure Vessel Code, Section I, Power Boilers.
2. American Boiler Manufacturers Association (ABMA) Manual of
Industry Standards.
3. Underwriters Laboratories, Inc. (UL), UL 795, CommercialIndustrial Gas-Fired Heating Equipment.
4. National Fire Protection Association (NFPA), 85A, Prevention
of Furnace Explosions in Fuel Oil and Natural Gas-Fired Single
Burner Boiler Furnaces.
5. Steel Structures Painting Council (SSPC), Surface Preparation
SP-1.
6. National Electric Code (NEC).
7. National Electrical Manufacturers Association (NEMA).
8. All equipment shall comply with the state, provincial or
municipal laws and regulations governing the location where
the equipment is to be installed.
C. Documentation Requirements
1. Dimension drawing with dry and flooded weights, major
component identification, and service connection location and
size.
2. Electrical drawings including elementary ladder logic and field
component interconnection diagram.
3. Fuel train schematics.
4. Two (2) copies of certified ASME Manufacturers Data Reports
on the pressure vessel.
5. Operating and maintenance manuals.
6. Recommended spare parts list.
D. Design Requirements
1. Design continuous capacity: _____ Btu/hr.
2. Design supply temperature: _____ F.
3. Design return temperature: _____ F.
C-74
09-09
E.
F.
G.
PART 2 PRODUCTS
2.1
Section C
4. Operating pressure: _____ psig.

5. Flow rate:_____ gph.
6. Elevation above sea level: _____ ft.
7. Electrical characteristics: _____ Volts, _____ phase, _____ Hz.
8. Primary fuel: _____, Supply pressure _____.
9. Standby fuel: _____, Supply pressure _____.
10. Insurance Requirements _____.
Manufacturer
1. Subject to compliance with requirements, provide watertube
generator manufactured by Cleaver-Brooks; Division of AquaChem, Inc.
1. Fuel-to-water efficiency at above capacity is ____% when firing
oil and ____% when firing gas.
Heating Surface
1. The unit will have the following heating surface:
a.
Boiler heating surface: _____ sq-ft.
b. Water wall projected surface: _____ sq-ft.
c. Total heating surface: _____ sq-ft.
d. Furnace volume: _____ cu-ft.
PACKAGED WATERTUBE GENERATOR(S)
Generator shall be factory-assembled, packaged, mounted on heavy steel base frame, complete
with integral forced draft burner, burner controls, generator trim, and refractory. Factory-assemble
and wire generators so that only water, steam, fuel, blowdown, electrical, and vent connections
are required.
2.2
DESIGN PRESSURE
A. The pressure vessel shall have a design pressure of 260 psig in
accordance with ASME Power Boiler Construction Code Section 1,
and the laws of the state or province in which the equipment is to be
installed. The generator shall be registered with the National Board
of Boiler and Pressure Vessel Inspectors (or Provincial Boiler
Inspection Agency in Canada), and with the specific state or
provincial boiler inspection department.
2.3
DRUMS
The generator shall have one upper drum and one lower mud drum extending the full length of the
generator setting. The upper drum shall be of all welded construction, and shall be complete with
all necessary openings. The lower drum shall be of all welded construction, and shall be complete
with all necessary openings and internal water distribution pipe. The lower drum shall have a
flanged thermal sleeve type water inlet connection. The lower drum internals shall be of the jet
inducing circulation and mixing type. The upper drum head shall have a 12" x 16" manhole opening with plate, yoke, and gasket. Furnish one operating set of gaskets and two complete spare sets.
Drums shall be X-rayed and stress-relieved, as required, and under the inspection of the Hartford
Steam Boiler Inspection and Insurance Company.
B.
Drum Connections
1. Provide the following openings in the drums for all accessories
and piping connections. All flanges shall be raised faced and
C-75
09-09
Section C
2.
drilled 300 psig ANSI.

a. Supply: one (1) flanged.
b. Return: one (1) flanged.
c. Safety relief valves: (as required by ASME) flanged.
d. Water column: two (2) 1" screwed.
e. Top vent: one (1) 1" screwed.
f.
Chemical feed: one (1) 1/2 screwed.
g. Blowdown: one (1) 1-1/4 screwed.
All openings shall be properly protected from damage and
weather during shipment.
2.4
BOILER AND FURNACE

A. Furnace
1. The furnace shall employ six-wall cooling with the following:
a. Front wall tubes closely spaced around the burner.
b. Membrane inner furnace wall.
c. Tangent floor, roof, and outer furnace wall.
d. Triple row of rear wall tubes.
e. Double row of screen tubes at furnace exit.
2. All tubes shall terminate in the upper and lower drums. No
headers are to be used, and all heating surfaces in the furnace
are based on actual projected tube surface and membrane
surface. All tubes shall be cleanable by mechanical tube
cleaners. All tubes to be expanded into upper and lower
drums.
B. Boiler Section
1. The boiler convection section shall consist of 2" OD tubes
arranged in line with longitudinal rows of tubes arranged on
wide and narrow spacing to ensure proper and effective
arrangement of sootblowing equipment. This arrangement
shall also permit removal of any tube without the necessity of
removing adjacent tubes.
2. Tube Material
a. All tubes in the unit for boiler and furnace shall be 2" OD,
SA-178, Grade A, electric resistance-welded construction
in accordance with ASME Code.
2.5
BOILER ENCLOSURE
A. Casing
1. The boiler shall be enclosed with Cleaver-Brooks standard
double-panel casing with the portion of the casing exposed to
the products of combustion completely seal-welded to form an
air and gas-tight enclosure. The outer casing panels shall also
be welded.
2. The casing is to be supported off the structural steel frame and
shall not be welded or attached to tubing, thereby ensuring
free expansion of pressure parts within the casing enclosure.
C-76
09-09

B.
C.
D.
E.
F.
G.
H.
I.
Section C
Arrangement of Casing
1. Construction of the boiler enclosure shall be as follows:
a. 2.5.2.1 Front Wall - Furnace Area
b. 3", 4-way interlocking tile.
c. 4" high-temperature block insulation.
d. 10-gauge inner seal welded casing.
e. 2-1/2 low density block insulation.
f.
1/4 burner front plate.
g. 2.5.2.2 Rear Wall - Furnace Area
h. 3", 4-way interlocking tile.
i.
4" high-temperature block insulation.
j.
k. 2-1/2 low-density block insulation.
2. 2.5.2.3 Convection Section - Furnace
a. 10-gauge inner seal welded casing.
b. 4-3/8 low-density mineral wool block.
Furnace Floor
1. Furnace floor tubes shall be covered with 1-1/2 square edge
tile.
Drum Enclosure
1. The steam drum shall be shop-insulated with mineral wool
block and enclosed in a welded 10-gauge casing. All drum
heads will be shop-insulated and enclosed in a 10-gauge
casing. No further insulation in the field shall be required.
Access
1. Access to the furnace shall be through the burner opening in
the front wall, and through a separate (optional) refractory
lined door on the rear wall.
Observation
1. Two (2) air-cooled observation ports, with Pyrex eye shields,
shall be provided in the rear wall.
Air Pressure Test
1. The inner seal welded 10-gauge casing shall be subject to an
air pressure test of 8" WC, and shall be considered
satisfactorily tight if the air pressure drop does not exceed 2"
WC in five (5) minutes.
Baffling
1. The convection section shall contain vertical baffles of 10gauge steel to direct the flow of flue gases. The baffles shall not
require removal for tube replacement.
Insulation
1. The setting and insulation shall be so designed to ensure that a
maximum casing surface temperature of 130F is not exceeded
under full load firing with an ambient air temperature of 80F
and with a surface air velocity of two feet per second when
C-77
09-09
Section C
J.
K.
2.6
burner is at maximum output. The manufacturer shall

guarantee the design against overheating, warping, or burning
of the casing.
Pressure Connection
1. Provide a sensing location in furnace, free of turbulence from
flame, for draft control sample connection.
Painting
1. The surfaces shall be prepared per SSPC SP-l specifications
and finished with rust resistant primer and a high-quality, hightemperature finish coat of enamel paint.
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

A. Each unit shall be provided with the following trim, designed for a
minimum of 240 psig:
1.
Drum pressure gauge (1).
2. Safety valves, Consolidated/Kunkle (ASME Code).
3. Water column, Cleaver-Brooks (1).
4. Water gauge, Reliance 404-RS (1).
5. Gauge cocks, Reliance no. GC-451 (3).
6. Column drain, Velan S274B (1).
7. Gauge drain, Velan S274B (1).
8. Low water cutoff, Warrick probe (2).
9. Drum blow-off valve, Edwards No. 848-849 (1 Set).
10. Air vent, Velan S274B (1).
11. Continuous blow-off, Velan/Vogt (1).
B. All above items, including required piping and supports, shall be
assembled in the shop to assure proper fit. Drain piping shall be
extended for installation of valves at hand height.
2.8
BURNER
A. Provide a forced-draft, register-type burner arranged to burn the
specified fuels complete with gas electric ignition, observation port.
The windbox shall be ruggedly constructed, and of a proven design
that will assure an even supply of air to all quadrants of the burner
register. The burner shall be a standard product of the generator
manufacturer, specifically designed for the generator.
B. Forced Draft Fan
1. Assembly shall be attached to the windbox in such a way that
will allow easy access for maintenance. An inlet screen shall
be provided, and air volume regulated by inlet vanes. The fan
shall develop sufficient static pressure to insure proper
distribution of air over the entire turndown range of the burner.
C-78
09-09

C.
D.
E.
Section C
Operating and Safety Controls

1. The unit shall be provided with a full complement of operating
and safety controls consisting of not less than the following
items and features which shall be shop assembled:
a. Automatic gas-electric ignition system for gas operation.
b. Underwriters Laboratories listed, and Factory Mutual
approved microprocessor burner programming and safety
controller to automatically provide proper cycling for precombustion purge, ignition, start, stop, post-combustion
purge, and safety shutdown for the fuels as specified. This
controller shall be a standard product of the generator
manufacturer.
c. Electronic-type flame failure protection as part of the
program controller to provide safety shutdown on failure of
either the main flame or the pilot flame, with manual
reset, flame failure and high temperature alarm, all on
either oil or gas-firing.
d. Separate high-pressure safety cutoff and low fire hold
pressure control.
e. A mounted 8-1/2 diameter pressure gauge for drum
pressure.
f.
Blower damper to automatically proportion combustion air
to firing rate.
g. Air flow safety switch.
If natural gas is specified, then the following is to be provided:
1. Main manual gas shutoff valve with square head and wrench
handle.
2. Gas pressure regulators for both pilot and main gas.
3. Gas control valve to regulate gas flow.
4. Gas safety shutoff valves to conform to Underwriters
Laboratories and the specified site insurance carrier
requirements, consisting of main shutoff valve(s). As a
minimum, one valve shall be with a proof-of-closure switch.
5. Two (2) pilot gas solenoid valves, pilot vent valve, and manual
stop cock.
If oil is specified, provide the following:
1. Main shutoff valve (two required for light oil).
2. Integral fuel oil metering controller with pressure gauges and
temperature gauges if heavy oil.
3. Components to be Factory Mutual and Underwriters
Laboratories approved. The configuration, along with safety
interlocks, shall be in accordance with the specified site
insurance requirements.
4. If heavy oil, a reverse oil-purge pump shall be supplied to
evacuate the oil gun on burner shutdown.
C-79
09-09
Section C

F.
G.
H.
All controls for the generator shall be enclosed in a suitable cabinet,

with hinged door and lock, and containing all necessary relays,
magnetic starters (if provided), conductors, terminal blocks, fuse
blocks, fuses, transformers, switches, rheostats and colored
indicating lights. All instruments on the panel front shall be
identified by nameplate. Provide, on the panel, an alarm horn to
indicate flame failure and low-water level. All wire terminations
shall be numbered in accordance with the applicable wiring
diagram. All wiring shall be done in conformity with the National
Electric Code.
Two (2) 6" diameter pressure gauges and two (2) 5" diameter
thermometers to be field-installed into the supply and return lines.
Provide an interlock to the burner operation for low water
circulation. This shall include an orifice plate and differential
pressure transmitter to be field-installed. The contractor shall supply
appropriate flanges. The generator manufacturer to supply a threevalve manifold assembly for the transmitter.
2.9
TESTS
A. A shop hydrostatic test shall be performed at 1-1/2 times the design
pressure under the inspection of the Hartford Steam Boiler
Inspection and Insurance Company.
B. The generator casing shall be subjected to a shop internal air test at
a minimum pressure of 8" WC and held for five minutes without
dropping 2" WC to insure that no leaks are present. Any detected
leaks shall be corrected.
C. Provide electronic continuity tests on all circuits to ensure minimal
start-up time.
2.10
INSTRUMENTATION AND CONTROL

A. System Instrumentation (Optional)
1. Provide a freestanding panel piped, pre-wired with a finish
coat of paint complete with the following:
2. Four (4) pen recorder for water flow, water supply temperature,
water return temperature, and stack temperature.
3. Draft gauges, illuminated vertical scales for windbox pressure,
furnace pressure and boiler outlet pressure.
4. Temperature indicators, digital readouts for return water
temperature, supply water temperature and stack temperature.
5. Annunciator, first-out indication, silence and reset buttons, per
Instrument Society of America (ISA) standard F3M-3-14.
6. Canopy light.
B. Combustion Control - Single Point
1. Provide a full modulating single point electronic positioning
combustion control consisting of the following:
a. Master regulator to maintain temperature at generator
outlet within 3% of control setpoint.
C-80
09-09

b.
c.
PART 3 EXECUTION
Section C
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.
3.1
GUARANTEE
A. The generator manufacturer shall guarantee the Btu/hr generating
capacity at the specified temperatures and pressures, and (fuel-towater) efficiency as stated herein, while the unit is being fired with
the primary fuel at the specified operating conditions.
B. Performance and efficiency tests shall be conducted immediately
after completion of start-up. The manufacturer must have a
representative in attendance at the time the test is conducted.
C. All equipment is to be guaranteed against defective design,
workmanship, or material for one year from the date of initial
operation, not to exceed eighteen (18) months from shipment.
3.2
EXAMINATION
Examine and verify size, location, and condition of concrete pads upon which the generators are
to be installed. Do not proceed with installation until unsatisfactory conditions have been corrected.
3.3
INSTALLATION
A. General
1. Install generators in accordance with manufacturers
installation instructions, requirements of state, provincial and
local code, and requirements of local utility company. Maintain
manufacturers recommended clearances around and over
generators.
B. Support
1. Install generators on 15" high concrete pads.
C. Erection
1. Assemble generators trim shipped loose or unassembled for
shipment purposes. Follow the manufacturers installation
instructions.
D. Gas Piping
1. Connect gas piping to the generators, full size of generator gas
train inlet, provide union with sufficient clearance for burner
removal and service.
E. Oil Piping
1. Connect oil piping to the generators, full size of inlet to burner,
provide shutoff valve and union with sufficient clearance for
burner removal and service.
F.
Connect supply and return piping.
G. Breeching
1. Connect breeching to generator outlet, full size of outlet.
C-81
09-09
Section C

3.4
CLEANING
Flush and clean generators upon completion of installation, in accordance with manufacturers
instructions.
3.5
FIELD QUALITY CONTROL

A. Hydrostatically test-assembled generator and piping in accordance
with applicable sections of ASME Boiler and Pressure Vessel Code.
B. Arrange with National Board of Boiler and Pressure Vessel
Inspectors (or Provincial Boiler Inspection Agency in Canada) for
inspection of generator installation, piping connections, observation
of hydrostatic testing, and for certification of completed generator
units.
3.6
DEMONSTRATIONS
A. Services
1. After testing and inspection is complete, provide the services of
an authorized factory service representative to perform start-up
and operation demonstration services.
B. Start-Up
1. Perform services in accordance with manufacturers written
start-up instructions. Test controls and demonstrate
compliance with requirements. Replace or repair damaged or
malfunctioning controls and equipment.
C. Maintenance and Operation Training
1. As a part of the maintenance and operating instructions,
review data in operating and maintenance manual, including
preventative maintenance schedule and procedures, and
procedures for obtaining repair parts and technical assistance.
Demonstrate all phases of operation including start-up and
shut-down.
2. Schedule training with the owner, and provide at least 7-day
notice to the Architect/Engineer.
C-82
09-09
Section D
CONTROLS
TABLE OF CONTENTS
HAWK ICS LEVEL COMPARISON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
CB-HAWK ICS BOILER MANAGEMENT CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5

SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS - PARALLEL POSITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-5
D-7
D-7
D-8
D-12
CB-HAWK ICS COMBUSTION AIR FAN VARIABLE SPEED DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-15
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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D-15
D-15
D-16
D-17
CB-HAWK ICS OXYGEN MONITORING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-18

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D-18
D-19
D-19
D-19
CB-HAWK ICS ETHERNET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-21

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D-21
D-21
D-21
D-22
CB-HAWK ICS PAGING and REMOTE DIAL-UP ACCESS with MODEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-23

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D-23
D-23
D-23
D-23
CB-HAWK ICS LEAD/LAG FOR TWO BOILER SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-24

APPLICATION AND SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-24
D-24
D-25
D-25
CB-HAWK ICS LEAD/LAG for up to EIGHT BOILERS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-26

APPLICATION AND SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-26
D-27
D-27
D-28
D-1
09-09
Section D
CB780E CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-29
FEATURES AND BENEFITS . . . . . . . . . . . .

PRODUCT OFFERING . . . . . . . . . . . . . . . .
ENGINEERING DATA . . . . . . . . . . . . . . . .
SAMPLE SPECIFICATION . . . . . . . . . . . . .
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.D-29
.D-30
.D-30
.D-31
CB120-120E CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-32

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.D-32
.D-33
.D-33
.D-33
CB100E CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-34

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.D-34
.D-35
.D-35
.D-35
CB110 CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-36

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.D-36
.D-36
.D-37
.D-37
LEAD/LAG SYSTEMS (TWO BOILER LEAD/LAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-38
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-38

PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-38
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-39
LEAD/LAG SYSTEMS (TWO THROUGH FOUR BOILER LEAD/LAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-41

SAMPLE SPECIFICATIONS . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-41
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-42
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-42
LOW FIRE HOLD CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-44

MINIMUM TEMPERATURE LOW FIRE HOLD CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-45

ASSURED LOW FIRE CUTOFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-47

REMOTE MODULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-48

SAMPLE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-48
D-2
09-09
Section D
AUTOMATIC FUEL CHANGEOVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-49
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-49

PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-49
SAMPLE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-49
AccuTrim O2 TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-50
FEATURES AND BENEFITS . .

PRODUCT OFFERING . . . . . .
ENGINEERING DATA . . . . . .
SAMPLE SPECIFICATIONS . .
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D-50
D-51
D-51
D-52
CB-HAWK ICS ADAC ADVANCED DEAERATOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-55

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D-55
D-56
D-57
D-57
LCS-150E LEVEL CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-63

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D-63
D-63
D-63
D-64
CB-HAWK Compact ICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-65

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D-65
D-66
D-66
D-66
CB SysteMAX HYDRONIC CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-69
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-69

ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-71
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-72
D-3
09-09
Section D
HAWK ICS LEVEL COMPARISON

Table D-1. Hawk ICS Level Comparison
Feature
Processor
5.5" Monochrome Screen
6" Color Screen
10" Color Screen
Honeywell CB780E
Fireye CB120E
O2 Monitoring
O2 Trim & Programming
O2 Hardware
Variable Speed Drive Programming
Variable Speed Drive Hardware
Parallel Positioning Programming
Parallel Positioning Hardware
Additional 4 User Analog Inputs (Base 2 IN's Only)
Expanded Annunciation/3 User DI
Combustion Air/Ambient Temperature Monitoring
2 Boiler Lead/Lag Programming
2 Boiler Lead/Lag Hardware
Dual Set Points
Stack Temp with High Cutoff Set Point
Thermal Shock Protection
Assumed Boiler Efficiency Reading
Corrected Boiler Efficiency Reading
Hot Stand By
Ethernet Communications
E-Mail and Paging (text messaging only) via Internet
Paging Via Phone Line (Requires modem)
Lan/Wan Interfacing
Building Automation Interface
Remote Monitoring Software (Rs-View)
Level Master Interface (Level and Alarm Only)
Master Panel Lead/Lag 3-8 Boilers
Remote Modulation or Set Point Input (See Note 1)
Remote Stop/Start (See Note 1)
PLC Based Combustion Control
Alternate Fuel Capabilities
Flash Card Reader - Touch Screen
Flash Card Reader - Processor
Draft Control - Integrated in PLC
Alarm Bell
Alarm Silencer Button Via Touch Screen
Base L32B
L32E
Standard
N/A
N/A
Standard
Optional
External
External
N/A
N/A
N/A
N/A
N/A
Optional
Optional
N/A
Included
Optional
Included
Included
Included
Included
N/A
Included
Included
Optional
Optional
Optional
Optional
Optional
N/A
Optional
Included
Included
Included
Included
Included
Included
External
Included
Included
N/A = Not Available

Note 1: Not avaialble when either 2 boiler Lead/Lag or
Master Panel options are selected
D-4
09-09
Intermediate L32I
L32E
N/A
Standard
Optional
Standard
Optional
Optional
External
Optional
Included
Optional
External
Optional
Optional
Optional
Optional
Included
Optional
Included
Included
Included
Included
With O2 Option
Included
Included
Optional
Optional
Optional
Optional
Optional
Included
Optional
Included
Included
Included
Included
Included
Included
External
Included
Included
Advanced L35E
L35E
N/A
N/A
Standard
Standard
Optional
Optional
Integrated
Optional
Included
Optional
Integrated
Optional
Included
Included
Optional
Included
Optional
Included
Included
Included
Included
With O2 Option
Included
Included
Optional
Optional
Optional
Optional
Optional
Included
Optional
Included
Included
Included
Included
Included
Included
Included
Included
Included
Section D
CB-HAWK ICS Integrated Boiler Control System

The CB-HAWK ICS is a state-of-the-art boiler control system that integrates the
functions of a Programmable Controller and Burner Management Controller, as well
as other boiler operating and ancillary controls. The CB-HAWK ICS system
incorporates a graphical Human Machine Interface (HMI), which displays boiler
parameters, fault annunciation and alarm history, as well as providing access to
boiler configuration and control functions. The CB-HAWK ICS system includes
complete boiler firing rate controls for steam or hot water boilers. The CB-HAWK
ICSs advanced technology features utilize the latest communication methods, such
as Modbus, Ethernet, and the Internet. The CB-HAWK ICS also has the capability of
interfacing with various building/plant automation systems. Additional features
include lead/lag capability; e-mailing and paging of alarms, remote monitoring, and
HMI alarm history printing.
The CB-HAWK ICS Integrated Control System may be used on most types of steam
or hot water boilers, including firetube, industrial watertube, and commercial
watertube. It is designed to operate with a gas, oil, or combination burner using a
single-point modulating control or a parallel-positioning fuel-air ratio control system.
In addition to installation on new boilers, the CB-HAWK ICS can be added as a
retrofit to existing boilers. Contact your local authorized Cleaver-Brooks
representative for details.
The CB-HAWK ICS system is offered in Advanced, Intermediate, and Base
packages. Table D-1 shows a feature comparison.

Advanced Technology
Standard Features:
Integrates control function of burner sequencing and safety with firing rate, fuelair ratio, and operating limit controls
Incorporates a programmable controller
Touch screen graphical human machine interface (HMI)
Monitors and displays connected boiler parameters
Optimizes boiler firing rate control
Alarm/fault indication and history
On-screen fault diagnostics
Built-in two boiler lead/lag control
Night/day setback control
Remote modulation
Remote setpoint
Assured low fire cut-off
Assured start permissive safety interlocking
High stack temperature alarm and shutdown
Boiler efficiency calculations
D-5
09-09
Section D
Optional Features:
E-Mail and pager alarm/fault forwarding
Fuel-air ratio control
Display of boiler water level with optional CB Level Master (Advanced and
Intermediate systems only)
Building/plant automation system interface
Remote monitoring and diagnostics
O2 monitoring and trim
Internet parts and service lookup
Lead/lag capability for multiple boiler systems
Variable speed drive on combustion air fan
Expanded annunciation
Safety Provisions and Diagnostics:

A. Integrated Burner Management
Utilizes the CB780E or CB120E flame safety control
Communicates with the programmable controller via Modbus
Burner Control status, faults, and diagnostics displayed on HMI
B. Integrated Boiler Controls
Operating and modulating controls
Variable speed drive fault shutdown communicates via Modbus (optional)
Password protection of programmable controller logic
Password protection of parallel positioning control (optional)
Powerful Display/Diagnostic Capabilities:
Touch screen graphical human machine interface (HMI).

Advanced system: 10 color touch screen
Intermediate system: 6 color touch screen standard - 10 color screen optional
Base system: 5.5 monochrome touch screen
HMI allows easy screen navigation to monitor various boiler parameters &
diagnostics and to configure boiler controls.
Displays alarms/faults, burner status, and flame signal from the flame safety
control.
Diagnostics in plain English and prioritized fault annunciation simplify

troubleshooting. Last 100 faults are stored.
Displays boiler steam pressure, water temperature, firing rate, Stack

temperature, boiler efficiency, combustion air temperature (optional), Flue
gas O2 concentration (optional), combustion air fan motor speed and kw
(vsd option), combustion air pressure (with VSD option), water level (CBLevel Master option), shell water temperature (steam boilers), and other
control points.
Displays boiler operating status (e.g. Warm Up, Auto/Manual, Boiler

On, fuel selection, etc.).
Displays boiler firing rate control parameters
D-6
09-09
Section D
and settings.
Provides remote monitoring and diagnostic capabilities (optional).
Touch screen controls simplify screen navigation and boiler configuration
Reliable and accurate controls using microprocessor-based programming
Simplified Servicing:
Diagnostics and fault history, up to 100 faults, through touch screen display
simplifies troubleshooting procedures
E-Mail forwarding and paging of system fault codes (optional)
Connection to user building automation system (optional)
PRODUCT OFFERING
Included in each CB-HAWK ICS system is the following:
Programmable controller
Touch screen HMI
Modbus communication interface to burner management or optional

Variable Speed Drive
Built-in Ethernet/IP capability via L35E (Advanced system) or L32E

(Intermediate and Base) processors
Various controller input/output modules
Flame safety controller (CB780E or CB120E)
Various temperature and pressure sensors
E-mailing via Ethernet
Optional Features and Equipment: (see individual specifications for these options)
OPC server software for interface with building/plant automation system
Lead/Lag control of multiple boilers
Fuel-Air Ratio Control system and actuators
Variable speed drive for combustion air fan motor
O2 analyzer and/or external O2 trim system
Combustion air temperature sensor
Economizer stack flue gas temperature, feed water temperature, oil

temperature, and gas & oil pressure sensors
Steam, water, and fuel flow monitoring
CB Level Master primary safety water level control
Paging via phone line with modem
ENGINEERING DATA
Supply voltage: 120 VAC (+10%/-15%) 50 or 60 Hz.
Maximum total connected load: 1200 VA
Operating temperature limits: 32 to 130F

D-7
09-09
Section D
85% RH continuous, non-condensing, humidity
0.5G continuous vibration
CB-HAWK ICS Integrated Boiler Control System

PART 1 GENERAL
1.1
GENERAL
A. Each unit shall be factory equipped with a boiler control system
providing technology and functions equal to the CB-Hawk ICS boiler
control system.
B. Each Boiler Control System shall be factory equipped with a preconfigured Programmable Controller and Human Machine Interface
(HMI).
PART 2 PRODUCTS
2.1
MAJOR SYSTEM COMPONENTS

A. Major system components shall include:
1. Programmable controller
2. Touch screen HMI
3. Modbus communication interface to burner management or
optional Variable Speed Drive
4. Various controller input/output modules
5. One burner management controller and wiring sub-base
6. One flame scanner: Infrared, Ultra-Violet, or UV Self-Check
7. One flame amplifier, to correspond with the selected flame
scanner
8. Various temperature and pressure sensors
B. Major functions that the Boiler Control System shall provide:
1. Automatic sequencing of the boiler through standby,
pre-purge, pilot flame establishing period, main flame
establishing period, run and post purge
2. Flame proving and lockout on flame failure during pilot flame
proving, main flame proving, or run
3. Low fire damper/valve position for flame ignition trials
4. Full modulating control of fuel and combustion air
5. Utilize solid state controls and sensors to provide various
control functions, such as:
a. On/Off, and Modulating control
b. Modulating control algorithm shall be ProportionalIntegral-Derivative (PID) type
c. Thermal shock protection based on water temperature
and setpoint
d. Various high and low limit alarms and shutdowns
6. Touch screen graphical operator interface and monitoring
a. Manual control of the boiler-firing rate utilizing control
screens on the HMI to increment and decrement the firing
rate
D-8
09-09
Section D
b.
C.
On screen indication of burner management controller

status and diagnostics
c. On screen real-time display of all connected process
parameters
d. On screen display of system alarms and faults
e. On screen history of alarms and faults
f.
On screen water level indication (optional) and alarm(s)
g. Printing Alarm/Fault history
7. E-mail or paging of boiler alarms (with either Ethernet/IP or
modem option)
8. Building/plant automation system interface (with Ethernet/IP
option)
9. Ethernet communications (with Ethernet/IP option)
10. Tamper resistant control logic and password protection.
11. Night/day setback control
12. Stack flue gas, combustion air (optional), and shell (water)
temperatures
13. Boiler efficiency calculation (corrected efficiency with O2
option - Advanced and Intermediate systems)
14. Outdoor reset for hot water boilers
15. Remote modulation or firing rate setpoint control
16. Assured low fire cut-off (ALFCO)
17. Assured start permissive safety interlocking
The Boiler Control System shall provide the following safety
provisions for:
1. Integrated burner management
a. Examine all load terminals to assure it is capable of
recognizing the true status of the external controls, limits
and interlocks. If any input fails this test, the burner
management system should lockout on safety shutdown.
b. Closed-loop logic test verifies integrity of safety critical
loads (ignition, pilot, and main fuel valves) and must be
c. Pre-ignition interlocks (fuel valve proof of closure, etc.)
and flame signal checked during Standby and Pre-Purge.
d. Dynamic checking of the flame signal amplifier. The
control flame signal amplifier must be able to recognize a
no flame signal during this dynamic amplifier check.
e. Safe start check and expand check to include monitoring
flame signal during standby.
f.
High and Low fire switches checked for proper
sequencing.
g. Tamper-proof purge timing and safety logic.
2. Integrated boiler controls
a. Operating and Modulating control
b. Variable Speed Drive (if used) fault shutdown
D-9
09-09
Section D
c.
d.
D.
E.
F.
G.
Password protection of programmable controller Logic

Password protection of parallel positioning control (if
used)
The Boiler Control System shall provide annunciation and
diagnostics:
1. Active alarm annunciation
2. Provide historical alarm information for on screen display
3. Detects and isolates an alarm, and reports internal circuit
faults
4. Printer output capable for logging alarms
5. Capability of printing alarm history of date, time, cycle of
occurrence and date and time of acknowledgement up to the
most recent 100 faults
6. English text description of the system fault and troubleshooting
procedures
7. Water level indication and low water shutdown alarm
8. Dynamic self-checking
The Boiler Control System shall be able to operate in these
environmental conditions.
1. Supply Voltage: 120 VAC (+10%/-15%) 50 or 60 Hz
2. Maximum total connected load: 1200 VA
3. Operating temperature limits: 32 to 130F
4. 85% RH continuous, non-condensing, humidity
5. 0.5G continuous vibration
All Boiler Control System wiring shall be in accordance with the
National Electrical Codes and local electrical codes.
Boiler Control System component functions shall be as follows:
1. Burner Management Controller: Provides burner sequencing
logic to meet FM/IRI/UL/cUL approval body requirements.
2. Touch Screen Graphical Interface: Provides user interface to
the control system, boiler overview screen with connected
boiler parameter readouts, burner management control status
screen, alarm banners, diagnostic screens for fault
troubleshooting, alarm history screen, system firing rate screen
and system configuration screens.
3. Modbus communication network: provides communication
between the programmable controller and burner management
system (and optional Variable Speed Drive).
4. Various programmable controller input/output modules:
Provides interface for discrete powered and/or isolated relay
signals, as well as for analog signals, from and/or to other
input/output devices.
D-10
09-09
Section D
5.
H.
Stack temperature sensor: measures and transmits a signal to

the programmable controller in relation to boiler exit flue gas
temperature. It is used for indication and in the calculation of
boiler efficiency; it can also be used for high stack temperature
alarm and shutdown.
6. Steam pressure transmitter (steam boiler): provides an analog
signal to the programmable controller for indication of boiler
steam pressure; utilized for on/off and modulating control of the
burner.
7. Water temperature transmitter (hot water boilers): provides an
analog signal to the programmable controller for indication of
boiler water temperature; utilized for thermal shock protection,
on/off, and modulating control of the burner.
8. Water (shell) temperature sensor (steam boilers): measures and
transmits a signal to the programmable controller in relation to
boiler water temperature; used for indication and thermal
shock protection.
Optional equipment/features (see also individual Boiler Book
sections below)
1. Lead/Lag Control for multiple boiler systems
2. Parallel Positioning hardware (Advanced and Intermediate
systems)
3. Variable Speed Drive for combustion air fan motor (Advanced
and Intermediate systems)
4. O2 analyzer and/or external O2 trim system
5. Combustion air temperature sensor (Advanced and
Intermediate systems): measures and transmits a signal to the
programmable controller in relation to the combustion inlet
temperature for indication and for use in the calculation of
boiler efficiency; also can be used for high combustion air
temperature alarm and shutdown, based on setpoint
6. Economizer flue gas inlet and outlet temperatures, feed water
temperature, economizer water in and out temperature (no
thermocouple inputs with Base system)
7. Steam, water & fuel flow monitoring
8. CB Level Master primary safety water level control
9. Email and paging (text messaging) via Ethernet
10. Paging via phone line (requires modem)
11. Building automation interface
12. Remote monitoring with RSView software
D-11
09-09
Section D
HAWK ICS Parallel Positioning System

PART 1 GENERAL
The purpose of the parallel positioning system is to control fuel, combustion air and
flue gas recirculation (FGR) if applicable. Individual actuators will be used to control
each of above functions.
PART 2 PRODUCTS
CONTROLLER - A/B COMPACT LOGIX PLC COMPRISING THE
FOLLOWING COMPONENTS
2.1
Row 1
Processor L35E
SM2 Modbus Module
Power Supply 1769-PA4
Discrete Input Module 1769-IA16
Discrete Output Module 1769-OW8I
Analog Input Module 1769-IF4
Analog Output Module 1769-OF2
Themocouple input module 1769-IT6
Discrete Input Module 1769-IA16
Analog Output Module1769-OF2
Row 2
Power Supply 1769-PA2
Analog Output Module 1769-OA16
Expansion cable
Right hand terminator
2.2
HMI (HUMAN MACHINE INTERFACE)
10 color PanelView touch screen with serial communication.
2.3
ACTUATORS
Quantity up to 4.
Typical actuators arrangement:
Combustion air
Gas
Oil
FGR
D-12
09-09
Section D
ACTUATOR SPECIFICATIONS
General: Reversing Motor with Position Feedback
Application: Control of Dampers and Fuel Valves
Note- Position will be controlled by a PLC; no Servo-Positioning Module is required.
Rotary: 90 Degree Rotation
30 Second Timing (for 90 Degrees)
36 in-lb Torque
0.1% Resolution (over 90 Degrees)
Electrical:
120 VAC Preferred
Control Signal: Pulse position with 0-10 VDC feedback
Duty: Continuous
Enclosure: NEMA 1 Minimum; NEMA 3 or 4 Optional
Approvals:
UL Listed or Recognized and/or FM Approved
Environmental: Temperature 0-130F.
Whenever possible design without linkages shall be used.
Control Description
Control shall be parallel positioning with cross limiting.
Note: System will not be capable for simultaneous fuel firing.
Air control
Firing rate control signal is compared with corrected fuel actuator position signal.
Highest of the two values is a control signal for the combustion air actuator. Velocity
limitter with adjustments in both directions (up and down) shall be provided.
Control signal to the actuator is compared with feedback signal. If unacceptable
error is detected for the preset amount of time, system will be shut down and fault
will be annunciated.
Fuel control
Firing rate control signal is compared with air actuator position signal. Lowest of the
two values is an input to the function generator. Output of the function generator is a
control signal for the fuel actuator. Function generator has to have a minimum of 10
break points. The X-axis and Y-axis parameters must follow the relationship:
X[1] < X[2] < X[3] <... < X[n]
Y[1] < Y[2] < Y[3] < < Y[n]
Where n is the number of break points (20 maximum).
Velocity limiter with adjustments in both directions (up and down) shall be
provided.
D-13
09-09
Section D
FGR control
Firing rate control signal is compared with air actuator position signal. Lowest of the
two values is an input to the function generator. Output of the function generator is
a control signal for the FGR actuator. Function generator has to have a minimum of
10 break points. The X-axis parameters must follow the relationship:
X[1] < X[2] < X[3] <... < X[n]
Where n is the number of break points (20 maximum).
Velocity limitter with adjustments in both directions (up and down) shall be
provided.
D-14
09-09
Section D
CB-HAWK ICS COMBUSTION AIR FAN

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

Improved Efficiency:
Energy Savings:
Reduces electrical energy consumption
Soft starting reduces electrical and mechanical stress on the motor,

extending the life of the motor
Provides Substantial Savings from Mid to Low Fire modulation points
Average Payback in approximately 6 8 Months
Communication:
Communicates with the Boiler Controller via Modbus
Provides Drive process information on the Boiler Control Panel Display
Provides Drive faults and troubleshooting suggestions, in Plain English, on

Boiler Control Panel Display
Cleaver-Brooks shall supply the following equipment:
Adjustable Frequency Variable Speed Drive.
VSD Compatible Combustion Air Fan Motor.
PRODUCT OFFERING
D-15
09-09
Section D
ENGINEERING DATA
Drive:
Ambient Operating Temperatures: 32 122F
Altitude: 3300 Ft (1000 m) Max without derating
Shock: 15G peak for 11ms duration (1.0 ms)
Vibration: 0.152 mm (0.0006 in.) displacement, 1G peak
Voltage Tolerance: -10% of minimum, +10% of Maximum
Frequency Tolerance: 47 63 Hz
Input Phases: Three-phase input provides full rating of all drives, Singlephase operation provides 50% of rated current
Frequency Accuracy: Digital Input Within 0.01% of set output

frequency, Analog Input Within 0.4% of maximum output frequency
Intermittent Overload: 110% Overload capability for up to

1 minute, 150% Overload capability for up to 3 seconds
Current Limit Capability: Proactive Current Limit programmable from 20 to

160% of rated output current; Independently programmable proportional
and integral gain
Line Transients: Up to 6000 volts peak per IEEE

C62.41-1991
Ground Fault Trip: Phase-to-ground on drive output
Short Circuit Trip: Phase-to-phase on drive output
Drive Overcurrent Trip: Software 20 to 160% of rated current, Hardware

200% of rated current (typical), Instantaneous 220 to 300% of rated
current (dependent on drive rating)
Electronic Motor Overload Protection: Class 10 protection with speed

sensitive response. Investigated by U.L. to comply with N.E.C. Article 430,
UL File E59272 Volume 12
See Drive Manual for other, Model and Voltage Specific, specifications.
Motor:
Motor suitable for variable speed drive service
Variable Torque, 3 phase
Other specifications based on Specific Horsepower, Voltage, and Frequency

requirements. Contact your local Authorized Cleaver-Brooks Representative
for further details.
D-16
09-09
Section D
CB-HAWK ICS Combustion Air Fan Variable
Speed Drive
PART 1 GENERAL
A.
B.
C.
D.
E.
The Boiler Manufacturer shall provide a Variable Speed Drive

controller for use on the burners Combustion Air Fan blower motor
for the purpose of providing Improved Boiler Efficiency and Reduced
Electrical Energy consumption.
The Drives voltage, frequency, and current ratings shall be rated in
accordance with the electrical requirements as dictated by job site
specifics, and for the properly rated motor horsepower.
The Variable Speed Drive must be capable of communicating over
the Modbus protocol.
A Motor suitable for variable speed drive service must be supplied
for use in conjunction with the Variable Speed Drive, and sized to
match the motor requirements of the Combustion Air Fan Blower.
Variable Speed Drive shall be interlocked with boiler control to
ensure safe operation.
D-17
09-09
Section D
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-50, Oxygen Trim, of the CB Boiler Book.

Integrated Type In-Situ Zirconia Oxygen Analyzer:
Reduces wiring, piping and installation costs
Allows replacement of the zirconia cell on site
Built-in heater assembly of the probe can be replaced on site
Can be configured on site without opening the cover using an infrared

sensor
O2 measurement circuitry built into probe head electronics
O2 Level percentages displayed on the Boiler Control Panel Human Machine

Interface (HMI)
Provides accurate Boiler Efficiency Calculations with the CB-HAWK ICS

Programmable Controller
Separate analyzer/converter display panel not required
User Configurable Alarm Points
Low O2 Alarm
Analyzer Probe is Direct Insertion, In-situ Zirconia Type Which Provides:
High accuracy
Fast Response
Proven Reliability
D-18
09-09
Section D
PRODUCT OFFERING
In-Situ Zirconia Probe and Analyzer
Process Variable% O2 Readout on Control Panel HMI
Accurate Efficiency Calculations
Options:
Separate O2 Converter/Display Panel
Replacement Zirconia Cell
Auto Calibration Pneumatics
Replacement Heater Assembly
Remote Indicator/Alarm
Probe Stack Mounting Adapter
Calibration Gas Kit
ENGINEERING DATA
Ambient Temperature: -4 to 131F (-20 to +55C)
Sample Gas Temperature: 32 to 1292F (0 700C)
Sample Gas Pressure: -1.5 to 73.8 in Hg (-5 to +250 kPa)
Output Signal: 4 20mA DC, One Point, Maximum Load Resistance 550 Ohms
Digital Output (HART): 250 500 Ohms
Contact Output Signal: Two Points, 30 VDC 3A, 250 VAC 3A (one is fail safe
normally open)
Contact Input Signal: Two Points
Reference Air: Natural Convection, Instrument Air, pressure compensated
Instrument Air: 200 kPa plus the pressure in the furnace
Power Supply: 100 240 VAC, 50/60Hz
Power Consumption: Max 300 W, approx. 100 W for ordinary use
CB-Hawk ICS Oxygen Monitoring System
PART 1 GENERAL
A.
B.
This specification covers the hardware and monitoring functions of

the CB-HAWK ICS Oxygen monitoring system. The system monitors
and displays Oxygen concentration and is used, in conjunction with
combustion air and stack flue gas temperature sensors, to calculate
the overall efficiency of the boiler.
The system shall be completely configured from the factory requiring
only job specific data to be entered (or modified) in the field.
Note: O2 Sensor Requires calibration in the field!
D-19
09-09
Section D
PART 2 PRODUCTS
2.1
PART 3 EXECUTION
This system is applicable to modulating burners using the CB-HAWK ICS Integrated
Control System. This system shall monitor and display O2 concentration in the
boilers exit flue gas and provide overall boiler efficiency calculations.
HARDWARE
A. Hardware shall consist of the following:
1. Oxygen Sensor
2. Integrated type Zirconia Oxygen Analyzer
3. Direct Insertion Type
4. Built-in Heater Assembly
5. 4-20mA DC Process Variable Output
6. Heater to be of field replaceable construction
7. Cell to be of field replaceable construction
B. Analyzer
1. Shall be of the Integrated Type (in probe head)
2. Provide 4 20mA DC Signal output in relation to process
variable for remote display
C. Monitoring System
1. Indicate O2 Percentages
2. Provide Low O2 Alarm Indication
3. Perform Efficiency Calculations and display results using
O2 percentages
D-20
09-09
Section D
CB-HAWK ICS ETHERNET COMMUNICATION

The CB-HAWK ICS Ethernet communication package provides Ethernet
communications between the CB-HAWK ICS programmable controller and other
Ethernet compatible devices such as the Boiler Room Master Lead/Lag Control
Panel, Building/Plant automation system, and the Internet.
Provides communication between the CB-HAWK ICS programmable controller

unit and other Ethernet Compatible Devices
Provides interface capability with many Building/Plant automation systems

when utilizing OPC server or protocol bridge
Provides interface with plants LAN/WAN
Provides interface to the Internet (requires static IP address)
E-mailing of boiler alarms/faults
Provides means of connection between various boiler room control systems,

such as the CB-HAWK ICS Master Panel for lead/lag control
Provides means of connection to a remote Personal Computer
Ethernet Industrial Protocol
IEEE 802.3 Physical and Data Link Standard
Ethernet TCP/IP protocol suite industry standard
Control and Information Protocol (CIP) Compliant
PRODUCT OFFERING
Optional Ethernet Communication Hub (necessary for stand-alone boiler (no

Master Panel) connection to LAN/WAN and/or Paging Modem option)
E-mail functionality requires customer provided e-mail service and address
Modular connection to CB-HAWK ICS Programmable Controller unit
Ethernet Industrial Protocol (Allen-Bradley EPIC)
Follows Ethernet Rules and Practices
High Noise Rejection
Cabling: Category 5E rated twisted pair cable (solid core, PVC jacket with RJ45
connections).
Meets Open Industrial Network Standards
OPC (OLE Process Control) communication compatibility with RSLinx OPC

Server software
ENGINEERING DATA
D-21
09-09
Section D
CB-HAWK ICS Ethernet Communication
PART 1 GENERAL
The Boiler Manufacturer shall furnish and install a control module capable of
Ethernet communications between the boilers programmable logic control system
and other Ethernet compatible devices, as needed, and provide the following
minimum requirements:
A.
B.
C.
D.
E.
F.
G.
H.
Interface with the Compact Logix Programmable Controller Protocol

Ethernet Industrial Protocol (Allen-Bradley EPIC)
Follows Ethernet Rules and Practices
High Noise Rejection
Open Industrial Network Standards
D-22
09-09
Section D
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.
Remote Access Paging Modem
Easy to use configuration software
Requires customer provided, dedicated phone line
Requires customer provided Paging Service and pagers (or paging

compatible cell phones)
Requires Pager Numbers and PINs supplied by customer
Configure up to 10 unique pagers
Voltage: 24 VDC
Baud Rate: 56K
Type: External, Serial
Paging functionality utilizes TAP Protocol
PRODUCT OFFERING
ENGINEERING DATA
CB-HAWK ICS Paging and Remote Dial-up Access With Modem
PART 1 GENERAL
The boiler manufacturer shall provide a Paging and Remote Dial-Up Access Modem,
using customer provided paging systems for the purpose of paging boiler system
alarms and providing remote access to the control system.
Pager number(s) and PINs to be supplied by customer.
Dedicated telephone connection to be supplied by customer.
D-23
09-09
Section D
CB-HAWK ICS LEAD/LAG FOR TWO

BOILER SYSTEMS
Provides Lead/Lag control for a two-boiler system when used in conjunction with the CBHAWK ICS integrated boiler control system.

Controls Header Pressure and Temperature:
Maintains steam pressure or hot water supply temperature based on system

load demand.
Compensates for varying losses between boiler and header.
Sequences of Operation for Two Boilers:
Provides maximum system efficiency.
Reduces cycling and boiler wear; thereby reducing maintenance and downtime
costs.
Optimizes fuel savings.
Lead/Lag Start with Lead/Lag Modulation:
Lead boiler operates at full capacity prior to starting lag boiler.
Lag boiler starts modulation when lead boiler reaches maximum firing rate
position.
Ideal for steam boilers.
Lead/Lag Start with Unison Modulation:
Lag boiler operates at the same firing rate as a lead boiler.
Ideal for hot water boilers.
PRODUCT OFFERING
Boiler control for each boiler shall be CB-HAWK ICS.
Pressure (steam) or temperature (hot water) transmitter shipped loose for

mounting in the common header.
D-24
09-09
Section D
CB-HAWK ICS Lead/lag For Two-Boiler Systems
PART 1 GENERAL
1.1
GENERAL
A. Lead/Lag Start with either Lead/Lag or Unison Modulation.
B. Boilers Start and Stop
1. Steam pressure, or hot water temperature, is compared with
the setpoint and controllers processor executes PID algorithm.
Lead boiler is commanded to come on line first. Lag boiler is
commanded to come on line when a firing rate signal for the
lead boiler reaches lag boiler start point. Lag boiler is
commanded to stop when a firing rate signal for the lag boiler
reaches lag boiler stop point.
C. Lead/Lag Modulation - Lag boiler starts modulation after lead boiler
reaches maximum firing rate.
D. Unison Modulation - Firing rates for both boilers are equal.
E. Hot Standby - System shall have a provision for keeping lag boiler in
hot standby. Standby routine shall be based on a water temperature
signal.
1.2
APPLICATION AND SYSTEM REQUIREMENTS

A. This option is applicable to full modulation burners utilizing the CBHAWK ICS advanced boiler control system and modulating controls.
B. All logic for Lead/Lag Control shall reside in the boiler controller. No
additional control panels shall be required.
D-25
09-09
Section D
CB-HAWK ICS LEAD/LAG for up to EIGHT

BOILERS SYSTEM
Provides Lead/Lag control for up to eight boilers when used in conjunction with the
CB-HAWK ICS integrated boiler control system.

Controls Header Pressure and Temperature:
Maintains steam pressure or hot water supply temperature based on system

load demand.
Benefits:
Maximizes system efficiency.
Reduces cycling and boiler wear, thereby reducing maintenance and downtime
costs.
System shall be provided with a sequence to automatically rotate sequence in

which the boilers are fired. Rotation shall be based on the elapsed time.
Lead/Lag Start with Lead/Lag Modulation:
Lead boiler operates at full capacity prior to starting lag boiler #1.
Lag boiler #1 starts when the lead boilers firing rate is close to the maximum.
Operator can select this parameter via HMI.
Lag boiler #1 starts modulation when the lead boiler reaches the maximum
firing rate position.
Subsequent lag boilers operate in the same fashion.
Ideal for steam boilers.
Lead/Lag Start with Unison Modulation:
Lead boiler operates at full capacity prior to starting the lag boiler.
All boilers operate at the same firing rate as the lead boiler.
Ideal for Hot Water boiler systems.
D-26
09-09
Section D
PRODUCT OFFERING
Boiler control for each boiler shall be the CB-HAWK ICS.
Pressure (Steam) or temperature (Hot Water) transmitter shipped loose for

mounting in the common header.
Master Control Panel shipped loose for field mounting.
Requires Ethernet/IP Communication Option
CB-HAWK ICS Lead/lag for up to Eight Boilers System
PART 1 GENERAL
1.1
GENERAL
A. Lead/Lag Start with either Lead/Lag or Unison Modulation.
B. Boilers Start and Stop
1. Steam pressure, or hot water temperature on hot water
systems, is compared with the setpoint and controllers
processor executes PID algorithm. Lead boiler is commanded
to come on-line first. Lag boiler #1 is commanded to come online when a firing rate signal for the lead boiler reaches lag
boiler start point. Lag boiler #1 is commanded to stop when a
firing rate signal for the lead boiler reaches lag boiler stop
point.
2. Lag boiler #2 is commanded to come on-line when a firing rate
signal for the lag boiler #1 reaches lag boiler #2 start point.
Lag boiler #2 is commanded to stop when a firing rate signal
for the lag boiler #1 reaches lag boiler #2 stop point.
3. Subsequent boilers operate in a similar fashion.
C. Lead/Lag Modulation
1. Lag boiler #1 starts modulation after lead boiler reaches
maximum firing rate (or firing rate selected by the operator).
2. Lag boiler #2 starts modulation after lag boiler #1 reaches
maximum firing rate (or firing rate selected by the operator).
3. Subsequent boilers operate in a similar fashion.
D. Unison Modulation - Firing rates for all boilers are equal.
E. Hot Standby - System shall have a provision for keeping lag boilers
in hot standby. Standby routine shall be based on a water
temperature signal.
F.
Firing Sequence Selection - Sequence in which boilers come on-line
shall be selected via HMI. Adequate check shall be provided that
does not allow improper sequence selection.
G. Automatic Rotation of the Boilers - System shall be provided with a
sequence to automatically rotate sequence in which the boilers are
fired. Rotation shall be based on the elapsed time.
D-27
09-09
Section D
1.2
HMI (HUMAN MACHINE INTERFACE)

A. Master panel shall include HMI for display and selection of the
following parameters:
B. Display
1. Available boilers
2. Number of boilers required
3. Selected sequence of firing
4. Control output to each boiler
5. Header steam pressure or water temperature on hot water
systems
6. Setpoint
7. Elapsed time from last rotation
C. Selection
1. Number of boilers
2. Sequence of firing
3. Automatic or manual rotation
4. Individual boiler start and stop points with timers
5. Setpoint
6. Proportional, integral and derivative gains for control algorithm
1.3
APPLICATION AND SYSTEM REQUIREMENTS

A. This option is applicable to full modulation burners utilizing the CBHAWK ICS advanced boiler control system and modulating controls.
B. Logic for Lead/Lag control shall reside in the Master Control Panel.
Communication between the Master Panel and the individual Boiler
Control Panels shall be via Ethernet communication or hard wiring.
D-28
09-09
Section D
CB780E CONTROL
The CB 780E is a microprocessor-based flame safeguard control used to monitor the
presence of a flame inside a boiler, and to sequence the burner through several stages of
operation to provide proper air purge, ignition, normal operation and shut down for safe
operation.

Dynamic self-check logic and diagnostics:
Dynamic self-check safety circuit checks microprocessor and safety relay to

ensure safe and proper operation.
Dynamic input check verifies controls ability to recognize the true status of
external controls, limits and interlocks.
Closed-loop logic test verifies integrity of safety critical loads (ignition, pilot, and
main fuel valves) for proper operation.
Pre-ignition interlocks and flame signal checked during Standby and Pre-Purge.
Tamper-proof Purge Timer Card.
Valve Proving System
Programmable valve proving system provides fuel valve proof-of-closure.
Powerful Display/Diagnostic Capabilities:
2 line x 20 character Vacuum Fluorescent Display is easy to read under all

lighting conditions.
Status and diagnostic messages displayed in English Language with no scrolling

necessary (Spanish also available).
Displays flame signal in Volts dc, eliminating need for separate meter.
Displays burner hours and numbers of cycles.
Diagnostic displays include on/off status of inputs and outputs, RUN/TEST

switch status, selected purge time, amplifier type and configuration data.
Fault history (retained in non-volatile memory) displays the cycle, hours, code,
description, and condition for the last six fault occurrences.
Capability to mount display on front of Control Panel for improved access, or

remotely, in separate control room. (Optional)
5 LEDs on base provide at-a-glance status of Power On, Pilot, Flame, Main
D-29
09-09
Section D
Valves, and Alarm conditions (Power LED blinks periodically to indicate proper
control operation).
Diagnostic display capabilities are further enhanced by the optional CB783

Expanded Annunciator which provides 36 additional specific HOLD and Fault
messages, as well as 26 LEDs to indicate current status or first-out alarm
indication (user-selectable).
Communication capabilities to a local or remote Personal Computer, with

optional CB-LINKcommunications module and Combustion System Manager
software (runs under Microsoft Windows).
Application Flexibility:
Purge Timing Cards available in 30, 60, 90 seconds or 2-1/2 minutes cover a
wide range of applications, while eliminating need for a separate purge timer.
Separate output for ignition transformer simplifies applications requiring early

spark termination.
Selectable configuration jumpers allow application-specific configuration.
Communication interface capability.
Simplified Servicing:
Diagnostic and fault history information available through display simplifies

troubleshooting procedures.
Removable access covers for checking voltage at terminals.
5-function RUN/TEST switch eases start-up procedure.
Flame signal display facilitates pilot/light-off test procedures.
PRODUCT OFFERING
Included in each CB 780E system is the following:
One CB780E chassis, including display module.
One Purge Timer Card.
One wiring sub-base.
One flame scanner, either Infrared, Ultra-Violet, or UV Self-Check.
One flame amplifier, to correspond with the selected flame scanner.
Included with the optional CB783 Expanded Annunciator:
One CB783 Annunciator.
All limits and interlocks are wired into wiring sub-base to provide individual
hold/fault indication on LEDs of Expanded Annunciator, as well as on display
module of CB 780E control.
Supply voltage: 120 Vac (+10%/-15%) 50 or 60 Hz.
Maximum total load: 2000 VA.
ENGINEERING DATA
D-30
09-09
Section D
Load rating-fuel valve output: 65 VA pilot duty plus 1150 VA inrush, 460 VA
opening, 250 VA holding.
Operating temperature limits: -40 to 140 F.
Maximum ambient humidity: 85% non-condensing.
CB780E Control
PART 1 GENERAL
Flame safeguard shall be a Cleaver-Brooks Model CB 780E microprocessor-based

control to monitor all critical boiler and burner interlocks, control and supervise
burner light off sequence, and initiate an orderly safety procedure in the event of
interlock or flame failure. The system shall provide status, fault history, and
diagnostic information by means of a two-line alpha-numeric display and alarm/
status LEDs. The system shall be approved by UL, FM, and CSA, and shall be
acceptable by IRI.
D-31
09-09
Section D
CB120/120E CONTROLS
The CB120 is a microprocessor-based burner management control system designed
to provide the proper burner sequencing, ignition, and flame monitoring protection
on automatically ignited oil, gas , and combination fuel burners. In conjunction with
limit and operating controls, it programs the burner/blower motor, ignition, and fuel
valves to provide for proper and safe burner operation
The CB120E includes all of the features of the CB120 with the addition of an
alphanumeric display.

Display and Diagnostic Capabilities:
(CB120E) 2 x 16 character display with keypad. Available display types are

vacuum fluorescent (VFD) and liquid crystal (LCD). VFD has increased
brightness and extended operating temperature range to -40F. Messages are
spelled out in English (optional Spanish version is also available). Provides
indication of flame signal during operation.
Lockout history stores last 10 lockouts with burner cycle and burner hour when
occurred.
Display module can be mounted remotely from the CB120 for external
indication (optional).
Optional expanded annunciator provides increased messaging and diagnostic

capabilities.
Optional communication via Modbus with local or remote PC.
Modular Design:
Interchangeable program modules in English or Spanish.
Adjustable purge time programmable via display.
Chassis available for infrared, ultra-violet, or UV self-check flame scanners.
Reduces part replacement costs.
D-32
09-09
Section D
PRODUCT OFFERING
Included in each CB120 System is the following:
Chassis with corresponding flame ampliifier
Plug-In Programmer Module.
Wiring base.
Flame scanner - either infrared, ultra-violet, or UV self-check.
Included in each CB120E System is the following:
All of the above
Alphanumeric display
Display is required for Modbus communication or to access special functions.
ENGINEERING DATA
Supply voltage: 120 Vac (+10%/-15%) 50/60 Hz.
Fuel valve output load rating: 65 VA pilot duty plus 3850 VA inrush, 700 VA
open, 250 VA hold.
Operating temperature limits: -40C (-40F) to 60C (140 F). LCD display min.
temp. limit -20C (-4F).
CB120/120E Control
PART 1 GENERAL
Flame safeguard shall be a Cleaver-Brooks Model CB120/120E microprocessorbased control to monitor all critical boiler and burner interlocks, control and
supervise burner light-off sequence, and initiate an orderly safety procedure in the
event of interlock or flame failure. CB120E system shall provide status, fault history,
and diagnostic information by means of a 2 x 16 VFD or LCD display. The system
shall be approved by UL, FM, and CSA, and shall be acceptable by IRI.
D-33
09-09
Section D
CB100E CONTROL
The CB100E is a microprocessor-based, flame safeguard control used to monitor
the presence of a flame inside a boiler, and include various interlocks to ensure safe
operation. The flame safeguard also sequences the burner through several stages of
operation to provide proper air purge, ignition, normal operation and shut down for
safe operation.

Display and Diagnostic Capabilities:
2 x 16 Backlit LCD display with a 3-key tactile dome keypad indicates 38

different messages regarding status and fault indication. Messages are spelled
out in English. (Optional Spanish version is also available.) Provides indication
of flame signal during operation.
Provides indication of burner cycles and run time.
Non-volatile memory retains last 6 fault/lockout conditions on power failure.
Display module can be mounted in cabinet door for external indication.

(Optional)
Optional E300 expansion module provides additional 31 messages pertaining

to fault or hold status indication.
Communication with local or remote PC by means of an optional E500

communication module.
Modular Design:
Interchangeable program modules in English or Spanish.
Purge time is selected via dip switches.
Interchangeable amplifiers for infrared, ultra-violet, or UV self-check flame

scanners.
D-34
09-09
Section D
PRODUCT OFFERING
Included in each CB100E System is the following:
One chassis, including a dust cover.
One 2-line display module.
One Programmer Module.
One flame scanner, either infrared, ultra-violet, or UV self-check.
One flame amplifier to correspond with the selected flame scanner.
Included with optional E300 Expansion Module is:
One E300 expansion module.
One wiring subbase.
One interconnection cable to E100E.
All interlocks are wired into wiring sub base to provide individual hold/fault
indication on display of CB100E control.
Supply voltage: 120 Vac (+10%/-15%) 50/60 Hz.
Fuel valve output load rating: 1250 VA opening, 500 VA holding.
Operating temperature limits:32 F to 125 F.
ENGINEERING DATA
CB100E Control
PART 1 GENERAL
Flame safeguard shall be a Cleaver-Brooks Model CB100E microprocessor-based

control to monitor all critical boiler and burner interlocks, control and supervise
burner light-off sequence, and initiate an orderly safety procedure in the event of
interlock or flame failure. The system shall provide status, fault history, and
diagnostic information by means of a 2 x 16 backlit LCD display. The system shall
be approved by UL, FM, and CSA, and shall be acceptable by IRI.
D-35
09-09
Section D
CB110 CONTROL
The CB 110 is a micro-processor-based, flame safeguard control used to monitor
the presence of a flame inside a boiler, and include various interlocks to ensure safe
operation. The flame safeguard also sequences the burner through several stages of
operation to provide proper air purge, ignition, normal operation and shut down for
safe operation.

Self Diagnostics:
Seven LED display provided to indicate: Fan, High Fire, Low Fire, Ignition,
Flame detected, Auto and Alarm.
23 Fault indications.
Modular Design:
Interchangeable amplifiers for infrared, ultra violet, or UV self-check flame

scanners.
Easily upgradeable to a CB 100E by replacing programmer and display

modules.
PRODUCT OFFERING
Included in each CB 110 System is the following:
One CB 110 chassis, including dust cover.
One Programmer/Display Module.
One wiring subbase.
One flame scanner, either infrared, ultra-violet, or UV self-check.
D-36
09-09
Section D
One flame amplifier to correspond with the selected flame scanner.
Supply voltage: 120Vac (+10%/-15%) 50/60 Hz.
Fuel valve output load rating: 1250 VA opening, 500 VA holding.
Operating temperature limits: -40 F to 125 F
ENGINEERING DATA
CB110 CONTROL
PART 1 GENERAL
Flame safeguard shall be a Cleaver-Brooks Model CB 110 microprocessor-based control to

monitor all critical boiler and burner interlocks, control and supervise burner light-off
sequence, and initiate an orderly safety procedure in the event of interlock or flame failure.
The system shall provide status, fault history, and diagnostic information by means of an
LED display. The system shall be approved by UL, FM, and CSA, and shall be acceptable by
IRI.
D-37
09-09
Section D
LEAD/LAG SYSTEMS (TWO BOILER LEAD/

LAG)
This section contains information on Multiple Boiler Lead/Lag systems. For Lead/
Lag systems used with boilers equipped with the CB-HAWK ICS system, refer to the
CB-HAWK ICS Two Boiler Lead/Lag and Eight Boiler Lead/Lag sections.

Controls Actual Header Pressure and Temperature:
Maintains steam or hot water supply to system load.
Sequences Operation of Two Boilers:
Maximum system efficiency.
Reduces cycling and boiler wear reducing maintenance and downtime costs.
Lead/Lag Start with either Lead/Lag Modulation or Lead/Lag High-Low Fire:
Ideal where load swings are infrequent and small such as heating applications.
Lead/Lag Start with either Unison Modulation or Unison High-Low Fire:
Boilers operate in unison when both are on line.
Ideal where load swings are frequent and large, such as process applications.
PRODUCT OFFERING
Lead/Lag selector switch mounted on one boiler.
On-off and firing rate controls shipped loose for mounting in common
header piping.
Minimum temperature low-fire-hold control steam boilers.
Low-fire-hold control hot water boilers.
Components shall be Underwriters Laboratories approved for intended

service.
D-38
09-09
Section D
Lead/Lag Systems (Two-boiler Lead/lag)
PART 1 GENERAL
1.1
GENERAL
A. Lead/Lag Start with either Lead/Lag Modulation or Lead/Lag HighLow Fire.
B. The boiler manufacturer shall supply a control system to lead and
lag two boilers. The system shall start, stop, and control the firing
rate of both boilers.
C. Upon system demand, the lead boiler shall start and operate to full
capacity prior to starting the lag boiler. When both boilers are on
line, the lead shall always operate to full capacity and the lag shall
operate between minimum and maximum output to satisfy demand
requirements.
D. When system demand decreases, the lag boiler shall return to the
minimum firing rate position and shut off. A further decrease shall
cause the lead boiler to reduce its firing rate to minimum and shut
off.
E. A switch shall be provided to rotate the lead position between both
boilers.
F.
For steam boilers, a means shall be provided to maintain minimum
boiler water temperature at low-fire when the boilers are off line.
G. For hot water boilers, a means shall be provided to keep the boilers
at low-fire rate until a predetermined minimum temperature is
reached. This releases the boiler to automatic operation from the
firing rate control.
H. All components shall be Underwriters Laboratories approved for
intended service.
I.
Lead/Lag Start with either Unison Modulation or Unison High-LowFire.
J. The boiler manufacturer shall supply a control system to lead and
lag start of two boilers. The system shall start, stop, and control the
firing rate of both boilers.
K. Upon system demand, the lead boiler shall start and operate to full
capacity prior to starting the lag boiler. When both boilers are on
line, they shall operate in unison between minimum and maximum
output to satisfy demand requirements.
L. When system demand decreases, both boilers shall reduce their
firing rate, in unison, to minimum. The lag boiler shall shut off and
the lead boiler shall operate between minimum and maximum until
demand is satisfied, and then shut off. A switch shall be provided to
rotate the lead position between both boilers.
M. For steam boilers, means shall be provided to maintain minimum
boiler water temperature at low-fire when boilers are off line.
N. For hot water boilers, means shall be provided to keep boilers in a
low-fire-hold mode until a predetermined minimum temperature is
reached. This shall then release the boiler to automatic operation
from firing rate control.
D-39
09-09
Section D
O.
P.
1.2
All components shall be Underwriters Laboratories approved for

intended service.
The lead/lag system is a specialized digital control that sequences
the starting, stopping, and controls modulation firing rate for two
boilers. It can be used for either steam or hot water applications.
APPLICATION
This option is applicable to full modulation burners utilizing standard Cleaver-Brooks modulating controls.
D-40
09-09
Section D
LEAD/LAG SYSTEMS (TWO THROUGH

FOUR BOILER LEAD/LAG)
The lead-lag system is a specialized digital control that sequences the starting,
stopping, and controls modulation firing rate for two through four boilers. It can be
used for either steam or hot water applications.

PID Control Logic:
Precise control.
Monitors rate of change to anticipate needs of system, turning boilers on or off

as needed.
Lead/Lag Start and Modulation:
Provides optimal control action for different applications.
Lead boiler rotates automatically every 24 hours or manually selected for fixed
lead position.
Boilers Controlled From Header Pressure or Temperature:
Maintain constant steam or hot water supply to system load.
Compensate for varying losses between boiler and header.
Sequences Optimal Number of Boilers on Line:
Maximum system efficiency.
Reduces cycling and boiler wear reducing maintenance and downtime costs.
PRODUCT OFFERING
Lead/lag sequencing control system for full modulating boilers (four boilers
maximum).
Relays on control system panel for start-stop control of boilers.
Pressure or temperature sensor and immersion well.
Assured low-fire cutoff upon boiler shut off (steam and hot water boilers).
Minimum temperature low-fire-hold control (steam boilers).
Low-fire-hold control (hot water boilers).
D-41
09-09
Section D
ENGINEERING DATA
Voltage input: 115 V, 60 Hz
Power consumption: 30 VA maximum
Output rating:
Relays: 1 amp inductive, 10 amp resistive at 115 V, 60 Hz. (up to 4 relays used,
plug in type).
Firing rate signal: 0 to 135 ohm resistive.
Sensor ranges:
Temperature: -30 F to 250 F accuracy plus or minimum 1F.
Pressure: 0-30 psig, 0-100 psig, 0-200 psig accuracy 1% full scale.
Standby battery: Operates for 100 days minimum with overall average life of 5
years.
Maximum ambient temperature: 120 F.
Lead/lag Systems (Two Through Four Boiler Lead/lag)
PART 1 GENERAL
1.1
GENERAL
A. The boiler manufacturer shall furnish a microprocessor based
control system. The control shall be engineered and programmed
exclusively for the operation of multiple steam or hot water full
modulation boilers. It shall incorporate the following integrated
functions:
1. Manual or automatic lead stage rotation; boiler sequencing and
burner firing rate (modulation control). The control shall be of
modular construction to facilitate field modification, upgrading
or repair. It shall include the following features.
B. The control shall have the capability of operating in a temperature
or pressure mode. Temperature sensors shall be of the thermistor
type, suitable for insertion into a 3/8 ID well. Standard operating
range shall be -30 F to +250 F. Pressure sensors shall be of the
4-20 ma type. Standard operating range shall be 0-30, 0-100, 0150 or 0-200 psig.
C. The control shall provide an integral sensor set point adjustment.
The set point shall be adjustable in 1 F or 1 psig increments (1/10
psig increments for 0-30 psig units) via a multi-turn knob. The
setting value shall be stored in EEPROM indefinitely.
D. The control shall provide a LED bar graph display of each boilers
approximate percent modulation. The control shall also provide a
digital LED display of actual temperature or pressure, set point
temperature or pressure, gain adjustment and each boilers exact
percent modulation. In addition, the digital display shall be used to
indicate the following four control settings as they are being
adjusted:
1. Modulation start point shall be adjustable from 50 to 100%.
This setting determines the percent modulation a stage must
achieve before the next stage is activated. There shall be
D-42
09-09
Section D
E.
F.
G.
H.
I.
J.
independent adjustment of this setting for each burner.

2. Purge timer shall be adjustable from 0-9.9 minutes. This
setting determines the delay time between a burner being
started and the beginning of modulation.
3. Set back (additional set point) shall be adjustable from 0-75
F/psig (0-7.5 psig on 0-30 psig units). This setting determines
the F/psig drop from the primary set point whenever the
setback mode is activated. An off setting shall also be
included for complete burner shutdown. The set back mode
shall be activated by an external switch closure.
4. Standby timer shall be adjustable from 1-60 minutes. This
setting determines the delay period which must elapse before
any designated standby boilers are activated. The timing
sequence shall begin when all active boilers reach 100% firing
rate.
LEDs shall be provided to indicate the lead stage and all activated
stages.
A lithium coin type battery shall be included to maintain the
correct lead stage and lead stage rotation timer in the event of power
failure. Storage capacity shall be 100 days.
A four position selector switch shall be provided to set the operating
mode of each stage. Positions include on, auto, off and standby.
The control shall have the capability of operating up to four full
modulation boilers. Each stage shall have the following outputs:
1. A normally open contact to start/stop the burner.
2. A 0-135 ohm output to independently control each burners
firing rate.
The control shall be UL listed, tested per Standard 873.
Temperature Indicating and Regulating Equipment. It shall be CSA
listed, tested per Standard C22.2 Number 24-1987 Temperature
Indicating and Regulating Equipment. It shall also be approved for
use in NYC by the City of New York; Department of Buildings,
Bureau of Electrical Control and Department of Environmental
Protection, Bureau of Air Resources.
A surface mounted, locking steel, NEMA 1 type, minimum 18 gauge
enclosure shall be provided.
1.2
APPLICATION
This option is applicable to full modulation burners utilizing standard Cleaver-Brooks
modulating controls.
D-43
09-09
Section D
LOW FIRE HOLD CONTROL

Prevents Automatic Control of Burner Firing Rate Until Pre- Determined Boiler
Water Temperature is Reached:
Equalizes water temperature in boiler.
Reduces possibility of thermal shock to pressure vessel and refractory.
PRODUCT OFFERING
Cleaver-Brooks shall provide a boiler water temperature control with sensor and
immersion well. The control is Underwriters Laboratories approved for intended
service and shall be mounted and wired on the boiler.
RECOMMENDED USE
The use of this control is recommended where a minimum temperature control has
not been installed and where operating personnel may not be diligent in manually
placing the boiler at low fire until the boiler shell is of equal temperature
throughout.
Note: In an emergency one can override this control by placing the Manual-Auto switch in the
Manual position.
Low Fire Hold Control

PART 1 GENERAL
1.1
GENERAL
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 preset temperature is satisfied. This shall then release boiler to automatic control of
system demand. Control shall be Underwriters Laboratories approved for intended
service.
1.2
APPLICATION
This option is applicable to full modulation and high-low fire burners.
D-44
BB_D-03-06
09-09
Section D
MINIMUM TEMPERATURE LOW FIRE

HOLD CONTROL
Maintains Minimum Boiler Water Temperature in Steam Boilers at Low-Fire Mode
of Operation During Off Periods:
Reduces lag-time to steaming rate.
Operational mode-manual or automatic.
PRODUCT OFFERING
Cleaver-Brooks shall supply:
Boiler water temperature control and immersion well.
Interface relay.
Operation mode.
Manual selector switch.
Automatic activated by remote on-off boiler control device.
Components Underwriters Laboratories approved for intended service.
RECOMMENDED USE
A common procedure at many steam boiler installations is to shut the boiler off
overnight, during weekends, or during holidays. During this off period boiler water
temperature decreases. This can effectively decrease boiler metal and refractory
temperatures to near room temperature. After this off period the boiler is placed
back into operation. Due to low boiler water temperature and a steam pressure
demand the boiler will immediately position itself at high fire. The important factors
to remember are that metals expand when heated; contract when cooled. This is
also true of boiler refractory. With repeated heating and cooling of any boiler,
premature deterioration of boiler refractory, metals, and resultant tube leakage can
occur. To minimize these effects, the installation of a combination minimum
temperature-low fire hold control is recommended.
Occasionally there are objections to the use of a combination minimum
temperature-low fire hold control. If the off period will be of prolonged duration
maintaining minimum temperature could represent a considerable waste of fuel.
Under this condition it is recommended that a low fire hold control be installed.
D-45
06-08
09-09
Section D
Minimum Temperature Low Fire Hold Control
PART 1 GENERAL
1.1
GENERAL
The boiler manufacturer shall furnish and install a control to sense boiler water
temperature. The control shall have an adjustable set point to maintain a minimum
temperature at a pre-set level when the boiler is off line. This shall be accomplished
at the burners minimum firing rate. The function can be activated either manually
or automatically. Components shall be Underwriters Laboratories approved for
intended service.
1.2
APPLICATION
D-46
09-09
Section D
ASSURED LOW FIRE CUTOFF

Assures that the burner shuts off at minimum firing rate when signaled from remote
disable source:
Prevents shutoff at firing rates above low fire.
PRODUCT OFFERING
Cleaver-Brooks shall provide terminal connection points for remote disable/enable
signals, and internally wire additional electrical components necessary to perform
this function.
Assured Low Fire Cutoff
PART 1 GENERAL
1.1
GENERAL
The boiler manufacturer shall make provisions to accept remote enable/disable
signal contact. Any disable signal shall cause the burner to return to minimum low
fire position prior to shutting off the main fuel.
1.2
APPLICATION
D-47
09-09
Section D
REMOTE MODULATION
Provides burner modulation from a customer supplied 4-20 mA control signal.
Ties boiler firing rate control with customer control system (for example,
building management, boiler room master, lead-lag control).
PRODUCT OFFERING
Standard Equipment
Resistor kit to allow standard firing rate motor to operate from a 4-20 mA
control signal.
Relay with gold flashed contacts to switch between automatic and manual
operation.
Manual firing rate potentiometer to allow local manual operation.
Optional Equipment
Local remote firing rate control selector switch.
Allows control of firing rate from standard local firing rate controller or
remote 4-20 mA signal.
Remote Modulation
1.1
GENERAL
Furnish and install components to allow burner to modulate from a remote 4-20 mA
control signal. Provisions shall be made for local manual firing rate control.
1.2
APPLICATION
This option is applicable to full modulation burners utilizing standard CleaverBrooks modulating controls.
D-48
09-09
Section D
AUTOMATIC FUEL CHANGEOVER

Provides sequence to allow burner to automatically change fuel.
Interfaces boiler-burner control with customer control system and avoids

premium charges for fuel.
PRODUCT OFFERING
A selector switch. With selector switch in the AUTO position, burner shall fire
primary fuel when auxiliary contact governing fuel selection (for an example, gas
pressure switch or outdoor thermostat) is closed. Upon opening of the above
contact: a burner shall modulate to the minimum firing rate position, shutdown
and restart firing stand by fuel.
Fuel auto changeover switch (a low gas pressure switch or outdoor thermostat).
This switch may be furnished by the boiler supplier, customer, or utility.
Automatic Fuel Changeover
PART 1 GENERAL
1.1
GENERAL
The boiler manufacturer shall furnish sequence to allow an automatic changeover
from primary to stand by fuel and back. An automatic fuel changeover shall be
initiated by gas pressure, outdoor temperature or other dry contact.
1.2
APPLICATION
This option is applicable to dual-fuel (i.e., gas-oil fired) boilers with exception of
Model LE Boilers.
D-49
09-09
Section D
Accu-Trim O2TRIM SYSTEM

The C-B Accu-Trim O2 Trim System is a stand-alone PLC-based control system
designed to maintain the proper fuel-air ratio of a boiler/burner. The system will
automatically compensate for changes in temperature, barometric pressure, or fuel
characteristics, as well as correcting for normal hystereses. The system is intended
for use on a Cleaver-Brooks boiler or burner with single point positioning, or
jackshaft-type, combustion controls; however, it may be customized for special
applications such as parallel positioning or alternate fuel firing. A complete system
includes oxygen and firing rate sensors, a control panel which houses the PLC, and
an actuator or VSD system which trims either the fuel or air flow.
Single unit PLC / HMI with 6 color touchscreen
Modular DIN rail mounted I/O - 8 analog inputs, 8 analog outputs, 4 digital
inputs, 4 relay outputs
Analog signals are 0-10 VDC, digital inputs are 24 VDC
Modbus RTU communication
Quick overview of O2 setpoint and actual value

Real time data trending for visual confirmation of system operation
Displays stack temperature, variable speed drive output, excess air, and fuel
selection
Uses CB O2 probe, Yokogawa probe, or any 4-20 mA probe

Compatible with natural gas, propane, and #2 oil using the CB O2 probe and
with heavy oils using the Yokogawa probe
Password protected operating parameter values
12-point setup for up to three fuel curves
Independent PID loops for each trim device/fuel
D-50
09-09
Section D
Ability to integrate with Base and Intermediate Hawk ICS packages
Active and historical alarms
Flash card available for data logging
PRODUCT OFFERING
Basic configurations:
The Accu-Trim system can be supplied for either fuel trim or air trim in the following
configurations:
Fuel trim - electric actuators only

Fuel trim - pneumatic actuators only
Fuel trim - electric and pneumatic actuators combined
Air trim with VSD
Analyzer:
Yokogawa integrated type Zirconia oxygen analyzer
OR
Cleaver-Brooks model oxygen analyzer

Controller:
Integrated PLC/touchscreen HMI
Discrete input/output module
Analog input module
Analog output module
Actuators:
Electric, pneumatic, or combination
Options:
O2 process value retransmission
ENGINEERING DATA
Electrical
120 VAC, 60 Hz, or 110 VAC 50 Hz 6 Amp 3-wire

grounded system.
Environmental
Temperature:
Control Panel 32-122 F
Firing Rate Sensor 0-180 F
Air Supply (For

pneumatic actuators only)
25-125 PSIG, 2 SCFM

CLEAN, DRY instrument quality air
Oil content 1 ppm maximum
Dew point 35 F or less at line pressure.
D-51
09-09
Section D
Accu-Trim
PART 1 GENERAL
1.1
PART 2 PRODUCTS
2.1
GENERAL
A. This specification covers the hardware and control of the C-B AccuTrim O2 Trim System. The system adjusts the fuel-to-air ratio in
order to maintain maximum efficiency and features reliable
monitoring and control of oxygen concentrations.
B. The system shall be completely configured from factory, requiring
only job-specific data to be entered (or modified) in the field.
Controller/analyzer shall be shipped with default values and have
a limit on the range of adjustments where applicable.
C. Oil fuel trim available on integral head boiler applications only.
HARDWARE
A. Analyzer - choose one of the following:
Yokogawa integrated type Zirconia oxygen analyzer
OR
Cleaver-Brooks model oxygen analyzer
B.
Actuator Siemens electric actuator for gas pressure, Controlair or

Bellofram mounted on the oil pressure regulator (system without air
trim via VSD).
C.
Controller
1. Integrated PLC/HMI touchscreen (6 color screen standard)
2. HMI shows bar graph and moving pen data value indication
3. Overview of O2 setpoint and process value
4. Display of stack temperature, VSD output, excess air, and fuel
selection
5. 8 Analog Inputs, 8 Analog Outputs
6. 4 Digital Inputs and 4 Relay Outputs
7. Modbus RTU
8. Password protection of operating parameters.
9. Active and historical alarms
Control algorithm shall be PID (Proportional, Integral, and Derivative) type.

Proportional action shall be applied to the process variable and not to the deviation.
PV (Process Variable) is oxygen concentration in flue gases. This is a 4-20 mA or
0-10 VDC signal from the oxygen analyzer. The O2 input is scaled from 0 to 25%
O2. When analyzer is not measuring O2 in flue gas (warm-up, calibration, fault)
control output shall be at 50%. The oxygen setpoint shall be based on the burner
firing rate. Set point curve shall have 12 adjustable break points. The setpoint
shall have independent settings for up to 3 fuels.
Systems with Fuel Trim - Correction to the fuel air ratio is accomplished by
changing fuel pressure. In the case of natural gas this is done via an
D-52
09-09
Section D
electric or pneumatic actuator mounted on the gas pressure regulator. In the
case of oil fuel, this is done by applying air pressure to the top side of the
PRV diaphragm.
Systems with Air Trim - Applying adjustment to the calculated combustion

air blower speed performs the correction to the fuel-air ratio.
2.2
APPLICATION
This system is intended for use on a Cleaver-Brooks boiler or burner with single
point positioning, or jackshaft-type, combustion controls; however, it may be
customized for special applications such as parallel positioning or alternate fuel
firing. System is compatible with natural gas, propane, and #2 oil using the CB O2
probe and with heavy oils using the Yokogawa probe.
D-53
09-09
Section D
D-54
09-09
Section D
CB-HAWK ICS ADAC ADVANCED DEAERATOR CONTROL

The CB ADAC Advanced Deaerator Control provides a PLC based control system for
a deaerator, surge tank, two tank deaerator-and-surge, or Duo-tank installations.
The system is capable of controlling operation of boiler feed and/or transfer pumps,
maintaining tank levels, monitoring and responding to system demands, and
recording/annunciating alarm conditions.
The ADAC can run as a stand-alone system or tie into a CB-HAWK ICS Master Panel
or customer building automation system.

Standard Features:
Integration of various deaerator and surge tank devices in a common control

system
Touch screen graphical Human Machine Interface (HMI)
Deaerator and surge tank water level modulating controls
Chemical feed pump control
Boiler feed pump control - up to 6 pumps via variable speed drive, soft starters,
combination starters, or contactors
Surge tank feed pump control (transfer pumps) - up to 3 pumps
Pump alternating, lead/lag, and automatic rotation
Serial, Ethernet, BAS, web server communications capability
Control of remote devices (valves, etc.)
Alarm/fault annunciation and history with audible alarm
Red/Yellow/Green stack light for visual status indication
Cumulative pump run time totals for maintenance purposes
Optional Features:
10 PanelView in lieu of 6 (10 is standard on two tank systems)
Dial-up paging modem (selecting this option and Ethernet communication

requires Ethernet PanelView and 5 port Ethernet hub)
Alarm bell, horn, or electric sounder
GEMS Mini Sure Site level indicator with 4-20 mA transmitter or discrete level
switches
Steam or water flow transmitters
Manual hard wired controls for any 4-20 mA controlled valve
Siemens motorized make-up valve
RSLinx OPC compliant remote monitoring software
Recirculation bypass (tank one only)
NEMA 4/12 entrance panel
NEMA 4x electrical panel

D-55
09-09
Section D
PRODUCT OFFERING
Standard Features, Single Tank System:
Compact Logix L32E processor
6 color touch screen HMI
Stack light
Programming and I/O cards for the following:
I/O for 1-6 pumps using contactors, soft starters, or combination starters
Hard wired fixed location level inputs for Hi and Low water alarms
Low water pump cutoff audible alarm output
Stack light outputs
Recirculation bypass output
Chemical feed relay
Boiler 1-6 Feed Water Required inputs
Analog inputs for tank pressure, temperature, level, and discharge header
pressure
Optional Features, Single Tank System:

NOTE: Options must be selected in order; each option requires all of the preceding
ones.
Option 1
Feedwater make up valve analog output
Option 2
1-6 pump proving flow switch inputs
Option 3
Single tank system emergency make up valve
Option 4
1-3 VSD driven pumps I/O
Option 5
4-6 VSD driven pumps I/O
Option 6
1-6 feed pump (1 pump per boiler) VSD driven pump analog inputs
Standard Features, Duo Tank or DA-and-Surge System:
Compact Logix L32E processor
10 color touch screen HMI
Stack light
Programming and I/O cards for the following:
I/O for 1-6 boiler feed pumps and 1-3 transfer pumps using contactors, soft
starters, or combination starters
Hard wired fixed location level inputs for HI and LO water alarms, and low
water pump cutoff for 2 tanks
Audible alarm output
Stack light outputs
D-56
09-09
Section D
Recirc bypass output
Chemical feed relay
Boiler 1-6 Feed Water Required inputs
Pump proving switch inputs for up to 6 feed pumps and 3 transfer pumps
DA tank pressure analog input
Tank temperature, level, discharge header pressure inputs for 2 tanks
1 customer configured analog input (future)
Optional Features, Duo Tank or DA-and-Surge System:

NOTE: Options must be selected in order; each option requires all of the preceding
ones.
Option 1
Feedwater make up valve analog output Tank 2
Option 2
Tank 1 Emergency make up valve analog output for 2 Tank systems
Option 3
Tank 2 Emergency make up valve analog output for 2 Tank systems
Option 4
I/O for 1-3 feed pumps and 1 transfer pump VSD driven
Option 5
I/O for 4-6 feed pumps and 2-3 transfer pump VSD driven
ENGINEERING DATA
Supply voltage: 120 VAC (102 VAC - 132 VAC), 50 or 60 Hz
Maximum total connected load: 500 VA
Operating temperature limits: 32 to 130F
Humidity: 85% relative humidity continuous, non-condensing
0.5G continuous vibration
CB ADAC Advanced Deaerator Control

PART 1 GENERAL
1.1
GENERAL
A. Each ADAC system shall be factory equipped with a pre-configured
Programmable Controller and Human Machine Interface.
B. System shall provide control logic for the following:
1. 1-6 feed pumps and 1-3 transfer pumps
2. Make up water level control for DA tank or DA and Surge
3. Low Water, Hi Water, and Aux Low Water alarms
4. Chemical feed control
D-57
09-09
Section D
PART 2 PRODUCTS
2.1
STANDARD SYSTEM AND OPTIONS

A. Hardware Platform - Standard System
1. Compact Logix L32E Processor
2. Power Supply
3. Discrete Input Module
4. Discrete Output Module
5. Analog Input Module 4 Channel
6. Analog Input Module 8 Channel
7. Analog Output Module 2 Channel
8. Analog Output Module 8 Channel
9. Right Termination End Cap
10. HMI Display, 6 Serial Color - Standard on single tank systems
11. HMI Display, 10 Serial Color Standard on two tank systems,
optional on single tank systems
B.
Optional Components
1. Remote Access Paging Modem
2. Veris Current Switch - sized for pump
3. Electric actuators for pump water recirculation bypass - sized
for system
4. PowerFlex 70, 400, or 700 Variable Speed Drive
2.2
SENSORS AND TRANSMITTERS

A. Tank level indication
1. Standard
a. DA tank - GEMS Mini Sure Site with transmitter
b. Surge tank - GEMS Mini Sure Site with transmitter
2. Optional
a. DA tank - Differential pressure level transmitter
Rosemount 3051CD
b. Surge tank - Differential pressure level transmitter
Rosemount 3051CD
B. Tank Pressure and Temperature (see table)
Tank Pressure/Temperature Transmitters
Standard
Optional
DA tank pressure transmitter
Setra-256
Rosemount-3051
DA pump discharge pressure transmitter
Setra-256
Rosemount-3051
Surge tank transfer pump pressure transmitter Setra-256
Rosemount-3051
DA tank temperature transmitter
ARI
Rosemount-3144
Surge tank temperature transmitter
ARI
Rosemount-3144
C.
D.
Pump flow proving sensors

1. Pressure switch mounted after each pump or differential
pressure switch across pump. Monitor pump running status
with Veris current switch.
Sierra flow transmitters - sized per application
D-58
09-09
Section D
2.3
VALVES
A. Make-up water valves - all sized per application
1. DA tank make-up valve - Siemens SK electronic actuator with
optional 3 valve bypass and strainer
2. DA tank emergency or raw water make-up valve - Siemens SK
electronic actuator with optional 3 valve bypass and strainer
3. Surge tank make-up valve - Siemens SK electronic actuator
with optional 3 valve bypass and strainer
2.4
PUMPS
A. Feed water pumps - Grundfos
B. Transfer pumps - Grundfos
2.5
SOFTWARE DEVELOPMENT PLATFORM

(software not required - for informational purposes only)
A.
B.
C.
D.
2.6
RSLogix 5000 (controller logic programming)

Allen-Bradley Panel Builder (HMI programming)
RSView32 (control room display and data acquisition)
RSLinx OEM version (OPC server - Building Automation System)
MAJOR FUNCTIONS THAT THE ADAC SYSTEM SHALL PROVIDE:

(controller functions based on customer configuration and purchase of options)
A.
B.
Feed water pump control

1. System will be able to support up to 6 pumps, selected using
the HMI (no PC or additional software required). Upon
selection, graphics and control logic will be activated
automatically.
2. Pumps may be part of a common header or may feed individual
boilers. If part of a common header pumps may be configured
to operate in a lead/lag sequence based on system demand.
3. Order of pump alternation can be automatically rotated to share
running time and wear equally between pumps.
4. For a common boiler feedwater pump discharge system, PLC
monitors 4-20 mA pressure/flow signal from boiler feedwater
header to determine when to command pumps to start/stop. In
a VSD system the 4-20 mA pressure/flow signal will determine
VSD output.
5. If the pumps are feeding individual boilers, pumps will be
turned on/off based on individual boiler feed water pressure
(when using VSDs) or discrete 110 VAC signals from each
boiler.
6. PLC/VSDs can only control pumps that are in AUTO mode.
Pumps in manual will run continuously. The hard wired Aux
Low Water pump cutoff will prevent pumps from running in any
mode if water level drops below set point.
Transfer pump control
1. System will be able to support up to 3 pumps for transferring
water from the Surge tank to the DA. Pumps are selected using
the HMI; no PC or additional software required. Upon
selection, graphics and control logic will be activated
automatically.
D-59
09-09
Section D
2.
C.
D.
E.
F.
Pumps may be configured to operate in a lead/lag sequence

based on system demand. In addition, order of pump
alternation can be automatically rotated to share running time
and wear equally between pumps.
DA make-up water level control
1. The lead pump runs continuously. If DA tank level falls below
set point, make up valve is already fully open, and condensate
tank discharge pressure falls below set point, the PLC will
command the lag pump to start.
2. When surge tank discharge pressure falls below set point, the
PLC will sound an alarm. Operator must respond to the alarm
condition and reset the alarm.
3. When level control is in manual mode, the make up valve can
be opened or closed from the HMI screen, or optionally by a
manual potentiometer. Either method will allow the operator to
manually adjust the valve between fully open and fully closed
to control the incoming flow of make up water.
Surge tank make up water level control
1. The PLC receives a 4-20 mA signal indicating surge tank water
level. Signal is compared to the operator input set point and
valve modulates accordingly to control the incoming flow of
make-up water.
2. When the valve is in manual mode the HMI or optional manual
potentiometers will allow the operator to manually adjust the
valve between fully open and fully closed.
Pump Lead/Lag and Alternating Control
1. Selection of pumps and rotation schedule are configurable
from the HMI. PLC will monitor all pumps and determine
availability; pumps may be taken out of rotation for
maintenance.
2. When system is in auto rotation, if a pump is not available the
PLC will alternate to the next available one. If no pumps are
available an alarm will sound, requiring manual reset. PLC will
maintain equal run time between all pumps.
3. If Lead/Lag option is selected, pump start/stop set points are
set from the HMI. Start point is based on percentage of set
point achieved by previous pump in sequence. PLC internal
timers will maintain minimum load fluctuations.
4. If Lead/Lag and VSD options are selected, VSD% to start/stop
lag pump is set from the HMI. When lag function is activated,
VSDs function in unison modulation until the speed reaches
VSD stop point; then lag pump shuts off.
5. When pump alternation is selected, alternation schedule is
configured from the HMI. When current pump run time is met,
next pump will start and come up to speed; previous pump will
then stop.
Chemical Feed Control
1. One set of dry contacts wired to terminal blocks will be
provided to change state when any boiler feed pump is
D-60
09-09
Section D
running, enabling customer chemical feed pump.
2.7
ADDITIONAL ADAC SYSTEM FUNCTIONS:

A. A pressure sensor mounted in steam space monitors Deaerator
pressure.
B. A set of contacts on each pumps overload relay provides indication
of pump failure. If VSDs or soft starters are used, a fault contact is
monitored by the PLC to indicate pump failure.
C. A set of contacts on each pump starter indicates pump running. If
VSDs or soft starters are used, a contact is monitored by the PLC to
indicate run status.
D. A selector switch is mounted at each pump starter to allow HandOff-Auto switching. Hand ignores all external signals except Aux
Low Water Cutoff, Off ignores all signals and prevents pump from
running, Auto allows pump to run based on commands from the
PLC.
2.8
ALARM FEATURES
A. DA Tank water level alarms
1. Low Water If water level as indicated by the tank level
device falls to a pre-set point, the PLC will sound an alarm,
display a message on the HMI, log a message to the alarm
history file, and turn on the appropriate stack light.
2. Low Low Water If water level falls further to the pre-set Low
Low Water point, the PLC will sound an alarm, display a
message on the HMI, log a message to the alarm history file,
and turn on the appropriate stack light.
3. Hi Water If water level as indicated by the tank level device
rises to a pre-set point, the PLC will sound an alarm, display a
message on the HMI, log a message to the alarm history file,
and turn on the appropriate stack light.
4. Aux Low Water If water level falls to the pre-set Aux Low
Water point, the hard wired Aux Low Water device will open,
signalling the PLC and shutting down all pumps for that tank.
The PLC will sound an alarm, display a message on the HMI,
log a message to the alarm history file, and turn on the
appropriate stack light.
B. Surge Tank water level alarms (same as above)
2.9
ADAC COMMUNICATION OPTIONS

A. Ethernet connectivity
1. PLC features an OPC compliant Ethernet/IP port for connection
to a Building/Plant Automation System or Local Area Network.
2. Remote monitoring/data logging available using RSView
software.
3. Connection to CB HAWK ICS Master Panel (Note: Existing
Master Panels would require a program upgrade and possibly
a processor upgrade to use this option).
4. Compliance with IEEE 802.3 Physical and Data Link, TCP/IP
protocol, and Control and Information Protocol (CIP) standards.
D-61
09-09
Section D
B.
Other communication options

1. Communication to most major building management system
interfaces such as Johnson Controls Metasys, ASHRAE
Bacnet, LON, and Siemens will be available via a CleaverBrooks protocol translator bridge. Check with Cleaver-Brooks
for specific information.
2. Data can be transferred by Ethernet through a CB Master Panel
to a customer BAS. If a Master Panel is unavailable, the
protocol translator can be configured to communicate directly
between the ADAC and the customer BAS.
D-62
09-09
Section D
CB LCS-150E LEVEL CONTROL SYSTEM

The Cleaver-Brooks LCS-150E Level Control System utilizes a level transmitter and
a programmable controller to control water level and water level alarms. System
includes modulating make-up valve with user-selectable manual or automatic
control.

Standard Features
Programmable controller with display
Set points, alarm points, transmitter span, and PI controls configurable using
controller keypad
Manual or automatic control of make-up valve
Easy-to-read level indication
No sight glass - water is contained in a pressure-tight housing
PRODUCT OFFERING
The following are included as standard in each LCS-150E control system:
Programmable controller
Controller display with keypad
I/O module
Level sensor and transmitter
Modulating feed water valve and actuator
Alarm horn and silence button
High, Low, and Low Water Cut-Off alarm lights
ENGINEERING DATA
Supply voltage 120 VAC
Max load 3 amps
Ambient temperature range 32 - 130 deg F
Humidity, non condensing 5-95%
Degree of protection
-
Display/keypad: IP65, Type 3R, Type 12R

Panel Nema 4/12
Lights and switches IP66
Level indicator / transmitter Nema 4
Siemens valve Nema 1; optional weather shield will change it to Nema 3R
D-63
09-09
Section D
CB LCS-150E Level Control System

PART 1 GENERAL
1.1
GENERAL
A. Each LCS-150E system shall be factory equipped with controller
including display and I/O, NEMA 12 cabinet, and GEMS magnetic
level sensor with transmitter.
B. System shall provide the following functions:
1. Adjustable transmitter span
2. Adjustable water level set point
3. Adjustable high water alarm point (with differential)
4. Adjustable low water alarm point (with differential)
5. Adjustable low water cutoff point (with differential)
6. Adjustable P and I (proportional and integral gain) parameters
7. Manual or automatic make-up valve operation
8. On-screen alarm indication and relay outputs for high water,
low water, low water cutoff, and general alarms
9. Alarm Silence input
PART 2 PRODUCTS
2.1
STANDARD SYSTEM
A. Hardware Platform
1. Pico GFX Controller with backlit graphic display
2. Power Supply 115VA/24VDC 30 Watts
3. I/O module:
(12) 24VDC inputs
(4) relay outputs
(1) 0-10 VDC analog output for make-up valve
(1) 0-10 VDC input for level transmitter
B.
C.
D.
Level sensor and transmitter

1. GEMS Mini Sure Site magnetic level indicator
2. Level transmitter 4-20 mA
Make-up valve
1. Siemens modulating feed water valve - sized per application
2. Electronic actuator 0-10 VDC
Alarms
1. Panel mounted alarm horn
2. Alarm silence switch
3. LED alarm lights for High and Low Water and Low Water CutOff
D-64
09-09
Section D
CB-HAWK Compact ICS

The CB-HAWK Compact ICS is a microprocessor based burner management and
single point combustion control system combining the CB120Z burner management
control/boiler controller with a 6 color touchscreen HMI. The CB120Z expands
upon the CB120/120E by adding firing rate control to burner sequencing/flame
supervision functions.

Standard Features:
6 color touchscreen HMI
Configurable overview screens
Solid state sensing of steam and water demand
Operating control functions for start/stop of boiler operating sequence
Full modulation control of fuel and combustion air
Solid state sensor inputs for steam pressure, water temperature, stack
temperature, boiler water temperature, outdoor temperature
Hot standby
Day/night setback
Cold start thermal protection
Programmable maximum high fire position (limits boiler firing rate)
Auto/Manual control with bumpless transfer
Lead/Lag for two or three boilers
Alarm history, data logging, and trending
E-mail capability
Password protection of system configuration, auto/manual functions
D-65
09-09
Section D
Optional Features:
Protocol translator for Modbus, Bacnet IP and Ethernet, Johnson Metasys
Remote monitoring
Internet web server
PRODUCT OFFERING
CB120Z:
Chassis with corresponding flame amplifier
Plug-in programmer module
Wiring base
UV, IR, or UV self-check flame scanner
Pressure (temperature) transducer
Communicates with HMI by Modbus
HMI:
2 line, 16 character, 4 button display
Misc.:
Additional equipment includes cable, 24VDC power supply, fuse, and DIN rail
mounted fuse holder
ENGINEERING DATA
Supply voltage: 120 VAC (+10%/-15%) 50 or 60 Hz.
Power consumption: 25 VA
Operating temperature limits: -40F to 130F
Pressure sensors: 0-15, 0-30, 0-200, or 0-300 psig
Temperature sensors: RTD type, 32F-350F or 32F-752F
CB-HAWK Compact ICS

PART 1 GENERAL
Burner management control/firing rate control shall be a Cleaver-Brooks Model

CB120Z microprocessor-based burner management control with integrated boiler
control operation. Status, fault history, diagnostic information, and operator
interface shall be provided by a 6 color touchscreen HMI. HMI shall be panel
mounted with 2 line x 16 character, 4 button display allowing access to all CB120Z
functions.
PART 2 PRODUCTS
A. Major system components shall include:

1. Touch screen HMI
2. Integrated burner management control/firing rate controller with wiring subbase
3. One flame scanner: Infrared, Ultraviolet, or UV self-check
4. One flame amplifier, to correspond with the selected scanner
5. Pressure/temperature sensors
D-66
09-09
Section D
B. Major functions that the boiler control system shall provide:
1. Automatic sequencing of the boiler through standby, pre-purge, pilot flame
establishing period, main flame establishing period, run, and post-purge
2. Flame proving and lockout on flame failure during pilot proving, main flame
proving, or run
3. Full modulating control of fuel and combustion air
4. Various high and low limit alarms
5. Manual control of boiler firing rate using touchscreen HMI
6. Lockout history
D-67
09-09
Section D
D-68
09-09
Section D
CB SysteMAX Hydronic Control System

The CB SysteMAX hydronic system controller is a microprocessor based boiler
sequencing and modulation control. This control is designed for controlling multiple
boilers of different or similar sizes. Additionally it can control and optimize the use of
condensing boilers, non-condensing boilers or hybrid boiler systems that integrate
condensing and non-condensing boilers.
Cleaver-Brooks recognizes the need for new and better controls that allow for greater
flexibility in the configuration of boiler operating parameters to take advantage of
high efficiency boiler designs and system designs. As often is the case, the advances
in system and boiler heat exchanger design have created a greater opportunity for
efficiency savings in hydronic heating systems. Further, we recognize that future
advances will require increased control over thermodynamic processes.
This control system was created with these advances in mind. By using a flow
measuring device along with an outdoor air sensor, system supply and system return
sensors, we have developed a control that is distinctly different from the typical
single or dual temperature sensor control. By allowing and accounting for boilers of
different sizes, we have enabled the system designer to easily include part load
operation of heating equipment into the design. These designs along with a CB
SysteMAX ISD allow the designer to manage a heating load as the control calculates
real time load needs, and using this data, selects and operates the appropriate
boiler or boilers. This approach eliminates the many detrimental effects on efficiency
(boiler and system) and equipment life reduction due to the unnoticed short cycling
of boilers.
The CB SysteMAX ISD control also offers as a main feature the ability to reset and
control both condensing and non condensing boilers within the same heating
system. With two unique and user definable reset temperature slopes, both types of
boilers can be utilized seamlessly. In short, condensing boilers can condense as
designed and non condensing boilers will be protected from the effects of
condensing. This advancement allows the designer the freedom to specify hybrid
boiler systems. These hybrid boiler systems can dramatically decrease fuel usage in
traditionally designed building comfort heating systems at a fraction of initial
equipment and installation costs.
7" LCD full color touch screen Graphical User Interface.

USB port for graphical and code based updates.
Wireless network configuration with 128 bit signal encryption.
Hardwire network back-up.
RTC = Real Time Clock.
User selectable modulation signal, 0 - 10VDC, 4 - 20 mA.
External system enable contact.
External system reset analog input.
Boiler modes are: Auto/Manual/Off/Standby (Auto and Standby based on condensing/
non-condensing priority).
Outdoor Reset: (3) reset slopes; 2 winter, 1 summer.
Summer/Winter modes; summer allows DHW (Domestic Hot Water; future) and reheat.
User defined summer reheat enable and reset.
D-69
09-09
Section D
DHW priority (future).

DHW supply set-point (future).
DHW priority override (future).
Condensing and non-condensing priority set-point.
Chooses boilers relative to priority of condensing or non-condensing (hybrid system).
Condensing protection program ensures non-condensing boilers see minimum water
return temperatures above 130 F.
Patent pending process calculates Real Time Load (measures supply, return, and
system flow to determine Real Time Load). Modulates boilers based on Real Time Load,
not supply temperature.
Utilizes/selects correct boiler based on base data of the min and max outputs of the
connected boilers in the system.
Intelligent load selection relative to the load required with intelligent load sharing.
Intelligent shutdown; uses load, size, type, priority, hours of operation for shut down of
boilers.
Occupied space set-point utilized in load calculations and predictions.
Controls boiler delta T.
Optimum Stop setback.
Optimum Start Boost.
Warm weather shutdown.
Soft stop.
Boiler minimum inlet temperature (per boiler).
Boiler maximum outlet temperature (per boiler).
Post cycle pump purge based on run time % with max limit (boost to 100%).
Process Acceleration Control for boiler modulation output. Uses boiler manufacturer's
unique product data in Acceleration Control Algorithm for modulation tuning.
Process Acceleration Control for boiler pump modulation output.
System pumps rotation (lead/lag).
Sequential/Parallel/Optimized modulation (boiler run time rotation with respect to size,
type, load, efficiency in range, and hours of operation).
Boiler alarm inputs remove boilers from rotation.
Fixed lead with respect to size, type, and load.
Fixed last with respect to size, type, and load.
Flame activation delay (seconds).
Low fire hold relative to load and occupied space temperatures.
User defined low fire hold with respect to set-point and outdoor conditions.
Event scheduling for occupancy used for start and stop.
Ignition start output percent.
Next stage delay based on user defined output percent.
Standby delay based on boiler failures and time below set-point.
Minimum stage delay at any percentage of boiler output.
Boiler Max. cycle time between one hour and 24 hours.
Damper prove circuits linked to ignition sequence.
Damper prove alarm for damper failure.
3-way valve control.
All points Alarm.
Minimum modulation signal during run cycle.
Internal load predictions based on outdoor air, redundancy factor, and history.
D-70
09-09
Section D
ENGINEERING DATA
POWER
Input Voltage..
24 - 130 VAC/DC
ENVIRONMENTAL
Operating Temperature.
Storage Temperature
Relative Humidity..
00 C to 700 C; 320 F to 1580 F

minus 200 C to 700 C; minus 40 F to 1580 F
0 to 95% Non-condensing
GENERAL
Display
Power Center.
Status Indicators..
LED Backlit 8" TFT LCD aspect (15/9) pixels (800/480)

Interface for navigation and data entry.
On/Off Switch
Red/Amber/Green LED for status. Blue LED blinks
with communication rate.
ENCLOSURES
Rating.
Construction..
NEMA 1
ABS Plastic
INPUTS
Digital..
RTD's..
Flow.
Boiler Delta T.
Up to 128 power supplied field dry contacts

(3) - return, supply, outdoor air temp. Type II 10K
Thermistors
(1) PFM or 4 - 20 mA
Up to (32) Type II 10K Thermistors or PT1000 RTD
inputs.
OUTPUTS
Contacts.
Signal..
Up to (128) SPDT 8A resistive, 1/4 HP

Up to (128) 0 - 10V or 4 - 20 mA standard
SELECTION GUIDE
CB SysteMax Wireless.
1 - 16 Boilers, 1 - 16 system pumps, 1 - 16 boiler

secondary pumps, 1 - 16 combustion air or draft
inducer controls.
STANDARD PERIPHERALS
Main System Temperature.
Outdoor Air
Flow
(2) Temperature Sensors with wells.

(1) Temperature Sensor w/sunlight shield
(1) Flow device w/2" NPT Hot Tap.
D-71
09-09
Section D
SPECIFICATIONS
CB SysteMAX Hydronic Control System

PART 1 GENERAL
The CB SysteMAX hydronic system controller is a microprocessor based boiler

sequencing and modulation control. This control is designed for controlling multiple
boilers of different or similar sizes. Additionally it can control and optimize the use
of condensing boilers, non-condensing boilers or hybrid boiler systems that
integrate condensing and non-condensing boilers.
PART 2 PRODUCTS
The boiler room system control shall consist of a Master Panel, to be located within
the mechanical equipment room, (3) thermistors for outside air, supply water
temperature, return water temperature, and a water flow measuring device.
The thermistors and flow device shall be field wired to a System Intelligence
Device (SID).
Each boiler within the heating system shall be equipped with a Boiler I/O Module
(BIM; up to 16 boilers on a single Master Panel). Each BIM shall be hard wired into
the boiler control circuit and mounted in a suitable location, preferably on the boiler
control panel.
If system pumps are to be controlled by the Master Panel, then an Auxiliary I/O
Module (AIM) shall be provided (up to two pumps per AIM), and field wired by the
installing contractor. Additionally, if fresh air dampers are to be interlocked with the
Master Panel, an AIM shall be installed (up to two damper drives per AIM) and field
hard-wired to the specific device.
The Master Panel shall include a high resolution (800 x 480 pixels) seven inch,
graphical touch screen interface. The touch screen shall be LED backlit and shall be
wide-screen format (15 x 9).
Through the use of the graphical user interface, the Master Panel shall provide all
functionality required for parameterization of the entire network and shall transmit
data wirelessly to the I/O modules for local storage or as an option may be
hardwired and communicate via the Live Fire ConnectTM communication protocol.
The Master Panel shall include the following:
USB Port for on screen "mouse" interaction with Graphical User Interface.
USB Port for updating/upgrading to new levels of functionality and interactivity.
Determination of all on/off states of equipment, all output rates of equipment and
communicate that data to the individual I/O devices wirelessly for the purpose of
boiler room control and heating operations.
All wireless communication shall be protected from other wireless signals through
the use of 128 bit encryption.
Switch to shutdown all wireless communication.
Alarm Output for notification of a boiler failure.
Capability of individually controlling up to sixteen boiler secondary pumps, with
timing off delays for post on cycle purge.
Capability to individually operate up to sixteen main system or zone pumps.
D-72
09-09
Section D
(System pumps can be individually identified as on, off, or lead lag.
Capability of individually operating up to sixteen combustion make-up air dampers,
mechanical combustion air make-up enable circuits, or mechanical draft enable
circuits, linked to the firing sequence of the boiler for which it operates.
Input/Output (I/O) Devices shall include:
Two single pole double throw output contacts rated for 8 amps @ 120 VAC.
Operation at 22 - 130 VAC/DC on the same power input post. The power supply on
board both devices shall recognize the power provided and transform appropriately
for printed circuit operation.
Each boiler I/O module shall be factory configured for the purpose of optimum boiler
operation and error free network parameterization.
Each boiler I/O module shall, when enabled, contact the Master Panel and
automatically parameterize the network with all necessary information on proper
boiler selection, operation, and modulation based on the boilers model number.
Each I/O module shall individually communicate confirmation of on/off status,
output rate status, and alarm status to the Master Panel for the purpose of boiler
room control and heating operations.
Each I/O module shall have a physical switch capable of shutting down all wireless
transmissions.
PART 3 EXECUTION
Functionality
The boiler controller shall be capable to individually operate between one (1) and
sixteen (16) boilers with full modulation burners, on/off burners, or two stage (high
low) burners. When a fixed firing rate (on/off) boiler is enabled, the controller shall
account for this occurrence by assigning the entire load in MBH required to meet the
rated output of the boiler to that boiler. The balance of the load, if any, will then be
assigned to either two stage or modulating boilers in the system. The control shall
have the capability of selectable parallel sequential modulation, and shall provide
parallel modulation at any percentage of rated output.
The boiler controller shall be enabled on outdoor air and via contact closure,
indicating a call for heat, enable one of three resets for supply temperature; two (2)
for winter operation, one (1) for summer operation, allowing changes in building
loop temperature based on outdoor air. A warm weather shut down option shall be
included.
The boiler controller shall have the capability of individually controlling up to sixteen
(16) boiler output temperatures; the target output temperatures for each boiler can
differ one from the other.
The boiler controller shall have the capability of choosing any boiler on the network
for operation according to outdoor air temperature, Real Time Load, load
predictions, alarm status, minimum output rating, maximum output rating,
minimum return temperature, maximum outlet temperature, condensing, noncondensing, winter priority, standby status, hot water priority, efficiency in a given
range, and hours of operation.
The boiler controller shall have the capability of calculating the required heating
load utilizing supply water temperature, return water temperature, and water flow
rate of the main supply header. Based on the load requirement, the control shall
D-73
09-09
Section D
assign all or part of any load to a condensing or non-condensing boiler at any
outdoor temperature, as required to meet the needs of the system, boiler, and the
building. It shall have the capability of overcoming burner output rate tuning issues
in order to meet the building load.
The boiler controller shall have the capability of determining individual minimum
return temperatures for the operation of non-condensing boilers according to the
manufacturers published guidelines. It shall be able to overcome minimum return
temperature errors by increasing boiler output or increasing system supply water
setpoint temperature or both. The control shall also have the capability of
determining individual maximum output temperatures for each system boiler
according to the manufacturers published guidelines.
The control shall be equipped to read both the inlet and outlet temperature of each
boiler on the system.
The control shall have the capability to control both boiler inlet temperature and
outlet temperature differential (Delta T) of each boiler by sending a modulating
signal to a customer supplied pump and appropriately sized frequency drive for this
purpose. The control shall adapt to temperature overshoot above the maximum
outlet temperature by assigning part of the load to another boiler during boiler delta
T operations. As the outlet temperature of a boiler approaches maximum
temperature, the boiler controller shall be able to respond by increasing the output
signal to the frequency drive attached to the boiler pump in order to reduce boiler
delta T and maintain compliance with the manufacturer's published maximum
boiler outlet temperature.
The boiler controller shall have the capability of an adjustable night and weekend
optimum stop/setback of building supply loop temperature. The optimum stop
shall allow a gradual setback beginning in advance of unoccupied times through the
use of customer input data and collected data.
The control shall have the capability of pre-occupancy system temperature
optimum start return and system boost. The optimum start shall allow a gradual
return and boost from setback beginning in advance of occupied times through the
use of customer input data and collected data. The control shall gradually ramp
down loading of boilers from boost setpoint operations.
The boiler controller shall utilize patent pending Live Fire ConnectTM "Load
Acceleration Control Algorithm" in meeting heating load through an analog signal to
the boilers which in turn affect the outputs of the selected boilers.
The boiler controller shall have the capability of a user definable summer reheat
mode, reset loop temperature based on outdoor air.
The boiler controller shall have a user definable low fire hold (1 - 60 minutes) time
period based on a system differential temperature during low load demands. The
controller shall determine if the building is warming up fast enough and if it is,
delay release of the boiler to modulation by maintaining low fire to increase
efficiency of operation.
The boiler controller shall have freeze protection programming that will overcome
heat being disabled in order to protect the building equipment and boilers from the
effects of freezing.
The boiler controller shall have the capability for individual boiler alarm inputs that
will ascertain if a boiler is available for operational rotation and shall share this
D-74
09-09
Section D
information with the network traffic, either wirelessly or as an option, hard wired.
Field Parameterization
It shall be the boiler manufacturer's authorized field service representation
responsibility to ensure that all I/O modules are field programmed for the specific
heating load application. Each I/O module will be tested to ensure system network
functionality and interface functionality of the Master Panel and temperature sensors
and flow modules that interface with the Administrator. The field service
representative shall demonstrate the functionality to the authorized boiler operator
and or owner, and demonstrate the method needed to obtain data information.
D-75
09-09
Section E
EMISSIONS
CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POLLUTANTS AND CONTROL TECHNIQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NITROGEN COMPOUNDS (NOx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOx CONTROL TECHNOLOGIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POST COMBUSTION CONTROL METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selective Non-catalytic Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selective Catalytic Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMBUSTION CONTROL TECHNIQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Excess Air (LEA) Firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Nitrogen Fuel Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water/Steam Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flue Gas Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHOOSING THE BEST NOx TECHNOLOGY FOR THE JOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turndown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Excess Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carbon Monoxide (CO) Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Total Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SULFUR COMPOUNDS (SOx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBON MONOXIDE (CO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARTICULATE MATTER (PM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBON MONOXIDE (CO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARTICULATE MATTER (PM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VOLATILE ORGANIC COMPOUNDS (VOCs)/HYDROCARBONS (HC) . . . . . . . . . . . . . . . . . . . . . .
CALCULATING BOILER EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emission Level Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Correcting Emissions to 3% Oxygen (15% Excess Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Converting Emissions between PPM And Lb/MMBTU . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calculation of Annual Emissions for Industrial Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NEW SOURCE PERFORMANCE STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-3
E-3
E-3
E-4
E-5
E-5
E-5
E-6
E-6
E-6
E-6
E-6
E-7
E-7
E-8
E-8
E-8
E-8
E-9
E-9
E-9
E-10
E-10
E-11
E-12
E-12
E-13
E-13
E-13
E-14
E-16
E-18
E-1
09-09
Section E
ILLUSTRATIONS
Figure E-1. Effects of Fuel-Bound Nitrogen on NOx Emissions for Fuel Oils . . . . . . . . . . . . . . . . . .E-4
Figure E-2. Selective Non-Catalytic Reduction (SNCR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
Figure E-3. Selective Catalytic Reduction (SCR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
Figure E-4. Effects of Fuel Sulfur Content on SOx Emissions for Fuel Oils . . . . . . . . . . . . . . . . . . .E-9
Figure E-5. CO Emissions Conversion Curves, 3% Oxygen, (15% Excess Air) . . . . . . . . . . . . . . . . .E-14
Figure E-6. NOx Emissions Conversion Curves, 3% Oxygen, (15% Excess Air) . . . . . . . . . . . . . . . .E-15
Figure E-7. SOx Emissions Conversion Curves, 3% Oxygen, (15% Excess Air) . . . . . . . . . . . . . . . .E-15
Figure E-8. Volatile Organic Compound Conversion Curves, 3% Oxygen, (15% Excess Air) . . . . . . .E-16
Figure E-9. Annual NOx Emissions for 250-800 Horsepower Boilers, NOx = 110 ppm
(Corrected to 3% O2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-17
(Corrected to 3% O2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-17
(Corrected to 3% O2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-17
(Corrected to 3% O2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-18
(Corrected to 3% O2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-18
Figure E-14. Summary of Federal EPA Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-20
E-2
09-09
Section E
INTRODUCTION
This section of the Boiler Book contains background information regarding boiler
emissions.
This section does not include emission performance for individual Cleaver-Brooks
boiler models. Emission information for each product is included in the specific
section of the Boiler Book for the product or you can contact your local CleaverBrooks authorized representative for the necessary information.
POLLUTANTS AND CONTROL TECHNIQUES

Combustion of standard fossil fuels (natural gas and ASTM Grade Oil) in commercial
and industrial boilers results in the following nine emissions; carbon dioxide,
nitrogen, oxygen, water, carbon monoxide, nitrogen oxide, sulfur oxides, volatile
organic compounds, and particulate matter. The latter five products of combustion
are considered pollutants and are known to, either directly or indirectly, cause
harmful affects on humans and the environment.
The following section describes the formation and control of each of the pollutants in
commercial and industrial boilers:
Carbon Monoxide
Nitrogen Oxides
Sulfur Oxides
Volatile Organic Compounds/Hydrocarbons
Particulate Matter
NITROGEN COMPOUNDS (NOX)

Although there is evidence proving NOx, in itself, is harmful to humans, the main
reason NOx is considered an environmental problem is because it initiates reactions
that result in the production of ozone and acid rain. Ozone and acid rain can
damage fabric, cause rubber to crack, reduce visibility, damage buildings, harm
forests and lakes, and cause health problems. By controlling NOx levels, along with
the other pollutants, the levels of acid rain and ozone can be reduced.
The principal nitrogen pollutants generated by boilers are nitric oxide (NO) and
nitrogen dioxide (NO2), collectively referred to as NOx.
The contribution from different NOx sources to the total NOx levels varies among
metropolitan areas. In general, the contribution of mobile sources to the total NOx
level ranges from 60 to 80 percent: For stationary sources, it ranges between 20
and 40 percent. A significant portion of the NOx from stationary sources can be
attributed to residential, commercial, and industrial sources, including industrial
boilers. In industrial boilers, NOx is primarily formed in two ways; thermal NOx and
fuel NOx:
Thermal NOx is formed when nitrogen and oxygen in the combustion air
combine with one another at the high temperatures in a flame. Thermal NOx
makes up the majority of NOx formed during the combustion of gases and light
oils.
Fuel 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 amounts of fuel-bound nitrogen, fuel NOx can account for up to 50%
of the total NOx emissions.
NOx emissions from boilers are influenced by many factors. The most significant
E-3
09-09
Section E
factors are flame temperature and the amount of nitrogen in the fuel. Other factors
affecting NOx formation are excess air level and combustion air temperature.
NOx Emissions(ppm at 3% O2)

Increasing
While flame temperature primarily affects thermal NOx formation, the amount of
0
0
Increasing
Fuel-Bound Nitrogen (% weight)
Figure E-1. Effects of Fuel-Bound Nitrogen on NOx

Emissions for Fuel Oils
nitrogen in the fuel determines the level of fuel NOx emissions. Fuel containing
more nitrogen results in higher levels of NOx emissions (see Figure E-1). Most NOx
control technologies for industrial boilers, with inputs less than 100 MMBtu/hr,
reduce thermal NOx and have little affect on fuel NOx. Fuel NOx is most
economically reduced in commercial and industrial boilers by switching to cleaner
fuels (fuels containing less fuel-bound nitrogen), if available.
NOX CONTROL TECHNOLOGIES

NOx controls can be classified into two types: post combustion methods and
combustion control techniques. Post combustion methods address NOx emissions
after formation while combustion control techniques prevent the formation of NOx
during the combustion process. Post combustion methods tend to be more
expensive than combustion control techniques and generally are not used on boilers
with inputs of less than 100 MMBtu/hr. Following is a list of different NOx control
methods.
Post combustion control methods include:
Selective Non-Catalytic Reduction
Selective Catalytic Reduction
Combustion control techniques include:
Low Excess Air Firing
Low Nitrogen Fuel Oil
E-4
09-09
Section E
Burner Modifications
Water/Steam Injection
Flue Gas Recirculation
Each method results in a different degree of NOx control. For example, when firing
natural gas, low excess air firing typically reduces NOx by 10%, flue gas
recirculation by 75%, and selective catalytic reduction by 90%.
POST COMBUSTION CONTROL METHODS

Selective Noncatalytic Reduction
Selective non-catalytic reduction involves the injection of a NOx reducing agent,

such as ammonia or urea, into the boiler exhaust gases at a temperature of
approximately 1400-1600 F (see Figure E-2). The ammonia or urea breaks down
the NOx in the exhaust gases into water and atmospheric nitrogen. Selective noncatalytic reduction reduces NOx up to 70%. However, the technology is extremely
difficult to apply to industrial boilers that modulate or cycle frequently. This is
because the ammonia (or urea) must be injected in the flue gases at a specific flue
gas temperature. And, in industrial boilers that modulate or cycle frequently, the
location of the exhaust gases at the specified temperature is constantly changing.
Thus, it is not feasible to apply selective non-catalytic reduction to industrial boilers
that have high turndown capabilities and modulate or cycle frequently.
Selective Catalytic
Reduction
Selective catalytic reduction involves the injection of ammonia in the boiler exhaust
gases in the presence of a catalyst (see Figure E-3). The catalyst allows the
ammonia to reduce NOx levels at lower exhaust temperatures than selective noncatalytic reduction. Unlike selective non-catalytic reduction, where the exhaust
AMMONIA (NH3)
NOx
FLUE GAS
NOx
*
**
**
FLUE GAS TEMPERATURE

1400 - 1600 F
NH3
H2O
NOx
NH3
N2
NOx
NH3
CLEAN GAS
H2O
N2
H2O
Figure E-2. Selective Non-Catalytic Reduction (SNCR)

AMMONIA (NH3)
NOx
FLUE GAS
NOx
*
**
**
CATALYST
NH3
H2O
NOx
NH3
N2
NOx
NH3
CLEAN GAS
H2O
N2
H2O
Figure E-3. Selective Catalytic Reduction (SCR)

E-5
09-09
Section E
gases must be approximately 1400-1600 F, selective catalytic reduction can be
utilized where exhaust gasses are between 500 F and 1200 F, depending on the
catalyst used. Selective catalytic reduction can result in NOx reductions up to 90%.
However, it is costly to use and can rarely be cost justified on boilers with inputs
less than 100 MMBtu/hr.
COMBUSTION CONTROL TECHNIQUES

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

Oil
When firing fuel oils, NOx formed by fuel-bound nitrogen can account for 20-50%
of the total NOx level. One method to reduce NOx levels from boilers firing distillate
oils is through the use of low nitrogen fuel oil. Low nitrogen oils can contain up to
15-20 times less fuel-bound nitrogen than standard No. 2 oil (less than 0.001%
fuel-bound nitrogen). When low NOx oil is fired in firetube boilers utilizing flue gas
recirculation, NOx reductions of 60%-70% over NOx emissions from standard No.
2 oils have been achieved. Low nitrogen oil is used most frequently in southern
California.
Burner
Modifications
Burner modifications for NOx control involve changing the design of a standard
burner in order to create a larger flame. Enlarging the flame results in lower flame
temperatures and lower thermal NOx formation which, in turn, results in lower
overall NOx emissions. The technology can be applied to most boiler types and
sizes. It is most effective when firing natural gas and distillate fuel oil and has little
affect on boilers firing heavy oil. To comply with the more stringent regulations,
burner modifications must be used in conjunction with other NOx reduction
methods, such as flue gas recirculation. If burner modifications are utilized
exclusively to achieve low NOx levels (30 ppm), adverse affects on boiler operating
parameters such as turndown, capacity, CO levels, and efficiency may result. It is
important to address all aspects of boiler performance when selecting NOx control
technologies.
Water/Steam
Injection
Water or steam injection can be utilized to reduce NOx levels. By injecting water or
steam into the flame, flame temperatures are reduced, thereby lowering thermal
NOx formation and overall NOx levels. Water or steam injection can reduce NOx up
to 80% (when firing natural gas) and can result in lower reductions when firing oils.
There is a practical limit to the amount of water or steam that can be injected into
E-6
09-09
Section E
the flame before condensation problems are experienced. Additionally, under normal
operating conditions, water/steam injection can result in a 3-10% boiler efficiency
loss. Many times water or steam injection is used in conjunction with other NOx
control methods such as burner modifications or flue gas recirculation.
Flue Gas
Recirculation
Flue gas recirculation, or FGR, is the most effective method of reducing NOx
emission from industrial boilers with inputs below 100 MMBtu/hr. FGR entails
recirculating a portion of relatively cool exhaust gases back into the combustion
process in order to lower the flame temperature and reduce NOx formation. It is
currently the most effective and popular low NOx technology for firetube and
watertube boilers. And, in many applications, it does not require any additional
reduction equipment to comply with regulations.
Flue gas recirculation technology can be classified into two types; external or
induced.
External flue gas recirculation utilizes an external fan to recirculate the flue
gases back into the flame. External piping routes the exhaust gases from the
stack to the burner. A valve controls the recirculation rate, based on boiler input.
Induced flue gas recirculation utilizes the combustion air fan to recirculate the
flue gases back into the flame. A portion of the flue gases are routed by duct
work or internally to the combustion air fan, where they are premixed with the
combustion air and introduced into the flame through the burner. New designs
of induced FGR that utilize an integral FGR design are becoming popular among
boiler owners and operators because of their uncomplicated design and
reliability.
Theoretically, there is no limit to the amount of NOx reduction with FGR; practically,
there is a physical, feasible limit. The limit of NOx reduction varies for different fuels
80% for natural gas and 20-25% for standard fuel oils.
The current trends with low NOx technologies are to design the boiler and low NOx
equipment as a package. Designing as a true package allows the NOx control
technology to be specifically tailored to match the boiler's furnace design features,
such as shape, volume, and heat release. By designing the low NOx technology as a
package with the boiler, the adverse effects of the low NOx technology on boiler
operating parameters (turndown, capacity, efficiency, and CO levels) can be
addressed and minimized.
CHOOSING THE BEST NOX TECHNOLOGY FOR THE JOB

What effect does NOx control technology ultimately have on a boiler's performance?
Certain NOx controls can worsen boiler performance while other controls can
appreciably improve performance. Aspects of the boiler performance that could be
affected include turndown, capacity, efficiency, excess air, and CO emissions.
Failure to take into account all of the boiler operating parameters can lead to
increased operating and maintenance costs, loss of efficiency, elevated CO levels,
and shortening of the boiler's life.
The following section discusses each of the operating parameters of a boiler and
how they are related to NOx control technologies.
E-7
09-09
Section E
Turndown
Choosing a low NOx technology that sacrifices turndown can have many adverse
effects on the boiler. When selecting NOx controls, the boiler should have a
turndown capability of at least 4:1 or more, in order to reduce operating costs and
the number of on/off cycles. A boiler utilizing a standard burner with a 4:1
turndown can cycle as frequently as 12 times per hour or 288 times a day because
the boiler must begin to cycle at inputs below 25% capacity.
With each cycle, pre- and post-purge air flow removes heat from the boiler and
sends it out the stack. The energy loss can be reduced by using a high turndown
burner (10:1), which keeps the boiler on even at low firing rates.
Every time the boiler cycles off, before it comes back on, it must go through a
specific start-up sequence for safety assurance. It takes between one to two
minutes to get the boiler back on line. If there is a sudden load demand, the
response cannot be accelerated. Keeping the boiler on line assures a quick response
to load changes.
Frequent cycling also deteriorates the boiler components. The need for maintenance
increases, the chance of component failure increases, and boiler downtime
increases. So, when selecting NOx control, always consider the burners turndown
capability.
Capacity
When selecting the best NOx control, capacity and turndown should be considered
together because some NOx control technologies require boiler derating in order to
achieve guaranteed NOx reductions. For example, flame shaping (primarily
enlarging the flame to produce a lower flame temperature thus lower NOx levels)
can require boiler derating, because the shaped flame could impinge on the furnace
walls at higher firing rates.
However, the boiler's capacity requirement is typically determined by the maximum
load in the steam/hot water system. Therefore, the boiler may be oversized for the
typical load conditions that may occur. If the boiler is oversized, its ability to handle
minimum loads without cycling is limited. Therefore, when selecting the most
appropriate NOx control, capacity and turndown should be considered together for
proper boiler selection and to meet overall system load requirements.
Efficiency
Some low NOx controls reduce emissions by lowering flame temperature,

particularly in boilers with inputs less than 100 MMBtu/hr. Reducing the flame
temperature decreases the radiant heat transfer from the flame and could lower
boiler efficiency. The efficiency loss due to the lower flame temperatures can be
partially offset by utilizing external components, such as an economizer. Or, the
offset technique can be inherent in the NOx design.
One technology that offsets the efficiency loss due to lower flame temperatures in a
firetube boiler is flue gas recirculation. Although the loss of radiant heat transfer
could result in an efficiency loss, the recirculated flue gases increase the mass flow
through the boiler thus the convective heat transfer in the tube passes increases.
The increase in convective heat transfer compensates for losses in radiant heat
transfer, with no net efficiency loss. When considering NOx control technology,
remember, it is not necessary to sacrifice efficiency for NOx reductions.
Excess Air
A boiler's excess air supply provides for safe operation above stoichiometric
conditions. A typical burner is usually set up with 10-20% excess air (2-4% O2).
NOx controls that require higher excess air levels can result in fuel being used to
heat the air rather than transferring it to usable energy. Thus, increased stack losses
and reduced boiler efficiency occur. NOx controls that require reduced excess air
E-8
09-09
Section E
levels can result in an oxygen deficient flame and increased levels of carbon
monoxide or unburned hydrocarbons. It is best to select a NOx control technology
that has little effect on excess air.
Carbon Monoxide
(CO) Emissions
High flame temperatures and intimate air/fuel mixing are essential for low CO
emissions. Some NOx control technologies used on industrial and commercial
boilers reduce NOx levels by lowering flame temperatures by modifying air/fuel
mixing patterns. The lower flame temperature and decreased mixing intensity can
result in higher CO levels.
An induced flue gas recirculation package can lower NOx levels by reducing flame
temperature without increasing CO levels. CO levels remain constant or are lowered
because the flue gas is introduced into the flame in early stages of combustion and
the air fuel mixing is intensified. Intensified mixing offsets the decrease in flame
temperature and results in CO levels that are lower than achieved without FGR. But,
the level of CO depends on the burner design. Not all flue gas recirculation
applications result in lower CO levels.
Total Performance
Selecting the best low NOx control package should be made with total boiler
performance in mind. Consider the application. Investigate all of the characteristics
of the control technology and the effects of the technology on the boiler's
performance. A NOx control technology that results in the greatest NOx reduction is
not necessarily the best for the application or the best for high turndown, adequate
capacity, high efficiency, sufficient excess air, or lower CO. The newer low NOx
technologies provide NOx reductions without affecting total boiler performance.
SULFUR COMPOUNDS (SOX)

The primary reason sulfur compounds, or SOx, are classified as a pollutant is
because they react with water vapor (in the flue gas and atmosphere) to form
sulfuric acid mist. Airborne sulfuric acid has been found in fog, smog, acid rain, and
snow. Sulfuric acid has also been found in lakes, rivers, and soil. The acid is
extremely corrosive and harmful to the environment.
The combustion of fuels containing sulfur (primarily oils and coals) results in
pollutants occurring in the forms of SO2 (sulfur dioxide) and SO3 (sulfur trioxide),
together referred to as SOx (sulfur oxides). The level of SOx emitted depends directly
on the sulfur content of the fuel (see Figure E-5). The level of SOx emissions is not
dependent on boiler size or burner design. Typically, about 95% of the sulfur in the
fuel will be emitted as SO2, 1-5% as SO3, and 1-3% as sulfate particulate. Sulfate
particulate is not considered part of the total SOx emissions.
1200
SOx Emission Level*

(ppm at 3% O2)
1000
800
600
400
200
0
0
.2 .4
.6 .8 1.0 1.2 1.4 1.6 1.8 2.0
Sulfur in Fuel (% weight)

*Based on EPA AP-42 Estimates
Figure E-4. Effects of Fuel Sulfur Content on SOx Emissions for Fuel Oils
E-9
09-09
Section E
Historically, SOx pollution has been controlled by either dispersion or reduction.
Dispersion involves the utilization of a tall stack, which enables the release of
pollutants high above the ground and over any surrounding buildings, mountains, or
hills, in order to limit ground level SOx emissions. Today, dispersion alone is not
enough to meet more stringent SOx emission requirements; reduction methods
must also be employed. Methods of SOx reduction include switching to low sulfur
fuel, desulfurizing the fuel, and utilizing a flue gas desulfurization (FGD) system.
Fuel desulfurization, which primarily applies to coal, involves removing sulfur from
the fuel prior to burning. Flue gas desulfurization involves the utilization of
scrubbers
to
remove
SOx
emissions
from
the
flue
gases.
Flue gas desulfurization systems are classified as either non-regenerable or
regenerable. Non-regenerable FGD systems, the most common type, result in a
waste product that requires proper disposal. Regenerable FGD converts the waste
by-product into a marketable product, such as sulfur or sulfuric acid. SOx emission
reductions of 90-95% can be achieved through FGD. Fuel desulfurization and FGD
are primarily used for reducing SOx emissions for large utility boilers. Generally the
technology cannot be cost justified on industrial boilers.
For users of industrial boilers, utilizing low sulfur fuels is the most cost effective
method of SOx reduction. Because SOx emissions primarily depend on the sulfur
content of the fuel, burning fuels containing a minimal amount of sulfur (distillate
oil) can achieve SOx reductions, without the need to install and maintain expensive
equipment.
CARBON MONOXIDE (CO)

Carbon monoxide is a pollutant that is readily absorbed in the body and can impair
the oxygen-carrying capacity of the hemoglobin. Impairment of the body's
hemoglobin results in less oxygen to the brain, heart, and tissues. Even short-term
over exposure to carbon monoxide can be critical, or fatal, to people with heart and
lung diseases. It may also cause headaches and dizziness in healthy people.
During combustion, carbon in the fuel oxidizes through a series of reactions to form
carbon dioxide (CO2). However, 100 percent conversion of carbon to CO2 is rarely
achieved in practice and some carbon only oxidizes to the intermediate step, carbon
monoxide.
Older boilers generally have higher levels of CO than new equipment because CO
has only recently become a concern and older burners were not designed to achieve
low CO levels. In today's equipment, high levels of carbon monoxide emissions
primarily result from incomplete combustion due to poor burner design or firing
conditions (for example, an improper air-to-fuel ratio) or possibly a leaky furnace.
Through proper burner maintenance, inspections, operation, or by upgrading
equipment or utilizing an oxygen control package, the formation of carbon monoxide
can be controlled at an acceptable level.
PARTICULATE MATTER (PM)

Emissions of particulate matter (PM) from combustion sources consist of many
different types of compounds, including nitrates, sulfates, carbons, oxides, and any
uncombusted elements in the fuel. Particulate pollutants can be corrosive, toxic to
plants and animals, and harmful to humans.
E-10
09-09
Section E
Particulate matter emissions generally are classified into two categories, PM and
PM10. PM10 is a particulate matter with a diameter less than 10 microns. All
particulate matter can pose a health problem. However, the greatest concern is with
PM10, because of its ability to bypass the body's natural filtering system.
PM emissions are primarily dependent on the grade of fuel fired in the boiler.
Generally, PM levels from natural gas are significantly lower than those of oils.
Distillate oils result in much lower particulate emissions than residual oils.
When burning heavy oils, particulate levels mainly depend on four fuel constituents:
sulfur, ash, carbon residue, and asphalenes. These constituents exist in fuel oils,
particularly residual oils, and have a major effect on particulate emissions. By
knowing the fuel constituent levels, the particulate emissions for the oil can be
estimated.
Methods of particulate control vary for different types and sizes of boilers. For utility
boilers, electrostatic precipitators, scrubbers, and baghouses are commonly utilized.
For industrial and commercial boilers, the most effective method is to utilize clean
fuels. The emission levels of parMethods of SOx reduction include switching to low sulfur fuel, desulfurizing the fuel,
and utilizing a flue gas desulfurization (FGD) system. Fuel desulfurization, which
primarily applies to coal, involves removing sulfur from the fuel prior to burning.
Flue gas desulfurization involves the utilization of scrubbers to remove SOx
emissions from the flue gases.
Flue gas desulfurization systems are classified as either non-regenerable or
regenerable. Non-regenerable FGD systems, the most common type, result in a
waste product that requires proper disposal. Regenerable FGD converts the waste
by-product into a marketable product, such as sulfur or sulfuric acid. SOx emission
reductions of 90-95% can be achieved through FGD. Fuel desulfurization and FGD
are primarily used for reducing SOx emissions for large utility boilers. Generally the
technology cannot be cost justified on industrial boilers.
For users of industrial boilers, utilizing low sulfur fuels is the most cost effective
method of SOx reduction. Because SOx emissions primarily depend on the sulfur
content of the fuel, burning fuels containing a minimal amount of sulfur (distillate
oil) can achieve SOx reductions, without the need to install and maintain expensive
equipment.
CARBON MONOXIDE (CO)

Carbon monoxide is a pollutant that is readily absorbed in the body and can impair
the oxygen-carrying capacity of the hemoglobin. Impairment of the body's
hemoglobin results in less oxygen to the brain, heart, and tissues. Even short-term
over exposure to carbon monoxide can be critical, or fatal, to people with heart and
lung diseases. It may also cause headaches and dizziness in healthy people.
During combustion, carbon in the fuel oxidizes through a series of reactions to form
carbon dioxide (CO2). However, 100 percent conversion of carbon to CO2 is rarely
achieved in practice and some carbon only oxidizes to the intermediate step, carbon
monoxide.
Older boilers generally have higher levels of CO than new equipment because CO
has only recently become a concern and older burners were not designed to achieve
low CO levels. In today's equipment, high levels of carbon monoxide emissions
primarily result from incomplete combustion due to poor burner design or firing
E-11
09-09
Section E
conditions (for example, an improper air-to-fuel ratio) or possibly a leaky furnace.
Through proper burner maintenance, inspections, operation, or by upgrading
equipment or utilizing an oxygen control package, the formation of carbon monoxide
can be controlled at an acceptable level.
PARTICULATE MATTER (PM)

Emissions of particulate matter (PM) from combustion sources consist of many
different types of compounds, including nitrates, sulfates, carbons, oxides, and any
uncombusted elements in the fuel. Particulate pollutants can be corrosive, toxic to
plants and animals, and harmful to humans.
Particulate matter emissions generally are classified into two categories, PM and
PM10. PM10 is a particulate matter with a diameter less than 10 microns. All
particulate matter can pose a health problem. However, the greatest concern is with
PM10, because of its ability to bypass the body's natural filtering system.
PM emissions are primarily dependent on the grade of fuel fired in the boiler.
Generally, PM levels from natural gas are significantly lower than those of oils.
Distillate oils result in much lower particulate emissions than residual oils.
When burning heavy oils, particulate levels mainly depend on four fuel constituents:
sulfur, ash, carbon residue, and asphalenes. These constituents exist in fuel oils,
particularly residual oils, and have a major effect on particulate emissions. By
knowing the fuel constituent levels, the particulate emissions for the oil can be
estimated.
Methods of particulate control vary for different types and sizes of boilers. For utility
boilers, electrostatic precipitators, scrubbers, and baghouses are commonly
utilized. For industrial and commercial boilers, the most effective method is to
utilize clean fuels. The emission levels of particulate matter can be lowered by
switching from a residual to a distillate oil or by switching from a distillate oil to a
natural gas. Additionally, through proper burner set-up, adjustment and
maintenance, particulate emissions can be minimized, but not to the extent
accomplished by switching fuels.
VOLATILE ORGANIC COMPOUNDS (VOCS) / HYDROCARBONS (HC)

Volatile organic compounds, or VOCs, are compounds containing combinations of
carbon, hydrogen, and sometimes oxygen. VOCs vaporize easily once emitted into
the air and are of concern because of their role in ground level ozone formation. In
reference to boiler performance, they are often referred to as hydrocarbons and
generally are divided into two categories methane and non-methane.
Formation of VOCs in commercial and industrial boilers primarily result from poor or
incomplete combustion due to improper burner set-up and adjustment. To control
VOC emissions from commercial and industrial boilers, no auxiliary equipment is
needed; properly maintaining the burner/boiler package will keep VOC emissions at
a minimum. Proper maintenance includes keeping the air/fuel ratio at the
manufacturer's specified setting, having the proper air and fuel pressures at the
burner, and maintaining the atomizing air pressure on oil burners at the correct
levels. An improperly maintained boiler/burner package can result in VOC levels
over 100 times the normal levels.
E-12
09-09
Section E
CALCULATING BOILER EMISSIONS

Emission Level
Units
Correcting
Emissions to 3%
Oxygen (15%
Excess Air)
This section describes the different units for emission levels. Emission levels can be
provided in many different units depending on whether the measurement is volume
or mass based.
ppm
Parts per Million Indicates emission levels on

a volume basis. Sometimes may be shown as
ppmv. Part per million must be referenced to
some oxygen level (excess air level) which, for
industrial boilers, is typically 3% oxygen (15%
excess air). Actual measurements recorded during boiler testing are usually in ppm.
lb/MMBtu
Pounds per Million Btu Indicates emission

levels on a mass basis. Emission levels are
shown in pounds of pollutant per million Btu input
to the boiler. This level is useful when hourly or
annual emission levels must be determined.
lb/hr
Pounds per Hour Indicates emission levels

on a mass basis. This unit represents the amount
of pollutant emitted on an hourly basis.
tpy
Tons per Year Indicates emission levels on a

mass basis. This unit corresponds to the annual
pollutant levels.
lb/106 cu-ft
Pounds per Million Cubic Feet Indicates

emission 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) input to the boiler. This is useful
when the actual gas usage of the boiler is known.
lb/103 gal
Pounds per Thousand Gallons Indicates

emission levels on a mass basis. This unit is
used for liquid (oil) fuels and indicates the emission level in pounds per thousand gallons of oil
fired. This is useful when the actual oil usage of
the boiler is known
The following equation shows how to correct emission readings to 3% oxygen (15%
excess air). Because boilers don't always operate at 3% oxygen, it is necessary to
convert ppm values measured at various excess air levels to 3% oxygen for
comparison and regulation compliance purposes. To correct emission levels to 3%
oxygen that are referenced to excess air levels other than 3%, use the following
equation.
ppm (@3%) =
21 3
21 O2 (actual)
x ppm (actual)
Example: What is the NOx level corrected to 3% oxygen

for a measured level of 27 ppm at 7.1% oxygen?
ppm (@3%) =
21 3
21 7.1
x 27 = 35 ppm NOx
E-13
09-09
Section E
Converting
Emissions Between
PPM And Lb/MMBTU
Although emission levels can be given in many different units, the most common are ppm (corrected to
3% oxygen) and lb/MMBtu. Conversion between these two types of units is very simple; however, it
does depend on the fuel type and excess air level.
The following graphs and equations show the relationships and conversions between ppm (corrected
to 3% oxygen) and lb/MMBtu. If the conversion involves a ppm level referenced to an oxygen level
other than 3%, the ppm level must be corrected to 3% oxygen (see previous section) before using the
following graphs (Figure E-5 through Figure E-8) and equations .
Dry Analysis
CO Emissions (lb/MMBtu)
0.18
0.16
No. 6 Oil
0.14
No. 2 Oil
Propane
Natural
Gas
0.12
0.10
0.08
0.04
0.02
0.00
0
20
40
60
80 100
120 140 160 180 200
CO Emissions (ppm)
Conversion Equations
No. 2 Oil:
Natural Gas:
ppm = (lb/MMBtu)*1290 ppm = (lb/MMBtu)*1370
lb/MMBtu = (ppm)/1290 lb/MMBtu = (ppm)/1370
No. 6 Oil:
ppm = (lb/MMBtu)*1260
lb/MMBtu = (ppm)/1260
Propane:
Figure E-5. CO Emissions Conversion Curves, 3% Oxygen, (15% Excess Air)
E-14
09-09
Section E
Dry Analysis
0.28
No. 2 and No. 6 Oil
0.26
Propane
0.24
Natural Gas
0.22
NOx Emissions (lb/MMBtu)
0.20
0.18
0.16
0.14
No. 2 and No. 6 Oil:

0.12
Natural Gas:
0.10
0.08
Propane:
0.06
0.04
0.02
0.00
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
SOx Emissions (lb/MMBtu)
2.0
1.8
1.6

1.4
1.2
1.0
0.8
0.6
0.4
0.2
0.0
0
100 200 300 400 500 600 700 800 900 1000 1100 1200
SOx Emissions (ppm)
Figure E-7. SOx Emissions Conversion Curves, 3% Oxygen, (15% Excess Air)
E-15
09-09
Section E
Dry Analysis
0.060
0.055
No. 2 and No. 6 Oil
VOC Emissions (lb/MMBtu)
0.050
0.045
0.040
Natural Gas and Propane
0.035
0.030
0.025

0.020
0.015
Natural Gas and Propane

ppm = (Ib/MMBtu)*2500
0.010
0.005
0.000
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)
Calculation Of
Annual Emissions
for Industrial Boilers
Many provisions of the 1990 Clean Air Act Amendments assess the impact of pollution sources based
on the potential annual emissions (usually expressed as tons per year, or tpy). When addressing industrial boilers, the potential annual emissions of NOx are of concern and frequently must be calculated.
Following is an example of how to calculate the potential annual NOx emissions for industrial boilers.
To determine the annual NOx emissions for an industrial boiler, three items must be known:
1. The NOx emission factor for the boiler.
2. The maximum rated input for the boiler.
3. The maximum allowable hours of operation for the boiler.
Once the information above is obtained, the following equation can be used to determine annual emissions.
Emission Factor x Boiler Input x Annual Hours of Operation = Total Annual Emissions
For example, the calculation of the total annual NOx emissions for an 800 hp boiler operating 24
hours/day, 365 days/year and having a NOx level of 110 ppm would be as follows.
Emission Factor = 0.13 lb/MMBtu (110 ppm = 0.13 lb/MMBtu)
Boiler Input = 33.5 MMBtu/hr (Based on 80% Efficiency)
Annual Hours of Operation = 8760 hours/year (24 hours/day x 365 days/year)
Substituting this data into the previous equation yields the annual NOx emissions for this specific
boiler, which is 19.1 tpy.
0.13 lb NOx x 33.5 MMBtu x 8760 hrs
MMBtu
hr
year
E-16
09-09
x 1 ton = 19.1 tpy NOx

2000 lb
Section E
The following graphs (Figure E-9 through Figure E-13) indicate the annual NOx emissions for boiler
sizes 250-800 horsepower firing natural gas at maximum input operating 24 hours/day, 365 days/
year. They are for NOx emission levels of 110, 60, 30, 25, and 20 ppm.
20
800 HP
Annual NOx Emissions (tpy)
700 HP
15
600 HP
500 HP
400 HP
350 HP
10
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
700 HP
600 HP
500 HP
400 HP
350 HP
300 HP
250 HP
Efficiency = 80%
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
(Corrected to 3% O2)
5
800 HP
4
700 HP
600 HP
500 HP
400 HP
350 HP
300 HP
250 HP
3
2
1
Efficiency = 80%
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
Figure E-11. Annual NOx Emissions for 250-800 Horsepower Boilers, NOx = 25 ppm (Corrected to 3% O2)
E-17
09-09
Section E
5
800 HP
4
700 HP
600 HP
500 HP
400 HP
350 HP
300 HP
250 HP
3
2
1
Efficiency = 80%
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
12
800 HP
10
700 HP
600 HP
500 HP
6
400 HP
350 HP
300 HP
250 HP
4
2
Efficiency = 80%
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
NEW SOURCE PERFORMANCE STANDARDS

The Federal EPA has established nationally uniform source-specific regulations
through the New Source Performance Standards, or NSPS, for which all applicable
sources must comply. The standards, which set minimal requirements for individual
sources, address approximately 65 categories of new or modified stationary sources,
including industrial boilers.
The NSPS for industrial boilers regulate levels for NOx, SOx, and particulate matter.
The regulated pollutants and requirements vary for different fuels and boiler sizes.
There are currently three categories for the NSPS:
Boilers with inputs greater than 250 MMBtu/hr
Boilers with inputs between 100-250 MMBtu/hr
Boilers with inputs between 10-100 MMBtu/hr
The Small Boiler NSPS apply to all new, modified, or reconstructed boilers with
inputs between 10-100 MMBtu/hr where construction, modification, or
E-18
09-09
Section E
reconstruction commenced after June 9, 1989. The Small Boiler NSPS set emission
standards for SOx and particulate matter for boilers firing coal, distillate and residual
oil, and wood. The Small Boiler NSPS also dictate record keeping requirements
regarding fuel usage for all fuels, including natural gas. Record keeping
requirements and compliance standards for the different emissions depends on the
type of fuel fired and on the boiler size. For a summary of the Small Boiler NSPS,
see Figure E-14.
Be sure your boiler complies with the New Source Performance Standards as noncompliance may result in fines and/or forced boiler shutdown.
Contact your local Cleaver-Brooks authorized representative if you have questions
regarding the New Source Performance Standards.
E-19
09-09
Section E
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-20
09-09
Section F
STACKS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3

PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4
Selection Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4
Special Stack Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7
Safety Specifications and Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7
Use of Noncombustible Enclosure or Chase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7
Clearance to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8
Connecting to the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8
Expansion and Installation Concerns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8
Clearances For Noncombustible Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-15
Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-15
Stack Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-17
Typical Stack Arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-17
SAMPLE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-21
F-1
09-09
Section F
ILLUSTRATIONS
Figure F-1. System Extension Above Boiler Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure F-2. Thermal Expansion Between Two Fixed Points in Stack System . . . . . . . . . . . . . . . . .
Figure F-3. Graphs for Calculating Thermal Expansion Movement . . . . . . . . . . . . . . . . . . . . . . . .
Figure F-4. Maximum Unsupported Distance Between Elbows, Tees, orWyes . . . . . . . . . . . . . . . .
Figure F-5. Maximum Support and Guide Assembly Spacing for Vertical, Horizontal, and
Sloping Stack Runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure F-6. Cable Guying Specifications for Roof Level Guide . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure F-7. Roof Framing and Curb Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure F-8. Cable Guying Installation Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure F-9. Model CBS-II Double Wall Stack Construction and Joint Details . . . . . . . . . . . . . . . . .
Figure F-10. Model ICBS Fiber-Insulated Stack Construction and Joint Details . . . . . . . . . . . . . . .
F-8
F-9
F-10
F-10
F-11
F-11
F-14
F-14
F-16
F-16
TABLES
Table F-1. Stack Product Offering and Application Information . . . . . . . . . . . . . . . . . . . . . . . . . .

Table F-2. System Component Names and Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table F-3. Maximum Stack Height Supported Per Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table F-4. Roof Opening Size for Penetration of Roof Support Assemblies . . . . . . . . . . . . . . . . . .
Table F-5. Stack System Clearances to Combustible Materials . . . . . . . . . . . . . . . . . . . . . . . . . .
Table F-6. Weight of Straight Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-5
F-6
F-12
F-15
F-18
F-19
This section contains information on the complete line of stacks. This line includes stack components in single,
double, and triple wall construction for discharging combustion gases and fumes from boilers, heaters, ovens
and other sources generating exhaust vapors at temperatures up to 1400 F.
F-2
09-09
Section F

Custom Built to Customer Specifications Using CAD Technology:
Assures proper system sizing and design.
Provides complete system drawing.
Provides bill of material based on prefabricated CB-Stack components.
System Designed to Use Standard Components:
Reduces on-site construction costs.
Additions and modifications can be made easily and economically.
All components are completely compatible.
10 Year Factory Warranty:
Guaranteed to last.
Longest warranty in the business.
Backed by Cleaver-Brooks.
Quick-Ship 10 Day Factory Delivery:
Provides the customer "What they want - when they want it".
Reduces downtime.
Efficient job construction scheduling.
Lowest Clearance to Combustibles:
Reduces needed clearances to combustibles and non- combustibles.
Increases usable floor space.
Saves on construction costs.
Shipped on Pallets and Shrink-Wrapped:
Simplified on-site handling.
Protects materials until installation.
Reduces freight damage.
No Welding or On-Site Fabrication Required:
Saves time and labor costs.
Components are light and easily assembled by one or two people.
No special equipment or supervision required.
Stack Sections and Fittings are Continuous Welded:
Prevents leakage from vented gases.
Meets stringent UL and ULC requirements.
Patented Spacer Design:

F-3
09-09
Section F
Assures consistent product alignment and support.
Built to perform under the most demanding conditions.
Built With Captive Nuts and Bolts:
Allows easy installation without the risk of losing hardware.
Saves on installation time and cost.
PRODUCT OFFERING
Cleaver-Brooks manufactures a complete line of fully compatible stack components
as follows:
Ameri-Vent type "B": gas vent.
Model CBS-I: single wall stainless steel.
Model CBS-II: double wall air insulated.
Model ICBS: double wall - 1", 2", and 4" material insulated.
See Table F-1 for the product that best fits your specific application.
Selection
Considerations
The information in this section applies to product selection which is governed by

four major considerations:
Type of heating equipment.
Fuels to be burned and vapor or gases to be removed.
Exhaust operating temperatures of the equipment.
Building use and type of construction materials used.
All CBS/ICBS chimney components will be custom fabricated for your

installation.
Cleaver-Brooks application engineers design and size stack systems based on data
provided by the engineer or contractor. These data include information such as jobsite elevation, equipment and fuel type, equipment input (Btu/hr), flue gas
temperature, as well as site dimensions and the need for offset, drains, fittings, roof
penetration, etc.
These data are used to generate a detailed installation drawing and component
parts list. Prior to fabricating the parts at our plant, the installation drawing and
parts list are returned to the engineer or contractor for verification. It is the
engineers or contractors sole responsibility to field verify all dimensions,
components, and layouts on the installation drawing. This verification must include
an authorized signature and date before the order will be fabricated and shipped.
Special Stack
Applications
Cleaver-Brooks can help in the design, layout and manufacture of the following
special stack applications:
Grease duct venting systems.
Engine/turbine venting systems.
Solid fuel venting systems.
Special stack applications may require unique design and product modifications.
Contact your local Cleaver-Brooks authorized representative for assistance.
Standard Components, Table F-2, lists the names and part numbers for the various
components of all Cleaver-Brooks model lines. Each model line has its own letter
designation. N is used to identify CBS-I single wall components. Double wall CBS-II
F-4
09-09
09-09
N/A
1" Air
Outer:
.025" 24-ga Aluminum
Coated Steel 6" to 24"
Optional 304 or 316SS
Available)
Inner:
.035" 20-ga 304SS
Standard (Optional .035"
20-ga 316SS Available)
6" through 48"
1" Material
2" Material or 4" Material
Outer:
CoatedSteel 6" to 24"
(Optional 304 or 316SS
Available)
Insulation Material:
Eleven Pound Fiber
Insulation of 1", 2" or 4"
thickness
Inner:
.035" 20-ga 304SS
Standard (Optional .035"
20-ga 316SS Available)
100 F Continuous, 1400 F Intermittent

1400 Continuous. 1800 F Intermittent
Grease Duct 500 F Continuous
Positive, Neutral or Negative
Complies with one or more of the following: AGA; HUD; NBC; UBC; UMC; NMC; SMC; SBCCI; ICBO; BOCA;
UL-103, 710, 411; ULC-S604; NFPA-85, A, B, D, 31, 34, 37, 54, 96, 211.
1/4" Air 3" through 6"

1/2 Air 7" through 30"
A. Recommended 316 Stainless Steel.
Application Ref. &

Listings
Insulation
Outer:
N/A
Outer:
28-ga Galvanized
Steel 3" to 30"
Air Product Containment or

2000F for Grease Duct
Inner:
Standard 304SS .035" All
Diameters (Optional .035"
316SS Available)
400F Plus Ambient
Exhaust Temp.
Continuous/Intermittent
Inner:
.012" Aluminum 3" to 6"
Neutral or Negative
Exhaust Pressures
Double wall either 1", 2" or 4"

Material Insulated
ICBS
Boiler and Breeching Systems, Engine/Turbine Exhausts,

Grease/Oven
Exhausts, Air/Particle Containment
Double Wall Air Insulated
CBS-II
LP; Natural Gas; #2, #4A, #5A or #6A Fuel Oil; Wood; CoalA; Grease Vapors;
Caustic Fumes; Particles
Materials
Natural or LP Gas
Fuel Types
Air/Product
Containment
Breeching
Systems, Grease Duct
3" through 30"
AGA Listed Gas

Appliances
Applications
Single Wall Stainless Steel
CBS-I
Diameters
Type "B" Gas Vent
AMERI-VENT
Description
MODEL NO.
Table F-1. Stack Product Offering and Application Information
Section F
F-5
Section F
Table F-2. System Component Names and Part Numbers
PART NAME
DESCRIPTION
MODEL NO.
PART NUMBERS
CBS-I
CBS-II
ICBS-1"
ICBS-2"
ICBS-4"
N18
S18
A18
B18
D18
N30
S30
A30
B30
D30
N42
S42
A42
B42
D42
90 tee
NT90
ST90
AT90
BT90
DT90
45 tee
NT45
ST45
AT45
BT45
DT45
Straight pipe
sectionA
Wye
NY
SY
AY
BY
DY
Drain wye
NDY
SDY
ADY
BDY
DDY
15 elbow
NEB15
SEB15
AEB15
BEB15
DEB15
30 elbow
NEB30
SEB30
AEB30
BEB30
DEB30
45 elbow
DEB45
NEB45
SEB45
AEB45
BEB45
Expansion joint
NEJ
SEJ
AEJ
BEJ
DEJ
Bellows joint
NBJ
SBJ
ABJ
BBJ
DBJ
NFAL
SFAL
AFAL
BFAL
DFAL
Fixed adjustable length

Nozzle section
NNS
SNS
ANS
BNS
DNS
Drain section
NDS
SDS
ADS
BDS
DDS
Horizontal drain
NHD
SHD
AHD
BHD
DHD
Stack base drain
NSBD
SSBD
ASBD
BSBD
DSBD
Drain plug
NDP
SDP
ADP
BDP
DDP
Inspection plug
NIP
SIP
AIP
BIP
DIP
Slip joint
NSJ
SSJ
ASJ
BSJ
DSJ
Stepped increaser
NSIR
SSIR
ASIR
BSIR
DSIR
NWPA
SWPA
AWPA
BWPA
DWPA
Roof support assembly
Wall penetration assembly
SRSA
ARSA
BRSA
DRSA
Penetration assembly
SPA
APA
BPA
DPA
NSC
SSC
ASC
BSC
DSC
Storm collar
Tall cone flashing
NTCF
STCF
ATCF
BTCF
DTCF
Stack closure ring
NSCR
SSCR
ASCR
BSCR
DSCR
Stack termination cap
NSTC
SSTC
ASTC
BSTC
DSTC
NOT
SOT
AOT
BOT
DOT
NSEC
SSEC
ASEC
BSEC
DSEC
CB1
CB1
CB1
CB1
CB1
Closure bands
CB2
ACB2
BCB2
DCB2
Half closure bands
HCB2
AHCB2
BHCB2
DHCB2
Open termination
Stack exit cone
Containment band
Boiler adapters
NBA
SBA
ABA
BBA
DBA
Generator adapters
NGA
SGA
AGA
BGA
DGA
Stack support assembly
NSSA
SSSA
ASSA
BSSA
DSSA
Split clamp flange
NSCF
SSCF
ASCF
BSCF
DSCF
Half split angle ring
NHSAF
SHSAR
AHSAR
BHSAR
DHSAR
Split angle ring
NSAR
SSAR
ASAR
BSAR
DSAR
Hanger bracket
NHB
SHB
AHB
BHB
DHB
Floor alignment guide
NFAG
SFAG
AFAG
BFAG
DFAG
Wall guide assembly
NWGA
SWGA
AWGA
BWGA
DWGA
STB
ATB
BTB
DTB
NWSA
SWSA
AWSA
BWSA
DWSA
INS-3
INS-3
INS-3
Transition band
Wall support assembly
Fiber insulation strips
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
09-09
Section F
uses the letter S.. Fiber-Insulated components use the letter A for 1" insulated, B for
2" insulated, and D for 4" insulated.
Every part shipped for your order has a label listing the component part number.
The first two digits identify the stack inner diameter. For example, a part labeled
16SEJ11 is a 16" ID, double wall, expansion joint. The last two digits of the part
number are for manufacturing control.
A part labeled 24BT9011 is a 24" ID, 90 tee that is fiber insulated with 2" of
insulation between its inner and outer walls.
ENGINEERING DATA
Information in this section outlines typical installation requirements when installing
a stack or breeching to a Cleaver- Brooks boiler. Actual installation and
arrangements will be dictated by design, state, provincial or local codes, job-site
conditions and number of boilers installed.
This information, in addition to information listed in Table F-1, will assist you in
determining equipment required.
For special applications or additional information contact your local Cleaver-Brooks
Application
Cleaver-Brooks CBS/ICBS stack systems comply with the requirements of the

approval bodies listed in Table F-1. These stack systems are not for installation in
one and two family dwellings.
These stack systems must be installed as complete systems that originate at the
boiler and terminate outdoors.
Installing or using CBS or ICBS stack systems, or parts of systems, in ways other
than those specified can be hazardous.
Always contact local building and/or fire officials concerning application restrictions
and installation inspection procedures. Obtain all required building permits.
Safety
Specifications and
Clearances
All CBS/ICBS stack systems should be sized in accordance with the instructions
provided by the manufacturer and pertinent job-site data.
Use of
Noncombustible
Enclosure or Chase
The following information on noncombustible chase and clearance to combustibles

pertains to all applications, except grease duct systems:
The stack system must never be jacketed, wrapped, or enclosed in combustible

materials. Never place insulation in required clearance spaces or ventilation
openings.
When the stack extends through any story above the one in which the boiler is
located, including drop ceilings and crawl spaces, it must be enclosed in a
continuous enclosure made of noncombustible materials. This enclosure or
chase should extend from the first ceiling above the boiler to, or through, the
roof of the building. Refer to Figure F-1. It must maintain the integrity of the fire
separations required for the construction and occupancy classification of the
building.
When the stack is installed in a noncombustible enclosure, this enclosure

becomes an extension of the boiler room to the outside of the building. It must
be designed and sized to allow boiler room air to mix with outside air. This
means there must be sufficient clearance between the walls of the enclosure
and the stack, its supports, and its guides.
F-7
09-09
Section F
Figure F-1. System Extension Above Boiler Room

Clearance to
Combustibles
Care must be taken when using combustible material around the stack. Refer to
"Clearances for Non-Combustible Enclosures" in this section for recommended
clearances.
Connecting to the
Boiler
CBS/ICBS stack systems, in most applications, can be connected directly to, and
supported by the boiler. Refer to Table F-6 for typical stack weights. For special
applications contact your local Cleaver-Brooks authorized representative.
Expansion and
Installation
Concerns
When stack systems are exposed to the heating and cooling of normal operation,
the components will expand and contract. The systems are designed to adjust to
this movement, provided the amount and direction of expansion is accurately
calculated, and the system is correctly installed.
The amount of thermal expansion that will occur depends on the length of
breeching, height of the stack, temperature of the flue gas, and arrangement of the
system. Therefore, the following must be considered.
Thermal Expansion
The CBS/ICBS systems use two different parts to compensate for thermal expansion
between two fixed points in the system. They are: expansion joints and bellows
joints.
Each type of joint is:
Designed to compensate for linear expansion only.
Never used to correct for misalignment between components.
Not load bearing. Therefore, these systems are usually between support or
guide assemblies.
Expansion Direction
To determine expansion direction, it is necessary to understand how the expansion
or bellows joint works. The expansion or bellows joint itself does not expand. In
fact, the opposite happens. It compresses to absorb the movement of the parts
expanding around it. This expansion movement occurs from fixed points in the
system toward the expansion or bellows joint. Refer to Figure F-3
F-8
09-09
Section F
Figure F-2. Thermal Expansion Between Two Fixed Points in Stack System
Calculating Expansion
The amount of thermal expansion that will occur is calculated by the following
equation:
Expansion = 1" per 100 of stack per 100 F above ambient temperature.
Expansion is calculated between fixed points in the system. If more than 1/4" of
expansion will occur between fixed points, an expansion or bellows joint must be
installed within that run of stack.
Thermal expansion can also be determined using the graphs shown in Figure F-3.
Support Assemblies
CBS/ICBS support assemblies are load bearing items. They are designed to carry the
weight of the system and withstand expansion forces.
Support assemblies are connected to the inner wall flange of the stack. They must
always be bolted or otherwise tied into rigid structural building supports. They must
never be suspended from lightweight rods or tubing.
Three different types of support assemblies are used:
Stack support assembly (SSA).
Wall support assembly (WSA).
Roof support assembly (RSA).

F-9
09-09
Section F
Figure F-3. Graphs for Calculating Thermal Expansion Movement
Figure F-4. Maximum Unsupported Distance

Between Elbows, Tees, orWyes
F-10
09-09
Section F
Figure F-5. Maximum Support and Guide Assembly

Spacing for Vertical, Horizontal, and Sloping Stack Runs
Refer to Figure F-3 for the maximum stack height supported per assembly.
Support assemblies must also be located within 6 of elbows, tees, or wyes. It may
be necessary to reduce this spacing if anticipated expansion is greater than 1/4"
between fixed points.
Refer to Figure F-4 for the maximum unsupported distance between elbows, tees, or
wyes.
Refer to Figure F-5 for the maximum support and guide assembly spacing for
vertical, horizontal and sloping stack runs.
Guide Assemblies
Guide assemblies are designed to provide lateral support and guidance for the stack
system. They must be rigidly mounted to the building and plumb with the stack.
Guide assemblies are not tied into, or attached to, the stack in any way, but they do
bear part of the overall load in horizontal and sloped runs.
Three types of guide assemblies are used:
Figure F-6. Cable Guying Specifications for Roof Level Guide

F-11
09-09
Section F
Table F-3. Maximum Stack Height Supported Per Assembly

MODEL
ID (INCHES)
SSA (FT)
WSA
RSA (FT)
ICBS-2
210
78
198
73
CBS-I
6-48
210
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
6-10
210
78
143
53
12
188
70
119
44
14
163
61
10
102
37
16
144
53
12
89
33
18
134
51
14
79
29
20
128
49
16
71
26
22
123
48
18
67
25
24
120
47
20
65
25
26
105
41
22
63
24
28
104
41
24
62
24
30
104
40
26-34
57
22
32-34
103
40
36
56
22
36
101
40
42
49
20
42
87
35
48
43
17
48
77
30
ICBS-1
78
6
8
ICBS-4
NOTE:
1. A. Single wall VSI-I piping prohibits the use of penetration assemblies. A transition to double wall VSI-II pipe will be required
where the piping passes through a penetration assembly.
2. Numbers in table are in inches.
3. SSA = Stack Support Assembly.
4. WSA = Wall Support Assembly.
5. RSA = Roof SUpport Assembly.
F-12
09-09
Section F
Split angle rings.
Wall guide assemblies.
Floor alignment guides.
The maximum spacing between any two guide assemblies, or between a support
assembly and a guide assembly, is 15 for vertical runs and 12 for horizontal or
sloping runs. Refer to Figure F-5.
The maximum height a vertical stack can extend above its uppermost guide or guy
cable location is 9. Refer to Figure F-6.
Load Bearing
When designing or installing a CBS/ICBS stack, remember the inner stack wall is
the load bearing member. All stack supports must be connected to the inner wall
flanges.
Outer or center walls (three wall stack) are not designed to bear loads. They act as
jackets only. Never connect system supports or pierce these walls.
Roof Penetrations
Proper selection and use of various components at the location the system
penetrates the roof, are based on a number of factors, including roof material
(combustible/noncombustible), the use of noncombustible enclosures or chases,
and the general layout of the system.
When a stack system passes through a roof made of combustible materials, a
penetration or roof assembly that consists of a ventilated storm collar must be used.
These assemblies are specifically designed to provide the proper clearances and
ventilation openings. These assemblies must be installed without modifications and
all ventilation openings must remain open and unobstructed.
When the stack system passes through floors or zones above the boiler room, it
must be installed in a noncombustible enclosure or chase. The enclosure must
extend to, or above, the roof deck and a penetration or roof assembly must be used
regardless of the roof material.
A third roof penetration uses tall cone flashing along with a storm collar. This
method may only be used if:
The roof deck and framing materials are noncombustible.
The stack does not pass through floors, drop ceiling or other occupance zones
on its way to the roof.
The area above the boiler, to the roof level, is basically open, providing adequate
air movement around the system.
Roof Opening Size, Framing and Curbing

Opening size varies according to stack OD. In most cases the opening will be square
and cut so it is basically flush with the framing members. If the roof is made of
noncombustible materials, the roof opening may be round.
The opening must be level and provide attachment points for external brackets. The
opening should be boxed in with structural steel or wood framing on all four sides.
The framing must be capable of supporting the load, or the penetration assembly,
when the stack is exposed to wind loading and thermal expansion forces.
F-13
09-09
Section F
Figure F-7. Roof Framing and Curb Details
Figure
FigureF-1.
F-8.Cable
CableGuying
GuyingInstallation
InstallationDetails
Details
On sloping roofs, a level curb must be constructed and tied into the openings
framing so that the stack maintains its true vertical positions.
Both framing and curbing can be constructed of combustible materials if proper
clearances are maintained.
Table F-4 list roof openings for all models in width of square, or diameter of circle.
Figure F-7 shows roof framing and curbing details for flat or sloping roofs.
Cable Guying Above the Roof - Guy cables are an acceptable method of providing
lateral support to stack sections that extend above the roof level. A stack should not
use cable guying at locations higher than 15 above a roof, pier or superstructure
may be used for this type of application. The stack may also extend 9 above guy
cable connections. Refer to Figure F-7 andFigure F-8.
Above the Roof Guiding
Stacks extending more than 24 above a roof, pier or wall should use a guide
assembly rigidly mounted to a superstructure, tower, or wall. The structure must be
capable of supporting lateral wind load and maintain plumb alignment between the
guide assemblies and the stack.
F-14
09-09
Section F
Clearances For
Noncombustible
Enclosures
Although consistent clearances are not critical, a minimum open area equivalent to
a 1-1/2" clearance between the enclosure, its supports and guides, must exist at
any plane within the enclosure. Refer to Figure F-1.
Clearances to
Combustibles
When installed within the same room or zone as the boiler, the stack must have a
minimum air space clearance to combustible construction, including building
insulation and electrical wiring as listed in Table F-5.
These minimum clearances must never be altered in any way. Lower than listed flue
gas temperatures do not alter the clearances listed. For example, if the maximum
flue gas temperature in a model CBS-II system will be 500 F, the full clearance for
that diameter listed for 1000 F stack system must be used.
When smaller clearances are desired, specify model ICBS fiber insulated stacks.
To assist with selection, the following figures will provide basic construction details
of the different types of stacks:
Figure F-9 shows model CBS-II double wall stacks.
Figure F-10 shows model ICBS fiber insulated stacks.
Each model includes:
Spacer bands that hold the sections together and maintain the proper air space
between the walls.
One air space is designed into model CBS-II.
Model ICBS are available with 1", 2", or 4" of fiber insulation between the walls.
For information on single wall or type "B" gas vent stacks, contact your local
Stack Weight
Table F-6 lists weights of all models in pounds per linear foot. These weights
Table F-4. Roof Opening Size for Penetration of Roof Support Assemblies
STACK ID
(INCHES)
WIDTH OF SQUARE OR DIAMETER OF CIRCLE

CBS-II
ICBS-1"
ICBS-2"
ICBS-4"
17-1/2
17-1/2
19-1/2
23-1/2
19-1/2
19-1/2
21-1/2
25-1/2
10
21-1/2
21-1/2
23-1/2
27-1/2
12
23-1/2
23-1/2
25-1/2
29-1/2
14
25-1/2
25-1/2
27-1/2
31-1/2
16
27-1/2
27-1/2
29-1/2
33-1/2
18
29-1/2
29-1/2
31-1/2
35-1/2
20
31-1/2
31-1/2
33-1/2
37-1/2
22
33-1/2
33-1/2
35-1/2
39-1/2
24
35-1/2
35-1/2
37-1/2
41-1/2
26
37-1/2
37-1/2
39-1/2
43-1/2
28
39-1/2
39-1/2
41-1/2
45-1/2
30
41-1/2
41-1/2
43-1/2
47-1/2
32
43-1/2
43-1/2
45-1/2
49-1/2
34
45-1/2
45-1/2
47-1/2
51-1/2
36
47-1/2
47-1/2
49-1/2
53-1/2
42
53-1/2
53-1/2
55-1/2
59-1/2
48
59-1/2
59-1/2
61-1/2
65-1/2
F-15
09-09
Section F
Figure F-9. Model CBS-II Double Wall Stack

Construction and Joint Details
Figure F-10. Model ICBS Fiber-Insulated Stack Construction

and Joint Details
F-16
09-09
Section F
include the stack sections and connecting hardware.
Typical Stack
Arrangements
The purpose of a stack and breeching on a boiler is to conduct the products of

combustion to a point of safe discharge (atmosphere).
The forced draft design of Cleaver-Brooks burner and boiler combinations,
eliminates the need for a stack designed to create a draft. A static pressure of 1/
2" WC at the boiler flue gas outlet will have no appreciable effect on burner
operation. Refer to the individual product sections for allowable pressure variations.
If the stack height is over 150 or if an extremely large breeching and stack
combination cause excessive draft, a simple barometric damper can be located in
the breeching - close to the stack.
Automatic or special draft controls are not required and are not recommended,
except where dictated by state, provincial or local codes.
A manual or automatic open-close outlet damper can be installed on a single boiler
installation, and is recommended for safety concerns on a multiple common
breeching or stack installation.
The amount of condensation in the stack will vary with the type of fuel utilized, the
type and operating pressure or temperature of the boiler, and the stack flue gas
temperature.
Stack condensation is most likely to occur on boiler installations where light loads or
intermittent firing causes a cool stack condition, which results in condensation of
the water vapor in the flue gas.
The following items should be considered when planning to keep stack
condensation to a minimum:
The boiler should be sized as close as possible to the true operating load.
Oversized boilers should be avoided.
An off-set stack is recommended, with bottom clean-out and drain connection,

to prevent any condensed water from draining back into the flue gas side of the
boiler.
State, provincial and local codes may govern the stack height above the roof. If
down drafts are unavoidable, the stack outlet can be provided with a ventilator.
A rain cap or hood should be used at the top of the stack to minimize the entrance
of snow or rain.
F-17
09-09
Section F
Table F-5. Stack System Clearances to Combustible
Materials
1400 F
CHIMNEY
500F
GREASE
DUCT
18
14-16
18
10
20
10
22
10
11
24
12
11
26
13
12
28
14
12
30
16
13
32
10
17
13
34
10
19
14
36
10
20
14
42
18
20
16
48
18
20
17
6-16
18
20
22
24
26
28
11
30
12
32
14
34
15
36
16
42
14
16
10
MODEL
NO.
ID
CBS-I
6-48
CBS-II
6-8
10-12
ICBS-1
ICBS-2
&
ICBS-4
1000F
CHIMNEY
48
14
16
11
6-16
0.5
0.5
1.0
18
1.0
2.0
2.0
20
1.5
4.0
2.0
22
2.0
5.0
3.0
24
2.0
6.0
3.0
26
3.0
8.0
4.0
28
3.0
9.0
4.0
30
4.0
11.0
5.0
32
4.0
12.0
5.0
34
5.0
13.0
6.0
36
5.0
15.0
6.0
42
12.0
15.0
8.0
48
12.0
15.0
9.0
NOTE: Numbers in table above are in inches.
F-18
09-09
Section F
Table F-6. Weight of Straight Stack

STACK ID
(INCHES)
WEIGHT IN POUNDS PER LINEAR FOOT

CBS-I
CBS-II
ICBS-1"
ICBS-2"
ICBS-4"
2.43
4.83
7.01
9.85
17.01
3.25
6.17
9.01
12.36
20.49
10
4.05
7.50
11.01
14.83
23.96
12
4.86
8.84
13.00
17.32
27.43
14
5.67
10.17
15.00
19.81
30.90
16
6.48
11.66
16.99
22.30
34.37
18
7.29
12.84
18.99
24.78
37.83
20
8.09
14.18
20.97
27.26
41.29
22
8.89
15.51
22.97
29.74
44.76
24
9.71
16.85
24.98
32.23
48.23
26
10.51
21.88
30.33
38.31
55.65
28
11.32
23.43
32.45
40.91
59.33
30
12.13
24.99
34.67
43.64
63.05
32
12.94
26.55
36.90
46.35
66.74
34
13.75
28.10
39.13
49.08
70.44
36
14.56
29.66
41.35
51.79
74.13
42
16.97
34.83
48.01
59.92
85.21
48
19.40
40.20
54.69
68.08
96.31
F-19
09-09
Section F
NOTES
F-20
09-09
Section F
Stack Specifications
The following sample specification is provided by Cleaver-Brooks to assist you in specifying your customers
F-21
09-09
Section F
PART 1 GENERAL
1.1
COMPONENT SPECIFICATIONS
PART 2 PRODUCTS
2.1
STANDARD SPECIFICATIONS
A. Boiler stack and breeching components, supports and terminations
shall be factory prefabricated.
B. All stack and breeching components shall be tested and listed by
Underwriters Laboratories (UL and ULC), for use with building
heating equipment burning gas, liquid, or solid fuels, as described
in NFPA 211, Chapter 2.
C. All stacks and breechings will have inner walls of 20-gauge Type
304 stainless steel for gas and No. 2 oil, or 20-gauge Type 316
stainless steel for coal, solid fuels, and No. 4 thru No. 6 oil.
D. Outer walls shall be 24-gauge aluminum-coated steel for sizes up to
24" ID and 20-gauge for sizes of 26" to 48" ID.
E. The stack and breeching shall be engineered, approved, and
manufactured for the boiler equipment manufacturer.
F.
The stack and breeching manufacturer must supply complete CAD
system design drawings which include a complete component bill of
materials.
G. Stack and breeching systems must be designed to adjust to thermal
expansion caused by the heating and cooling of normal boiler
operation.
H. All stack and breeching components must be warranted for a
minimum of 15 years when installed according to the
manufacturers installation instructions.
I.
The stack and breeching shall comply with national safety
standards and all building codes where applicable.
J. The stack section joints shall be field sealed by use of containment
bands with captive fasteners and high temperature joint sealant.
K. All stack and breeching components shall be shipped on pallets and
shrink-wrapped to simplify on-site handling and protect materials
until installation.
L. The system is to maintain air-tight integrity at pressures up to 72"
WC at room temperature.
M. The system shall have a ______" minimum clearance to
combustibles with flue gas temperatures greater than 1000 F and
not exceeding 1400 F continuous, and a _____" minimum
clearance to combustibles with flue gases not exceeding 1000 F
continuous.
2.2
SPECIFICATIONS SPECIFIC TO DOUBLE WALL AIR INSULATED

COMPONENTS
There shall be a minimum of 1" air space between the inner and outer wall.
2.3
SPECIFICATION SPECIFIC TO DOUBLE WALL 1", 2", OR 4" MATERIAL

INSULATED COMPONENTS
There shall be a minimum of (1", 2", or 4") bonded fiber insulation between the
inner and outer wall.
F-22
09-09
Section F
F-23
09-09
Section F
Notes
F-24
09-09
Section G
ECONOMIZERS
CONTENTS

Standard Economizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condensing Economizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIMENSIONS AND WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G-3
G-3
G-4
G-4
G-4
G-4
G-7
G-17
G-1
09-09
Section G
ILLUSTRATIONS
Dimension diagram, C2X condensing economizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6
Economizer mounting to firetube boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-10
Installation options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-10
Typical piping diagram, CCE/CRE economizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-11
Typical piping diagram, condensing economizers - single boiler with deaerator . . . . . . . . . . . . . . . . . . . . . . G-12
Typical piping diagram, condensing economizers - single boiler with deaerator and surge tank. . . . . . . . . . G-13
Typical piping diagram, condensing economizers - two boilers with deaerator . . . . . . . . . . . . . . . . . . . . . . . G-14
Typical piping diagram, condensing economizers - two boilers with deaerator and surge tank. . . . . . . . . . . G-15
TABLES
Firetube boiler economizers dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5
Dimensions, C2X condensing economizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7
Economizer weights, C2X condensing economizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7
Firetube boiler economizer performance data (Model CB boilers). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8
Firetube boiler economizer efficiencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8
This section contains information on Economizers. An economizer recovers heat from flue gases and uses it to increase
boiler feedwater temperatures, prior to entering the boiler. Cleaver-Brooks offers a variety of types, sizes, and custom
designs. Each assures proper match for your specific firetube or watertube boiler.
G-2
09-09
Section G

Reduces Fuel Use and Cost:
Recovers heat from flue gases that would otherwise be wasted.
Heat is used to raise boiler feedwater temperature prior to entering the boiler.
Load Changes:
Rapid changes in load demands can be met faster due to higher feedwater
temperature.
Emissions:
Reduced fuel-firing rates for any given steam output means reduced NOx emissions.
ASME Construction:
Ensures high quality design and manufacturing standards.
Provides safety and reliability.
High Efficiency Heat Exchanger:
Provides uniform fin-to-tube contact for maximum heat transfer.
Fin tubing offers up to 12 times the heat exchange surface of bare tubing of the same
diameter.
Self-Draining Design:
Suitable for outdoor installation.
Low Pressure Drop:
Provides low gas side pressure drops.
Permits use of smaller forced draft fans.
Permits use of existing fans in almost all installations.
Gas Tight Combustion Stack:
Stainless Steel casing.
Compact dimensions provide for easy installation.
Guaranteed Efficiency on Model CB Firetube Boilers:
$10,000 rebated for every full 1.0% efficiency point less than guaranteed.
G-3
09-09
Section G
PRODUCT OFFERING
Standard
Economizers
Cleaver-Brooks offers a line of custom-engineered economizers for boiler sizes up to

and including 150 MMBtu/hr. input. The model CRE Fuel Economizers are available for
firetube boilers up to 1800 HP.
Standard Equipment
Standards for all C-B Economizers include:
Designed and fabricated in accordance with the ASME Boiler and Pressure Vessel
Code, UM stamp standard, U stamp and Section I optional.
Thermometer and safety valve connections at the feedwater headers.
Incorporates self-draining design.
Safety valve.
Optional Equipment
Condensing
Economizers
Vertical or horizontal flue gas flow patterns on rectangular design.
Utilization of waste gas.
Soot blowers for oil firing.
In addition to incorporating many of the standard economizer features, the Model C2X
condensing economizer utilizes a 2-stage design allowing makeup water to be heated
before it enters the deaerator, or in a second stage between the deaerator and the boiler.
DIMENSIONS AND WEIGHTS

Information in this section outlines typical dimensions and weights of an economizer.
Table G-1 lists dimensions and weights for a CCE and CRE Economizers typically
installed with a firetube boiler.
Figure G-1 and Table G-2 give dimensions for the C2X condensing economizer. Table
G-3 lists C2X weights.
The selection of an economizer for a particular application will depend on type and
capacity of the boiler and job site conditions.
G-4
09-09
Section G
Table G-1. Firetube Boiler E+Plus Economizers Dimensions and Weights

(Model CB Boilers)
DIMENSIONS
(APPROX)
BOILER
HP
ECONOMIZER
MODEL
NUMBER
WIDTH
(IN.)
DEPTH
(IN.)
HEIGHT
(IN.)
DRY
UNIT
WEIGHT
(LBS)
100 hp
CCE 16A6AL
30RD
25
270
125 hp
CCE 18D7AL
30RD
37
380
150 hp
CCE 18D7AL
30RD
37
381
200 hp
CCE 18E6AL
30RD
41
410
250 hp
CRE 30H7AL
52
43
58.3
1320
300 hp
CRE 30H7AL
52
43
58.3
1320
350 hp
CRE 30F7AL
52
43
50
1120
400 hp
CRE 36F7AL
60
50
50
1470
500 hp
CRE 36G 6AL
60
50
54.2
1596
600 hp
CRE 36H5AL
60
50
58.3
1716
700 hp
CRE 36J5AL
60
50
66.8
1961
800 hp
CRE 36J5AL
60
50
66.8
1961
NOTES:
2. Boiler firing natural gas only.
3. Boiler operating pressure is 125 psig (acceptable tolerance is
5 psig).
4. Contact your local Cleaver-Brooks representative for sizing detail.
Model CCEs are cylindrical
Model CREs are rectangular
G-5
09-09
Section G
Figure G-1. Dimension Diagram, C2X Condensing Economizer
BB
G-6
09-09
Section G
Table G-2. Dimensions, C2X Condensing Economizer
Table G-3. Economizer Weights, C2X Condensing Economizer

4WI Boilers
Boiler HP
250-300
350-400
500
600
700
800
Economizer
Economizer
Model
Dry Weight
C2X-2M386AL
1980
C2X-2M3A6AL
2220
C2X-2R3A6AL
2520
C2X-2R3B6AL
2820
C2X-2S3B6AL
3240
C2X-2S3C6AL
3720
CBLE Boilers
Economizer
Wet Weight
2130
2410
2730
3070
3530
4060
Boiler HP
250-300
350
400
500
600
700
800
Economizer
Economizer
Model
Dry Weight
C2X-2M386AL
1980
C2X-2M3A6AL
2220
C2X-2M3A6AL
2220
C2X-2R3A6AL
2520
C2X-2R3B6AL
2820
C2X-2S3B6AL
3240
C2X-2S3C6AL
3720
Economizer
Wet Weight
2130
2410
2410
2730
3070
3530
4060
PERFORMANCE DATA
Tables listed here contain performance data for:
Gas fired, 100 through 800 hp firetube boilers operating at 125 psig, and utilizing a
CCE or CRE fuel economizer.
For additional operating pressures, load capacity or fuel selections, contact your local
Table G-4 lists typical water and gas side temperatures when utilizing a CCE or CRE
Economizer with a firetube boiler.
Table G-5 lists typical increases in efficiency for a firetube boiler.
Figure G-2 shows CB-LE and 4WI efficiencies using the C2X 2-stage economizer.
Notice
Do not use on boilers equipped with flue gas recirculation. Contact your local
G-7
09-09
Section G
Table G-4. Firetube Boiler CCE/CRE Economizer Performance Data (Model CB Boilers)
WATER SIDE
BOILER
HP
LOAD
%
ECONOMIZER
MODEL NO.
FLOW
PPH
TEMPERATURE
IN F
OUTF
GAS SIDE
PRESS.
DROP
PSIG
FLOW
PPH
TEMPERATURE
IN F
OUT F
PRESS.
DROP
IN. WC
ENERGY
SAVED
BTU/HR
HEATING
SURFACE
SQ-FT
100
100
CCE-16A6AL
3356
227
258
1.5
3611
410
303
0.22
125500
151
125
100
CCE-18D6AL
4195
227
275
3.92
4586
465
301
0.13
247800
316
150
100
CCE-18D7AL
5034
227
265
5.44
5432
420
290
0.18
229900
316
200
100
CCE-18E6AL
6711
227
256
10.4
7191
395
295
0.2
229400
309
250
100
CCE-30H7AL
8389
227
271
0.01
9158
460
310
0.1
451800
733
300
100
CRE-30H7AL
10067
227
265
0.01
10910
435
304
0.14
466800
733
350
100
CRE-30F7AL
11745
227
259
0.01
12638
410
301
0.26
447500
611
400
100
CRE-36F7AL
13423
227
262
0.02
14470
425
304
0.24
571900
733
500
100
CRE-36G6AL
16779
227
251
0.03
17883
385
299
0.24
490900
699
600
100
CRE-36H5AL
20134
227
247
0.03
21399
370
305
0.24
476200
645
700
100
CRE-36J5AL
23490
227
245
0.03
24895
365
300
0.24
513600
753
800
100
CRE-36J5AL
26846
227
245
0.04
28491
370
304
0.31
597700
753
NOTES:
1. Feedwater temperature to economizer is at least 220 F (Deaerated).
2. Boiler operating pressure is 125 psig (acceptable tolerance 5 psig).
3. Gas side flow (pph) determined with 10% excess air (50 to 100% of capacity).
4. Continuous modulated feedwater flow must be provided.
5. Boiler firing natural gas
Table G-5. Firetube Boiler CCE/CRE Economizer

Efficiencies
BOILER
HP
LOAD
%
ECONOMIZER
MODEL NO.
EFF
W/0
ECON
% FUEL
SAVED
EFF
WITH
ECON
100 hp
100
CCE-16A6AL
82.05
2.50
84.55
125 hp
100
CCE-18D6AL
80.76
3.84
84.6
150 hp
100
CCE-18D7AL
81.81
3.04
84.85
200 hp
100
CCE-18E6AL
82.40
2.34
84.74
250 hp
100
CRE-30H7AL
80.87
3.52
84.39
300 hp
100
CRE-30H7AL
81.46
3.07
84.53
350 hp
100
CRE-30F7AL
82.05
2.55
84.6
400 hp
100
CRE-36F7AL
81.89
2.84
84.73
500 hp
100
CRE-36G6AL
82.83
2.01
84.84
600 hp
100
CRE-36H5AL
83.07
1.63
84.7
700 hp
100
CRE-36J5AL
83.30
1.54
84.84
800 hp
100
CRE-36J5AL
83.18
1.55
84.73
NOTES:
1. Feedwater temperature to Economizer 227 F (Deaerated).
2. Selections are based on best Btu savings per dollar costs.
3. Boiler is firing natural gas.
4. Boiler operating pressure is 125 psig (acceptable tolerance
5 psig).
G-8
09-09
Section G
Figure G-2 shows CB-LE and 4WI efficiencies using the C2X 2-stage economizer.
Efficiencies are based on the following conditions:
C-B published stack-loss method and condensate removal

Ambient air temperature of 80 deg F
15% excess air in exhaust
Feed water at 227 deg F circulated through lower economizer stage
Includes C-B published radiation and convection losses
Figure G-2. C2X Efficiencies
CBLE & 4WI Boiler Efficiency with 2-stage economizer

Natural Gas, Operating 80-125 psig
91
90
0
Efficiency %
Makeup water @50 F
89
88
87
86
85
84
25
50
75
100
% Makeup water
ENGINEERING DATA
Information in this section outlines typical installation. Actual installation and piping
arrangements will be dictated by design, state, provincial or local codes, and job-site
conditions.
G-9
09-09
Section G
Firetube Boilers - Installation
Economizers weighing over 500 lb must be supported either by the four (4) support channels
on the economizer base or from the ceiling by threaded rods.
The economizer outlet transition can typically support up to 500 lb stack or breeching (dead
weight only). Economizer support still required as described above.
If an expansion joint is used, the economizer and stack must be supported to ensure all
loading is removed from the expansion joint.
Refer to Figure G-3 for suggested mounting to a firetube boiler.
Figure G-4 shows installation options using external supports (floor or ceiling mounted) for
horizontal and vertical flow units.
For information on other Cleaver-Brooks Firetube Boilers, contact your local CleaverBrooks authorized representative.
Note: Spool between economizer and boiler may be required to clear front head davit
arm (consult factory).
Feedwater Piping
Piping arrangements are dictated by ASME Code, location of the economizer in relation
to the boiler, and feedwater regulating system.
Figure G-5 shows a typical CCE/CRE economizer piping arrangement.
Figure G-6 through Figure G-9 show some typical C2X condensing economizer
piping arrangements.
Support structure
by others
Vertical Flow Units

BOLT SPECIFICATIONS
Boiler hp
No. of Bolts
100
125-200
250-350
400-800
12
12
16
Bolt Size
3/8 - 16 (threads per inch)
Bolt Circle
13-7/8
17-7/8
21-7/8
25-7/8
Vent Opening (OD)
12
16
20
24
Support structure
by others
NOTES:
2. For allowable weights on vent stub refer to dimensions and
weights in this section.
3. For information on stacks refer to Section F.
Horizontal Flow Units
Figure G-4. Installation options
Figure G-3. E+Plus Economizer Mounting to Firetube

Boiler (Model CB Boilers)
G-10
09-09
Section G
Figure G-5. Typical Piping Diagram, CCE/CRE Economizers
G-11
09-09
SEE NOTE #9
Section G
Figure G-6. Typical piping diagram, condensing economizers - single boiler with deaerator
G-12
09-09
SEE NOTE 9
Section G
Figure G-7. Typical piping diagram, condensing economizers - single boiler with deaerator and surge tank
G-13
09-09
Section G
Figure G-8. Typical piping diagram, condensing economizers - two boilers with deaerator
G-14
09-09
Section G
Figure G-9. Typical piping diagram, condensing economizers - two boilers with deaerator and surge tank
G-15
09-09
Section G
NOTES to Figures G-6 - G-9
SINGLE BOILER SYSTEMS:
TWO BOILER SYSTEMS:
G-16
09-09
Section G
CRE Rectangular Economizers
for Firetube Boilers
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-22
Construction Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-22
Selection Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-23
Quality Control And Code Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-23
The following sample specification is provided by Cleaver- Brooks to assist you in specifying your customers specific
G-21
09-09
Section G
PART 1 GENERAL
1.1
GENERAL
Specifications for CRE rectangular economizers shall include the furnishing of (__CREXXXX) complete packaged, extended surface boiler economizer(s), as furnished by
Cleaver-Brooks.
PART 2 PRODUCTS
2.1
CONSTRUCTION SPECIFICATIONS
A. The economizer's heating surface shall consist of finned tubes attached
to water manifolds as mounted to the exterior of the shell to minimize
corrosion and to achieve low liquid pressure drop. The finned tubes
shall be attached with compression fittings to the header manifolds for
ease of tube replacement requiring no welding. The finned tube shall
have a maximum of 2 rows in the exhaust stream in order to achieve
visual access of the heating surface and effective cleaning when needed.
The finned tubes shall not have any tube to tube welds in the exhaust
flow for extended economizer life:
Header manifold: thickness: Sch80; material: [ ] SA 53 GrB carbon
steel or [ ] TP304 stainless steel.
Alternate finned tube heating surfaces:
[ ] 316L stainless steel tube x .065" minimum wall thickness with
aluminum fin x .020" thickness x .50 high brazed to the tube
[ ] Carbon steel tube SA 178 ERW GrA x .085" minimum wall
thickness with carbon steel fin x .030" thickness x .50 high brazed
to the tube
[ ] Duplex stainless steel tube x .049" minimum wall thickness with
stainless steel fin x .020" thickness x .50 high brazed to the tube
Fins per inch shall be per fuel type fouling requirements.
B. The gas tight housing shall consist of a structural reinforced design
exterior and designed with a 10GA minimum thickness SA36 carbon
steel thickness ([ ] alternate 304 stainless steel). A hinged access door
shall be provided which can provide for complete access to the heating
surface for inspection, cleaning, or tube removal. The economizer shall
be insulated with 2" thickness of high temperature insulation and shall
be lined with 304 stainless steel. A pair of stack adapters and gaskets
shall also be provided to connect the economizer flanged exhaust
connections with the boiler exhaust diameter size for slip fit connection.
C. Exterior surfaces other than stainless shall be painted with high
temperature paint suitable for exhaust temperatures entering and for
outdoor installation. Additional required equipment included shall
include: (2) 50-300(F 3" dial bimetallic water thermometers with well,
(2) 150-750(F 3" dial adjustable bimetallic flue gas temperature
thermometers, (1) 250 PSI ASME safety relief valve.
G-22
09-09
Section G
D.
2.2
Maximum heat transfer performance shall result from counter flow

water to the exhaust gas flow, maximizing entering temperature
differences. A condensate drain catch ring assembly with 1" NPT drain
shall be provided for draining condensation away from the boiler as it
could occur either within the economizer and/or economizer outlet stack
breaching. The economizer's design shall also include an internal heat
resistant design exhaust gas damper, allowing for the reduction of
combustion back pressure as required, and/or for controlling exhaust gas
temperature exiting, and/or for controlling heat transfer for minimum
performance as necessary.
SELECTION PARAMETERS
Performance design parameters for the economizer are as follows:
Primary fuel type: [ ] natural gas [ ] No.2 fuel oil
Maximum Firing output rate to the economizer:
Exhaust Flow Rate, pph:
-Inlet exhaust temperature (F:
Cooled exhaust temperature (F:
-Pressure drop " W.C. Max.:
Water Flow Rate, lbs/hr:
-Entering Temp.(F:
-Heated Temp.(F:
Press. Drop, PSIG
Heat transferred, MBtu/hr.:
PART 3 EXECUTION
3.1
QUALITY CONTROL AND CODE REQUIREMENTS

A. Economizer is to be designed and fabricated in accordance with the
ASME Boiler and Pressure Vessel Code, Section VIII Division I (UM
stamp).
Options available:
[ ] Optional U stamp.
[ ] Optional Section I stamp
[ ] Optional CRN stamp
B. Minimum design temperature is to be 700 F.
C. Unit shall be hydrostatically tested at 1.5 times the design pressure in the
presence of a Code Inspector.
D. Unit is to be ASME Code Stamped, and is to include nameplate and
applicable code papers.
G-23
09-09
Section G
NOTES
G-24
09-09
Section G
CCE Cylindrical Economizers
for Firetube Boilers
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-18
Construction Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-18
Selection Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-19
Quality Control And Code Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-19
The following sample specification is provided by Cleaver- Brooks to assist you in specifying your customers specific
G-17
09-09
Section G
PART 1 GENERAL
1.1
GENERAL
Specifications for CCE cylindrical economizers shall include the furnishing of (__CCEXXXX) complete packaged, extended surface boiler economizer(s), as furnished by
Cleaver-Brooks.
PART 2 PRODUCTS
2.1
CONSTRUCTION SPECIFICATIONS
A. The economizer's heating surface shall be a multiple circular coil design
with manifold for minimum water pressure drop as required:
Headers: thickness: Sch80; material: [ ] SA 53 GrB carbon steel or [ ]
TP304 stainless steel.
[ ] Carbon steel tube SA 178 ERW GrA x .085" minimum wall
thickness with carbon steel fin x .030" thickness x .50 high brazed to the
tube
[ ] Duplex stainless steel tube x .049" minimum wall thickness with
stainless steel fin x .020" thickness x .50 high brazed to the tube
Fins per inch shall be per fuel type fouling requirements.
B. The gas tight housing shall consist of a structural reinforced design shell
and designed with a 10GA minimum thickness SA36 carbon steel
thickness cylindrical lid ([ ] alternate 304 stainless steel). 18GA
stainless steel 'gull wing' type access doors shall be provided which can
provide for complete access to the heating surface for inspection and/or
cleaning. In addition the inspection panels shall be hinged and secured
by quick release tension latches requiring no tools to open and close for
access to the heating surface. Access doors shall be insulated with 2"
thickness of high temperature insulation and shall contain a stainless
steel door panel. Customer stack mating flanges and gaskets shall also
be provided and designed to match the economizer gas connections.
Exterior surfaces other than stainless shall be painted with high
temperature paint suitable for exhaust temperatures entering and for
outdoor installation. Additional required equipment included shall
include: (2) 50-300(F 3" dial bimetallic water thermometers with well,
(2) 150-750(F 3" dial adjustable bimetallic flue gas temperature
thermometers. (1) 250 PSI ASME safety relief valve.
C. Maximum heat transfer performance shall result from counter flow
water to the exhaust gas flow, maximizing entering temperature
differences. A condensate drain catch ring assembly with 1" NPT drain
shall be provided for draining condensation away from the boiler as it
could occur either within the economizer and/or economizer outlet stack
breaching. The economizer's design shall also include an internal heat
resistant design exhaust gas damper, allowing for the reduction of
combustion back pressure as required, and/or for controlling exhaust
gas temperature exiting, and/or for controlling heat transfer for
minimum performance as necessary.
G-18
09-09
Section G
PART 3 EXECUTION
2.2
SELECTION PARAMETERS
Design Requirements
Maximum Firing output rate to the economizer:
Exhaust Flow Rate, pph:
-Inlet exhaust temperature (f:
Cooled exhaust temperature (f:
-Pressure drop " W.C. Max.:
Water Flow Rate, lbs/hr:
-Entering Temp.(f:
-HeatedTemp.(f:
Press. Drop, psig
Heat transferred, MBtu/hr.:
3.1
QUALITY CONTROL AND CODE REQUIREMENTS

A. Economizer is to be designed and fabricated in accordance with the
ASME Boiler and Pressure Vessel Code, Section VIII Division I (UM
stamp).
Options available:
[ ] Optional U stamp.
[ ] Optional Section I stamp
[ ] Optional CRN stamp
B. Minimum design temperature is to be 700 F.
C. Unit shall be hydrostatically tested at 1.5 times the design pressure in the
presence of a Code Inspector.
D. Unit is to be ASME Code Stamped, and is to include nameplate and
applicable code papers.
G-19
09-09
Section G
NOTES
G-20
09-09
Section G
C2X 2-Stage Condensing Economizers
Boiler exhaust to feedwater preheater economizer(s) model number C2X-XXXXXX shall be furnished and installed in
the exhaust duct of the boiler(s) in accordance with the following specifications, as supplied by Cleaver-Brooks. The
Economizer shall be a rectangular configuration designed for ease of installation, shall include two separate water
manifolds for make-up water and boiler feedwater, and shall be designed, manufactured and tested in accordance with
the requirements of Section VIII, Division I or Section I (as required) of the ASME Boiler and Pressure Vessel Code. It
shall be stamped to a minimum of 250 PSIG design pressure to the appropriate Section and hydrostatically tested to
375 PSIG.
The economizers heating surface shall consist of finned tubes attached to water manifolds as mounted to the exterior
of the shell to minimize corrosion and to achieve low liquid pressure drop. The finned tubes shall be attached with
compression fittings to the header manifolds for ease of tube replacement requiring no welding. The finned tube shall
have a maximum of 2 rows in the exhaust stream in order to achieve visual access of the heating surface and effective
cleaning when needed. The finned tubes shall not have any tube to tube welds in the exhaust flow for extended
economizer life. Fins per inch shall be per fuel type fouling requirements.
Header manifold:
Thickness: Sch80
Material: [ ] SA 53 GrB carbon steel or [ ] TP304 stainless steel.
[ ] 316L stainless steel tube x .065 minimum wall thickness with aluminum fin x .020 thickness x .50 high brazed to
the tube
[ ] Carbon steel tube SA 178 ERW GrA x .085 minimum wall thickness with carbon steel fin x 030 thickness x .50
high brazed to the tube
[ ] Duplex stainless steel tube x .049 minimum wall thickness with aluminum fin x .020 thickness x .50 high brazed
to the tube
[ ] 316L stainless steel tube x .065 minimum wall thickness with stainless steel fin x.020 thickness x .50 high brazed
to the tube
The gas tight housing shall consist of a structurally reinforced exterior with a 10GA minimum thickness SA36 carbon
steel ([ ] alternate 304 stainless steel) body. A hinged access door shall be provided which can provide for complete
access to the heating surface for inspection, cleaning, or tube removal. The economizer shall be insulated with 2
thickness of high temperature insulation and shall be lined with 304 stainless steel. A pair of stack adapters and gaskets
shall also be provided to connect the economizer flanged exhaust connections with the boiler exhaust diameter size for
slip fit connection.
G-25
09-09
Section G
Exterior surfaces other than stainless shall be painted with high temperature Cleaver Brooks Blue paint suitable for
exhaust temperatures entering and for outdoor installation. Additional required equipment included shall include: (4)
50-300F 3" dial bimetallic water thermometers with well, (2) 150-750F 3" dial adjustable bimetallic flue gas
temperature thermometers, (1) 300 PSI ASME safety relief valve for the boiler feedwater loop, and (1) 150 PSI
ASME safety relief valve for the make-up water loop.
Maximum heat transfer performance shall result from counter flow water to the exhaust gas flow, maximizing
entering temperature differences. A condensate drain catch ring assembly with 1 NPT drain shall be provided for
draining condensation away from the boiler as it occurs either within the economizer and/or economizer outlet stack
breaching. The economizers design shall also include an internal heat resistant design exhaust gas damper, allowing
for the reduction of combustion back pressure as required, and/or for controlling exhaust gas temperature exiting,
and/or for controlling heat transfer for minimum performance as necessary.
Economizer Design Considerations:
Exhaust Gas:
Flow Rate, pph:
Inlet Temperature F:
Outlet Temperature F:
Pressure drop W.C. Max:
Make-Up Water:
Flow Rate, gpm:
Pressure Drop, PSIG:
Boiler Feedwater:
Flow Rate, gpm:
Pressure Drop, PSIG:
Heat transferred, MBtu/hr:
G-26
09-09
Section H1a
SPRAYMASTER CLASSIC
DEAERATORS (Single Tank)
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-4
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-6
RETURN ON INVESTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-10
Flash Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-10
Exhaust Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-10
Surface Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-10
Chemical Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-10
Makeup Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-10
Sewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-10
Intangibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-10
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-11
ILLUSTRATIONS
Figure H1a-1. Spraymaster Tank Supports and Saddles, Details and Dimensions . . . . . . . . . . . . . . . . . . . . H1-7
Figure H1a-2. Spraymaster Deaerator Dimensions and Ratings (Single Tank) - Sheet 1 of 2 . . . . . . . . . . . H1-8
TABLES
Table H1a-1. Spraymaster Deaerator Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-4
H1a-1
09-09
Spraymaster Deaerators (Single Tank)
Section H
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 CleaverBrooks authorized representative for component sizing information.
H1a-2
09-09
Section H

Low Profile Design:
Low head allows installation in space restricted areas.
Two-Stage Deaeration in a Common Vessel:
Recycle pumps are not required.

Packaged for easy maintenance.
ASME Code Design (Section VIII):
Assures deaerator vessel quality in materials and fabrication to meet safety

requirements.
Internal Stainless Steel Vent Condenser:
Protects deaerator vessel against corrosive gases while providing a means for
removal of corrosive gases from boiler feedwater.
Self-Cleaning Water Spray Valve:
Angles associated with the water spray valve assembly and actual water spray
pattern, maintains deposit-free surfaces.
Reduces maintenance requirements.
Internal Automatic Check Valves Prevent Back Flooding:
Both the water spray valve and steam atomizing valve are in the normally closed
position under no flow conditions.
Prevents steam back-flow through the water spray valve and water back flow
through the steam atomizing valve.
Removable Water Spray Inlet Assembly:
Flanged assembly allows easy access for maintenance and/or inspections.
Stainless Steel Deaeration Assembly:
Ensures a longer life of wetted materials in intimate contact with corrosive liquids
and released corrosive gases.
Pressurized Tank Reduces Flashing and Minimal Venting:
Recovery of exhaust and turbine steam.

Saves Btus that would normally be exhausted to atmosphere. Improves plant
efficiency.
Auto Vent Valve Eliminates Dissolved Gases at Start-Up:
Atmospheric contamination virtually eliminated for incoming water.
Exceeds ASME Recommendations for Oxygen Level:
Guaranteed to remove oxygen concentrations to 0.005 cc/liter while operating

between 5% and 100% capacity.
Carbon dioxide concentrations are practically reduced to zero.
H1a-3
09-09
Section H
Capacity Not Affected by Mixed Inlet Temperature:
Consistent performance under variable conditions.
Integral Level Control Automatically Introduces Cold Water Make-Up to

Supplement Condensate Only When Necessary to Meet Boiler Demand:
Saves Btus by accepting condensate before cold make-up water. Maintains a

minimal water level within the deaerator vessel to prevent damage to the boiler
feedpumps, and to maintain system operation.
Variety of Tank Sizes to Handle Volume-Swings in Condensate Return:
Provides flexibility for selecting a tank for specific applications, limiting the loss of
hot condensate to drain.
Packaged Units for Cost Effective Installation:
Complete packages are pre-fabricated in the manufacturing facility to ensure piping

alignment and control wiring function. The unit is partially disassembled, and match
marked for efficient field re-assembly.
Available in Horizontal and Vertical Configuration:
Provides adaptability for installation in space restricted areas.
Internal Pump Suction Vortex Breakers:
Eliminates the problems of loss in NPSHA and cavitation associated with the
creation of vortices within pump suction piping.
PRODUCT OFFERING
Information in this section applies directly to Cleaver- Brooks packaged Spraymaster
Deaerators ranging from 7,000 to 280,000 pounds/hour. For larger capacities contact
your local Cleaver-Brooks authorized representative. The product offering for
Spraymaster Deaerators is shown in Table H1a-1.
Table H1a-1. Spraymaster Deaerator Product Offering

MODEL NO.
RATING
(LBS/H)
TANK
CAPACITY
STORAGE CAP.
(MIN)
SM- 7
7000
230
16
SM-15
15000
300
10
SM- 30
30000
600
10
SM- 45
45000
900
10
SM -70
70000
1400
10
SM-100
100000
2000
10
SM-140
140000
2800
10
SM-200
200000
4000
10
SM- 280
280000
5600
10
NOTE: Model number designation (example, SM-7) is: SM = Spraymaster

Deaerator. 7 = 7,000 lbs/hr rating. Optional tank sizes available, contact
your local Cleaver-Brooks authorized
representative.
H1a-4
09-09
Section H

The Spraymaster Deaerator is a pressurized low-headroom system designed to remove
dissolved oxygen in boiler feedwater to 0.005 cc per liter, or less, and eliminate carbon
dioxide. A typical deaerator package includes the deaerator tank mounted on a stand of
appropriate height along with all operating controls, feed pumps assembled and piped
(typically knocked down for shipment and field assembly). The tank conforms to section
VIII of the ASME code.
The main deaerating portion is located internally and consists of a water collector and
steam atomizing valve. Built into a flange on top of the tank is a spring loaded water
spray nozzle which includes an automatic and manual vent valve.
Packaged Spraymaster systems offer substantial advantages through, lower cost
installation and simplified operation and maintenance. Spraymaster Deaerators arrive on
site ready for hookup to your water, steam, and electric power connections.
The deaerator stand comes with feed pump/motor set mounted on a solid base. The base
is specially reinforced to prevent vibration wear on vital system components. Rugged
square structural tubing combines lasting strength with generous working space for
inspection or routine servicing.
Control Panel
The control panel, complete with starters, fuse protection, switches, lights and pre-wired
terminal blocks is mounted on the stand assembly. Wiring to feed pump motor and all
controls is standard.
Deaerator Tank
ASME construction - certified to 50 psig. All tanks provided with manhole, individual
pump suction tappings and other openings as required. Saddles or legs standard on all
sizes. Select from sizes for 5 to 30 minutes of storage to overflow.
Piping
Pump and motor sets are mounted on individual bases before mounting on stand base.
Individual suction piping (including strainer, shutoff valve, flexible connector) are
provided for all feed pumps.
Standard Equipment
Spraymaster deaerator.
Deaerator storage tank.
Deaerator water inlet atomizing valve.
Deaerator steam inlet atomizing valve.
Deaerator manual and automatic vent.
Gauge glass.
Feedwater thermometer.
Required tappings.
Optional Equipment
Steam pressure reducing valve.
Three valve bypass and strainer (PRV).

H1a-5
09-09
Section H
Water level controller with make-up valve.
Three valve bypass and strainer (MUV).
Steam relief valves.
High water alarm.
Low water alarm.
Low water pump cut off.
High temperature condensate diffuser tube (over 227 F).
Boiler feed pump and motor sets.
Recirculation orifice or relief valve
Suction shutoff valve.
Suction strainer.
Suction flexible fitting.
Discharge check valve.
Discharge shutoff valve.
Discharge pressure gauge.
Discharge manifold.
Overflow drainer.
Control panel.
Chemical feed quill.
Vacuum breaker.
Insulation and lagging.
Sentinel relief valve.
Tank drain valve.
Back pressure relief valve.
Magnesium anode (not available with lined tanks).
Stand.
Packaging
Fully packaged, factory piped and wired.

Half packaged, suitable for field erection with interconnecting piping and wiring by
others.

Dimensions and ratings for Spraymaster Deaerators are shown in Figure H1a-1 and
Figure H1a-2.
H1a-6
09-09
Section H
TANK SUPPORT LEGS

FRONT HEAD
"E"
SADDLES
FRONT HEAD
"E"
"A"
"A"
STANDARD ON 36"
48" & 54" TANKS
(4) 1.125" E HOLES
FOR .75" E BOLTS
(4) .875" E HOLES

FOR .75" E BOLTS
"D"
"C" "D"
"C"
"H"
"F"
6
"B"
"F"
"B"
"G"/2
"G"
TANK CAPACITY (GALLONS)

230
300
450
600
700
LEGS
900
1000
1400
2000
2800
4000
5600
SADDLES
47
67.5
102
86
102
95
102.5
138
156
138
128
145
52.5
74
108.5
92.5
108.5
101
108.5
144
162
144
134
151
29.5
38
38
44.75
44.75
44.75
44.75
50
52
62
72
83
31.25
40
40
46.75
46.75
57
57
62
67
77.5
88
98.75
12
14.25
16
16
17
17
19.75
19
21.5
22.5
24.5
26
0.875
6.125
6.125
7.5
7.75
7.875
5.5
6.5
6.5
6.5
6.5
N/A
N/A
N/A
N/A
N/A
N/A
N/A
9.75
9.75
13.75
13.75
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Figure H1a-1. Spraymaster Tank Supports and Saddles, Details and Dimensions
H1a-7
09-09

"B"
0 "E"
(NOTE 14)
Section H
"D"
4
(9" FOR SM15)

1/2" NPT AUTO. VENT VALVE
"C"
0"
"D"
"E"
"F" "G" "J"
"H" "K" "L"
12"
2" DIA. HOLE
IN LIFTING LUGS
"R" NPT. MANUAL VENT VALVE

SM7 - 230 GALLON
WATER & STEAM INLET DETAIL
"N" 2
20
12
21
13
"A"
"P"
TANK
DIA.
8
10
14
21
5"
7
(NOTE 1) 15
11
"M"
16 (NOTE 2)
18
STAND HEIGHT
VARIES PER
PROJECT
REQUIREMENTS
17 (NOTE 3)
22
19 (NOTE 4)
"D4"
"B2"
(4) "E5" DIA. HOLES

FOR "F6" DIA. BOLTS
"C3"
"A1"
FRONT VIEW
RIGHT SIDE
1. Mounted at dim. "H" (top of tank) on non-packaged units.

2. Tank mounted on non-packaged units.
3. Packaged units only. Mounted on front of stand.
4. Suction piping includes strainer, gate valve and flexible connector.
5. All couplings are 3000# F.S.
6. All flanges are 150# F.F. except as noted.
7. SM-200 is the same as SM-100 and SM-280 is the same as SM-140 except 2 water & steam inlets are used per vessel (dual inlet).
8. Customer to plug all fittings not being used.
9. Mount tank above pump at elevation necessary for static head including safe allowance for piping friction as approved by pump manufacturer.
10. Deaerator tank is built to ASME Code.
12. Add Suffix "P" to Model No. for packaged units (SMP-45).
13. Optional tanks available for 5 minutes storage (except SM7 & SM15), other combinations of capacities as required - contact your local Cleaver-Brooks
14. Dimension "B" will change depending on controls required - contact your local Cleaver-Brooks authorized representative.
15. No interconnecting piping or wiring furnished on non-packaged units unless specified, contact your local Cleaver-Brooks representative for specific piping
or wiring furnished on packaged assemblies.
16. Weights shown are without controls or packaging - contact your local Cleaver-Brooks representative for additions.
17. Capacities other than shown as standard available by proper selection of controls - contact your local Cleaver-Brooks authorized representative.
18. Optional tank sizes and ratings available - contact your local Cleaver-Brooks authorized representatives.
19. Lifting lugs are for lifting empty tank only.
RATINGS
SM TANK
Capacity (Gal. to Overflow)
230
300
450
600
700
900
1000
1400
2000
2800
4000
5600
Tank W eight (Dry) (lb)
1050
1700
2150
2200
2450
2600
2800
4100
4900
5700
7300
9450
15500
17000
Tank W eight (Flooded) (lb)

Tank Size (Dia x Length)
3600
7850
10700
11750
13450
36 x 71
48 x 96
48 x 134
54 x 118
54 x 136
60 x 129.5 60 x 142.5
25450
33650
41550
52500
73600
66 x 177
72 x 200
84 x 184
96 x 179
108 x 199
TANK DIMENSIONS
A
Overall Height
58
70
70
76
76
82
82
88
94
108
120
132
Overall Width
51
63
63
69
69
75
75
81
87
99
111
123
Front Head
10
10
11
11
12
12
14
15
17.5
20
21.5
Water Inlet - SM 7
17.5
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Water Inlet - SM 15 thru 100
N/A
20
22
22
22
22
22
22
22
22
22
22
Water Inlet - SM140
N/A
N/A
N/A
N/A
N/A
N/A
N/A
18
18
18
18
18
Steam Inlet
6.5
40
42
42
42
42
42
42
42
42
42
42
Level Alarm
32
50
54
54
54
54
54
56
56
56
56
56
High Temperature Return
27
55
62
62
62
62
62
63
63
63
63
63
Figure H1a-2. Spraymaster Deaerator Dimensions and Ratings (Single Tank) - Sheet 1 of 2
H1a-8
09-09
Section H
Level Control
44.5
60
79
79
79
79
79
90
90
90
90
90
Relief Valve
38.5
66 *
70
70
70
70
70
100
100
100
100
100
Relief Valve
50
66 *
86
86
86
86
86
111
111
111
111
111
Relief Valve
N/A
N/A
N/A
N/A
N/A
N/A
N/A
122
122
122
122
122
Drain
10
30
98
84
98
93
103
135
153
135
127
144
Overflow
10
10
10
10
10
10
14
14
14
14
14
Overflow
10
3.75
3.75
6.75
6.75
6.5
14.5
26.5
27.5
Sprayhead
R
Manual Vent Valve Size
SM15
SM30
SM45
SM70
SM100/200
SM140/280
0.75
0.75
0.75
1.5
STAND DIMENSIONS
230
300
450
600
700
900
1000
1400
2000
2800
4000
5600
A1
Overall Length
52.5
74
108.5
92.5
108.5
101
108.5
144
162
149
134
151
B2
C/L to C/L Bolt Holes
47.5
69
102.5
87.5
102.5
95
102.5
138
155
146
127
144
C3
Overall Width
49
62
66
64
66
71
71
76
83
86.5
102
113
D4
46
59
63
61
63
68
68
73
80
79.5
99
110
E5
Hole Size
0.75
0.75
1.125
1.125
1.25
1.125
1.125
1.125
1.25
F6
Anchor Bolt Size
0.625
0.875
0.875
0.625
0.875
1.125
1.125
6"-150#
FF
6"-150# FF
CONNECTIONS AND TRIM

1
2
Relief Valve Size

Overflow Size
Steam Inlet Size
1.5" NPT
3" NPT
3" NPT
Contact Your Local Cleaver-Brooks Authorized Representative

3" NPT
3" NPT
3" NPT
3" NPT 4"-150# FF 4"-150# FF 4"-150# FF
See Table Below

See Table Below
Water Inlet Size
High Temperature Return Size
1.5" NPT
1.5" NPT
2" NPT
2" NPT
2" NPT
2" NPT
2" NPT
Drain Size
1.5" NPT
2" NPT
2" NPT
2" NPT
2" NPT
2" NPT
2" NPT
Suction Size
2.5" NPT
2.5" NPT
2.5" NPT
2.5" NPT
2.5" NPT
2.5" NPT
Thermometer (3/4" NPT)
Sample (1/2" NPT)
10
Chemical Feed (1" NPT)
11
Recirculation (1" NPT)
12
Gauge Glass Assembly
13
Level Controller (1.5" NPT)
14
Make-Up Valve
15
Pressure Gauge
16
Thermometer
17
Control Panel (Optional)
3" NPT
3" NPT
3" NPT
2" NPT
2" NPT
2" NPT
2.5" NPT 4"-150# FF 4"-150# FF 4"-150# FF
3" NPT
3" NPT
2" NPT
4"-150#
FF
2" NPT
4"-150# FF
N/A
18
Feed Pump/Motor (Optional)
19
Suction Piping (Optional)
20
Manway Size - SM 7
20"
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Manway Size - SM 15 thru 70
N/A
28"
28"
28"
28"
28"
28"
28"
28"
28"
28"
28"
Manway Size - SM100, 200
N/A
32"
32"
32"
32"
32"
32"
32"
32"
32"
32"
32"
Manway Size - SM140, 280
N/A
N/A
N/A
N/A
N/A
N/A
N/A
36"
36"
36"
36"
36"
21
Level Alarms (Optional) (1" NPT)
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 Flg
SM-30
300 thru 5600
30000
6"-150# FF Flg
2"-150# RF Flg
SM-45
300 thru 5600
45000
6"-150# FF Flg
2"-150# RF Flg
SM-70
300 thru 5600
70000
6"-150# FF Flg
2.5"-150# RF Flg
SM-100
300 thru 5600
100000
6"-150# FF Flg
3"-150# RF Flg
SM-140
2000 thru 5600
140000
8"-150# FF Flg
4"-150# RF Flg (2)
SM-200 (NOTE 7)
2000 thru 5600
200000
6"-150# FF Flg
3"-150# RF Flg
SM-280 (NOTE 7)
2000 thru 5600
280000
8"-150# FF Flg
4"-150# RF Flg (2)
* 2 relief valve tappings for SM 300 located at 66" are offset 6" on either side of top centerline.
Figure H1-2. Spraymaster Deaerator Dimensions and Ratings (Single Tank) - Sheet 2 of 2
H1a-9
09-09
Section H
RETURN ON INVESTMENT
Payback for a pressurized deaerator verses an atmospheric boiler feed system is based
on an additional capital expenditure required divided by the yearly operating cost
savings. The differential in yearly operating costs are in the following areas:
Flash steam
Exhaust steam
Blowdown
Chemical treatment
Makeup water
Sewer
Intangibles
Flash Steam
A percentage of the high-pressure condensate returns will flash to steam and be lost in
an atmospheric vessel application. This flash steam loss can be converted to an energy
loss and associated fuel cost.
Exhaust Steam
Exhaust steam cannot be recovered in an atmospheric vessel application. This exhaust

steam loss can be converted to energy loss and associated fuel cost. An example would
be steam turbine exhaust.
Surface Blowdown
Increased makeup water is required because of lost flash and exhaust steam. This
increase in makeup water requires an increase of surface blowdown. This is directly
related to cycles of concentration in the boiler. The additional blowdown loss can be
converted to an energy loss and associated fuel cost. The additional surface blowdown
may also result in an increase in capital expenditure for a larger blowdown heat recovery
system.
Chemical Treatment
Dissolved oxygen content in an atmospheric boiler feedwater system is a function of

water temperature. Lowering the dissolved oxygen content below what is naturally
present, based on mixed water temperature at atmospheric pressure, requires the addition
of a chemical treatment program. The most common oxygen scavenger used is sodium
sulfite. Sodium sulfite reacts with dissolved oxygen as follows:
2Na2SO3 + O2
2Na2SO4
Theoretically, it takes approximately 8 ppm of sodium sulfite as Na2S03 to scavenge 1

ppm of dissolved O2
Makeup Water
Increased make-up water is required because of lost flash steam, lost exhaust steam, and
additional surface blowdown. This additional makeup water can be associated to a cost.
Makeup water cost should be a combination of the utility charge plus pretreatment
equipment consumable costs.
Sewer
Utilities often base a sewer charge on make-up water usage. Increased makeup water
usage with an associated increase in surface blowdown can affect these costs.
Intangibles
Some cost savings are difficult to calculate - in general, best practices in deaeration will
prolong the life of boiler room equipment, reducing repair and maintenance costs.
H1a-10
09-09
Section H1a
Deaerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-12
Make Up Valve and Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-13
Steam Pressure Reducing Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-14
Boiler Feedwater Pump And Motor Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-15
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-16
H1a-11
09-09
Section H
PART 1 GENERAL
1.1
DEAERATOR SPECIFICATION
1. Provide one Cleaver-Brooks Model _________ spray type,
pressurized, horizontal deaerator rated at _____ pounds per hour.
The system shall be of the single tank design and shall guarantee
oxygen removal to not more than 0.005 ccs/liter in the effluent
throughout all load conditions between 5 and 100 percent. Twocompartment 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.
PART 2 PRODUCTS
2.1
HARDWARE
A. Deaerator
1. Feedwater and condensate shall be admitted to the deaerator
through a single spring-loaded, self-cleaning, adjustable stainless
steel spray valve, which shall provide proper internal vent
condensing and water distribution at any load between 5 and 100
percent of rated capacity. The water temperature in the primary
heating and vent concentrating section is to be raised within 2 or 3
F of steam temperature and most of the gases released. The water
is then to be collected in a conical water collector. From there, it is
to flow to an atomizing valve where high velocity steam strikes it,
breaks it down into a fine mist, and heats it to a full steam
saturation temperature. The mixture is to strike a deflecting baffle,
which separates water and steam. Hot, gas-free water is to then
drop to the storage compartment to complete the cycle. The steam
and non-condensables are to flow upward, through the primary
heating spray, into the internal vent concentrating section, where
they contact the cold influent water. Here, the steam is to be
condensed to continue the cycle. Released gasses are discharged to
atmosphere through the vent outlet. All internal surfaces, which
come in contact with un-deaerated water, shall be constructed of
Type 316 stainless steel.
2. Automatic vent valve shall be thermostatically controlled to
provide a fast means of venting when a sudden buildup of gases
occurs, such as seen at start up. The manual vent valve shall have
an orifice for continuous minimum venting. Venting rate shall not
exceed 0.1 of 1% of the rated deaerator capacity at 5 psig.
3. The deaerated water storage tank shall have _____ minutes of
storage and have a capacity of
_____ gallons measured to overflow. The tank shall be _____
diameter x ____ long. An _____ manhole shall be provided for
access. All nozzles 3" and under shall be 3000 lbs forged steel
couplings and over 3" shall be 150 lbs flat face flanges. Heads to
be ASME torispherical type constructed of ASTM A516 GR 70
carbon steel with a minimum thickness of 0.25 inches. Shell plate
to be fabricated of ASTM A36 carbon steel with a minimum
thickness of 0.25 inches. The tank shall be designed in accordance
with ASME, Section VIII of the Pressure Vessel Code for 50 psig
at 650 F and stamped accordingly. Certification shall be required.
Joint efficiencies to be 70% circumferential per Table UW-12,
which does not require stress relieving or nondestructive
examination.
H1a-12
09-09
Section H

Load Specifications
LOAD
PERCENTAGE
Make up
LBS/HR
GPM
Pumped Low Temp Returns

High Temp Returns
TEMP
PRESSURE
25 psig Minimum
10 psig Minimum
Not To Exceed 30%
4.
B.
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
above that of the deaerator operating temperature.
5. Optional - The tank shall be factory-insulated and lagged with
blanket insulation, pins, clips, and a durable steel jacket. Blocktype insulation is not acceptable. The blanket insulation is to be
fiberglass, 2" thick, 1 lb/cu-ft, and have a rating of R5. Pins are to
be located on 18" centers and holding clips attached. The steel
jacket or lagging shall have a shell thickness of 18 gauge
(0.0478") minimum and head thickness of 18 gauge (0.0478")
minimum.
6. Optional - The magnesium or sacrificial anode shall provide
cathodic protection against galvanic corrosion. This rod shall be 15/16" diameter with a 1/4" steel core to assure a good electrical
contact and added strength. The design shall have a small weep
hole to signal it has been consumed. Linings shall not be
acceptable in this application.
7. Optional - The high temperature diffuser or sparge tube shall be
located beneath the normal tank water level. The tube shall be
constructed of 2-1/2 inch pipe. This tube shall provide even
distribution and blending of high-temperature condensate returns.
8. Optional - The chemical feed quill shall be located beneath the
normal tank water level. The quill material shall be constructed of
stainless steel. The tube shall provide even distribution and
blending of chemical.
9. Optional - The basic deaerator shall be equipped with the
following trim and accessories. Piping on packaged units shall
comply with ASME Power Piping Code B31.1.
Make Up Valve and Controller
1. Option (Mechanical) - ____ " inlet water regulating lever valve
with ______ body and _______ connections. The valve Cv shall
not exceed ______ and be rated for _____ gpm at ______ psig
inlet pressure. The pressure drop across the valve shall not exceed
a delta-P of 10 psig. This valve shall be suitable for temperatures
up to 300 F. The valve manufacture shall be _______, Model
_____ . This valve shall be mechanically controlled by an external
float cage with cast iron body and 8" stainless steel float. The float
cage manufacturer shall be __________, Model ______.
H1a-13
09-09
Section H
2.
C.
Option (Electronic) - ______" inlet water motorized regulating

valve with steel body and threaded NPT connections. Motor shall
be 110V bi-directional, with a permanently lubricated gear train,
and be directly coupled to the valve stem. The valve Cv shall not
exceed _____ and be rated for_____ gpm at ______ psi inlet
pressure. Valve shall not exceed a delta-P of 10 psig. This valve
shall have teflon seats and be suitable for temperatures up to 300
F. The motorized valve manufacturer shall be __________. This
valve shall be electronically controlled by a solid state control
with internally mounted capacitance probes. The electronic solid
state control shall be able to set desired level point and acceptable
deviation. The electronic solid state control shall include a
selection for automatic and manual operating mode. The internals
shall include two additional probes for high and low water alarm.
The controller manufacturer shall be Cleaver-Brooks Model
TW82. A solenoid valve and float switch are not acceptable.
(Available only in the U.S.)
3. Option (Pneumatic) - _______" inlet water diaphragm actuated
regulating valve with cast iron body and _____ connections. The
valve shall be globe type with proportional control and a spring
opposed diaphragm actuator arranged for 3 - 15 psig operating
signal. The valve shall be normally open on loss of air. The valve
Cv shall not exceed _____ and be rated for ______ gpm at ______
psig inlet pressure. Valve shall not exceed a delta-P of 10 psig.
This valve shall have stainless steel trim with TFE packing and be
suitable for temperature up to 410 F. The diaphragm actuated
valve manufacturer shall be ___________, Model _____. This
valve shall be pneumatically controlled by an external
proportional type sensor. The sensor shall be a 14" displacer that
produces a pneumatic output signal. The controller manufacturer
shall be _________, Model ______. A filter regulator is to be
provided to reduce 50 psig instrument air supply to 3 - 15 psig for
proper operation.
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.
Steam Pressure Reducing Station
1. Option (Mechanical) - _______" steam pressure reducing valve
with cast iron body and _____ connections. The valve shall be a
self-contained unit capable of reducing ____ psig saturated steam
to the operating pressure of the deaerator at a flow rate of _____
lbs/hr. The valve shall be 250 lb class with stainless steel trim and
an adjustable pilot. The valve manufacturer shall be _____, Model
_____.
H1a-14
09-09
Section H
2.
D.
Option (Pneumatic) - _______" diaphragm actuated steam

pressure reducing valve with cast iron body and _______
connections. The valve shall be globe type with proportional
control and a spring opposed diaphragm actuator arranged for
____ psig operating signal. The valve shall be normally closed on
loss of air. The valve shall be capable of reducing _____ psig
saturated steam to the operating pressure of the deaerator at a flow
rate of ____ lbs/hr. This valve shall be 250 lb class and have
stainless steel trim. The diaphragm actuated valve manufacturer
shall be ________, Model _______. This valve shall be
pneumatically controlled by an external transmitter. The
transmitter set pressure shall be adjustable. The transmitter
manufacturer shall be _________________, Model _________.
3. Optional - The steam pressure reducing valve shall include a three
valve bypass with Y-type cast iron strainer. Strainer screen to be
removable and of stainless steel construction.
4. Optional - Quantity ______, _______ " relief valves sized to
relieve full capacity of the pressure reducing valve in the event of
its failure. Valves to meet Paragraph UG-125 of ASME Unfired
Pressure Vessel Code, Section VIII. Valve body to be of bronze
construction. Relieving set pressure to be 50 psig. Relief valve
manufacturer to be _______________________,
Model____________.
5. Optional - High level alarm switch. This shall be an externally
mounted float type switch. The switch shall make contact on rise
and break on fall. The float cage construction shall be cast iron.
(Not required with electronic make up controller.)
6. Optional - Low level alarm switch. This shall be an externally
mounted float type switch. The switch shall make contact on fall
and break on rise. The float cage construction shall be cast iron.
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 _______.
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.
Boiler Feedwater Pump And Motor Set
1. Option (Intermittent) - Quantity________, turbine type boiler
feedwater pump and motor set. Centrifugal type pumps are not
acceptable in this application. Pump to be rated for _____ gpm at
_____ feet TDH with ______ feet NPSH required. Pump to be
______ materials of construction and have ______ seals for a
maximum water temperature of 250 F. Pump impeller to be
hydraulically balanced. The pump shall be mounted on a steel
baseplate and flexibly coupled with an OSHA type coupling guard
H1a-15
09-09
E.
Section H
to a ____ hp, _____ phase, ______ Hz, ______ Volt, _______

rpm, ________enclosure motor. Motor to be non-overloading at
the rated condition without using any portion of the service factor.
Pump and motor set to be factory aligned prior to shipment. Pump
manufacturer to be______________, Model ________, size ____
" x _______".
2. Option (Continuous) - Quantity ______, centrifugal type boiler
feedwater pump and motor set. Turbine type pumps are not
______ 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 supplied
with the pump and shipped loose for field installation to provide
minimum bypass flow.
3. Optional - The stand shall elevate the deaerator tank to provide the
net positive suction head required by the pump at the rated
condition to prevent cavitation plus a 1-1/2 foot safety factor. The
stand shall be constructed of heavy square steel tubing for the legs
and 1/4" steel plate covering the floor.
Control Panel
1. Optional (Base) - Control panel shall be in a NEMA 1 enclosure
and wired to the National Electric Code. The wire shall be black
number coded. The assembly is to contain individual motor
starters with 120 Volt holding coil and fuse protection. Individual
green oil-tight pump run lights shall be provided. All switches and
lights to have nameplate identification. The assembled panel shall
be given a factory continuity test prior to shipment.
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.
H1a-16
09-09
Section H

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.
H1a-17
09-09
Section H
Notes
H1a-18
09-09
Section H1b
SPRAYMASTER
SERIES
DEAERATORS (Single Tank)
CONTENTS
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-3
Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-4
Dimensions and Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-6
Return On Investment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-10
Flash Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-10
Exhaust Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-10
Surface Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-10
Chemical Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-10
Makeup Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-10
Sewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-10
Intangibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-10
H1b-1
09-09
Spraymaster Signature Deaerators (Single Tank)
Section H
ILLUSTRATIONS
Figure H1-1. Spraymaster Signature Deaerator Tank Supports and Saddles, Details and Dimensions . . . . H1b-7
Figure H1-2. Spraymaster Signature Deaerator Deaerator Dimensions and Ratings (Single Tank) - Sheet 1 of 2 H1b8
TABLES
Table H1-1. Signature Deaerator Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-4

oxygen and other dissolved gases in boiler feed water. Thus, it is the answer to
maintaining long-lasting boiler equipment for industrial and commercial boiler users.
The Cleaver-Brooks deaerator is constructed of corrosion-resistant alloys for a long
lifetime of service. The deaerator design employs those basic principals of gas removal
that have proven to be the most effective and economical means of proper operation.
Contact your local Cleaver-Brooks authorized representative for component sizing
information.
H1b-2
09-09
Section H

Low Profile Design:
Low elevation and small footprint allows installation in space restricted areas.

Packaged assembly for easy installation and maintenance.

requirements.
removal of these corrosive gases from boiler feedwater.
Angles associated with the water spray valve assembly and water spray pattern allow
deposit-free surfaces to be maintained.
Internal Automatic Check Valves Prevent Back Flooding:
Both the water spray valve and steam atomizing valve are in the normally closed
position under no flow conditions.
Prevents steam back-flow through the water spray valve and water back flow
through the steam atomizing valve.
Ensures a longer life of all wetted materials in intimate contact with corrosive liquids
and the released corrosive gases.
Recovery of flash steam exhaust and turbine steam.

Saves BTUs that would normally be exhausted to atmosphere. This in turn improves
overall system and plant efficiency.
Auto Vent Valve Eliminates Dissolved Gases at Start-Up:
Guaranteed to remove oxygen concentrations to 0.005 cc/liter while operating

between 5% and 100% capacity.
H1b-3
09-09
Section H
Carbon dioxide concentrations are practically reduced to zero.
Capacity Not Affected by Mixed Inlet Temperature:
Consistent performance under variable loads and conditions.

Saves BTUs by accepting condensate before cold make-up water. Maintains a

Provides flexibility for selecting a tank for specific applications, limiting the loss of
hot condensate to drain (minimum offering available is 10 minutes of storage).
Complete packages are pre-fabricated in the manufacturing facility to ensure piping

alignment and control wiring function. The unit is partially disassembled, and match
marked for efficient field re-assembly.
Available in Horizontal Configuration:
Provides adaptability for installation in space restricted areas.
PRODUCT OFFERING
Information in this section applies directly to Cleaver- Brooks packaged Spraymaster
Signature Deaerators ranging from 7,000 to 100,000 pounds/hour. For larger capacities
contact your local Cleaver-Brooks authorized representative. The product offering for
Spraymaster Signature Series Deaerators is shown in Table H1-1.
The Spraymaster Signature Deaerator is a pressurized low-headroom spray-type
Table H1-1. Spraymaster Signature Deaerator Product Offering
MODEL NO.
RATING
(LBS/H)
Typical TANK STORAGE CAP.

CAPACITY
(MIN)
SS-15
15000
415
SS- 30
30000
610
10
10
SS- 45
45000
1105
10
SS -70
70000
1400
10
SS-100
100000
2485
10
NOTE: Model number designation (example, SM-7) is: SS = Spraymaster

Signature Signature Deaerator. 7 = 7,000 lbs/hr rating.
Storage capacities greater than 10 minutes are available. Please contact
your local Cleaver-Books authorized representative.
H1b-4
09-09
Section H

deaerator system designed to remove dissolved oxygen in boiler feedwater to 0.005 cc
per liter, or less, and eliminate carbon dioxide. A typical deaerator package includes the
deaerator tank mounted on a stand of appropriate height along with all operating
controls, feed pumps assembled and piped (typically knocked down for shipment and
field assembly). The tank conforms to section VIII of the ASME code.
The main deaerating portion is located internally and consists of a water collector cone
and steam atomizing valve. Built into a flange on top of the tank is a spring loaded water
spray nozzle which includes an automatic and manual vent valve.
Packaged Spraymaster Signature Deaerator systems offer substantial advantages
through, lower cost installation and simplified operation and maintenance. Spraymaster
Signature Spraymaster Signature Deaerators arrive on site ready for installation and
hookup to your water, steam, and electric power connections.
The deaerator stand comes with feed pump/motor set mounted on a base. The base is
specially reinforced to prevent vibration wear on vital system components. Rugged
square structural tubing combines lasting strength with generous working space for
inspection or routine servicing.
Control Panel
The control panel, complete with starters, fuse protection, switches, lights and pre-wired
terminal blocks is mounted on the stand assembly. Wiring to feed pump motor and all
controls is standard.
Deaerator Tank
ASME construction - certified to 50 psig. All tanks provided with manhole, individual
pump suction tappings and other openings as required. Legs are standard on all sizes.
Storage in the vessels is designed for a minimum of 10 minutes.
Piping
Pump and motor sets are mounted directly on the base channel.
Individual suction piping (including strainer, shutoff valve, flexible connector) is
standard and provided for all feed pumps.
Standard Equipment
Spraymaster Signature deaerator.
Deaerator steam inlet atomizing valve.
Deaerator manual and automatic vent.
Gauge glass.
Water temperature thermometer.
Required tappings.
Optional three valve bypass and strainer (PRV).

H1b-5
09-09
Optional three valve bypass and strainer (MUV).
High water alarm.
Low water alarm.
Recirculation orifice.
Suction strainer.
Optional discharge check valve.
Optional discharge shutoff valve.
Optional discharge pressure gauge.
Optional discharge manifold.
Overflow drainer.
Control panel.
Optional chemical feed quill.
Optional vacuum breaker.
Optional insulation and jacket.
Optional tank drain valve.
Optional magnesium anode.
Stand.
Section H
Packaging

Dimensions and ratings for Spraymaster Signature Deaerators are shown in Figure H1-1
and Figure H1-2.
H1b-6
09-09
Section H
"A"
"C" "D"
TANK DIAMETER
"E"
"J"
"B"
"K"
OVERALL LENGTH
"H"
"L"FOR AN
"M" BOLT
"F"
"G/2"
"G"

A
B
C
D
E
F
G
H
J
K
L
M
260
47
53
38
40.5
22.31
1.25
6
10
48
83.31
0.87
0.75
415
86
92
38
40.5
22.78
1.25
6
10
48
123.33
0.87
0.75
610
86
92
44.75
47.25
23.59
1.25
6
14.37
54
124.93
0.87
0.75
840
86
92
44.75
48.25
24.84
1.75
6
16
60
127.36
1.12
1
1105
86
92
50
53
25.91
1.5
6
18.25
66
129.56
1.12
1
1400
86
92
52
55
26.78
1.5
6
21.25
72
131.23
1.12
1
2485
110
116
62
65.5
29.59
1.75
6
23.12
84
160.58
1.12
1
Figure H1-1. Spraymaster Signature Series Tank Supports, Details and Dimensions
H1b-7
09-09
Note:
1. Packaged units only. Mounted on side stand.
2. Suction piping includes strainer, gate valve and flexible connection.
7. Deaerator tank is built to SAME Code.
8. Accompanying dimensions , while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints.
9. Add Suffix P to Model No. for packaged units (SSP-45).
10. Dimension B will change depending on controls required - contact your local Cleaver-Brooks autho-
RATINGS
Tank Weight (Dry) (lb)
Package Weight (Total Dry)(lb)
Package Weight (Total Flooded) (lb)
Section H
rized representative.
11. No interconnecting piping or wiring furnished on non-packaged units unless specified, contact your
local Cleaver-Brooks representative for specific piping or wiring furnished on packaged assemblies.
12. Weights shown are without controls or packaging - contact your local Cleaver-Brooks representative for additions.
13. Capacities otherthan shown as standard available by proper selection of controls - contact your
local Cleaver-Brooks autherized representative.
14 Optional tank sizes and ratings available - contact your local authorized Cleaver-Brooks representative.
15. Lifting lugs are for lifting EMPTY tanks only.
16. For zone IIB Stand dimensions - contact your local Cleaver-Brooks representatve
TANK SIZES
260
415
610
840
1105
1400
2485
48 x 75
48 x 115
54 x 117
60 x 119
66 x 121
72 x 123
84 x 152
SS7
SS15
0.75
0.75
1400
1800
2100
2400
2900
3200
4200
SS30
0.75
4500
5600
6750
7200
7600
8100
11,100
SS45
0.75
6900
9250
12050
14,450
17,100
20,000
29,700
SS70
SS100
1.5
RATINGS FOR
SPRAYMASTER MODEL
Conn. 3 Steam Inlet
SS-7
6"-150# FF Flg
1" NPT.
SS-15
6"-150# FF Flg
1.5"-150# RF Flg
SS-30
6"-150# FF Flg
2"-150# RF Flg
SS-45
6"-150# FF Flg
2"-150# RF Flg
SS-70
6"-150# FF Flg
6"-150# FF Flg
2.5"-150# RF Flg
3"-150# RF Flg
SS-100
Conn. 4 Water Inlet
Figure H1-2. Spraymaster Signature Series Deaerator Dimensions and Ratings (Single Tank) - Sheet 1 of 2
H1b-8
09-09
Section H

OVERALL DIMENSIONS (TANK AND STAND)
Overall Package Width
81
81
95
98
101
99
117
Overall Package Height
157
157
163
169
175
181
205
Overall Package Length
87
127.5
129.5
131.5
160.5
Overall Tank Height
73
73
80
85
91
97
109
Overall Tank Width
70
68
70.5
76.5
82.5
88.5
100.5
Front Head
12.31
12.31
13.13
14.37
15.44
16.31
18.81
High Temperature Return
49
20
Level Control
18
18
18
18
18
30
Water Inlet
17.5
37.5
37.5
37.5
37.5
37.5
49.5
Steam Inlet
37.5
57.5
57.5
57.5
57.5
57.5
69.5
Relief Valve
49
70
70
70
70
70
82
Relief Valve
N/A
78
78
78
78
78
90
Spare
N/A
86
86
86
86
86
98
123.5
125
TANK DIMENSIONS
Spare
N/A
N/A
N/A
N/A
N/A
N/A
106
Drain
46
85
85
85
85
85
97
M
N
Overflow
REAR HEAD
75
75
75
75
75
87
Overflow
1.56
1.59
4.62
7.62
10.87
13.81
18.25
2485
STAND DIMENSIONS -FOR ZONE IV- see note 16.

260
415
610
840
1105
1400
A1
Overall Length
52
91
91
91
91
91
116
B2
47
86
86
86
86
86
110
C3
Overall Width
72.75
72.75
72.75
72.75
78
80
91
D4
68.25
68.25
68.25
68.25
73.5
75.5
86.5
E5
Hole Size
1.37
1.37
1.37
1.37
1.37
1.37
1.37
F6
Anchor Bolt Size
1.25
1.25
1.25
1.25
1.25
1.25
1.25

Relief Valve Size / Quantity
Overflow Size
Steam Inlet Size
6"-150# FF 6"-150# FF 6"-150# FF 6"-150# FF 6"-150# FF 6"-150# FF 6"-150# FF
Water Inlet Size
8"-150# FF 8"-150# FF 8"-150# FF 12"-150# FF 12"-150# FF 12"-150# FF 12"-150# FF
High Temperature Return Size
1 1/2" NPT
2" NPT
2" NPT
2" NPT
3" NPT
3" NPT
3" NPT
Drain Size
2" NPT
2" NPT
2" NPT
2" NPT
2" NPT
2" NPT
2" NPT
Suction Size
2.5" NPT
2.5" NPT
2.5" NPT
2.5" NPT
Thermometer
3/4" NPT
3/4" NPT
3/4" NPT
3/4" NPT
3/4" NPT
3/4" NPT
3/4" NPT
Sample
1/2" NPT
1/2" NPT
1/2" NPT
1/2" NPT
1/2" NPT
1/2" NPT
1/2" NPT
10
Chemical Feed
11
Recirculation
12
13
Level Controller
14
Make-Up Valve
3" NPT
3" NPT
3" NPT
3" NPT
4"-150# FF 4"-150# FF 4"-150# FF
3"-150# FF 3"-150# FF 4"-150# FF
1" NPT
1" NPT
1" NPT
1" NPT
1" NPT
1" NPT
1" NPT
1.5" NPT
1.5" NPT
1.5" NPT
1.5" NPT
1.5" NPT
1.5" NPT
2" NPT
1.5" NPT
1.5" NPT
1.5" NPT
1.5" NPT
1.5" NPT
1.5" NPT
1.5" NPT
1/4" NPT
1/4" NPT
1/4" NPT
1/4" NPT
1/4" NPT
1/4" NPT
1/4" NPT
15
Pressure Gauge
16
Control Panel
Per Design Per Design Per Design Per Design Per Design Per Design Per Design
17
Feed Pump/Motor
18
Suction Piping
19
Manway Size - SSP 15-70
20
Manway Size - SSP 100
21
Level Alarms
22
Overflow Drainer
12" x 16"
12" x 16"
12" x 16"
12" x 16"
12" x 16"
12" x 16"
N/A
N/A
N/A
N/A
N/A
N/A
N/A
14" x 18"
1" NPT
1" NPT
1" NPT
1" NPT
1" NPT
1" NPT
1" NPT
Figure H1-2. Spraymaster Signature Deaerator Dimensions and Ratings (Single Tank) - Sheet 2 of 2
H1b-9
09-09
Section H
Payback for a pressurized deaerator verses an atmospheric boiler feed system is based
on an additional capital expenditure required divided by the yearly operating cost
savings. The differential in yearly operating costs are in the following areas:
Flash steam
Exhaust steam
Blowdown
Chemical treatment
Sewer
Intangibles
Flash Steam
A percentage of the high-pressure condensate returns will flash to steam and be lost in
an atmospheric vessel application. This flash steam loss can result in an energy loss and
associated fuel cost. Returning condensate to a pressurized vessel decreases the amount
of flash steam created and reduces losses to atmosphere.
Exhaust Steam

Surface Blowdown
related to cycles of concentration in the boiler. The additional blowdown loss can result
in an energy loss and associated fuel cost. The additional surface blowdown may also
result in an increase in capital expenditure for a larger blowdown heat recovery system.
Chemical Treatment

2Na2SO3 + O2
2Na2SO4

ppm of dissolved O2
Makeup Water
Sewer
Intangibles
H1b-10
09-09
Section H1b
Spraymaster Signature Series Deaerators (Single Tank)
Packaged Deaerator Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-12
Deaerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-12
Deaerator Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-12
Deaerator Load Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-13
Deaerator Standard Trim and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-13
Deaerator Make-Up Valve and Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-13
Deaerator Steam Pressure Reducing Valve (PRV) Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-13
Deaerator Safety Relief Valve(s) (SRV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-14
Deaerator Water Level Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-14
Deaerator Overflow Drainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-14
Deaerator Suction Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-14
Boiler Feedwater Pump And Motor Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-14
Deaerator Support Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-15
Deaerator Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-15
Electric Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-15
Deaerator Preparation and Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-16
Deaerator Manuals and Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-16
H1b-11
09-09
Section H
PART 1 GENERAL
1.1
PACKAGED DEAERATOR SPECIFICATION

A. Provide one (1) Cleaver-Brooks Model SSP_____ Signature Series
spray type, pressurized, horizontal deaerator rated at _____ pounds per
hour. The system shall be a single tank design. Performance is
guaranteed to remove oxygen to not more than 0.005 ccs/liter in the
effluent throughout all load conditions between 5 and 100 percent with a
20:1 turndown ratio. The deaerator shall be designed for operation at 5
PSIG, but shall be suitable for use from 2 to 15 PSIG. Feedwater, low
and medium temperature condensate shall be admitted to the deaerator
through a single spring-loaded, self-cleaning, adjustable stainless steel
spray valve, which shall provide proper internal vent condensing and
water distribution at any load between 5 and 100 percent of rated
capacity.
PART 2 PRODUCTS
2.1
DEAERATOR
A. The water temperature in the primary heating and vent concentrating
section is to be raised within 2 to 3 F of steam saturation temperature
causing the majority of non-condensable gases to be released. The water
is then to be collected in a stainless steel conical water collector. From
the collector, it shall flow to an atomizing valve where high velocity
steam shall contact the water stream and break it into a fine mist. At this
stage, the water shall be heated to full steam saturation temperature. The
mixture is to strike a deflecting baffle, which separates water and steam.
Hot, gas-free water shall then drop to the storage compartment of the
pressure vessel to complete the deaeration process. The noncondensable gases released during the process and steam shall flow
upward, through the primary heating spray portion, into the internal vent
concentrating section, where they contact the cold influent water. Here,
the steam is to be condensed to continue the cycle. Released gasses are
discharged to atmosphere through the vent outlet.
B. All internal surfaces, which come in contact with un-deaerated water,
shall be constructed of Type 316 stainless steel. An automatic vent valve
shall be thermostatically controlled to provide a swift means of venting
during a sudden buildup of gases. This condition is most typically seen
at start up. The manual vent valve shall contain a fixed orifice for
continuous venting. Venting rate shall not exceed 0.1 of 1% of the rated
deaerator capacity at 5 PSIG.
2.02
DEAERATOR VESSEL
A. The deaerated water storage tank shall have a minimum of 10 minutes of
storage and have a capacity of _____ gallons measured to overflow. The
tank shall be _____ diameter x _____ long. A 12 x 16 inch elliptical
manway shall be provided for access to the deaerator. All nozzles 3" and
under shall be 3000 lbs. forged steel couplings. All nozzles over 3" shall
be 150 lbs. flat face flanges. Heads to be ASME torispherical type
constructed of ASTM A516 GR 70 carbon steel with a minimum
thickness of 0.25 inches. Shell plate to be fabricated of ASTM A36
carbon steel with a minimum thickness of 0.25 inches. The tank shall be
designed in accordance with ASME, Section VIII of the Pressure Vessel
Code for 50 PSIG at 650 ?F and stamped accordingly. Certification shall
be required. Joint efficiencies to be 70% circumferential per Table UW12, which does not require stress relieving or nondestructive
examination.
H1b-12
09-09
Section H

B.
2.03
A quantity of two (2) , inch tappings for water sampling and chemical
injection shall be provided under the water line.
DEAERATOR LOAD SPECIFICATION
Load Specifications
LOAD
PERCENTAGE
LBS/HR
Raw Make up
GPM
TEMP
PRESSURE
25 psig Minimum
Low Temperature Returns

(Less than 200 F
10 psig Minimum
Med. Temp Returns

(200 - 230 F)
10 psig Minimum
High Temp Returns

(greater than 230 F)
Not To Exceed 25%
2.04
DEAERATOR STANDARD TRIM AND ACCESSORIES

A. The basic deaerator shall be equipped with the following trim and
accessories. Piping on packaged units shall comply with ASME Power
Piping Code B31.1.
2.05
DEAERATOR MAKE-UP VALVE AND CONTROLLER

A. A _____" inlet make-up water regulating valve with bronze body and
threaded NPT connections that is electronically actuated. The valve
shall be a globe style Siemens Flowrite VF 599 Series two-way valve
designed to operate with an electronic actuator with a 3/4-inch (20 mm)
stroke. The electronic actuator shall be the Siemens Flowrite EA 599
Series SKB/C Electronic Valve Actuator. The actuator shall receive a 0
to 10 Vdc or a 4 to 20 mA control signal to proportionally control the
valve. The valve shall be rated for _____ GPM at _____ PSIG inlet
pressure. The valve shall meet ANSI leakage class IV (0.01% of Cv)
shutoff standards. The valve shall be normally closed, with stainless
steel trim, linear control, include Teflon V-ring packing and be suitable
for temperatures up to 330F.
B. A McDonnell & Miller 93-7B level controller shall electronically
control the make-up valve.
C. The make-up valve shall optionally be included in an assembly using
an ANSI Class 125 LB three-valve bypass with inlet Y-type cast iron
strainer. Strainer screen to be removable and of stainless steel
construction.
2.06
DEAERATOR STEAM PRESSURE REDUCING VALVE (PRV)

STATION
A. A _____" steam pressure reducing valve with cast iron body and
______ connections. The valve shall be a self-contained unit capable of
reducing _____ PSIG saturated steam to the operating pressure of the
deaerator at a flow rate of _____ LBS./HR. The valve shall be 250 lb.
class with stainless steel trim and an adjustable pilot. The valve
H1b-13
09-09
B.
Section H
manufacturer shall be Spence, Model _____.

The steam pressure reducing valve shall optionally be included in an
assembly using a three valve bypass with Y-type cast iron strainer.
Strainer screen to be removable and of stainless steel construction.
2.07
DEAERATOR SAFETY RELIEF VALVE(S) (SRV)

A. Include a quantity of _____, _____" relief valves sized to relieve full
capacity of the pressure reducing valve in the event of its failure. Valves
to meet Paragraph UG-125 of ASME Unfired Pressure Vessel Code,
Section VIII. Valve body to be of _____construction. Relieving set
pressure to be 50 PSIG. Relief valve manufacturer to be Kunkle, Model
_____.
2.08
DEAERATOR WATER LEVEL ALARMS

A. A NEMA 1 high water alarm shall be an externally mounted float type
switch. The switch shall make contact on rise and break on fall. The
float cage construction shall be cast iron.
B. A NEMA 1 low water alarm shall be an externally mounted float type
switch. The switch shall make contact on fall and break on rise. The
float cage construction shall be cast iron.
C. A NEMA 1 low-water cutout alarm and switch shall be an externally
mounted float type switch. The switch shall make contact on fall and
break on rise. The float cage construction shall be cast iron. The cutout
will protect the pumps from a dry-run condition.
2.09
DEAERATOR OVERFLOW DRAINER

A. A _____ overflow drainer sized to relieve full capacity at the operating
pressure of the deaerator. The overflow drainer shall be a float type trap.
The construction is to be a steel housing with stainless steel float ball.
The overflow drainer manufacturer shall be
B. Warren Model _____.
2.010
DEAERATOR SUCTION PIPING

A. Suction piping for pumps shall consist of a _____ gate valve, cast iron
Y-type strainer with replaceable stainless steel screen and flexible
connector or hose. This piping assembly shall be 125 LB class
construction. The vortex breaker shall be located in the tank nozzle.
2.011
BOILER FEEDWATER PUMP AND MOTOR SET

Pumps may be selected to run either on/off or intermittent.
A.
Intermittent
Quantity _____, vertically oriented, multistage centrifugal type boiler
feedwater pump and motor set. Pump to be rated for _____ GPM at
_____ feet TDH with _____feet NPSH required. Pump to be _____
materials of construction and have mechanical seals for a maximum
water temperature of 250 F. Pump impeller to be hydraulically
balanced. The pump shall be mounted on a steel baseplate channel and
flexibly coupled with an OSHA type coupling guard to a _____ HP,
_____ phase, _____ Hz, _____ Volt, _____RPM, _____ enclosure
motor. Motor to be non-overloading at the rated condition without using
any portion of the service factor. Pump and motor set to be factory
H1b-14
09-09
Section H
B.
aligned prior to shipment. Pump manufacturer to be Grundfos Model

_____k
Continuous
Quantity _____, vertically oriented, multistage centrifugal type boiler
_____ feet TDH with _____ feet NPSH required. Pump to be _____
materials of construction and have mechanical seals for a maximum
water temperature of 250 F. Pump impeller to be hydraulically
balanced. The pump shall be mounted on a steel baseplate channel and
flexibly coupled with an OSHA type coupling guard to a _____ HP,
_____ phase, _____ Hz, _____ Volt, _____ RPM, _____ enclosure
motor. Motor to be non-overloading at the rated condition without using
any portion of the service factor. Pump and motor set to be factory
aligned prior to shipment. Pump manufacturer to be Grundfos Model
_____k A stainless steel recirculation orifice is to be supplied with the
pump and shipped loose for field installation to provide minimum
bypass flow.
2.012
DEAERATOR SUPPORT STAND

A. The _____ feet high stand shall elevate the deaerator tank to provide the
net positive suction head required by the pump at the rated condition to
prevent cavitation plus a 2 foot safety factor. The stand shall be
constructed of heavy square steel tubing.
B. The stand shall be designed for Seismic Zone 2B.
C. Calculations for Seismic Zone 2B or a design upgrade to Seismic Zone
4 may be provided optionally.
2.013
DEAERATOR CONTROL PANEL

A. Control panel shall be in a NEMA 1 enclosure and wired to the National
Electric Code. The wire shall be black number coded. The assembly is
to contain individual motor starters with 120 Volt holding coil and fuse
protection. Individual oil-tight pump run lights shall be provided. All
switches and lights to have nameplate identification. The assembled
panel shall be given a factory continuity test prior to shipment.
2.014
ELECTRIC COMPONENTS
A. Audible and visual high, low-water and low-water cutout alarm
functions shall be provided by a bell, horn or electronic sounder with
silence switch and individual oil-tight lights. Control circuit transformer
to supply 110-120 Volts, single-phase power supply. The transformer
shall be mounted, wired and fused. Auxiliary contacts shall be
optionally furnished per customers requirements. Contacts shall be
normally open.
B. The deaerator shall have a gauge glass assembly that covers the
operating range of the unit. The gauge glass shall be quartz, 0.625 inch
diameter by 24 inch maximum length. Each length of glass shall be
furnished with a bronze gauge cock set and protector rods. The
deaerator shall be supplied with a pressure gauge that has a 4-1/2 inch
dial with a 0-60 PSIG range and a thermometer with a 50 to 300 ?F
range.
H1b-15
09-09
PART 3 EXECUTION
Section H
2.015
DEAERATOR PREPARATION AND PACKAGING

A. The deaerator is to be hand cleaned with a solvent to SSPC- SP-1
standards prior to painting. Prime coated to not less than 1 mil thick and
finish coated with enamel paint to not less than 1 mil thick prior to
shipment.
B. The deaerator vessel, stand, controls and piping shall be packaged
together as a complete system. The unit is to be disassembled for
shipment. Piping is to be matched marked for ease of reassembly.
3.1
DEAERATOR MANUALS AND WARRANTY

A. All units shall include three (3) bound, Operating and Maintenance
manuals. The warranty period to be not less than twelve months after
start-up or eighteen months after shipment, whichever comes first.
B. Deaerator Options for Trim and Accessories
1. The tank shall be optionally factory-insulated and lagged with
blanket insulation, pins, clips, and a durable steel jacket. The
blanket insulation is to be fiberglass, 2" thick, 1 LB/CU-FT, and
have a rating of R3.85. Pins are to be located on 18" centers and
holding clips attached. The steel jacket or lagging shall have a
shell thickness of 22 gauge (0.299") minimum and head thickness
of 12 gauge (0.1046") minimum.
2. The optional magnesium or sacrificial anode shall provide
hole to signal it has been consumed.
3. The optional chemical feed quill shall be located beneath the
4. Additional discharge piping, manifold piping and recirculation
piping may be provided optionally.
H1b-16
09-09
Section H2
SPRAYMASTER DEAERATORS (Duo-Tank)
CONTENTS

H2-3
H2-3
H2-3
H2-9
ILLUSTRATIONS
Figure H2-1. Spraymaster Duo-Tank Supports and Saddles, Details and Dimensions . . . . . . . . . . . . . . . . . H2-4
Figure H2-2. Spraymaster Deaerator (Duo-Tank) Dimensions and Ratings - Sheet 1 of 3 . . . . . . . . . . . . . H2-5
TABLES
Table H2-1. Spraymaster Deaerator Duo-Tank Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-4
H2-1
09-09
Spraymaster Deaerators (Duo-Tank)
Section H
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
09-09
Section H

The Duo Tank product combines a surge tank with a Spraymaster deaerator in to a single
combined vessel, providing the following features and benefits in addition to the benefits
of the deaerator and surge tank independently.
Double Inner Head Separates the Deaerator Pressure Vessel From Surge
Tank:
Ensures the deaerator and surge tank are two separate vessels while structurally
attached for space considerations. This also limits heat transfer from the deaerator
pressure vessel to the surge atmospheric vessel, preventing energy loss due to surge
tank water boiling.
Vented and Insulated Gap Between the Deaerator and Surge Tank:
Insulation is placed between the double inner head to further limit heat transfer from
the deaerator pressure vessel to the surge atmospheric vessel. A vent is placed
between the double inner head to allow moisture evaporation eliminating corrosion
potential.
Low Profile Design:
Low head room allows for installation in space restricted areas.
Complete packages are pre-fabricated in the Cleaver-Brooks manufacturing facility

to ensure piping alignment and control wiring function. The unit is disassembled,
match marked for efficient field re-assembly.
PRODUCT OFFERING
Information in this section applies directly to Cleaver-Brooks packaged Spraymaster
Deaerators in duo-tank arrangement ranging from 7000 to 280,000 lbs/hr.
The product offering for Duo-Tank packaging is a combination of the product offering
for the Spraymaster Deaerator and the Surge Tank. The combined package product
offering for Duo-Tank products is shown in Table H2-1

Dimensions and ratings are shown in Figure H2-1 and Figure H2-2
H2-3
09-09
Section H

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
to Overflow
230
300
600
900
1400
2000
2800
4000
5600
Deaerator Storage
Capacity (min)
16
10
10
10
10
10
10
10
10
Surge Gallons to
Flooded
160
300
600
900
1400
2000
2800
4000
5600
Surge Storage
Capacity (Min)
11.5
10
10
10
10
10
10
10
10
NOTE: Model designation (example SD-7) is: S = Spraymaster Deaerator, D = Duo-tank, 7 = 7,000 lbs/h rating,
combined deaerator and surge tank package.

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
N/A
N/A
N/A
N/A
N/A
N/A
N/A
AG
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
7-1/2
7-3/4
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
09-09
Section H
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 authorized representative.
16. No interconnecting piping or wiring furnished on non-packaged units unless specified, contact your local Cleaver-Brooks authorized representative for specific
piping or wiring furnished on packaged assemblies.
17. Weights shown are without controls or packaging - contact your local Cleaver-Brooks authorized representative for additions.
18. Capacities other than shown as standard available by proper selection of controls - contact your local Cleaver-Brooks authorized representative.
19. Optional tank sizes and ratings available - contact your local Cleaver-Brooks authorized representative.
21. Raw water make-up should first pass through a water softener if hardness is present.
22. All dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimensional prints.
Figure H2-2. Spraymaster Deaerator (Duo-Tank) Dimensions and Ratings - Sheet 1 of 3
H2-5
09-09
Section H
STORAGE TANK DETAIL AND DIMENSIONS

SPRAYMASTER
MODEL NO.
SM-7D
SM-15D
SM-30D
SM-45D
SM-70D
SM-100D
SM-140D
Ratings (lb/h)
7000
15000
30000
45000
70000
100000
140000
200000
280000
Tank Weight (lbs)
1530
2500
3650
4500
6770
8810
10760
12975
18735
Tank Weight Flooded

(lbs)
5165
10835
17720
24440
38450
52310
68045
80290
106475
Tank Cap-Deaerator
(Gal to Overflow)
230
300
600
900
1400
2000
2800
4000
5600
SM-200D
SM-280D
Storage Cap (Min)
16
10
10
10
10
10
10
10
10
Tank Cap-Rec Section

(Gal to Flooded)
160
300
600
900
1400
2000
2800
4000
5600
11.5
10
10
10
Storage Cap (Min)

A
Overall Height
Overall Width
36 x 106-1/2 48 x 141-1/2
58
66-1/2
10
10
10
10
54 x 181
60 x 207
66 x 270-1/2
72 x 302
74-1/2
80-1/2
88
96-1/2
10
84 x 302-1/4 96 x 308-3/4
109
120-1/2
108 x 349
133
51
62
68
75
80
87
99
111
123
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
28-1/2
72-1/2
92-1/2
101
146
164
146
4 136
4 153
43
54-1/2
74
83
124
142
124
24 116
24 133
44
48 109
48-1/2
34-1/2
54
63
104
122
104
11
16
31
42
68
68
73
60
59
21
26
45
54
80
104
86
82
98
130
144
96
52
56
90
102
N/A
31
50
32
35
36
28
35
28
N/A
47
65
74
115
132
126
106
123
38
60
64
90
144
164
147
Consult Your Local Cleaver-Brooks Authorized Representative
90
27
27
32
27
36
27
109
126
169
224
205
160
186
69
95
120
145
198
192
177
196
196
85
115
155
171
230
266
258
258
249
KK
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
1-1/2
2 @ 1-1/2
2@2
MM
10
12
12
NN
10
6-1/2
14-1/2
26-1/2
27-1/2
PP
68
94
112
127
180
197
173
175
191
RR
74
101
120
133
200
227
205
201-1/2
211
SS
72
95
126
138
188
214
183
190
229
TT
82
109
144
160
218
243
232
213
249
W
W
75
108
132
153
208
267
249
206
279
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
XX
H2-6
09-09
Section H
STAND BASE DIMENSIONS

TANK CAPACITY (GAL)
230
300
600
900
1400
2000
A1
Outside Length
87
115
154
B2
C to C Anchor Bolt
L
L
Holes
82
110
148
C3
Outside Width
49
62
66
71
76
D4
C to C Anchor Bolt
L
L
Holes
46
59
63
68
73
E5
3/4
1-1/8
F6
5/6
7/8
7/8
7/8
2800
4000
5600
175-1/2
237-1/2
276
268
144
297
169-1/2
230-1/2
269
265
137
294
81
86-1/2
102
112
78
79-1/2
99
101
1-1/8
1-1/8
1-1/8
1-1/8
6 FLG
6 FLG
TANK CONNECTION SIZES

1
Relief-Valve(s)
Overflow (Dea)
Pump Suction (Optional)
Steam Inlet (Dea Flg)
High Temp Return
Water Inlet (150# RF Flg)
Drain (Dea)
Overflow (Rec)
Contact Your Local Cleaver-brooks Authorized Represaentative

1-1/4 NPT
3 NPT
3 NPT
3 NPT
4 FLG
4 FLG
4 FLG
2@6
2@8
1-1/4 NPT
1-1/2 NPT
2 NPT
2 NPT
3 NPT
3 NPT
3 NPT
2 @ 3 NPT
2 @ 3 NPT
1 NPT
1-1/2
2-1/2
2@3
2@4
1-1/4 NPT
2 NPT
2 NPT
2 NPT
2 NPT
2 NPT
2 NPT
2 NPT
2 NPT
2 NPT
2 NPT
2 NPT
3 NPT
3 NP
3 NPT
4 NPT
4 NPT
6 NPT
Pump Suction (Optional)
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)
13
Drain (Rec)
2 NPT
2 NPT
2 NPT
2 NPT
2 NPT
2 NPT
2 NPT
2 NPT
3 NPT
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)
20
21
Pressure Gauge
22
Thermometer (3/4 NPT)
23
Level Alarms (1 NPT), (optional)
24
Level Control (1-1/2 NPT), (optional)
25
Sample Connection (1/2 NPT)
26
Recirculation Connection (1 NPT), (optional) (For each pump)
27
High Temp Return Connection-Rec (3 NPT)
28
Diffuser Tube (2-1/2 NPT, (optional)
29
Breather Connection (1/2 NPT -Do Not Plug)
30
Discharge Piping, (optional) (For each pump) (NOTE 5)
Sizes listed for items 22 thru 29

are for tank connections only.
H2-7
09-09
Section H
Notes
H2-8
09-09
Section H2
Deaerator and Surge Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-10
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-12
Boiler Feedwater Pump and Motor Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-14
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-16
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-17
H2-9
09-09
PART 1 GENERAL
Section H
The following sample specifications are provided by Cleaver-Brooks to assist you in

specifying your customers specific needs and application.
1.1
DEAERATOR AND SURGE TANK

A. Cleaver-Brooks Model _________ spray type, pressurized, horizontal
deaerator is rated at _____ pounds per hour. The system shall be
guarantee oxygen removal to not more than 0.005 CCS/liter in the
effluent throughout all load conditions between 5 and 100 percent. The
deaerator shall be designed for operation at 5 psig, but shall be suitable
for use from 2 to 15 psig.
B. The surge tank shall receive returning condensate and supplement make
up water to maintain the desired operating level. Condensate and make
up water mix into a blended temperature, as determined by the
percentage of each. The surge tank shall be vented to atmosphere. The
collected water is then transferred to the deaerator.
C. The collected water shall be admitted to the deaerator through a single
spring-loaded, self-cleaning, adjustable stainless steel spray valve,
which shall provide proper internal vent condensing and water
distribution at any load between 5 and 100 percent of rated capacity. The
water temperature in the primary heating and vent concentrating section
is to be raised within 2 or 3 F of steam temperature and most of the
gases released. The water is then to be collected in a conical water
collector. From there, it is to flow to an atomizing valve where high
velocity steam strikes it, breaks it down into a fine mist, and heats it to a
full steam saturation temperature. The mixture is to strike a deflecting
baffle, which separates water and steam. Hot, gas-free water is to then
drop to the storage 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 undeaerated water, shall be constructed of Type 316 stainless steel.
D. Automatic vent valve shall be thermostatically controlled to provide a
fast means of venting when a sudden buildup of gases occurs, such as
seen at start up. The manual vent valve shall have an orifice for
continuous minimum venting. Venting rate shall not exceed 0.1 of 1% of
the rated deaerator capacity at 5 psig.
E. The duo tank shall be divided into two separate sections. The deaerator
water storage and condensate surge section shall be divided by a double
inner head. The dead air space between the two inner heads shall be
packed with a fiberglass insulation and have a breather and drain
connection. The duo tank shall be _____ " diameter and _____ " long.
H2-10
09-09
Section H

F.
G.
H.
I.
J.
K.
L.
M.
N.
The deaerated water storage tank section shall have _____ minutes of
storage and have a capacity of _______ gallons measured to overflow.
An _________ manhole shall be provided for access. All nozzles 3" and
under shall be 3000 lbs forged steel couplings and over 3" shall be 150
lbs flat face flanges. Heads to be ASME torispherical type constructed of
ASTM A516 GR 70 carbon steel with a minimum thickness of 0.25
inches. Shell plate to be 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 _________ manhole
shall be provided for access. All nozzles shall be 3000 lbs forged steel
couplings. Heads to be ASME torispherical type (flat heads are not
acceptable) constructed of ASTM A516 GR 70 carbon steel with a
minimum thickness of 0.25 inches. Shell plate to be fabricated of ASTM
A36 carbon steel with a minimum thickness of 0.25 inches.
The loads shall be as specified in the table above. Low temperature
returns are defined as condensate with a temperature below that of the
deaerator operating temperature. High temperature returns are defined as
condensate with a temperature above that of the deaerator operating
temperature.
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.
Optional - The duo tank shall be factory-insulated and lagged with
blanket insulation, pins, clips, and a durable steel jacket. Block-type
insulation is not acceptable. The blanket insulation is to be fiberglass, 2"
thick, 1 lb/cu-ft, and have a rating of R3.85. Pins are to be located on 18"
centers and holding clips attached. The steel jacket or lagging shall have
a shell thickness of 18 gauge (0.0478") minimum and head thickness of
18 gauge (0.0478") minimum.
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.
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.
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.
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.
H2-11
09-09

PART 2 PRODUCTS
2.1
Section H
HARDWARE
A. Make Up Valve and Controller
not exceed ______ and 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
cage manufacturer shall be ___________________, Model
______.
2. Option (Electronic) - ______" inlet water motorized regulating
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
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
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
valve manufacturer shall be ___________, Model _____. This
valve shall be pneumatically controlled by an external
proportional type sensor. The sensor shall be a 14" displacer that
produces a pneumatic output signal. The controller manufacturer
shall be _________, Model ______. A filter regulator is to be
provided to reduce 50 psig instrument air supply to 3 - 15 psig for
proper operation.
4. Optional - The make up valve shall include an ANSI Class 125 lb
A. Steam Pressure Reducing Station
H2-12
09-09
Section H
B.

an adjustable pilot. The valve manufacturer shall be
____________, Model _____.
2. Option (Pneumatic) - _______" diaphragm actuated steam pressure
reducing valve with cast iron body and _______ connections. The
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 ____.
manufacturer to be ________________, Model _______.
manufacturer shall be _______, Model _______.
Boiler Feedwater Pump and Motor Set
1. Option - Intermittent - Quantity________, turbine type boiler
H2-13
09-09
C.
Section H

to a ____ hp, _____ phase, ______ Hz, ______ Volt, _______
rpm, ________enclosure motor. Motor to be non-overloading at
the rated condition without using any portion of the service factor.
manufacturer to be_____________, Model ________, size ____ "
x _______".
________ feet TDH with ____ feet NPSH required. Pump to be
flexibly coupled with an OSHA type coupling guard to a ______
hp, ______ phase, _______ Hz, ______ Volt, _____ rpm, _______
enclosure motor. Motor to be non-overloading at the rated
3. Optional - The basic surge tank shall be equipped with the
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 manufacturer shall be
_______________, Model __________.
H2-14
09-09
Section H

1)
2.
3.
4.
Option (Electronic) - ______" inlet water motorized

regulating valve with steel body and threaded NPT
connections. Motor shall be 110V bi-directional type,
with a permanently lubricated gear train, and directly
coupled to the valve stem. The valve Cv shall not
exceed _____ and be rated for_______ gpm at
________ psi inlet pressure. Valve shall not exceed a
delta-P of 10 psig. This valve shall have teflon seats and
be suitable for temperatures up to 300 F. The
motorized valve manufacturer shall be _________. This
valve shall be electronically controlled by a solid state
control with internally mounted capacitance probes.
The electronic solid state control shall be able to set
desired level point and acceptable deviation. The
electronic solid state control shall include a selection for
automatic and manual operating mode. The internals
shall include two additional probes for high and low
water alarm. The controller manufacturer shall be
Cleaver-Brooks, Model TW82. A solenoid valve and
float switch are not acceptable. (Available only in the
U.S.)
2) Option (Pneumatic) - _______" inlet water diaphragm
actuated regulating valve with cast iron body and _____
connections. The valve shall be globe-type with
proportional control and a spring-opposed diaphragm
actuator arranged for 3 - 15 psig operating signal. The
valve shall be normally open on loss of air. The valve
Cv shall not exceed _____ and be rated for ________
gpm at ______ psi inlet pressure. Valve shall not exceed
a delta-P of 10 psig. This valve shall have stainless steel
trim with TFE packing and be suitable for temperature
up to 410 F. The diaphragm actuated valve
manufacturer shall be ___________, Model _______.
This valve shall be pneumatically controlled by an
external proportional type sensor. The sensor shall be a
14" displacer that produces a pneumatic output signal.
The controller manufacturer shall be _____________,
Model __________. A filter regulator is to be provided
to reduce 50 psig instrument air supply to 3 - 15 psig for
proper operation.
Optional - The make up valve shall include a ANSI Class 125 lb
Optional - High-level alarm switch. This shall be an externally
mounted float-type switch. The switch shall make contact on rise
Optional - Low-level alarm switch. This shall be an externally
mounted float-type switch. The switch shall make contact on fall
H2-15
09-09
Section H
5.
D.
E.
Optional - Suction piping for pumps shall consist of a gate valve,

6. Transfer Pump and Motor Set - Quantity ______, centrifugal type
transfer pump and motor set. Turbine type pumps are not
acceptable in this application. Pump to be rated for _______ gpm
at ________ feet TDH with ______ feet NPSH required. Pump to
be _______ materials of construction as defined by the Hydraulic
Institute, and have _______ seals for a maximum water
flexibly coupled with an OSHA type coupling guard to a ______
7. Optional - The duo stand shall elevate the deaerator and surge tank
sections to provide the net positive suction head required by the
pump at the rated condition to prevent cavitation. The stand shall
be constructed of heavy square steel tubing for the legs and 1/4"
steel plate covering the floor.
Control Panel
silence switch and individual red oil-tight lights.
a. Control circuit transformer to supply 110-120 Volts, singlephase power supply. The transformer shall be mounted,
wired and fused.
b. Auxiliary contacts shall be furnished for chemical feed pump
initiation. Contacts shall be normally open.
Standard
1. The deaerator and surge section shall have a gauge glass assembly
that covers the entire tank diameter. The gauge glass shall be
quartz 0.625 inch diameter by 24 inch maximum length. Each
length of glass shall be furnished with a bronze gauge cock set and
protector rods.
a. The deaerator section shall be supplied with a pressure gauge
H2-16
09-09
Section H
b.
c.
d.
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 SSPCSP-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.
Load Specifications
LOAD
PERCENTAGE
LBS/HR
Make up to Deaerator
GPM
Make up to Surge Tank
GPM
TEMP
PRESSURE
25 psig Min.

Gravity Feed Low Temp
Returns
High Temp Returns
H2-17
09-09
Section H
Notes
H2-18
09-09
Section H3
TRAYMASTER DEAERATORS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-3

ILLUSTRATIONS
Figure H3-1. Cleaver-Brooks Traymaster Deaerator Dimension Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . H3-7
Figure H3-2. Traymaster Deaerator Dimensions and Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-8
Figure H3-3. Traymaster Tank Supports and Saddles, Details and Dimensions . . . . . . . . . . . . . . . . . . . . . . H3-10
H3-1
09-09
Traymaster Deaerators
Section H
H3-2
09-09
Section H

The following features and benefits apply to the Traymaster Deaerator product line.
Less Mechanical Movement of Deaerator Components:
The water spray valve is the only internal moving component within the deaerator
vessel.

requirements.
Maintains deposit-free surface.
Internal Automatic-Check Valve Prevents Steam Back-Flow:
The water spray valve is normally closed at no flow.
Prevents steam back flow through the water spray valve at no flow conditions.
Pressurized Tank Reduces Flashing and Minimizes Venting:
Saves BTUs that would normally be exhausted to atmosphere.
Improves plant efficiency.
Auto Vent Valve Eliminates Gases at Start-Up:
Cleaver-Brooks deaerator is guaranteed to remove oxygen concentrations to 0.005

cc/liter while operating between 5 and 100% capacity.
Carbon dioxide concentration is practically reduced to zero.
H3-3
09-09
Section H

Saves BTUs by accepting condensate before cold make-up water. Maintains a

Provides flexibility for selecting a tank for specific applications to limit the loss of
Complete packages are pre-fabricated in the Cleaver- Brooks manufacturing facility

to ensure piping alignment and control wiring function. The unit is partially
disassembled, match marked for efficient field re-assembly.
PRODUCT OFFERING
Information in this section applies directly to Cleaver-Brooks packaged Traymaster
deaerators ranging from 30,000 lbs/hr to 500,000 lbs/hr at 50 F makeup.
The Traymaster deaerator is a pressurized low maintenance system designed to remove
dissolved oxygen in boiler feed water to 0.005 cc per liter or less and eliminate carbon
dioxide. A typical deaerator package includes the tray column and storage tank mounted
on a stand of appropriate height along with all operating controls, feed pumps assembled
and piped (typically knocked down for shipment and field assembly). The tank conforms
to Section VIII of the ASME code.
The tray column design is best for handling high-temperature returns. The column is
constructed of carbon steel. Built into the top of the tray box is a spring loaded selfcleaning water spray nozzle. Automatic and manual vent valves are built into the top of
the vent condenser.
From experience, large industrial plants and utilities have learned that the most practical
and economical way to remove oxygen from feedwater is through mechanical
deaeration. The Traymaster deaerator economically effects oxygen removal through a
design that is trouble free in performance.
Raw water, untreated and not deaerated, contains as much as ten cubic centimeters of
corrosion-causing oxygen per liter. Oxygen in water corrodes and shortens the life of
boiler feed lines, boilers and condensate return lines.
oxygen and other dissolved gases in boiler feed. Thus, it is the answer to long-lasting
boiler equipment for industrial and commercial boiler users. Built of corrosion-resistant
alloys for lifetime service, the deaerator employs those basic principals of gas removal
proved to most effective and economical to every boiler owner. Contact your local
Cleaver-Brooks authorized representative for component and sizing information.
The design of the Traymaster deaerator offers simplicity in both operation and service.
H3-4
09-09
Section H
The tray section, the heart of the deaerator, requires no maintenance. There are no
moving parts to adjust or maintain. Installation is simple and quick.
Standard Equipment
Tray column.
Stainless steel trays of riveted construction.
Gauge glass.
Deaerator manual and automatic vent valve.
Feed water thermometer.
Required tappings.
Optional Equipment
High water alarm.
Low water alarm.
High-temperature condensate diffuser tube (over 227 F).
Recirculation orifice or relief valve.
Suction strainer.
Discharge manifold.
Overflow drainer.
Control panel.
Vacuum breaker.
Tank drain valve.

H3-5
09-09
Section H
Magnesium anode.
Stand.
Packaging
Half packaged, suitable for field erection with interconnecting piping and wiring
by others.

Dimensions and ratings for Traymaster Deaerators are shown in the following figures
and tables.
H3-6
09-09
Section H
Figure H3-1. Traymaster Deaerator Dimension Diagram
H3-7
09-09
Section H
Table H31. Dimensions, TM030-TM125
TRAYMASTER DETAILS AND DIMENSIONS
MODEL NUMBER
A
HEIGHT ABOVE STAND
B
OVERALL LENGTH
C
OVERALL WIDTH
D
COLUMN DIAMETER
E
STORAGE TANK DIA.
F
C/L TO C/L BOLT HOLES
G
STAND LENGTH
H
J
STAND WIDTH
K
TEMP./PRESS. SENSOR
L
HIGH TEMP. RETURN
M STEAM INLET
N
DAVITED MANWAY
P
WATER INLET
TRAY CLEARANCE
Q
TRAY QTY.
COLUMN WEIGHT (LB)
STORAGE TANK CAPACITY (GAL.)
STORAGE TANK WEIGHT (DRY) (LB)
STORAGE TANK WEIGHT (FLOODED) (LB)
MODEL NUMBER
A1
B1
C1
D1
E1
F1
G1
TEMP./PRESS. SENSOR
HIGH TEMP. RETURN
STEAM INLET
WATER INLET
DOWNCOMER
MANWAY
VENT PIPE
TM030
143
120-1/2
75
36
42
79-1/2
84-1/2
55
58
15-5/8
41-5/8
54-5/8
54-5/8
SEE "A"
18
20
1600
600
1500
6500
TM045
154
133
78
36
48
95
101
59
62
15-5/8
39-5/8
52-5/8
52-5/8
81-3/8
24
20
1800
900
1800
9300
COLUMN CONNECTIONS
TM030
3/4" NPT
2" NPT
6"-150#" RFSO
2-1/2"-150# RFSO
10"-150# FFSO
16"
3/4" NPT
TM045
3/4" NPT
2" NPT
8"-150# RFSO
3"-150# RFSO
12"-150# FFSO
18"
1-1/2" NPT
TM070
169
137
85
48
60
95
101
68
71
18
40
55
55
84-1/4
36
20
2300
1400
2400
14000
TM100
179-1/2
160
91
54
66
112-1/2
119-1/2
73
76
23-7/8
40-7/8
55-7/8
55-7/8
87-1/8
36
30
3000
2000
3800
20500
TM125
197-1/2
168
97
54
72
112-1/2
119-1/2
80
83
18-7/8
52-3/4
67-3/4
67-3/4
99-1/8
36
36
3300
2500
4300
25100
TM070
3/4" NPT
2-1/2" NPT
8"-150# RFSO
3"-150# RFSO
14"-150# FFSO
18"
1-1/2" NPT
TM100
3/4" NPT
3" NPT
10"-150# RFSO
4"-150# RFSO
16"-150# FFSO
20"
2" NPT
TM125
3/4" NPT
3" NPT
10"-150# RFSO
4"-150# RFSO
16"-150# FFSO
20"
2" NPT
TM200
218-1/2
197
107-1/2
72
84
137
144
88-1/2
91-1/2
21-7/8
44-7/8
69-7/8
69-7/8
107-1/8
36
56
5600
4000
6900
40200
TM225
232
190-1/2
119
72
96
127-1/2
134-1/2
99
102
21-7/8
44-7/8
69-7/8
69-7/8
108-1/8
36
65
5800
4500
7900
45400
TM250
232
195-1/2
119
72
96
137
144
99
102
24-3/8
47-3/8
72-3/8
72-3/8
109-5/8
36
70
6000
5000
8100
49800
TM200
3/4" NPT
6"-150# RFSO
14"-150# RFSO
6"-150# RFSO
18"-150# FFSO
24"
2-1/2" NPT
TM225
3/4" NPT
6"-150# RFSO
16"-150# RFSO
6"-150# RFSO
18"-150# FFSO
24"
3" NPT
TM250
3/4" NPT
8"-150# RFSO
16"-150# RFSO
6"-150# RFSO
20"-150# FFSO
24"
3" NPT

MODEL NUMBER
A
HEIGHT ABOVE STAND
B
OVERALL LENGTH
C
OVERALL WIDTH
D
COLUMN DIAMETER
E
STORAGE TANK DIA.
F
G
STAND LENGTH
H
J
STAND WIDTH
K
TEMP./PRESS. SENSOR
L
HIGH TEMP. RETURN
M STEAM INLET
N
DAVITED MANWAY
P
WATER INLET
TRAY CLEARANCE
Q
TRAY QTY.
COLUMN WEIGHT (LB)
MODEL NUMBER
A1
B1
C1
D1
E1
F1
G1
TEMP./PRESS. SENSOR
HIGH TEMP. RETURN
STEAM INLET
WATER INLET
DOWNCOMER
MANWAY
VENT PIPE
TM140
200
186
97
60
72
137
144
80
83
20
45
69-1/2
69-1/2
103-1/4
36
42
3700
2800
4700
28000
TM175
218-1/2
188
107-1/2
72
84
135-1/2
142-1/2
88-1/2
91-1/2
21-7/8
44-7/8
69-7/8
69-7/8
107-1/8
36
42
3700
3500
6600
35800
COLUMN CONNECTIONS
TM140
3/4" NPT
4"-150# RFSO
12"-150# RFSO
6"-150# RFSO
16"-150# FFSO
20"
2" NPT
TM175
3/4" NPT
6"-150# RFSO
14"-150# RFSO
6"-150# RFSO
18"-150# FFSO
24"
2-1/2" NPT
H3-8
09-09
Section H
MODEL NUMBER
A
HEIGHT ABOVE STAND
B
OVERALL LENGTH
C
OVERALL WIDTH
D
COLUMN DIAMETER
E
STORAGE TANK DIA.
F
G
STAND LENGTH
H
J
STAND WIDTH
K
TEMP./PRESS. SENSOR
L
HIGH TEMP. RETURN
M STEAM INLET
N
DAVITED MANWAY
P
WATER INLET
TRAY CLEARANCE
Q
TRAY QTY.
COLUMN WEIGHT (LB)
MODEL NUMBER
A1
B1
C1
D1
E1
F1
G1
TEMP./PRESS. SENSOR
HIGH TEMP. RETURN
STEAM INLET
WATER INLET
DOWNCOMER
MANWAY
VENT PIPE
TM300
252
198
130
84
108
137
144
110
113
24-1/4
41-1/4
68-1/4
68-1/4
112-3/8
36
84
7300
6000
11000
61000
TM350
259
205-1/2
130
96
108
144
151
110
113
27-1/2
43
70
70
119-3/8
36
98
8500
7000
11400
69700
COLUMN CONNECTIONS
TM300
3/4" NPT
8"-150# RFSO
18"-150# RFSO
8"-150# RFSO
24"-150# FFSO
28"
3" NPT
TM350
3/4" NPT
8"-150# RFSO
18"-150# RFSO
8"-150# RFSO
30"-150# FFSO
28"
3" NPT
TM400
260-1/2
246
130
108
108
185
192
110
113
28-3/4
44-1/4
71-1/8
69-1/4
102-5/8
36
120
10700
8000
13200
79900
TM450
262-1/2
258-1/2
130
108
108
197
204
110
113
28-3/4
40-1/4
71-1/4
69-1/4
120-5/8
36
132
10900
9000
13700
88700
TM500
262-1/2
304
130
108
108
243
250
110
113
28-3/4
40-1/4
71-1/8
69-1/4
119-5/8
36
144
11100
10000
15700
99000
TM400
3/4" NPT
10"-150# RFSO
20"-150# RFSO
8"-150# RFSO
36"-150# FFSO
36"
3" NPT
TM450
3/4" NPT
10"-150# RFSO
20"-150# RFSO
8"-150# RFSO
36"-150# FFSO
36"
4" NPT
TM500
3/4" NPT
10"-150# RFSO
22"-150# RFSO
10"-150# RFSO
36"-150# FFSO
36"
4" NPT
Table H34. Connections and Trim

MODEL NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
RELIEF VALVE SIZE

OVERFLOW SIZE
DRAIN SIZE
SUCTION SIZE
RECIRC.
THERMOMETER (3/4" NPT)
SAMPLE (1/2" NPT)
CHEM. FEED (1" NPT)
GAUGE GLASS ASSEMBLY
LEVEL CONTROLLER
OVERFLOW DRAINER (OPT)
CONTROL PANEL (OPT)
FEED PUMP/MOTOR (OPT)
SUCTION PIPING (OPT)
MANWAY 12" X 16"
LEVEL ALARMS (OPT)
VACUUM BREAKER

TM030 - TM500
CONTACT YOUR LOCAL CLEAVER-BROOKS AUTHORIZED REPRESENTATIVE
H3-9
09-09
Section H
Figure H3-2. Storage Tank Saddle Footprint
600
TANK DIA. 42
A
79
B
84-1/2
C
34-1/2
D
46
E
5-3/4
F
7/8
900
48
94
100
38
48
5
1-1/8
TANK CAPACITY (GAL.)

1400
2000
2500
2800
3500
4000
4500
60
66
72
72
84
84
96
113-1/2 113-1/2 138 136-1/2 138
128
95
101 119-1/2 119-1/2 144 142-1/2 144
134
44-3/4
50
70
70
62
62
72
57
66
52
52
82
82
92
6-1/8
8
9
9
10
10
10
1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8
H3-10
09-09
5000
96
138
144
72
92
10
1-1/8
6000
7000
8000
9000 10000
108
108
108
108
108
138
145
186
198
244
144
151
192
204
250
83
83
83
83
83
104
104
104
104
104
10-1/2 10-1/2 10-1/2 10-1/2 10-1/2
1-1/8 1-1/8 1-1/8 1-1/8 1-1/8
Section H
Payback for a pressurized deaerator versus an atmospheric boiler feed system is based on
an additional capital expenditure required divided by the yearly operating cost savings.
The differential in yearly operating costs are in the following areas:
Flash steam
Exhaust steam
Blowdown
Chemical treatment
Makeup water
Sewer
Intangibles
Flash Steam
A percentage of the high-pressure condensate returns will flash to steam and be lost in an
atmospheric vessel application. This flash steam loss can be converted to an energy loss
and associated fuel cost.
Exhaust Steam

Surface Blowdown
system.
Chemical Treatment


ppm of dissolved O2
2Na2SO3 + O2
2Na2SO4
Makeup Water
Sewer
Intangibles
H3-11
09-09
Section H
NOTES
H3-12
09-09
Section H3
Traymaster Series Deaerators
Packaged Deaerator Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-14
Deaerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-14
Deaerator Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-14
Deaerator Load Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-15
Deaerator Standard Trim and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-15
Deaerator Make-Up Valve and Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-15
Deaerator Steam Pressure Reducing Valve (PRV) Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-16
Deaerator Safety Relief Valve(s) (SRV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-17
Deaerator Water Level Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-17
Deaerator Overflow Drainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-17
Deaerator Suction Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-17
Boiler Feedwater Pump And Motor Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-17
Deaerator Support Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-18
Deaerator Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-18
Electric Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-18
Deaerator Preparation and Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-18
Deaerator Manuals and Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-19
H3-13
09-09
Section H
PART 1 GENERAL
1.1
PACKAGED DEAERATOR SPECIFICATION

A. Provide one Cleaver-Brooks Model TM _________ tray type,
pressurized, deaerator rated at _____ pounds per hour. The system shall
be of the two tank design and shall guarantee oxygen removal to not
more than 0.005 ccs/liter (7 ppb) in the effluent throughout all load
conditions between 5 and 100 percent. The deaerator shall be designed
for operation at 5 PSIG, but shall be suitable for use from 2 to 15 PSIG.
PART 2 PRODUCTS
2.1
DEAERATOR
A. A vertically oriented deaerator section shall be Y ft. -Y.1 in. x Z ft. - Z.1
in. shell length. The deaerator shall be of the counter flow design.
Undeaearated water shall enter through the top of the column into a true
Internal Direct Contact Vent Condenser. Units not implementing a True
Internal Direct Contact Vent Condenser shall not be accepted. The
water shall be evenly sprayed through a spring-loaded, self-cleaning,
adjustable stainless steel spray valve(s) over the trays. The valves shall
be constructed of type 304 stainless steel material. Trays shall be all
riveted construction using 16 gauge type 430 Stainless Steel material.
Welded trays shall not be accepted. Trays shall be stacked within a
stainless steel tray box with a minimum thickness of 1/4". The tray box
shall be constructed using type 304 Stainless Steel material. The tray
box shall include a wear plate at the saturated steam inlet area to ensure
durability. The tray box shall have an access door for ease of inspection
of the trays. This access area to the tray box shall be through a X in.
round davited manhole located on the shell of the deaerator. The tank
shall be designed in accordance with ASME, Section VIII of the
Pressure Vessel Code for 50 PSIG at 650 F and stamped accordingly.
Connections shall include steam inlet, vent, water inlet, high
temperature return, and downcomer to the storage vessel. Unit shall
provide proper internal vent condensing and water distribution at any
load between 5 and 100 percent of rated capacity.
B. All internal surfaces, which come in contact with un-deaerated water,
shall be constructed of stainless steel. Automatic vent valve shall be
thermostatically controlled to provide a fast means of venting when a
sudden buildup of gases occurs, such as seen at start up. The manual
vent valve shall have an orifice for continuous minimum venting.
Venting rate shall not exceed 0.1 of 1% of the rated deaerator capacity at
5 PSIG.
2.2
DEAERATOR VESSEL
A. The deaerated water storage tank shall have _____ minutes of storage
and have a capacity of_____ gallons measured to overflow. The tank
shall be _____ diameter x ____ long. An 12 x 16 elliptical manhole shall
be provided for access. All nozzles 3" and under shall be 3000 lbs forged
steel couplings and over 3" shall be 150 LB. flat face flanges. Heads to
be ASME torispherical type constructed of ASTM A516 GR 70 carbon
steel with a minimum thickness of 0.25 inches. Shell plate to be
fabricated of ASTM A36 carbon steel with a minimum thickness of 0.25
inches. The tank shall be designed in accordance with ASME, Section
VIII of the Pressure Vessel Code for 50 PSIG at 650 F and stamped
accordingly. Certification shall be required. Joint efficiencies to be 70%
circumferential per Table UW-12, which does not require stress
relieving or nondestructive examination.
H3-14
09-09
Section H
The tank shall be factory-insulated and lagged with blanket insulation, pins, clips, and a
durable steel jacket. The blanket insulation is to be fiberglass, 2" thick, 1 LB/CU-FT, and
have a rating of R3.85. Pins are to be located on 18" centers and holding clips attached.
The steel jacket or lagging shall have a shell thickness of 22 gauge (0.299") minimum
and head thickness of 12 gauge (0.1046") minimum.
The magnesium or sacrificial anode shall provide cathodic protection against galvanic
corrosion. This rod shall be 1-5/16" diameter with a 1/4" steel core to assure a good
electrical contact and added strength. The design shall have a small weep hole to signal
it has been consumed.
The high temperature diffuser or sparge tube shall be located beneath the normal tank
water level. The tube shall be constructed of 2-1/2 inch pipe. This tube shall provide
even distribution and blending of high-temperature condensate returns.
The chemical feed quill shall be located beneath the normal tank water level. The quill
material shall be constructed of stainless steel. The tube shall provide even distribution
and blending of chemical.
2.3
DEAERATOR LOAD SPECIFICATION
The surge tank loads shall be as specified in the following table.
LOAD
PERCENTAG
E
LBS/HR
TEMP
PRESSURE
Make up
Low Temp Returns
(<210 F)
Medium Temp
Returns (211 230F)
High Temp Returns
(>230F)
2.4
DEAERATOR STANDARD TRIM AND ACCESSORIES

A. The basic deaerator shall be equipped with the following trim and
accessories. Piping on packaged units shall comply with ASME Power
Piping Code B31.1.
2.5
DEAERATOR MAKE-UP VALVE AND CONTROLLER

A. ____ " inlet water regulating lever valve with ______ body and
_______ connections. Rated for _____ GPM at ______ PSIG inlet
pressure. This valve shall be suitable for temperatures up to 300 F. The
valve manufacture shall be _______, Model _____ . This valve shall be
mechanically controlled by an external float cage with cast iron body
and 8" stainless steel float. The float cage manufacturer shall be
__________, Model ______.A McDonnell & Miller 93-7B level
controller shall electronically control the make-up valve.
H3-15
09-09
Section H
B.
C.
D.
2.6
______" inlet water motorized regulating valve with steel body and
threaded NPT connections. Motor shall be 110V bi-directional, with a
permanently lubricated gear train, and be directly coupled to the valve
stem. Rated for_____ GPM at ______ PSIG inlet pressure. This valve
shall have teflon seats and be suitable for temperatures up to 300 F.
The motorized valve manufacturer shall be __________. This valve
shall be electronically controlled by a solid state control with internally
mounted capacitance probes. The electronic solid state control shall be
able to set desired level point and acceptable deviation. The electronic
solid state control shall include a selection for automatic and manual
operating mode. The internals shall include two additional probes for
high and low water alarm. The controller manufacturer shall be Model
TW82.
_______" inlet water diaphragm actuated regulating valve with cast iron
body and _____ connections. The valve shall be globe type with
proportional control and a spring opposed diaphragm actuator arranged
for 3 - 15 PSIG operating signal. The valve shall be normally open on
loss of air. Rated for ______ GPM at ______ PSIG inlet pressure This
valve shall have stainless steel trim with TFE packing and be suitable
for temperature up to 410 F. The diaphragm actuated valve
manufacturer shall be ___________, Model _____. This valve shall be
pneumatically controlled by an external proportional type sensor. The
sensor shall be a 14" displacer that produces a pneumatic output signal.
The controller manufacturer shall be _________, Model ______. A
filter regulator is to be provided to reduce 50 PSIG instrument air
supply to 3 - 15 PSIG for proper operation.
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
DEAERATOR STEAM PRESSURE REDUCING VALVE (PRV)

STATION
A. _______" steam pressure reducing valve with cast iron body and _____
connections. The valve shall be a self-contained unit capable of
reducing ____ PSIG saturated steam to the operating pressure of the
deaerator at a flow rate of _____ LB./HR. The valve shall be 250 lb
class with stainless steel trim and an adjustable pilot. The valve
manufacturer shall be _____, Model _____.
B. _______" diaphragm actuated steam pressure reducing valve with cast
iron body and _______ connections. The valve shall be globe type with
proportional control and a spring opposed diaphragm actuator arranged
for ____ PSIG operating signal. The valve shall be normally closed on
loss of air. The valve shall be capable of reducing _____ PSIG saturated
steam to the operating pressure of the deaerator at a flow rate of ____
LB./HR. This valve shall be 250 LB class and have stainless steel trim.
The diaphragm actuated valve manufacturer shall be ________, Model
_______. This valve shall be pneumatically controlled by an external
transmitter. The transmitter set pressure shall be adjustable. The
transmitter manufacturer shall be _________________, Model
_________.
C. The steam pressure reducing valve shall include a three valve bypass
with Y-type cast iron strainer. Strainer screen to be removable and of
stainless steel construction.
H3-16
09-09
Section H
2.7
DEAERATOR SAFETY RELIEF VALVE(S) (SRV)

A. Quantity ______, _______ " relief valves sized to relieve full capacity
of the pressure reducing valve in the event of its failure. Valves to meet
Paragraph UG-125 of ASME Unfired Pressure Vessel Code, Section
VIII. Valve body to be of __________ construction. Relieving set
pressure to be 50 PSIG. Relief valve manufacturer to be
_______________________, Model ____________.
2.8
DEAERATOR WATER LEVEL ALARMS

A. High Level Alarm - NEMA 1 This shall be an externally mounted float
type switch. The switch shall make contact on rise and break on fall.
The float cage construction shall be cast iron.
B. Low Level Alarm - NEMA 1 This shall be an externally mounted float
type switch. The switch shall make contact on fall and break on rise.
The float cage construction shall be cast iron.
2.9
DEAERATOR OVERFLOW DRAINER

A. ________ " overflow drainer sized to relieve full capacity at the
operating pressure of the deaerator. The overflow drainer shall be a float
type trap. The construction is to be a steel housing with stainless steel
float ball. The overflow drainer manufacturer shall be _______, Model
_______.
2.10
DEAERATOR SUCTION PIPING

A. Suction piping for pumps shall consist of a __ gate valve, cast iron Ytype strainer with replaceable stainless steel screen and flexible
connector or hose. This piping assembly shall be 125 LB class
construction. The vortex breaker shall be located in the tank nozzle.
2.11
BOILER FEEDWATER PUMP AND MOTOR SET

A. Intermittent - Intermittent Quantity ________, turbine type boiler
_____ feet TDH with ______ feet NPSH required. Pump to be ______
materials of construction and have ______ seals for a maximum water
temperature of 250 F. Pump impeller to be hydraulically balanced. The
pump shall be mounted on a steel baseplate and flexibly coupled with
an OSHA type coupling guard to a ____ HP, _____ phase, ______ Hz,
______ Volt, _______ RPM, ________enclosure motor. Motor to be
non-overloading at the rated condition without using any portion of the
service factor. Pump and motor set to be factory aligned prior to
shipment. Pump manufacturer to be ______________, Model
________, size ____ " x _______".
H3-17
09-09
Section H
B.
Continuous - Continuous Quantity ______, centrifugal type boiler

______ 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
_______ ".
A stainless steel recirculation orifice is to be supplied with the pump and shipped loose
for field installation to provide minimum bypass flow.
2.12
DEAERATOR SUPPORT STAND

A. The ___ feet high stand shall elevate the deaerator tank to provide 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.
2.13
DEAERATOR CONTROL PANEL

A. Control panel shall be in a NEMA 1 enclosure and wired to the National
Electric Code. The wire shall be black number coded. The assembly is
to contain individual motor starters with 120 Volt holding coil and fuse
protection. Individual green oil-tight pump run lights shall be provided.
All switches and lights to have nameplate identification. The assembled
panel shall be given a factory continuity test prior to shipment.
2.14
ELECTRIC COMPONENTS
A. Audible and visual high and low water alarm function shall be provided
by a bell or horn with silence switch and individual red oil-tight lights.
Control circuit transformer to supply 110-120 Volts, single-phase power
supply. The transformer shall be mounted, wired and fused. Auxiliary
contacts shall be furnished for chemical feed pump initiation. Contacts
shall be normally open.
B. The deaerator shall have a gauge glass assembly that covers the entire
tank diameter. The gauge glass shall be quartz, 0.625 inch diameter by
24 inch maximum length. Each length of glass shall be furnished with a
bronze gauge cock set and protector rods. The deaerator shall be
supplied with a pressure gauge that has a 4-1/2 inch dial with a 0-60
PSIG range and a thermometer with a 50 to 300 F range. Packaged
units are required to have both gauges bracket-mounted at eye level.
2.15
DEAERATOR PREPARATION AND PACKAGING

A. The deaerator is to be hand cleaned with a solvent to SSPC- SP-1
standards prior to painting. Prime coated to not less than 1 mil thick and
finish coated with an enamel paint to not less than 1 mil thick prior to
shipment.
B. Unit is to be knocked down for shipment. Piping is to be matched
marked.
H3-18
09-09
Section H
2.16
DEAERATOR MANUALS AND WARRANTY

A. Three, bound, Operating and Maintenance manuals to be provided.
Warranty period to be twelve months after start-up or eighteen months
after shipment, whichever comes first.
H3-19
09-09
Section H
NOTES
H3-20
09-09
Section H4
BOILERMATE DEAERATORS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-3

ILLUSTRATIONS
Figure H4-1. Cleaver-Brooks Boilermate Deaerator Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-7
Figure H4-2. Boilermate Deaerator Dimensions and Ratings - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . H4-8
Figure H4-3. Boilermate Tank Supports and Saddles, Details and Dimensions . . . . . . . . . . . . . . . . . . . . . . H4-10
H4-1
09-09
Boilermate Deaerators
Section H
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.
H4-2
09-09
Section H

The following features and benefits apply to the Boilermate Deaerator product line. The
Boilermate design uses a packed column to deaerate the water.
Less Mechanical Movement of Deaerator Components:
The water spray valve is the only internal moving component within the deaerator
vessel.

requirements.
Maintains deposit-free surface.
Internal Automatic-Check Valve Prevents Steam Back-Flow:
The water spray valve is normally closed at no flow.
Prevents steam back flow through the water spray valve at no flow conditions.
Saves Btus that would normally be exhausted to atmosphere.
Improves plant efficiency.
Auto Vent Valve Eliminates Gases at Start-Up:
H4-3
09-09
Section H
Cleaver-Brooks deaerator is guaranteed to remove oxygen concentrations to 0.005

cc/liter while operating between 5 and 100%capacity.
Carbon dioxide concentration is practically reduced to a zero.

Saves Btus by accepting condensate before cold make-up water. Maintains a

Provides flexibility for selecting a tank for specific applications to limit the loss of
Complete packages are pre-fabricated in the Cleaver- Brooks manufacturing facility

to ensure piping alignment and control wiring function. The unit is partially
disassembled, match marked for efficient field re-assembly.
PRODUCT OFFERING
Information in this section applies directly to Cleaver-Brooks packaged boilermate
deaerators ranging from 1,500 lbs/hr at 50 F makeup to 135,000 lbs/hr at 200 F makeup. Larger capacities can be obtained by using two columns. The Boilermate deaerator
product offering is shown in Figure H4-1.
The Boilermate deaerator is a pressurized packed column, low maintenance system
designed to remove dissolved oxygen in boiler feed water to 0.005 cc per liter or less and
eliminate carbon dioxide. A typical deaerator package includes the packed column and
storage tank mounted on a stand of appropriate height along with all operating controls,
feed pumps assembled and piped (typically knocked down for shipment and field
assembly). The tank conforms to Section VIII of the ASME Code.
The packed column design is best for handling high-temperature returns. The column is
constructed of a carbon steel casing with a stainless steel liner. Built into a flange on top
of the column is a spring loaded self-cleaning water spray nozzle and an automatic and
manual vent valve.
From experience, large industrial plants and utilities have learned that the most practical
and economical way to remove oxygen from feedwater is through mechanical
deaeration. The Boilermate deaerator economically effects oxygen removal through a
design that is trouble free in performance.
Raw water, untreated and not deaerated, contains as much as ten cubic centimeters of
corrosion-causing oxygen per liter. Oxygen in water corrodes and shortens the life of
boiler feed lines, boilers and condensate return lines.
H4-4
09-09
Section H
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 proved
to most effective and economical to every boiler owner. Contact your local CleaverBrooks authorized representative for component and sizing information.
The design of the Boilermate deaerator offers simplicity in both operation and service.
The exchange packing, the heart of the deaerator, requires no maintenance. There are no
moving parts to adjust or maintain. Installation is simple and quick.
Standard Equipment
Boilermate column.
Stainless steel exchange packing.
Gauge glass.
Deaerator manual and automatic vent valve.
Feed water thermometer.
Required tappings.
Optional Equipment
High water alarm.
Low water alarm.
High-temperature condensate diffuser tube (over 227 F).
Suction strainer.
Discharge manifold.
Overflow drainer.
Control panel.

H4-5
09-09
Section H
Vacuum breaker.
Tank drain valve.
Stand.
Packaging
by others.

Dimensions and ratings for Boilermate Deaerators are shown in Figure H4-2 and Figure
H4-3.
H4-6
09-09
Section H
140
140
120
120
100
100
80
80
60
60
36
MODEL
INLET CAPACITY - LBS/HR X 1000 WATER
42
30
40
40
24
20
20
20
16
12
8
50
70
110
90
150
130
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
250
350
410
560
960
1,275
1,810
2,390
Weight (lbs)
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.
Figure H4-1. Cleaver-Brooks Boilermate Deaerator Selection Guide

H4-7
09-09
Section H
(9" FOR MODEL 8 & 16)

.5" NPT AUTO.
VENT VALVE
"D" NPT. MANUAL
VENT VALVE
B
B
2" NPT. INSPECTION

PORT (PLUGGED)
(1.5" NPT. FOR
MODELS 8 & 12)
"C"
"A"
"S"
"T"
2 DIA. HOLE
IN LIFTING LUGS
"E"
"F" "G" "J" "H" "K" "L"
(NOTE 18)
20
"R"
(NOTE 12)
TANK
DIA.
12
"P"
21
13
10
14
5
"M"
(NOTE 1)
15
11 (NOTE 2)
18
17 (NOTE 3)
STAND HEIGHT
VARIES PER
PROJECT
REQUIREMENTS
16
19 (NOTE 4)
"D4"
"C3"
"B2"
(4) "E5"E HOLES

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.
prints.
11. Add suffix "P" to Model no. for packaged units (BMP-24).
12. Dimension "R" will change depending on controls required- contact your local Cleaver-Brooks authorized representative.
13. No interconnecting piping or wiring furnished on non-packaged units unless specified, contact your local Cleaver-Brooks authorized 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.
A
Height
Water Inlet (150# RF Flg)
Column Outside Diameter
12
16
20
24
30
36
42
46
48.5
58
62
64
71.5
78.5
80
1.25
1.5
1.5
2.5
8.63
12.8
16
20
24
30
36
42
.5" NPT
.5" NPT
.75" NPT
.75" NPT
.75" NPT
1" NPT
1.5" NPT
2" NPT
Column Weight (lb)
250
350
450
600
750
850
1050
1300
Volume Packing (Cu ft)
0.7
1.6
3.0
5.0
8.0
12.0
18.0
29.0
Packing Weight (lb)
25
50
150
200
300
450
650
1050
Figure H4-2. Boilermate Deaerator Dimensions and Ratings - Sheet 1 of 2

H4-8
09-09
Section H
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
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
Level Alarm
23
26
45
50
High Temp Return
35
21
39
43
Level Control
42
41
61
69
Relief Valve
48
50
69
77
Relief Valve
N/A
60
79
86
Relief Valve
N/A
N/A
N/A
95
Drain
36
47
76
93
Overflow
Rear Hd
60
10
10
Overall Width
39
51
51
63
Front Head
10
Column
8.5
8.5
69
75
11
22
12
101
STANDARD DIMENSIONS
A1
Overall Length
54
61
86
B2
49
56
80
95
C3
Overall Width
42
49
64
71
D4
39
46
61
68
E5
Hole Size
0.75
1.125
F6
Anchor Bolt Size
0.625
0.875
0.875
CONNECTIONS & TRIM

1
Relief Valve Size
Overflow Size
1.25" NPT
2" NPT
Steam Inlet Size
2" NPT
3" NPT
Suction Size
3" NPT
3" NPT
3" NPT
4"-150# FF
High Temp Return Size
1" NPT
1.5" NPT
2" NPT
3" NPT
Drain Size
2" NPT
2" NPT
2" NPT
2" NPT
Recirc (1" NPT)
Thermometer (.75" NPT)
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)
Contact your local Cleaver-Brooks authorized representative

3" NPT
4"-150# FF
6"-150# FF
3" NPT
6"-150# FF
Figure H4-2. Boilermate Deaerator Dimensions and Ratings - Sheet 2 of 2

H4-9
09-09
Section H
TANK SUPPORT LEGS
SADDLES
STANDARD ON 110, 330,

430 & 800 GALLON TANKS
FRONT HEAD
STANDARD ON 1070 &

1500 GALLON TANKS
FRONT HEAD
"E"
"A"
"A"
"E"
(4) 1.125"E HOLES

FOR .75" E BOLTS
(4) .875" E HOLES

FOR .75" E BOLTS
"D" "C"
"C" "D"
"H"
"F"
6
"F"
"B"
"G"/2
"B"
"G"
TANK CAPACITY (GAL.)

MODEL
110
330
430
LEGS
800
1070
1500
SADDLES
48.5
55.5
80
95
54
61
85.5
86.5
101
22.5
29.5
29.5
38
44.75
24.25
31.25
31.25
40
51.5
57
11
15
15
17
16
17
0.875
0.875
0.875
3.38
6.13
5.5
5.5
5.5
6.5
N/A
9.75
N/A
Figure H4-3. Boilermate Tank Supports and Saddles, Details and Dimensions
H4-10
09-09
Section H
Payback for a pressurized deaerator verses an atmospheric boiler feed system is based on
an additional capital expenditure required divided by the yearly operating cost savings.
The differential in yearly operating costs are in the following areas:
Flash steam
Exhaust steam
Blowdown
Chemical treatment
Makeup water
Sewer
Intangibles
Flash Steam
A percentage of the high-pressure condensate returns will flash to steam and be lost in an
atmospheric vessel application. This flash steam loss can be converted to an energy loss
and associated fuel cost.
Exhaust Steam

Surface Blowdown
system.
Chemical Treatment


ppm of dissolved O2
2Na2SO3 + O2
2Na2SO4
Makeup Water
Sewer
Intangibles
H4-11
09-09
Section H
NOTES
H4-12
09-09
Section H4
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-14
Deaerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-14
Boiler Feedwater Pump and Motor Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-17
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-18
H4-13
09-09
Section H
PART 1 GENERAL
1.01
GENERAL
specifying your customers specific needs and application
PART 2 PRODUCTS
2.01
HARDWARE
A. Deaerator
1. Cleaver-Brooks Model _________ packed column type,
pressurized, horizontal deaerator is rated at _____ pounds per hour
at ____ F mixed inlet water temperature. The system shall be of
the single tank design and guarantee oxygen removal to not more
than 0.005 CCS/liter in the effluent throughout all load conditions
between 5 and 100 percent. Tray-type designs are not acceptable.
The deaerator shall be designed for operation at 5 psig, but shall be
suitable for use from 2 to 15 psig. Atmospheric operating designs
are not acceptable.
2. Feedwater and condensate shall be admitted to the deaerator
through a single spring-loaded, self-cleaning, adjustable stainless
steel spray valve, which shall provide proper internal vent
condensing and water distribution at any load between 5 and 100
percent of rated capacity. The water temperature in the primary
heating and vent concentrating section is to be raised within 2 or 3
F of steam temperature and most of the gases released. The water
is then to drop down through the columns stainless steel exchange
packing counterflow to the steam, which enters at the top of the
storage tank and rises up through the column. The column is to be
____" in length and ____ " in diameter. The column shall have a
stainless liner and grid support. Hot, gas-free water is to then drop
to the storage 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
contact with un-deaerated water, shall be constructed of Type 316
stainless steel.
3. Automatic vent valve shall be thermostatically controlled to
provide a fast means of venting when a sudden buildup of gases
occurs, such as seen at start up. The manual vent valve shall have
an orifice for continuous minimum venting. Venting rate shall not
exceed 0.1 of 1% of the rated deaerator capacity at 5 psig.
Load Specifications
LOAD
PERCENTAGE
LBS/HR
TEMP
PRESSURE
Make up
25 psig Minimum
10 psig Minimum
High Temp Returns
Not To Exceed 30%
H4-14
09-09
Section H
4.
B.
The deaerated water storage tank shall have _____ minutes of

storage and have a capacity of _____ gallons measured to
overflow. The tank shall be _____ diameter x _____ long. An 11" x
15" elliptical manhole shall be provided for access. All nozzles 3"
and under shall be 3000 lbs forged steel couplings and over 3" shall
be 150 lbs flat face flanges. Heads to be ASME torispherical type
constructed of ASTM A516 GR 70 carbon steel with a minimum
thickness of 0.25 inches. Shell plate to be fabricated of ASTM A36
carbon steel with a minimum thickness of 0.25 inches. The tank
and column shall be designed in accordance with ASME, Section
VIII of the Pressure Vessel Code for 50 psig at 650 F and stamped
accordingly. Certification shall be required. Joint efficiencies to be
70% circumferential per table UW-12, which does not require
stress relieving or nondestructive examination.
5. The deaerator loads shall be as specified in the table below. Low
below that of the deaerator operating temperature. High
above that of the deaerator operating temperature.
6. Optional - The tank and column shall be factory-insulated and
lagged with blanket insulation, pins, clips, and a durable steel
jacket. Block-type insulation is not acceptable. The blanket
insulation is to be fiberglass, 2" thick, 1 lb/cubic foot, and have a
rating of R3.85. Pins are to be located on 18" centers and holding
clips attached. The steel jacket or lagging shall have a shell
thickness of 22 gauge (0.299") minimum and head thickness of 12
gauge (0.1046") minimum.
7. Optional - The magnesium or sacrificial anode shall provide
8. Optional - The high temperature diffuser or sparge tube shall be
constructed of 2 inch pipe. This tube shall provide even
distribution and blending of high-temperature condensate returns.
10. Optional - The basic deaerator shall be equipped with the
1. Option (Mechanical) - ___ " inlet water regulating lever valve 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
H4-15
09-09
Section H
C.
cage manufacturer shall be _______________, Model ______.
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
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
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
valve manufacturer shall be ________, Model _____. This valve
shall be pneumatically controlled by an external proportional type
sensor. The sensor shall be a 14" displacer that produces a
pneumatic output signal. The controller manufacturer shall be
_________ , Model ______. A filter regulator is to be provided to
reduce 50 psig instrument air supply to 3 - 15 psig for proper
operation.
Steam Pressure Reducing Station
an adjustable pilot. The valve manufacturer shall be _____ Model
_____.
H4-16
09-09
Section H
2.
D.
Option (Pneumatic) - _______" diaphragm actuated steam pressure

reducing valve with cast iron body and _______ connections. The
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
_______.
manufacturer to be ___________________ , Model ______.
manufacturer shall be ____________, Model _______.
Boiler Feedwater Pump and Motor Set
1. Option (Intermittent) - Quantity________, turbine type boiler
to a ____ hp, _____ phase, ______ Hz, ______ Volt, _______ rpm,
________enclosure motor. Motor to be non-overloading at the
rated condition without using any portion of the service factor.
H4-17
09-09
Section H
E.

manufacturer to be_____________, Model ________, size ____ "
x _______".
______ feet TDH with ____ feet NPSH required. Pump to be
flexibly coupled with an OSHA type coupling guard to a _____
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.
Control Panel
a. Control circuit transformer to supply 110-120 volts, singlephase power supply. The transformer shall be mounted,
wired and fused.
3. Standard
a. The deaerator shall have a gauge glass assembly that covers
the entire tank diameter. The gauge glass shall be quartz
0.625 inch diameter by 24 inch maximum length. Each
length of glass shall be furnished with a bronze gauge cock
set and protector rods.
H4-18
09-09
Section H
b.
c.
d.
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 SSPCSP-1 standards prior to painting. Prime coated to not less than
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.
H4-19
09-09
Section H
Notes
H4-20
09-09
Section H5
SURGE TANKS
CONTENTS

ILLUSTRATIONS
Figure H5-1. Surge Tank Dimensions and Ratings - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-5

Figure H5-2. Surge Tank Supports and Saddles, Details and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . H5-7
TABLES
Table H5-1. Surge Tank Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-3
H5-1
09-09
Surge Tanks
Section H
This section contains information on the complete line of surge tanks ranging in sizes from 300 to 3000 gallon
capacities.
The Cleaver-Brooks Surge Tank products provide additional storage time and handle volume swings in condensate
returns. Because condensate return volume is largely unpredictable, a surge tank provides a means to collect
intermittent condensate returns and supply water at a relatively constant volume, while limiting discharge to drain.
Contact your local Cleaver-Brooks authorized representative for component sizing information.
H5-2
09-09
Section H
Surge Tanks

The following features and benefits apply to Cleaver-Brooks Surge Tank Products.
ASME Heads:
Assures vessel quality in materials and fabrication.
1/4" Thick (Minimum) Shell:
Quality construction.
Longer material life.
Boosts Condensate Return Pressure:
Acts as a collecting point for low pressure and gravity returns.
Allows pumping of returns to a pressurized vessel.
Accepts Gravity Returns:
Vessels are vented to atmosphere, therefore providing no pressure resistance that

would inhibit gravity return.
PRODUCT OFFERING
Information in this section applies directly to Cleaver- Brooks package surge tanks
ranging from 300 to 3,000 gallon capacity. Contact your local Cleaver-Brooks authorized
representative for larger capacities. The product offering for surge tanks is shown in
Table H5-1.
Surge tanks can reduce dependance on cold, untreated raw water to replace boiler system
losses, by collecting condensate for re-use in the boiler. Dedicated surge tanks are
required when intermittent peak loads of condensate can exceed the surge capacity of the
deaerator.
The surge tank receives returning condensate and is supplemented by raw make-up water
to maintain the desired operating level. Condensate and make-up water mix into a blend
temperature as determined by the percentage of each. The surge tank is vented to
atmosphere.
Surge tanks are designed to work with the deaerator. They can be packaged with transfer
pumps, stand and controls of the same sturdy construction as the deaerator. Custom
Table H5-1. Surge Tank Product Offering
MODEL NO.
FLOODED CAPACITY (GAL.)
SRG-300
300
SRG-450
450
SRG-600
600
SRG-900
900
SRG-1200
1200
SRG-1400
1400
SRG-1600
1600
SRG-2000
2000
SRG-2500
2500
SRG-3000
3000
NOTE: Model number (example, SRG-300) is: SRG = surge tank.

300 = 300 gal. capacity.
H5-3
09-09
Surge Tanks
Section H
arrangements are also available. Contact local Cleaver-Brooks authorized representative
for component and sizing information.
Surge tanks provide additional storage time and handle volume swings in condensate
return. Surge tanks are used when gravity or pumped condensate returns do not have
enough pressure to enter the deaerator on their own. Water and treatment costs are
reduced by recycling condensate that has already been treated.
Integral control automatically introduces cold water makeup to supplement condensate
only when necessary to meet boiler demand. This translates into reduced fuel costs for
heating boiler feedwater.
Standard Equipment
Surge tank.
Thermometer.
Gauge glass.
Required tappings, and manway.
Optional Equipment
ASME code tank.
Three valve bypass and strainer.
Suction strainer.
Discharge manifold.
High water alarm.
Low water alarm.
Condensate diffuser tube.
Control panel.
Transfer pump and motor.
Drain valve.
Stand.
Packaging
by others.
H5-4
09-09
Section H
Surge Tanks

Dimensions and ratings for surge tanks are shown in Figure H5-1 and Figure H5-2.
NOTES:
1. Mounted on packaged units only.
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 representative.
10. 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.
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
1-1/8
1-1/8
FZ
7/8
7/8
7/8
7/8
7/8
7/8
7/8
7/8
Figure H5-1. Surge Tank Dimensions and Ratings - Sheet 1 of 2
H5-5
09-09
Surge Tanks
Section H
STORAGE TANK DETAIL AND DIMENSIONS

Tank Capacity (gal)
300
450
600
900
1200
1400
1600
2000
2500
3000
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
12
20
12
14
15
15
15
23-1/2
23
30
34
52
34
43
37
41
36
32
32-1/2
45
52
68
50
55
51
59
52-1/2
40
42
60
69-1/2
91-1/2
66
75
64-1/2
84-1/2
70-1/2
57-1/2
59
82
91-1/2
123-1/2
88
104
86-1/2
110-1/2
91-1/2
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
9-1/2
11
14
14
28
14
21
17
19
16
54
54
76
89-1/2
115-1/2
86
97
84-1/2
106-1/2
90-1/2
11
14
14
16
15
20-1/2
20-1/2
25-1/2
29-1/2
31
10
10
10
12-1/2
12-1/2
19-1/2
19-1/2
25
25
30
51
57
57
63
63
75
75
87
87
99
TANK CONNECTION SIZES

300
450
600
900
1200
1400
1600
2000
2500
3000
Low Pressure Return (2)
Tank Capacity (gal)
3 NPT
3 NPT
3 NPT
3 NPT
4 NPT
4 NPT
4 NPT
4 NPT
4 NPT
4 NPT
Vent
3 NPT
3 NPT
3 NPT
3 NPT
4 NPT
4 NPT
4 NPT
4 NPT
4 NPT
4 NPT
Cold Water Inlet
1-1/4
NPT
1-1/4
NPT
1-1/4
NPT
1-1/4
NPT
1-1/4
NPT
1-1/4
NPT
1-1/4
NPT
1-1/4
NPT
1-1/4
NPT
1-1/2
NPT
3 NPT
3 NPT
3 NPT
3 NPT
4 NPT
4 NPT
4 NPT
4 NPT
4 NPT
4 NPT
Overflow Connection
Pump Suction (For Each Pump)
High Temperature Return (3 NPT)
Suction Piping (Optional) (For Each Pump) (Note 2)
Pump/motor (Optional)

ITEM LIST
Manway (11 X 15)
10
Diffuser Tube (2-1/2 NPT) (Optional)
11
Makeup Valve (Optional)
12
13
Control Panel (Optional)
14
Drain (2 NPT)
15
Thermometer (3/4 NPT)
16
Level Alarms (1 NPT (Optional)
17
Level Control (1-1/2 NPT) (Optional)
18
Recirculating Connection (1 NPT) (For Each Pump)
Sizes Listed for items15 thru 18

are for Tank Connections Only.
Figure H5-1. Surge Tank Dimensions and Ratings - Sheet 2 of 2
H5-6
09-09
Section H
Surge Tanks
VENT CAPACITY CHART

SIZE (NPT)
CAPACITY
(lbs/hr)
175
1-1/4
350
1-1/2
525
1000
2-1/2
1600
300
450
600
900
1200
1400
1600
2000
2500
3000
AA
55-1/2
55
79
93-1/2
N/A
N/A
N/A
N/A
N/A
N/A
AB
59-1/2
59
83
99-1/2
N/A
N/A
N/A
N/A
N/A
N/A
AC
31-3/4
36-3/4
36-3/4
40-1/2
N/A
N/A
N/A
N/A
N/A
N/A
AD
29-1/2
34-1/2
34-1/2
38
N/A
N/A
N/A
N/A
N/A
N/A
AE
6-1/8
6-1/8
7-1/4
N/A
N/A
N/A
N/A
N/A
N/A
AF
N/A
N/A
N/A
N/A
N/A
N/A
2800
AG
N/A
N/A
N/A
N/A
N/A
N/A
4800
AH
5/8
3/4
3/4
3/4
N/A
N/A
N/A
N/A
N/A
N/A
10500
17000
35000
AJ
12-1/2
14-1/2
15
15-1/2
N/A
N/A
N/A
N/A
N/A
N/A
AK
3/4
7/8
7/8
7/8
N/A
N/A
N/A
N/A
N/A
N/A
AL
N/A
N/A
N/A
N/A
4-1/4
6-1/8
6-1/8
7-1/2
7-1/2
7-3/4
AM
N/A
N/A
N/A
N/A
115-3/4
88
102-1/2
89-1/2
113-1/2
94-1/2
AN
N/A
N/A
N/A
N/A
121-3/4
94
108-1/2
95-1/2
119-1/2
100-1/2
AP
N/A
N/A
N/A
N/A
46-1/2
57
57
67
67
77-1/2
AR
N/A
N/A
N/A
N/A
38
44-3/4
44-3/4
52
52
62
AS
N/A
N/A
N/A
N/A
24-1/2
18-1/2
20-1/4
20-1/2
20-1/2
21-7/8
Values given based on:

1) 50 ft. equivalent pipe length.
2) Schedule 40 pipe
3) 2 psi back pressure
4) Vent capacities should be compared with anticipated venting
needs. Oversized vents are available.
Figure H5-2. Surge Tank Supports and Saddles, Details and Dimensions
H5-7
09-09
Surge Tanks
Section H
Notes
H5-8
09-09
Section H5
Surge Tanks
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-10
Surge Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-10
Transfer Pump and Motor Set (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-12
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-12
specific needs and application
H5-9
Surge Tanks
Section H
PART 1 GENERAL

specifying your customers specific needs and application
PART 2 PRODUCTS
1.1
HARDWARE
A. Surge Tank
1. Cleaver-Brooks Model _________________ shall be an
atmospheric, horizontal Surge Tank.
2. The surge tank shall receive returning condensate and supplement
make up water to maintain the desired operating level. Condensate
and make up water mix into a blended temperature, as determined
by the percentage of each. The surge tank shall be vented to
atmosphere. The collected water is then transferred to the
deaerator.
3. The surge tank shall have _______ minutes of storage and have a
capacity of _______ gallons flooded. The tank shall be ____"
diameter x ______" long. An 11" x 15" elliptical manhole shall be
provided for access. All nozzles shall be 3000 lbs forged steel
couplings. Heads shall be ASME torispherical type (flat heads are
not acceptable) constructed of ASTM A516 GR 70 carbon steel
with a minimum thickness of 0.25". Shell plate to be fabricated of
ASTM A36 carbon steel with a minimum thickness of 0.25".
4. The surge tank loads shall be as specified in the following table.
Load Specifications
LOAD
PERCENTAGE
Make up
LBS/HR
TEMP
PRESSURE
20 psig Minimum
Low Temp Returns

High Temp Returns
5.
6.
7.
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.
Optional - The tank shall be factory-insulated and lagged with
blanket insulation, pins, clips, and a durable steel jacket. Blocktype 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.
Optional - The magnesium or sacrificial anode shall provide
H5-10
09-09
Section H
Surge Tanks
8.
B.
Optional - The high-temperature diffuser or sparge tube shall be

constructed of 2" pipe. This tube shall provide even distribution
and blending of high-temperature condensate returns.
10. Optional - The basic surge tank shall be equipped with the
not exceed ______, and shall be rated for _____ gpm at ______
psig inlet pressure. The pressure drop across the valve shall not
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 __________.
be 110V bi-directional type, with a permanently lubricated gear
train, and directly coupled to the valve stem. The valve Cv shall
not exceed _____ and be rated for_______ gpm at ________ psig
inlet pressure. Valve shall not exceed a 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
The controller manufacturer shall be Cleaver-Brooks, Model
TW82. A solenoid valve and float switch is not acceptable.
H5-11
09-09
Surge Tanks
Section H
3.
C.
Option (Pneumatic) - _______" inlet water diaphragm actuated

valve shall be globe-type with proportional control and a springopposed diaphragm actuator arranged for 3 - 15 psig operating
Cv shall not exceed _____ and be rated for ________ gpm at
______ psig inlet pressure. Valve shall not exceed a delta-P of 10
psig. This valve shall have stainless steel trim with TFE packing
and be suitable for temperature up to 410 F. The diaphragm
actuated valve manufacturer shall be ___________, Model
_______. This valve shall be pneumatically controlled by an
external proportional type sensor. The sensor shall be a 14"
displacer that produces a pneumatic output signal. The controller
manufacturer shall be _____________, Model __________. A
filter regulator is to be provided to reduce 50 psig instrument air
supply to 3 - 15 psig for proper operation.
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.)
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.)
Transfer Pump and Motor Set (Optional)
1. Quantity ______, centrifugal type transfer pump and motor set.
Turbine type pumps are not acceptable in this application. Pump to
be rated for _______ gpm at ________ feet TDH with ______ feet
NPSH required. Pump to be _______ materials of construction as
defined by the Hydraulic Institute, and have _______ seals for a
to a ________ hp, ________ phase, _______ Hz, ________ Volt,
_____ rpm, _______ enclosure motor. Motor to be nonoverloading at the rated condition without using any portion of the
service factor. Pump and motor set to be factory aligned prior to
shipment. Pump manufacturer to be _________, Model _______,
size _____ " x _______ ". A stainless steel recirculation orifice is
to be supplied with the pump and shipped loose for field
installation to provide minimum bypass flow.
H5-12
09-09
Section H
Surge Tanks
2.
D.
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.
Control Panel
number coded. The assembly is to contain individual motor starters
with 120 Volt holding coil and fuse protection. Individual green
oil-tight pump run lights shall be provided. All switches and lights
to have nameplate identification. The assembled panel shall be
given a factory continuity test prior to shipment.
a. Control circuit transformer to supply 110-120 Volts, singlephase power supply. The transformer shall be mounted, wired
and fused.
3. Standard
a. The surge tank shall have a gauge glass assembly that covers
the entire tank diameter. The gauge glass shall be quartz
0.625 inch diameter by 24-inch maximum length. Each
length of glass shall be furnished with a bronze gauge cock
set and protector rods.
b. The surge tank shall be supplied with a thermometer with a
50 to 300 F range.
c. The surge tank is to be hand cleaned with a solvent to SSPCSP-1 standards prior to painting. Prime coated to not less than
d. 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.
H5-13
09-09
Surge Tanks
Section H
Notes
H5-14
09-09
Section H6
BOILER FEED SYSTEMS
CONTENTS
FEATURES AND BENEFITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-3

PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-3
SELECTION GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-5
PACKAGE CONCEPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-8
ILLUSTRATIONS
Figure H6-1. Dimensions and Ratings for Boiler Feed Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H6-6
TABLES
Table H6-1. Boiler Feedwater Systems Tank Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-4
Table H6-2. Internal Steam Heater Assemblies for High Pressure Systems . . . . . . . . . . . . . . . . . . . . . . . . . H6-7
Table H6-3. Internal Steam Heater Assemblies for Low Pressure Systems . . . . . . . . . . . . . . . . . . . . . . . . . H6-8
H6-1
09-09
Boiler Feed Systems
Section H
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.
H6-2
09-09
Section H
Boiler Feed Systems

The following features and benefits apply to Cleaver-Brooks Boiler Feed system
products.
All Pumps Deliver the Required Capacity at 210 F:
Guaranteed pump performance.
All Pumps Have Mechanical Seals (Standard):
Reduces maintenance when compared to packing type seals.
Specifically Designed for Compatibility With Cleaver-Brooks Boilers:
Quick, accurate equipment selection.
Single source responsibility.
Proven performance.
Provides Additional Storage Time and Handles Volume-Swings in Condensate Return:
Feedwater tank collects intermittent condensate returns and supplies water at a

relative constant volume.
Minimizes problem from unpredictable condensate flow rates.
Boosts Condensate Return Pressure:
Acts as a collecting point for low pressure and gravity returns.
Allows the introduction of returns to a high pressure vessel.
Accepts Gravity Returns:
Vessels are vented to atmosphere, providing no pressure resistance that would inhibit
gravity return.
PRODUCT OFFERING
Information in this section applies directly to Cleaver- Brooks Feed Systems for low and
high pressure (15 - 200 psig) boilers (15 - 800 horsepower). Selection of Boiler Feed
Systems is based on boiler size, pump requirements (flow, pressure, hp), and water
storage requirements (tank size). Contact your local Cleaver-Brooks authorized
representative for detailed component sizing information.
Table H6-1 shows available tank sizes for boiler feedwater systems.
When equipped with an automatic steam preheater, feedwater temperature can be
maintained at 210 F. At this higher temperature, oxygen and carbon dioxide are
released, reducing corrosion problems in the boiler. Pre-heating is recommended if return
condensate constitutes 50% or less of the feedwater required.
Cleaver-Brooks Packaged Feedwater Systems include pumps, control panel with
H6-3
09-09
Boiler Feed Systems
Section H
Table H6-1. Boiler Feedwater Systems Tank Capacities
CAPACITY (GAL.)
45
75
100
200
270
340
500
750
1000
magnetic starters, and necessary switches. Systems are available in simplex, duplex,
dual and triplex arrangements. Custom arrangements are also available. Accessories
include high temperature diffuser tube, automatic preheater, make-up valves, electrolytic
corrosion inhibitor, ASME tanks, galvanized tank, high & low water alarms, and
Warrick probes.
Contact your local Cleaver-Brooks authorized representative for information on
alternate Cleaver-Brooks/Aurora Pump Feed Systems.
Simplex Units
Simplex units include one pump set complete with open drip-roof motor on steel
channel base with flexible coupling between pump and motor, one large receiver
mounted on structural steel stand, complete with make-up valve, gauge glass with
shutoff valves, thermometer, and suction piping from receiver to pump with Y-type
strainer, flexible hose and gate valve.
Duplex Units
Duplex units are similar to simplex units, but with two pumps and one receiver.
Magnetic starters (where required) are mounted in a NEMA I enclosure, with manual
transfer switch for standby pump.
Dual Unit
Dual units are similar to duplex units, except that receiver tank is sized for two boiler
operation. Transfer switch is not required.
Triplex Units
Triplex units are similar to Dual units but with three pumps and one receiver.
Boiler Feedwater Systems
Standard equipment includes the following:
Tank.
Stand.
Boiler feed pump and motor.
Magnetic starter.
H6-4
09-09
Section H
Boiler Feed Systems
Suction strainer.
Suction flexible fittings.
Gauge glass.
Internal float switch and solenoid make-up valve.
Thermometer.
Required tappings.
Optional equipment
Preheating systems.
High temperature diffuser tube.
Manhole (standard with 270 gal. and larger tank).
External float make-up valve.
Electric alternator.
Special electrical requirements.
ASME Code tank.
Magnesium anode.
Galvanized tank.
Stainless tank.
High-low water cutoff.
Insulated.
Seismic construction.

Dimensions and ratings for boiler feed systems are shown in Figure H6-1.
SELECTION GUIDE
Optional Steam Preheating Equipment
All standard tanks are supplied with extra openings for preheating equipment. Preheating
systems are provided with thermostatically controlled steam pressure regulators
connected to the perforated tube installed in the tank by means of a special bushing. Feed
systems with optional steam preheat also include a sentinel valve installed on the tank.
On standard high pressure units (30 through 250 psi) the following equipment is
furnished (refer to Table H6-2):
1. Perforated heater tube with special bushing.
2. Pressure/temperature regulating valve.
3. Strainer for regulating valve.
4. Pressure gauge.
5. Sentinel valve on tank.
H6-5
09-09
Boiler Feed Systems
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
W
X
Y
Z
45
18.25
80.25
76.25
66.875
35.5
26.5
43
28
2
56
1.25
0.5
6.25
6.25
11.75
11.75
19
5.5
0.75
0.625
2
75
24.25
86.25
82.25
69.875
33
26.5
40
28
2
56
1.25
0.75
9
9
11.5
11.5
19
7
0.75
0.625
2
Section H

100
200
270
340
24.25
30.375
36.375
36.375
86.25
100.563 106.75
106.75
82.25
96.563
102.75
102.75
69.875
80.875
83.875
83.875
47.5
58.5
54.5
69.5
26.5
38.5
38.5
38.5
55
67
63
78
28
42
42
42
2
3
3
3
56
64
64
64
1.25
2
2
2
0.75
0.75
0.75
1
9
11.5
14
14
9
11.5
14
14
16.25
14.5
13.5
17.25
16.25
14.5
13.5
17.25
25
25
25
30
7
10.5
13
13
0.75
0.75
0.75
0.75
0.625
0.625
0.625
0.625
2
3
3
3
500
42.5
120.688
116.688
102.5
73
44
84
48
3
72
2
1
17
17
19.5
19.5
30
16
1
0.875
3
750
48.5
127.688
122.688
105.5
85
44
96
48
3
72
2
1.5
19
19
22.5
22.5
30
19
1
0.875
3
1000
48.5
127.688
122.688
105.5
117
44
128
48
3
72
2
1.5
19
19
30.5
30.5
30
19
1
0.875
3
NOTES:
1) Control Panel on Simplex unit is not mounted or wired to the motors unless specifed.
2) Dim. "H" may not reflect the overall unit width. Overall width may be greater due to the enclosure on
the panel and any component that is or will be mounted on the exterior of the tank. Contact your local
Cleaver-Brooks representative for any adjustments.
3) All above dimensions while sufficiently accurate for layout purposes , must be confirmed for
construction by certified dimension prints.
4) Manway (not show here) is standard on tanks 270 gallon or larger. This would be placed in the center
of the back tank head.
Figure H6-1. Dimensions and Ratings for Boiler Feed Systems

H6-6
09-09
VENT CAPACITY CHART

SIZE (NPT)
CAPACITY
(#/hr)
4800
10,500
17,000
35,000
Values given based on:

1) 50 ft. equivalent pipe
length
2) Schedule 40 pipe
3) 2 psi back pressure
4) Vent capacities should be
compared with anticipated
venting needs. Oversized
vents are available.
Section H
Boiler Feed Systems
Table H6-2. Internal Steam Heater Assemblies for High Pressure Systems (30-250 psig Steam), Thermostatic
Regulating Valve with Pressure Reducing Attachment
Model
Number
ET134 1
ET134 .75
ET134 .5
ET134 .5
ET134 .5
ET134 .5
ET134 1.25
ET134 1
ET134 .75
ET134 .75
ET134 .5
ET134 .5
ET134 1.5
ET134 1.25
ET134 1
ET134 .75
ET134 .75
ET134 .75
ET134 2
ET134 1.5
ET134 1.25
ET134 1
ET134 1
ET134 .75
ET134 2.5
ET134 2
ET134 1.2
ET134 1.2
ET134 1
ET134 1
ET134 3
ET134 2.5
ET134 1.5
ET134 1.5
ET134 1.2
ET134 1.2
ET134 4
ET134 2.5
ET134 2
ET134 2
ET134 1.5
ET134 1.2
ET134 2.5
ET134 2
ET134 1.2
ET134 1.2
ET134 1
ET134 1
Heating Rate ( GPM )

50 deg Temp
Rise
19.3
28.8
48.2
72
96.4
144.0
192.8
96.4
100 deg
Temp Rise
9.6
14.4
24.0
36.0
48.2
72.0
96.4
48.2
150 deg
Temp Rise
Size of Steam
Control
Valve &
Strainer
(inches)
Minimum
Steam
Supply Line
(inches)
Minimum
Steam
Supply
Pressure
Maximum
Steam
Supply
Pressure
6.4
1
3/4
1/2
1/2
1/2
1/2
1 1/4
1
3/4
3/4
3/4
3/4
30
50
100
125
150
200
50
100
125
150
200
250
9.6
1 1/4
1
3/4
3/4
1/2
1/2
1 1/2
1 1/4
1
1
3/4
3/4
30
50
100
125
150
200
50
100
125
150
200
250
16.0
1 1/2
1 1/4
1
3/4
3/4
3/4
2
1 1/2
1 1/4
1
1
1
30
50
100
125
150
200
50
100
125
150
200
250
24.0
2
1 1/2
1 1/4
1
1
3/4
2 1/2
2
1 1/2
1 1/4
1 1/4
1
30
50
100
125
150
200
50
100
125
150
200
250
2 1/2
2
1 1/4
1 1/4
1
1
3
2 1/2
1 1/2
1 1/2
1 1/4
1 1/4
30
50
100
125
150
200
50
100
125
150
200
250
3
2 1/2
1 1/2
1 1/2
1 1/4
1 1/4
4
3
2
2
1 1/2
1 1/2
30
50
100
125
150
200
50
100
125
150
200
250
4
2 1/2
2
2
1 1/2
1 1/4
4
3
2 1/2
2 1/2
2
1 1/2
30
50
100
125
150
200
50
100
125
150
200
250
2 1/2
2
1 1/4
1 1/4
1
1
3
2 1/2
1 1/2
1 1/2
1 1/4
1 1/4
30
50
100
125
150
200
50
100
125
150
200
250
32.0
48.0
64.0
32.0
H6-7
09-09
Boiler Feed Systems
Section H
Table H6-3. Internal Steam Heater Assemblies for Low Pressure Systems (10-15 psig Steam), Thermostatic
Regulating Valve without Pressure Reducing Attachment
Heating Rate ( GPM )
Model
Number
50 deg Temp
Rise
100 deg
Temp Rise
150 deg
Temp Rise
Size of Steam
Control
Valve &
Strainer
(inches)
Minimum
Steam
Supply Line
(inches)
E2T14 - 1"
9.6
4.8
3.2
1"
1.25"
E2T14 - 1.5"
14.4
7.2
4.8
1.5"
E2T14 - 2"
25.5
12.7
8.5
2"
2.25"
E2T14 - 2.5"
39.6
19.2
12.8
2.5"
3"
E2T14 - 2.5"
51
25.5
17
2.5"
3"
E2T14 - 2.5"
72
36.2
24
2.5"
3"
E2T14 - 3"
102
51
34
3" flg
4"
PACKAGE CONCEPT
Cleaver-Brooks line of packaged catalog feed systems is based on the following
parameters.
Intermittent (On-Off)
Pump Operation
As the water level in the boiler falls to a certain level, contacts close in the float switch
on the boiler and the pump starts. As the water level in the boiler rises to a certain level,
the contacts open in the float switch on the boiler and the pump stops. The operation
repeats as the water levels drop again.
The intermittent operation, normally used on Cleaver-Brooks firetube boilers, is well
suited to the regenerative turbine pump, for the following reasons:
Pump Flow
The pump covers a broad range of pressures, which covers a wide boiler pressure
range.
Comparatively low capacities are ideal for the small and medium range boilers.
The pump is allowed to operate at a nearly constant head-capacity point and not over
the entire pump curve as with continuous operation using a modulating feedwater
valve, normally used on large industrial watertube boilers.
The pump can obtain rated flow and head at a relatively low speed. The pumps are
run at 1750 rpm, which gives a longer desired life.
The pump is flexibly coupled to the motor, which reduces the possibility of heat
transfer from the liquid being pumped to the driver.
One Boiler Horsepower is equal to an evaporation rate of 34.5 pounds of water per
hour at 212 F. To convert the value to gallons per minute, divide by the weight of one
gallon water, or 8.33 lbs, to obtain gallons per hour. Divide this value by 60 to determine
the number of gallons per minute. The result of this calculation is 0.069 gallons per
minute, which is the theoretical evaporation rate for each boiler horsepower. When
selecting the boiler feed pump flow, it is necessary to provide for excess capacity to take
care of the boiler load without running the pump continuously. For this reason,
selections for intermittent boiler feed pumps are based on a value of 1-1/2
H6-8
09-09
Section H
Boiler Feed Systems

to 2 times the theoretical evaporation rate.
Pump Total Dynamic

Head
The pump head to be developed by a boiler feed pump that is returning water directly to
the boiler must be equal to the boiler pressure, plus static head differences, plus friction
losses in the piping, valves and any other equipment between the pump and the boiler.
EXAMPLE: Boiler operating at 100 psig.
CALCULATION: 100 psig (oper) + 5 psig (loss) x 2.31 (constant) 0.96 (specific
gravity) = 252 TDH.
Pump Material of
Construction
Material of construction for a boiler feed pump should be carefully selected for
compatibility of the liquid being pumped. In general, the Cleaver-Brooks stainless steel/
cast iron-fitted pump is best suited for most applications. Factors that will affect this
decision are water quality and treatment. An example: In situations when alkalinity is
higher than a pH of 8.5, do not use a bronze-fitted pump. There is no substitute for
experience in selecting materials for pump construction. Previous experience in handling
a particular application should be the main criteria.
Receiver Size
The receiver should be sized for a capacity sufficient to allow feed water for a minimum
of 10 to 15 minutes of boiler operation at rated horsepower.
The run time is essential because of unpredictable surges of condensate returns. Since
0.069 gpm is the theoretical rate of evaporation per boiler horsepower, the maximum
tank size should be approximately 0.069 boiler hp x 10 minutes.
If it is known that the receiver will see 100% make-up with no returns, a five minute
capacity tank can be substituted. The reduced storage capacity is acceptable, since the
receiver will have a steady predictable load.
Receiver
Construction
The receivers are manufactured as a non-code tank for venting to atmosphere. As an

option, Cleaver-Brooks offers receivers constructed for ASME Section VIII, Division 1
of the ASME Pressure Vessel Code. When an ASME Code receiver is required, contact
your local Cleaver-Brooks authorized representative for additional factors to be
considered in this application. Coded tanks supplied will normally be furnished unlined
because of possible increased operating temperature limitations.
Galvanized or stainless steel tanks are available as options.
Optional Steam
Preheater Size
Three basic factors are considered when sizing a preheater:

1. The heating rate in gallons per minute. It is generally assumed the same as the total
evaporation rate of the boilers being supplied with water, unless otherwise specified.
2. The temperature rise required to raise the temperature in the tank based on
condensate returns and make-up water mixed inlet temperature to 212 F.
3. The available steam supply pressure at the regulating valve is generally assumed the
same as the operating pressure of the boiler from which the steam is being tapped,
unless otherwise specified.
Two basic benefits are gained by supplying a preheat package.
1. The risk of damage to the boiler caused by thermal shock is reduced.
2. The dissolved oxygen content can be reduced, slowing corrosion and showing a
savings in the chemical treatment program of the boiler. Oxygen in 212 F feedwater
is roughly 1.8 cc/liter as opposed to 50 F feedwater, which is 5.9 cc/liter. The
American Society of Engineers, in a paper called Consensus On Operating
Practices For The Control of Feedwater and Boiler Water Quality in Modern
H6-9
09-09
Boiler Feed Systems
Section H
Industrial Boilers, suggests dissolved oxygen limits that should be considered. A
preheater by no means deaerates water to an acceptable level by itself.
Preheater
Components
Preheater Components include the following:
Make-up Valve Size
The valves are sized for the maximum theoretical evaporation rate of the boiler, with no
condensate return as a supplement. The sizing criteria makes the water level in the
receiver self-adjusting for any loss of condensate return.
1. Perforated heater tube, also referred to as a diffuser or sparge tube. The tube is
located under the water level in the tank, and its purpose is steam distribution.
2. Regulating valve to control the incoming steam supply. When the steam supply
pressure is between 10-15 psi, a one-element regulating valve (temperature sensor)
is used. On higher pressure packages, when the steam supply is between 30-250 psi,
a two-element regulating valve, sensing pressure and temperature, is used. The twoelement regulating valve is furnished and packaged with higher steam supply
pressures, instead of one element regulating valve for added safety, even through the
receiver is vented and pressurization should not occur.
3. Strainer for arresting any dirt or scale carried over with the supply steam. For its
protection, the strainer is located upstream of the regulating valve.
4. Pressure gauge for monitoring down stream steam pressure from the regulating
valve.
5. Sentinel valve to warn if the receiver is pressurized, if the regulating valve fails, or
a vent becomes plugged. The valve is not required by a code, but is added for safe
operation.
These parameters are based on more than 60 years experience at Cleaver-Brooks in the
packaged boiler room equipment market, and should not be ignored.
H6-10
09-09
Section H
Boiler Feed Systems
Notes
H6-11
09-09
Section H6
Boiler Feed Systems
PART 1 GENERAL
1.1
GENERAL
A. The following sample specifications are provided by Cleaver-Brooks to
assist you in specifying your customers specific needs and application
B. Boiler Feed System shall be Cleaver-Brooks Model
_______________________ (Specify simplex, duplex, dual, or triplex)
packaged boiler system suitable for ______gpm, at a discharge pressure
of ___________ psig. (Refer to Table H6-2, Table H6-3, and Table H6-4.)
PART 2 PRODUCTS
2.1
SYSTEM COMPONENTS
A. The unit shall consist of the following components:
1. One (substitute two for duplex or dual; three for triplex) bronzeringed, pump(s) certified by Cleaver-Brooks for a minimum of
________________ gpm or 212 F water at __________ psig. The
pump(s) shall be guaranteed for one year against defects in
workmanship and material. The pump(s) shall be equipped with
mechanical seals for temperatures up to 225 F.
2. One non-code welded receiver made of structural grade steel. The
tank shall be furnished with integral supports and connections for
inlet, outlet drain, makeup valve, thermometer and gauge glass.
3. Tank size shall be __________ inches diameter with _______ gallon
capacity.
4. One fresh water makeup valve consisting of a float switch and
solenoid valve suitable for tight shutoff against 100 psig inlet
pressure.
H6-12
09-09
5.
Boiler Feed Systems
Section H
Notes
H6-13
09-09
Section H7
CHEMICAL FEED SYSTEMS AND METERING PUMPS
CONTENTS
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-4
ILLUSTRATIONS
Figure H7-1. Manual System Dimensions (By-Pass Feeders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-5
Figure H7-2. Manual System Dimensions (Shot Feeders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-5
Figure H7-3. Automatic System Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-6
TABLES
Table H7-1. Automatic Chemical Feed System Pump Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-4
H7-1
09-09
Chemical Feed Systems and Metering Pumps
Section H
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.
H7-2
09-09
Section H

Complete Standard Packaging Provides:
Lower installation costs.
Easy installation.
Alternative Materials of Construction:
Product selection to match system requirements.
Custom Pump Selection:
Piston or diaphragm.
Direct Drive, Clamp Mounted Agitator:
Ability to mix and dilute powdered materials.
Ease of maintenance.
Adjustable Pump Parameters:
Ability to adjust pump output based upon system requirements.
Controls chemical cost.
Standard 6" Funnel on Manual Chemical Feed Systems:
Less product loss due to spillage.
PRODUCT OFFERING
Cleaver-Brooks chemical feed systems treat feedwater and condition blowdown sludge
where an extra measure of protection against corrosion and scaling is required.
Automatic systems are available for single- or multiple-boiler installations. They are
fully packaged and can be equipped with either piston or diaphragm pump(s) capable of
accurately injecting chemical from 0 to 6 gph at up to 1000 psig.
Automatic Systems
Tank materials: polyethylene, stainless steel, carbon steel or overpack (steel tank
with polyethylene liner and cover).
Tank sizes: 30 to 200 gal.
Pressures: up to 1000 psig.
Agitator included.
Manual Shot Feeders

Manual shot feeders are used for batch feeding of chemicals into closed loop or low
makeup water systems. They are completely assembled and ready for installation for:
Pressures: 125 to 300 psig.
Capacities: 3/4 to 25 gal.

Dimension and rating information is shown in Figure H7-1 through Figure H7-3, and
H7-3
09-09
Section H
Table H7-1..
ENGINEERING DATA
The V-10 Simplex Piston Pump and V-10 Duplex Piston Pump are used in this system.
These pumps are of the high pressure, low volume, reciprocating plunger, positive
placement type, ideal for use in feeding chemicals to hot water and steam boilers. These
pumps are designed for trouble-free operation where a controlled volume of chemical
treatment is required. Units have over 20 years of proven field installations. All are
equipped with relief valves for positive protection at all times. Max pump discharge
pressure is 1000 psig.
The stroke can be simply and quickly adjusted by loosening the nut and turning the head
screw to the desired length stroke; then, re-tighten nut against the slide. The stroke
adjustment (0 to maximum capacity) may be performed while the pump is running or
when the pump is shut down.
Table H7-1. Automatic Chemical Feed System

Pump Ratings
MODEL TYPE
STROKING
RATE
PISTON
DIA
(IN.)
GPH
MAX
SIMPLEX
V-10 - 1560 (Std)A
60
5/8
6.00
V-10 - 1530
30
5/8
3.00
V-10 - 1460
60
1/2
3.00
V-10 - 1430
30
1/2
1.50
V-10 - 1360
60
3/8
1.60
V-10 - 1330
30
3/8
0.80
V-10 - 1260
60
1/4
1.00
V-10 - 1230
30
1/4
0.50
DUPLEX
V-10 - 2560 (Std)A
60
5/8
12.00B
V-10 - 2530
30
5/8
6.00B
V-10 - 2460
60
1/2
6.00B
V-10 - 2430
30
1/2
3.00B
V-10 - 2360
60
3/8
3.20B
V-10 - 2330
30
3/8
1.60B
V-10 - 2260
60
1/4
2.00B
V-10 - 2230
30
1/4
1.00B
A. Unless otherwise specified, Model V-10 - Type 1560 pumps will be

shipped for Simplex systems and Model V-10 - Type 2560 for Duplex systems.
B. For both pumping heads.
Specifications subject to change without notice.
H7-4
09-09
Section H
TANK
CAPACITY
3/4 Gal
1 Gal
1-1/2 Gal
2 Gal
2-1/2 Gal
5 Gal
10 Gal
18 Gal
25 Gal
A
WIDTH
(INCH)
B
BODY
(INCH)
C
OVERALL
HEIGHT
(INCH)
4
6
6
8
8
10
10
14
18
15
10
12
10
12
15
29
32
28
35
28
30
28
30
33
47
50
46
CONNECTIONS
IN
OUT
SAMPLE
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
By Pass Feeders Include:
Tank
1/2" screwed inlet
3/8" screwed outlet
3/8" flow control valve
Sight glass with gauge valves and guards
1/2" sample valves
6" diameter funnel
Tanks 5 gallon capacity and larger have three 12-inch support legs.
Figure H7-1. Manual System Dimensions (By-Pass Feeders)
TANK
CAPACITY
3/4 Gal
1 Gal
1-1/2 Gal
2 Gal
2-1/2 Gal
5 Gal
10 Gal
18 Gal
25 Gal
A
WIDTH
(INCH)
B BODY
(INCH)
4"
6"
6"
8"
8"
10"
10"
14"
18
15"
10"
12"
10"
12"
15"
29"
32"
28
C
OVERALL
HEIGHT
(INCH)
33"
23"
25"
23"
25"
27"
42"
45"
41
CONNECTIONS
IN
OUT
SAMPLE
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2
1/2"
1"
1"
1"
1"
1"
1"
1"
1
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2
Shot Feeders Include:

Tank
1/2" screwed inlet
1/2" or 1" screwed outlet
1/2" sample valve
6" diameter funnel
Tanks 5 gallon capacity and larger have three support legs.
Figure H7-2. Manual System Dimensions (Shot Feeders)
H7-5
09-09
Section H
STAINLESS & CARBON STEEL TANKS

MIXER
GAUGE
GLASS
STAINLESS & CARBON

STEEL TANKS
DIMENSIONS (INCHES)
CAPACITY
(GAL.)
50
23
48
31
17
22
18
100
36
51
31
20
31
27
150
36
56
36
20
31
27
200
36
68
48
20
31
27
VALVE
PRV
V-10
STRAINER
DISCHARGE
SERIAL #
POLYETHYLENE TANKS
POLYETHYLENE TANKS
MIXER (OPTIONAL)
REMOVABLE LID
(SS HINGE OPTIONAL)
B
A
POLY SUPPLY
VALVE
DIMENSIONS (INCHES)
CAPACITY
(GAL.)
30
18
30
12
49
55
22
34
17
60
100
28
42
18
70
150
31
47
18
66
PRV
V-10 PUMP
C
SERIAL #
STRAINER
50-OP-1-V10
MIXER (OPTIONAL)
REMOVABLE LID
(SS HINGE OPTIONAL)
OVER PACK CHEMICAL SYSTEMS

The Over Pack chemical feed system is recommended for
almost all industrial applications. A polyethylene liner and cover
are inserted into a steel tank with welded steel frame and pump
support.
VISUAL
SLIT
34"
63"
POLY SUPPLY
VALVE
PRV
1/4" NPT
V-10 PUMP
17"
13"
(3) 3/8" BOLT HOLES
SERIAL #
STRAINER
21 3/4"
26"
20 1/4"
23"
Figure H7-3. Automatic System Dimensions

H7-6
09-09
Section H7
PART 1 GENERAL
1.1
GENERAL
The following specifications are provided by Cleaver-Brooks to assist you in specifying
your customers requirements.
Provide completely preassembled, packaged chemical feed system(s)/chemical metering
pump(s), as manufactured by _______________. Package shall be hydraulically and
electrically tested at the factory and shall be assembled to the fullest extent possible.
Package shall be furnished with all required lubricants, special tools, and installation
instructions.
PART 2 PRODUCTS
2.1
HARDWARE
A. Pump
1. Pump capacity shall be adjustable through 100% of the range by
manual micrometer dial while the pump is running or stopped.
Pump stroking speed shall not exceed 60 spm.
2. The pump shall be sized to deliver the required capacity at 85% of
maximum stroke length. Stroke adjustment shall be a variable
micrometer type mechanism, with the plunger powered through its
entire travel. Lost motion designs are not acceptable.
3. The pump shall include an automatic vent and refill mechanism on
the hydraulic side, which operates once each stroke. The pump shall
have an external hydraulic relief valve which is adjustable.
4. Double ball check valves shall be provided on the discharge to
ensure accurate repeatable metering. The pump valves shall be
removable for cleaning or replacement without the need to disturb
suction or discharge piping.
5. The pump shall be field convertible to automatic stroke adjustment
without the use of special tools, and without the need to replace any
major frame parts.
6. The pump shall be furnished with a factory-mounted driver suitably
sized for continuous operation at the maximum relief setting. The
motor shall be (integrally mounted direct coupled flange mounted
with flexible coupling). No belts or pulleys should be used in the
drive train or for capacity adjustment.
B. Feed System
1. Complete chemical feed system(s) shall be furnished suitable for
handling ___________________. Each system will consist of
______ pump(s), tank, piping, and accessories as defined below.
Manufacturer will select all materials in contact with the chemical
H7-7
09-09
Section H
and guarantee their suitability for the particular service. Pump(s)

shall be mounted below the tank.
C.
D.
Tank
1. The tank(s) shall be constructed of (polyethylene/304SS/316SS/
other) and furnished with a hinged or removable cover. Tank shall
include connections for pump suction, drain, level gauge,
chemical fill, dilution water, and relief valve return piping. Drain
connection shall be separate from pump suction connection. Drain
shall be located in the bottom of the tank for complete emptying of
contents.
2. Tank shall be furnished with (drain valve) (level switch) (level
gauge).
Mixer
1. An angle plate mount mixer with 304SS shaft and propeller shall
be furnished. The mixer propeller shall operate at 1750 rpm. The
purpose of the mixer shall be to (mix liquids/dissolve powder in
liquid/create and maintain a suspension).
H7-8
09-09
Section H8
FILTERS
CONTENTS
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIMENSIONS, RATINGS, AND SIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chlorine, Organics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Particles Down to 10-Micron Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sand, Heavy Sediment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H8-3
H8-3
H8-3
H8-4
H8-4
H8-4
H8H8-6
H8-6
H8-6
H8-6
H8-7
H8-13
ILLUSTRATIONS
Figure H8-1. Dimensional Data, Filter System Without Regeneration Tanks . . . . . . . . . . . . . . . . . . . . . . . H8-5
TABLES
Table H8-1. Model CF Activated Carbon Media Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-7
Table H8-2. Model MF Multi-Layered Media Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-8
H8-1
09-09
Filters
Section H
Table H8-3. Model SF Sand Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-9

Table H8-4. Model IF Iron Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-9
Table H8-5. Engineering Data (Filters) (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-10
This section contains information on water filters used for the removal of impurities from raw water. Filters discussed
here remove:
Chlorine and organics.
Particles down to 10-micron size.
Sand and heavy sediment.
Iron.
H8-2
09-09
Section H
Filters

Complete Range of Sizes and Filter Media Available:
Precisely match customer needs (system specific).
Pre-Engineered Packaged Units Shipped From Stock:
Short lead times.
Minimum down time.
Industrial Grade Multiport Control Valve:
Long lasting.
High reliability.
Easy maintenance.
Backwash Control Actuated On a Time Clock, Pressure Differential Switch, or Water

Meter Basis:
Versatility.
Inlet and Outlet Pressure Gauges and Sample Cocks:
Easy monitoring of system performance.
Fully Assembled Manifold Piping:
Ease of installation, lower installation costs.
Heavy Duty Steel Tanks With Galvanized or Prime Coat Exterior Finish (Specialty
Linings Optional):
Corrosion resistance and longer life.
Premium Grades of Filter Media:
Optimum performance.
PRODUCT OFFERING
The need for special filter equipment for removal of impurities can be readily determined
by raw water analysis. Where filters are recommended, cost is quickly recovered by
eliminating need for frequent equipment cleaning and servicing, inefficient performance,
damage to system components, and premature equipment failure.
Standard Equipment
Automatic Units 12" - 16" Diameter:
Skirt type tanks.
Epoxy lined interior.
Painted exterior.
Locking bayonet cover.
Fine slotted tubular PVC distributor.
Automatic time clock operation.
Automatic Units 20" - 42" Diameter:

H8-3
09-09
Filters
Section H
Structural steel legs.
Double hot-dipped galvanized interior and exterior.
ML and AC filters are epoxy lined with prime coat exterior.
20" - 30" have access handhole in top head and lower sideshell.
36" - 42" have 11" x 15" elliptical manhole in top head.
PVC radial distribution.
Automatic Units 48" Diameter and Larger:
Optional Equipment
Adjustable jack support legs.
Prime coat exterior.
12" x 16" elliptical manhole in top head.
Header and lateral distribution system.
Inlet and outlet pressure gauges.
Air relief valve.
Flanged tank openings.
ASME code tanks.
Specialty tank linings.
Skid mounted, fully pre-piped and wired.
Automatic operation by pressure differential or water meter.
Manual backwash controls.
Backwash with water from auxiliary source.
DIMENSIONS, RATINGS, AND SIZING

Dimensions for filter systems without regenerant tanks are shown in Figure H8-1.
Sizing
In addition to service flow, the selection of a filter system must take into account the
available backwash flow rate. This is the most important function in the proper operation
of a filter. A periodic backwash and rinse is required to cleanse and reclassify the filter
media.
Backwash flow rates are always higher than service flow rates and therefore limit the
filter size that can be installed. As a general rule, select the largest filter that can be back
washed with the flow rate available at the point of filter installation. Then note the
service flow rate for the filter selected. If it is not adequate for the flow to be treated, a
twin filter installed in parallel is required.
A parallel installation will increase the service flow and permit each filter to be back
washed separately with the existing water supply.
Generally, lower flows produce higher quality water and a larger volume of treated
water between backwashing.
Cleaver-Brooks rates the performance of each filter as follows:
H8-4
09-09
Section H
Filters
SYSTEM DIMENSIONS
FILTER
TANK
SIZE (IN)
AxB
SINGLE
TWIN
TRIPLE
QUAD
L1
L2
L3
L4
20x54
20
58
96
24x54
24
66
30x54
30
36x60
36
42x60
OTHER APPLICABLE DIMENS IONS

W
134
28-1/2
72
38
15-1/2
43
3-1/4
5-3/8
3-9/16
4/12
108
150
33
75
42
18
43
3-1/4
5-7/8
3-9/16
4-1/2
78
126
174
40
78
48
21-1/8
43
4-5/8
11
4-1/2
90
144
198
46
89
54
24-1/8
43
4-5/8
11-1/4
4-1/2
9-1/2
42
102
162
222
53-1/2
91
60
27-1/8
43
6-5/8
14-1/4
6-7/16
10-7/8
48x60
48
114
180
246
64
86
66
35
36-1/2
6-5/8
14-1/2
6-7/16
11-1/4
54x60
54
126
198
270
70
87
72
38
37-1/4
6-5/8
14-1/2
6-7/16
12-7/8
60x60
60
138
216
294
76
89
78
41
38
6-5/8
14-1/2
6-7/16
12-7/8
72x60
72
162
252
342
88
93
90
47
41-1/4
6-5/8
14-1/2
6-7/16
12-7/8
84x60
84
186
288
390
100
97
102
53
43
6-5/8
53-1/4
6-7/16
17-3/4
96x60
96
210
324
438
114
101
114
41-1/4
45
6-5/8
53-1/4
6-7/16
17-3/4
NOTES:
1. All values are in inches.
2. System dimensions based on 18" space between pressure tanks.
Figure H8-1. Dimensional Data, Filter System Without Regeneration Tanks

H8-5
09-09
Filters
Section H
Superior
Recommended for most applications under all operating conditions.
Best quality water.
Maximum on line time between backwashing.
Lowest pressure loss.
Recommended for influent suspended solids loads up to or greater than 300 ppm.
High
Well suited for many applications.
Very good quality water.
Moderate on line time between backwashing.
Increased pressure loss.
Recommended for influent suspended solids loads less than 300 ppm.
Utility
Chlorine, Organics
Flow rates listed are at peak design: operation at higher flows not recommended.
Satisfactory water quality.
Shorter on line time.
Higher pressure loss.
Recommended for influent suspended solids loads less than 150 ppm.
CB activated carbon filters (Table H8-11) remove free chlorine, some dissolved organics
and sediment, down to 40-micron particle size, from boiler makeup water. By removing
sediment, activated carbon filters also help control sludge buildup in boilers. They
protect pretreatment equipment by: 1) removal of free chlorine, which is corrosive and
attacks the ion exchange resin cross-linking agent in water softeners and dealkalizers,
and the membranes in reverse osmosis equipment, and 2) removing organics which
promote fouling in ion exchange beds, that can contaminate water supplies and cause
foaming in boilers and heat exchange equipment.
Periodic backwashing is required to remove collected matter from the filter bed.
Particles Down to
10-Micron Size
Sand, Heavy
Sediment
Flow rates: 3 to 226 gpm.
Tank sizes: 12" to 72" dia.
Operating temperatures: 40 F to 120 F.
Multilayered filters (Table H8-2) are used for finer levels of filtration and for handling
heavy flow rates. They remove sediment, suspended solids and colloidal matter, down to
10-micron particle size, from boiler makeup water. They are highly effective in
controlling sludge buildup. Periodic backwashing is required to remove collected matter
from the filter bed.
Sand filters (Table H8-3) can handle heavy loads in controlling sludge buildup. They
remove heavy, large-particle sediment and suspended solids, down to 40-micron size,
from makeup water. Periodic backwashing is required to remove collected matter from
the filter bed.
H8-6
09-09
Section H
Filters
Iron
Cleaver-Brooks iron filters (Table H8-4) remove both soluble and insoluble iron,
suspended solids and colloidal matter down to 40-micron particle size from boiler
makeup water. They are used to control sludge buildup caused by iron precipitation.
Water pH must be at least 6.2. Occasional regeneration with potassium permanganate
may be required.
ENGINEERING DATA
Select a filter from the tables to produce the desired flow rate and pressure drop. Check
to assure the required backwash flow rate is available. Twin filters may be required to
produce maximum flow rate and still enable backwash with the existing piping system.
Table H8-1. Model CF Activated Carbon Media Filter

MODEL
NUMBER
WATER QUALITY
PIPE
SIZE
SUPERIOR
HIGH
UTILITY
FLOW PRESS. FLOW PRESS. FLOW PRESS.

RATE LOSS RATE LOSS RATE LOSS
CFB-
BACKWASH
RATE
TANK
SIZE
DIA
x
SIDE
SHELL
FILTER
MEDIA
LOAD
FLOOR
SPACE
REQ'D
HEIGHT
OPER
WT
IN.
GPM
PSIG
GPM
PSIG
GPM
PSIG
GPM
IN.
CU FT
IN.
IN.
LBS
2-1
4.5
8.3
12x54
13x21
60
450
3-1
10
14x60
15x23
66
550
4-1
11
13.5
16x60
17x25
66
700
5-1/2-1
13
17
20
20x54
5.5
21x29
72
100
7-1-1/4
1-1/4
13
19
25
30
24x54
25x33
74
1650
12-1/2-1-1/2
1-1/2
20
29
39
46
30x54
12.5
31x40
79
2700
18-2
28
42
57
70
36x60
18
37x48
90
4200
25-2
38
58
77
95
42x60
25
43x56
92
5800
2-1/2
38
58
77
95
42x60
25
43x57
92
5900
34-3
50
75
100
115
48x60
34
49x64
86
7100
44-3
64
95
127
150
54x60
44
55x70
87
9100
54-3
79
118
157
180
60x60
54
61x76
89
11400
78-3
113
170
226
11
270
72x60
78
73x88
93
15700
78-4
113
170
226
270
72x60
78
73x90
93
15800
25-2-1/2
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.
H8-7
09-09
Filters
Section H
Table H8-2. Model MF Multi-Layered Media Filter

MODEL
NUMBER
WATER QUALITY
PIPE
SIZE
SUPERIOR
HIGH
UTILITY
FLOW PRESS. FLOW PRESS. FLOW PRESS.

RATE LOSS RATE LOSS RATE LOSS
MFB-
BACKWASH
RATE
TANK
SIZE
DIA
x
SIDE
SHELL
FILTER FLOOR
MEDIA SPACE HEIGHT
LOAD
REQ'D
OPER
WT
IN.
GPM
PSIG
GPM
PSIG
GPM
PSIG
GPM
IN.
CU-FT
IN.
IN.
LBS
2-1
12
16
12
11.5
12x54
13x21
60
500
2-1/2-1
11
16
11
21
17
15
14x60
2.5
15x23
66
690
4-1-1/4
1-1/4
14
21
12
28
18
20
16x60
17x25
66
850
5-1-1/4
1-1/4
22
33
12
44
19
30
20x54
21x29
72
1800
5-1-1/2
1-1/2
22
33
44
10
30
20x54
21x30
72
1850
7-1-1/4
1-1/4
31
47
18
63
29
45
24x54
25x33
74
2350
7-1-1/2
1-1/2
31
47
63
16
45
24x54
25x34
74
2400
10-1-1/2
1-1/2
49
10
74
19
98
26
75
30x54
10
31x40
79
3675
10-2
49
74
13
98
20
75
30x54
10
31x41
79
3700
15-2
71
106
17
141
27
105
36x60
15
37x46
90
5550
15-2-1/2
2-1/2
71
106
10
141
15
105
36x60
15
37x48
90
5650
21-2-1/2
2-1/2
96
144
13
192
20
150
42x60
21
43x53
92
8295
21-3
96
144
11
192
16
150
42x60
21
43x54
92
8350
27-3
126
188
11
251
17
180
48x60
27
49x64
86
10400
27-4
126
188
251
180
48x60
27
49x66
86
10500
34-3
159
239
15
318
22
240
54x60
34
55x70
87
12800
34-4
159
239
318
10
240
54x60
34
55x72
87
12900
43-3
197
10
295
20
393
31
300
60x60
43
61x76
89
15800
43-4
197
295
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.
H8-8
09-09
Section H
Filters
Table H8-3. Model SF Sand Filter
WATER QUALITY
MODEL
NUMBER
SUPERIOR
PIPE
SIZE
SFB-
HIGH
UTILITY
FLOW
RATE
PRESS.
LOSS
FLOW
RATE
PRESS.
LOSS
FLOW
RATE
PRESS.
LOSS
BACKWASH
RATE
TANK
SIZE
DIA
x
SIDE
SHELL
FILTER
MEDIA
LOAD
FLOOR
SPACE
REQ'D
HEIGHT
OPER
WT
IN.
GPM
PSIG
GPM
PSIG
GPM
PSIG
GPM
IN.
CU-FT
IN.
IN.
LBS
2-1
10
12x54
13x21
60
490
3-1
13.5
14x60
15x23
66
650
4-1
15
16x60
17x25
66
850
6-1
10
13
25
20x54
21x29
72
1700
9-1-1/4
1-1/4
14
19
35
24x54
25x33
74
2250
14-1-1/2
1-1/2
15
22
29
60
30x54
14
31x40
79
3500
20-2
21
32
42
85
36x60
20
37x46
90
5300
28-2
29
43
58
115
42x60
28
43x53
92
7900
28-2-1/2
2-1/2
29
43
58
115
42x60
28
43x54
92
8000
34-3
38
57
75
150
48x60
34
49x64
86
9900
44-3
48
72
95
190
54x60
44
55x70
87
12200
54-3
59
88
118
230
60x60
54
61x76
89
15100
78-4
4 BWA
85
127
170
330
72x60
78
73x88
93
21700
NOTES:
1. Filter media consists of silica sand.
2. 4BWA - minimum 4" water supply required. FIlter manifold connections are 3" inlet/outlet and 3" backwash assist.
3. All pressure drop data based on new filter media and 60 F water temperature.
4. Backwash when pressure drop increases by 12-15 psig over pressure drop of a clean filer.
5. Consult Cleaver-Brooks for larger diameter tanks.
6. Allow a minimum of 24" above filter for access into top of tank.
Table H8-4. Model IF Iron Filter

MODEL
NUMBER
WATER QUALITY
PIPE
SIZE
SUPERIOR
HIGH
UTILITY
BACKWASH
RATE
TANK
SIZE
DIA
x
SIDE
SHELL
FILTER
MEDIA
LOAD
FLOOR
SPACE
REQ'D
HEIGHT
OPER
WT
IN.
CU-FT
IN.
IN.
LBS
FLOW
RATE
PRESS.
LOSS
FLOW
RATE
PRESS.
LOSS
FLOW
RATE
PRESS.
LOSS
IN.
GPM
PSIG
GPM
PSIG
GPM
PSIG
GPM
2-1
8.3
12x54
13x21
60
490
3-1
10
14x60
15x23
66
660
4-1
11
13.5
16x60
17x25
66
850
IFB-
6-1
13
17
20
20x54
21x29
72
1550
9-1-1/4
1-1/4
13
19
25
10
30
24x54
25x33
74
2200
13-1-1/2
1-1/2
20
29
39
46
30x54
13
31x40
79
3600
18-2
28
42
57
69
36x60
18
37x46
90
5200
28-2
38
58
77
13
90
42x60
28
43x53
92
7500
28-2-1/2
2-1/2
38
58
77
90
42x60
28
43x54
92
7600
34-3
50
75
100
115
48x60
34
49x64
86
9800
44-3
64
95
127
150
54x60
44
55x70
87
10800
54-3
79
118
157
10
190
60x60
54
61x76
89
13900
78-3
113
170
226
15
270
72x60
78
73x88
93
20400
78-4
113
170
226
270
72x60
78
73x90
93
20500
Note: Filter media consists of manganese greensand. It must periodically be regenerated with potassium permanganate (KMnO ).
4
H8-9
09-09
Filters
Section H
Table H8-5. Engineering Data (Filters) (Page 1 of 2)
MODEL
NUMBER
TANK SIZE
(DIA x HT)
PIPE
SIZE
(IN.)
FREE
MEDIA
BOARD
(CU-FT)
(IN.)
SUPPT
BED
(LBS)
NO.
OF
DIST
ACC-MFB
SERV
FLOW
(GPM)
PRESS.
LOSS
(PSIG)
PEAK
FLOW
GPM)
PRESS.
LOSS
(PSIG)
BACK
WASH
GPM
DRAIN
PIPE
SIZE
(IN.)
SHIP
WT
(LBS)
OP
WT
(LBS)
MULTI-LAYERED
2-1
12x54
19
40
16
12
11.5
3/4
377
500
2-1/2-1
14x60
2.5
24-1/2
60
11
21
17
15
3/4
483
690
4-1-1/4
16x60
1-1/4
25
85
14
28
18
20
621
850
5-1-1/4
20x54
1-1/4
19
200
22
44
19
30
1-1/4
955
1800
5-1-1/2
20x54
1-1/2
19
200
22
44
10
30
1-1/4
982
1850
7-1-1/4
24x54
1-1/4
23-1/2
200
31
63
29
45
1/1/4
1283
2350
7-1-1/2
24x54
1-1/2
23-1/2
200
31
63
16
45
1-1/4
1314
2400
10-1-1/2
30x54
1-1/2
10
23
400
49
10
98
26
75
2046
3675
10-2
30x54
10
23
400
49
98
20
75
2066
3700
15-2
36x60
15
30-1/2
500
71
141
27
105
3180
5550
15-2-1/2
36x60
2-1/2
15
30-1/2
500
12
71
141
15
105
3391
5650
21-2-1/2
42x60
2-1/2
21
31
700
12
96
192
20
150
2-1/2
3741
8295
21-3
42x60
21
31
700
16
96
192
16
150
2-1/2
3761
8350
27-3
48x60
27
31
1000
26
126
251
17
180
5370
10400
27-4
48x60
27
31
1000
26
126
251
240
5888
10500
34-3
54x60
34
31
1300
36
159
318
22
240
6566
12800
34-4
54x60
34
31
1300
36
159
318
10
240
7087
12900
43-3
60x60
43
31
1800
36
197
10
393
31
300
8999
15800
43-4
60x60
43
31
1800
36
197
393
13
300
9213
15900
ACC-SFB
SAND
2-1
12x54
16
40
10
3/4
386
490
3-1
14x60
18
60
13.5
3/4
534
650
4-1
16x60
17-1/2
85
15
701
850
6-1
20x54
13
200
13
25
1-1/4
1073
1700
9-1-1/4
24x54
1-1/4
15
200
19
35
1-1/4
1545
2250
14-1-1/2
30x54
1-1/2
14
15
400
15
29
60
2532
3500
20-2
36x60
20
22-1/2
500
21
42
85
3630
5300
28-2
42x60
28
22
700
12
29
58
115
2-1/2
4781
7900
28-2-1/2
42x60
2-1/2
28
22
700
16
29
58
115
2-1/2
5385
8000
34-3
48x60
34
24
1000
10
38
75
150
6045
9900
44-3
54x60
44
24
1300
16
48
95
190
7566
12200
54-3
60x60
54
24
1800
16
59
118
230
9623
15100
78-4
72x60
78
24
2600
26
85
170
330
14727
21700
H8-10
09-09
Section H
Filters
Table H8-5. Engineering Data (Filters) (Page 2 of 2)

MODEL
NUMBER
TANK SIZE
(DIA x HT)
PIPE
SIZE
(IN.)
FREE
MEDIA
BOARD
(CU-FT)
(IN.)
SUPPT
BED
(LBS)
ACC-CFB
NO.
OF
DIST
SERV
FLOW
(GPM)
PRESS
LOSS
PSIG)
PEAK
FLOW
(GPM)
PRESS
LOSS
(PSIG)
BACK
WASH
GPM
DRAIN
PIPE
SIZE
(IN.)
SHIP
WT
(LBS)
OP
WT
(LBS)
ACTIVATED CARBON
2-1
12x54
16
40
8.3
3/4
206
450
3-1
14x60
18
60
10
3/4
324
550
4-1
16x60
17-1/2
85
11
13.5
421
700
5-1/2-1
20x54
5-1/2
16
200
17
20
1-1/4
633
1200
7-1-1/4
24x54
1-1/4
22-1/2
200
13
25
30
1-1/4
855
1650
12-1/2-1-1/2
30x54
1-1/2
12-1/2
18-1/2
400
20
39
46
1407
2700
18-2
36x60
18
26
500
28
57
70
2170
4200
25-2
42x60
25
25-1/2
700
38
77
95
2-1/2
2731
5800
25-2-1/2
42x60
2-1/2
25
25-1/2
700
12
38
77
95
2-1/2
3335
5900
34-3
48x60
34
24
1000
16
50
100
115
3652
7100
44-3
54x60
44
24
1300
16
64
127
150
4462
9100
54-3
60x60
54
24
1800
26
79
157
190
5856
11400
78-3
72x60
78
24
2600
26
113
226
11
270
8662
15700
78-4
72x60
78
24
2600
26
113
226
270
9113
15800
ACC-IFB
IRON
2-1
12x54
16
40
8.3
3/4
356
490
3-1
14x60
18
60
10
3/4
489
660
4-1
16x60
17-1/2
85
11
13.5
633
850
6-1
20x54
13
200
17
20
1-1/4
983
1550
9-1-1/4
24x54
1-1/4
15-1/2
200
13
25
10
30
1-1/4
1380
2200
13-1-1/2
30x54
1-1/2
13
17-1/2
400
20
39
46
2232
3600
18-2
36x60
18
26
500
28
57
69
3160
5200
28-2
42x60
28
22
700
38
77
13
90
2-1/2
4361
7500
28-2-1/2
42x60
2-1/2
28
22
700
12
38
77
90
2-1/2
4965
7600
34-3
48x60
34
24
1000
16
50
100
115
5522
9800
44-3
54x60
44
24
1300
16
64
127
150
6882
10800
54-3
60x60
54
24
1800
26
79
157
10
190
8813
13900
78-3
72x60
78
24
2600
26
113
226
15
270
12952
20400
78-4
72x60
78
24
2600
26
113
226
270
13403
20500
H8-11
09-09
Filters
Section H
NOTES
H8-12
09-09
Section H8
Filters
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-14
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-14
Mineral Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-14
Upper Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-14
Lower Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-14
Main Operating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-14
Filter Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-15
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-15
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-15
Guarantees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-15
requirements.
H8-13
09-09
Filters
Section H
PART 1 GENERAL
11
GENERAL
Furnish, install, and place in service an assembled vertical, pressure type, water filtration
system of an approved design fabricated by a manufacturer regularly engaged in the
production of water conditioning equipment. It shall be a Cleaver-Brooks Model ___
having ____ cubic feet of filter media in each filter tank. Service flow rate through each
filter tank shall be ____ gpm at pressure loss not to exceed ____ psig.
PART 2 PRODUCTS
21
HARDWARE
A. Mineral Tank
1. The mineral tank(s) shall be of welded construction of tank quality
carbon steel. It shall be _____ " diameter with a _____ " straight
shell with reinforced openings for pipe connections and an 11" x
15" manhole in the top head (for tank 30" diameter and smaller;
two (2) 4" spin off handholes are provided in the top head and
lower sideshell). The mineral tank shall be rated for 100 psig
working pressure and hydrotested to 150 psig. Support legs shall
be strap type - permanently welded to the lower tank head.
Mineral tank(s) shall have both the exterior and interior protected
with a hot dipped galvanized application prior to fabrication and
shipment.
2. Option. ASME Code 100 psig working pressure, 150 psig test
pressure stamped and certified. Cold set epoxy polyamide internal
lining 8-10 mils DFT, with external rust resistance prime coat, 2-3
mils DFT. (For activated carbon and multilayer filters, cold set
epoxy lining must be used due to highly corrosive effects of
activated carbon.)
3. A minimum freeboard of 50% shall be provided for backwash
expansion above the normal filter media bed level.
B. Upper Distributor
a. The upper distributor system shall be of the single point
baffle type. Constructed of Schedule-40 galvanized steel and
fittings.
C. Lower Distributor
1. The lower radial distribution system shall be the hub and radial
type of Schedule-80 PVC construction with a sub-fill of 1/8" x
1/16" gravel covering the distributor system laterals with slotted
full flow non-clogging replaceable polypropylene strainers.
D. Main Operating Valve
1. The main operating valve on the filter shall be of the automatic
multiport type, consisting of five (5) individual diaphragm valves
housed in a compact casting. These valves are to be pressure
actuated by an external pilot valve, automatically or manually. The
valve shall be manufactured by the same manufacturer as the
entire filtering system. The valve guides, seats, and diaphragm
shall be constructed of Noryl plastic.
2. Pressure gauges and sample cocks to be provided on the inlet and
outlet of the filter system.
H8-14
09-09
Section H
Filters
3.
E.
F.
PART 3 EXECUTION
An automatic backwash control shall be provided to maintain a

proper backwash and flush flows over wide variations of operating
pressure. Controller shall contain no moving parts and require no
field adjustment.
4. The regeneration sequence shall be the accepted standard, which is
backwash, fast flush, and return to service.
5. An external PVC constructed eductor is to be provided to draw
regenerant solution and rinse water to regenerate the filter media
mineral. (On iron removal filters only.)
6. The pipings shall be galvanized Schedule-40 galvanized steel with
galvanized fittings.
7. All face piping shall be preassembled to the tank in a professional
manner.
Filter Media
1. The filter media shall be S (No. 26 sand) for removal of sand and
heavy sediment from water.
2. The filter media shall be ML (Multi-Media) consisting of reverse
grading of fine gravel, coarse gravel, red flint sand, and activated
carbon.
3. The filter media shall be M (Manganese Greensand) that will be
periodically regenerated with potassium permanganate (KMnO4).
4. The filter media shall be AC (Granular Activated Carbon).
Controls
1. Regeneration shall be controlled by a fully automatic time clock
control (TCC) which is fully adjustable or a remote manual
controller. For fully automatic operation, the regeneration shall be
initiated by a calendar clock. A pointer shall indicate the cycle of
operation at all times.
2. When two (2) filters, or more, are required, a lockout shall be
provided to allow only one (1) unit to regenerate at any one time.
3. In the event of a power failure, a complete regeneration can be
performed by manual operation of the external pilot valve.
4. Control Options: Regeneration to be initiated by head loss across
the filter(s). A delay timer is to be provided to prevent false
backwashing due to pressure surges in the system.
31
INSTRUCTIONS
A complete set of installation and operating instructions shall be included.
3.2
GUARANTEES
A. Attrition loss of mineral is guaranteed not to exceed 3% per year for a
period of three (3) years.
B. All mechanical equipment is guaranteed for one (1) year against any
defects in workmanship or materials. Any part proving defective will be
replaced or repaired within this period.
H8-15
09-09
Filters
Section H
C.
The manufacturer guarantees that under actual operating conditions, the

mineral shall not be washed out of the system during the service run or
backwashing period; that the turbidity and color of the effluent, by
reason of passing through the filter system, shall not be less than the
incoming water; and that the under-drain system, gravel, and mineral
shall not become fouled, either with turbidity or by dirt, while operating
as noted on manufacturers instructions.
H8-16
09-09
Section H9
SOFTENERS
Model SMR
Models SSE & FSE
CONTENTS
MODELS SSE & FSE FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9- 3

MODELS SMR FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9- 5
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9- 6
DIMENSIONS, RATINGS AND SIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9- 7
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9- 7
Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9- 7
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9- 7
Sizing Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9- 8
SAMPLE SPECIFICATIONS (SSE/FSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-19
SAMPLE SPECIFICATIONS (SMR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-27
ILLUSTRATIONS
Figure H9-1. SSE Models (Size 30-1200) Softener Dimensions - Page 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . H9-9
Figure H9-2. (1 of2) Model FSE (Size 30-600) Softener Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-11
Figure H9-3. CRS Crossover Twin Dimensions (Size 30-300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-13
Figure H9-4. SMR Dimensions (Size 150-1050) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-14
Figure H9-5. Water Softener Sizing Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-18
H9-1
09-09
Softeners
Section H
TABLES
Table H9-1. SSE Water Softener Ratings Polybond Lined Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-15
Table H9-2. FSE Water Softener Ratings, Fiberglass Softeners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-16
Table H9-3. CRS Water Softener Ratings, Fiberglass Softeners with Crossover Controls . . . . . . . . . . . . . . H9-16
Table H9-4. SMR Water Softener Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-17
This section contains information on Cleaver-Brooks cation, ion exchange, and water softeners available in package designs
for virtually any commercial or industrial application. Softeners should be used whenever raw water hardness exceeds 5
ppm.
Cleaver-Brooks water softeners remove hardness, preventing scale buildup on heat transfer surfaces, while maintaining peak
boiler efficiency. Removing hardness also reduces the need for chemical treatment used to control scale.
H9-2
09-09
Section H
Softeners
MODELS SSE & FSE FEATURES AND BENEFITS

Quality Constructed Tanks:
Two types of softener resin tanks are available to meet environmental requirements. Both
rugged lined steel or fiberglass (FRP) vessels are available.
Exclusive Polybond tanks are made of industrial grade steel. The tank interior is lined
with a heat-fused virgin polyethylene lining, creating a 40-60 mil thick, resilient, and
non-corrosive tank within a tank. The lining material is Food and Drug Administration
(FDA) listed. All surfaces that contact water during system operation, including valve
flanges and openings, are covered with the lining material, so that water never touches
bare steel, providing maximum protection against rust and corrosion. In addition,
gasketed tank openings provide dry thread closures, eliminating coated threads which
can be weak spots in tank linings.
All tanks are 100% spark tested to ensure the integrity of the tank lining.
All steel tanks up to 48 in diameter are hot-quench phosphatized prior to the application
of a 4- 6 mil thick exterior epoxy coating for further protection against rust and
corrosion, providing years of good appearance on the job. Tanks over 48 diameter are
coated with a zinc oxide-rich protective coating, suitable for field painting where
desired.
Fiberglass tanks are available for applications where environmental conditions or
budgetary constraints prevail. They are especially useful in providing rust and corrosion
protection. All FRP tanks are provided with a minimum of 5 year warranties.
Electronic Demand Programmable (ED) Controls
ED controls offer precise control over water softener operation. All controls have stateof-the-art electronics, and are microprocessor-based and completely programmable.
Operating efficiency combines with ease of use -- a 4-button keypad and alphanumeric
LCD display permit easy programming and observation of system functions (no
complicated jumper pins or dip switches to set). Simple programming prompts the
operator through set-up. Model code programming makes set-up as easy as selecting
model, pipe size, salt dosage, water hardness, and time. Controls perform all calculations
to minimize set-up errors.
An EEPROM memory retains all programmed and accumulated data, eliminating the
need to re-program the control after a power loss. A capacitor operates the
microprocessor in case of short term power loss.
An easy-to-read LCD display continuously displays system status and allows instant
access to current operating conditions, including flow rate, total treated flow, remaining
capacity, valve position and many more important features. The display is illuminated
for easy reading, even in low-light conditions. Self-diagnostic electronics provide 24hour per day review of the system, and stores historical data to allow system
optimization and simplify troubleshooting. A built-in speaker can transmit this System
Performance Analysis (SPA) data via regular telephone lines to a remote service center
for computerized troubleshooting, or, data can be recorded for later transmission.
Controls have a look-ahead feature. The main memory monitors operation, tracks data,
then adjusts regenerations automatically for high- and low-water use periods.
All controls are designed for use with Fleck regeneration valves as well as traditional
valve nest operated systems. Pre-wired components with indexed cables make
installation quick and simple, and eliminate the need for complicated wiring diagrams
and wiring connection instructions. Low voltage 24-volt operation simplifies installation
and minimizes electrical hazards.
Two models are available to meet varying needs: EDS/EDT, and VF.
EDS/EDT controls are capable of operating one or two softener tanks in single, parallel,
H9-3
09-09
Softeners
Section H
or alternating modes.
VF controls can operate two, three, or four softener tanks in parallel, alternating, or
variable flow mode. Each tank has its own flowmeter, so that the control knows how
much softening capacity remains in each tank. If water demand increases, the system
can be expanded by adding more softener tanks, and the control can be reprogrammed to
handle the larger system. If one softener tank is taken of-line, the VF control adjusts the
remaining tanks to maintain the same system flow rate. It also staggers tank regeneration
to prevent all tanks from being exhausted simultaneously, thus maintaining sufficient
softened water flow to the boiler or process need.
In variable mode, the VF control monitors flow rate and switches tanks into service to
meet changes in system demand, thus making sure that sufficient softened water is
available, and that each tank is efficiently used.
Versatile Control Valve:
Each softener control valve is a low-lead brass, mechanically actuated, hydraulically

balanced, self-cleaning six (6) position type to accomplish the regeneration steps of
backwash, brine draw, slow rinse, fast rinse, and tank refill. Separate rinse and timed
refill positions are used to reduce regeneration water use.
The valve is fitted with a fixed orifice eductor nozzle and self-adjusting backwash flow
control. The bypass body, like the main control valve, is actuated by a mechanical drive.
The valve is capable of stepping through all regeneration phases without electrical
power.
Brine System and Salt Storage
Positive action brine piston eliminates the need for constant line pressure at the salt
storage tank, minimizing brine tank overflows.
Timed tank refill provides highly reliable brine levels and salt usage. Salt dosage is
easily changed from the system control, eliminating the need to empty salt tanks.
Simple protected brine well design eliminates the need for gravel subfill and minimizes
brine tank maintenance.
High density FDA approved polyethylene tank and cover provide maximum strength
and corrosion resistance.
High Quality Softener Resins
All water softeners contain a high-quality, high-capacity, solvent-free synthetic ion

exchange resin, that exchanges the hardness minerals of calcium and magnesium ions
with soluble sodium ions, a soft and non-scaling mineral that does not build up on pipes
to cause hot spots and weaknesses. All resins have a minimum exchange capacity of
30,000 grains per cubic foot when regenerated with 15 pounds of salt per cubic foot.
Resins provide efficient exchange capacity at lower salt dosages (20,000 grains per
cubic foot at 5 pounds of salt per cubic foot). In addition to softening water, resins also
provide iron and manganese removal from the water. Softener resins are stable over the
entire pH range.
They are suitable for high flow rates and high hardness waters, and are physically stable
at high temperatures. Resins feature low attrition loss, and minimum backwash water is
required.
All resins are in solid bead form with uniform particle size, clean and free of dirt and
extraneous matter which might interfere with the ion exchange process.
All resins rest on a bed of quartz particles that have been screened not to exceed 16 mesh
H9-4
09-09
Section H
Softeners
size by 3/16-inch particle size. The quartz bed is at least two inches in depth and is
placed above the softened water distributor mounted in the bottom of the tank. The
quartz is washed and dried to remove debris and fines.
Automatic Self-Adjusting Backwash and Rinse Controls
This feature assures maximum cleansing of the resin bed during backwash, and prevents
loss of resin across the entire operating range of 30-100 PSIG. The flow control
eliminates the need for troublesome and time-consuming field adjustments.
Availability:
All softener systems are available from stock, with short lead times.
Optional Skid Mounting:
Tanks may be ordered skid-mounted for easy handling and easier and lower-cost field
installation.
Efficient Water Distributors:
Inlet water distributors are designed to produce uniform flow through the entire resin bed
and thus ensure maximum exchange capacity with low pressure loss.
MODELS SMR FEATURES AND BENEFITS

Automatic Control Center Engineered for Efficient Trouble-Free Service Includes:
Industrial grade multi-valve with integral brine injector.

Electrically operated cycle controller with position indicator.
Automatic backwash flow control.
The exclusive multi-valve design, features five hydraulically-operated diaphragm valve
assemblies conveniently arranged. The valve seats are positioned vertically in the valve
casting, reducing the possibility of dirt or debris lodging in the seat area. This design
provides a positive shut-off with no leaking or dripping, as is often the case with
horizontally-positioned valve seats.
Single unit softeners are provided with an automatic bypass valve that provides service
water during regeneration. Cycling of the diaphragm assemblies is smooth and entirely
free of water hammer.
Automatic Self-Regulating Brine Injector:
Assures efficient brining without time-consuming field adjustments.
Automatic Brine Maker, Includes Heavy Gauge Polyethylene Brine Tank for
Maximum Strength and Corrosion Resistance:
Platform brine system allows use of pure, clean, efficient salt pellets or nuggets,
eliminating costly and time consuming brine tank cleaning.
The system eliminates need for gravel subfills, reducing shipping weight and freight
costs.
Automatic brine valve provides reliable refill of the brine system with fresh water and is
fully serviceable. All critical seal areas of the brine valve are designed to prevent
corrosion or scaling to assure trouble-free operation.
High Capacity Resin, Adaptable to Wide Range of Applications:
High exchange capacity (30,000 grains per cubic foot at 15 lbs. salt dosage).
H9-5
09-09
Softeners
Section H
Efficient exchange capacity at lower salt dosages (20,000 grains per cubic foot at 6 lbs.
salt).
Iron and manganese removal.
Stability over entire pH range.
Suitable for high flow rates.
Suitable for high hardness waters.
Physically stable at high temperatures.
Low attrition loss.
Minimum backwash water required.
Automatic Self-Adjusting Backwash And Flush Controls:
Assures maximum cleansing of the resin bed during backwash and prevents loss of
costly resin across the entire operating range of 30-100 psig.
Eliminates the need for troublesome and time consuming field adjustments because the
flow control is pre-sized at the factory.
Available From Stock:
Short lead time or minimum down time.
Optional Skid Mounting:
Ease of installation in the field; lower installation cost.
System of Non-Clogging Strainers Arranged in a Radial Network:
Assures uniform flow through the entire resin bed, resulting in maximum exchange
capacity from the resin with low pressure loss.
Eliminates wasted capacity in the bottom area of the resin tank.
PRODUCT OFFERING
Water softeners require periodic regeneration with salt brine.
Standard Equipment - SSE & FSE

Single, duplex, triplex, or quadraplex unit systems include resin tank(s), brine tank, resin,
piping, multi-position piston valves, flowmeters and electronic demand controller.
Single tank exchange capacities: 30,000 to 1,200,000 grains.

Tank sizes: 9 to 48 diameter standard (larger diameters available).
Operating temperatures: 40 to 100 F.
Water meter for automatic regeneration.
24 Volt operation.
Heat fused polyethylene lined steel or FRP tanks.
Standard Equipment - SMR

Single, twin, or triple unit system includes resin tank(s), brine tank, resin, face-piping,
diaphragm, valve nest and cycle controller.
Size range in capacities: 30,000 to 2,100,000 grains.

H9-6
09-09
Section H
Softeners
Optional Equipment - SSE & FSE
ASME Code tank construction.

Alternating Parallel or Variable Flow operation.
Skid mounting, pre-wired and pre-piped.
High temperature operation.
Alternate linings and external coatings.
Optional Equipment - SMR
ASME Code tank construction.

Water meter for automatic regeneration.
Alternating operation.
Skid mounting, pre-wired and pre-piped.
External corrosion protection.
Operating Specifications
Pressure Range: 25 to 100 psig.

Temperature: Standard equipment suitable for water up to 100 F. Above 100 F, special
fitted valves are available. Specify water temperature when ordering.
Electrical: 120 Volt, 60 Hz is standard. Alternate voltages and frequencies available.
Specify electrical requirements when ordering. Transformers for control operation
voltage will be supplied with the SSE &FSE, SMR with MX controls.
Power: 6 Watts per cycle controller.
DIMENSIONS, RATINGS AND SIZING

Dimensions
Dimensions for the SSE Model Polybond lined Steel Softeners (sizes 30 - 1200) are shown in
Figure H9-1.
Dimensions for the FSE Model FRP Softeners (sizes 30 - 600) are shown inFigure H9-2.
Dimensions for the Model SMR Softeners (sizes 150-1050) are shown in Figure H9-4.
Ratings
Softener capacity and flow ratings are shown in Table H9-1, Table H9-2,Table H9-3 and
Table H9-4.
Sizing
Five things are required to size a softener:

1. Flow Rate/Pressure Loss
Softeners have two published flow rates:
Continuous - Used for sizing when actual flows are known. This rating of a softener will
generally produce a pressure loss of 15 psig.
Peak - Used to establish the absolute upper limits of a softener. This rating of a softener will
produce a pressure loss of 25 psig.
2. Time On-Line
Single softeners should be sized to stay on-line for at least one day. For continuous usage
when an alternating twin softener is used, each tank should be sized to stay on-line for 8-12
hours.
3. Water Hardness
To size the softener, the total water hardness must be determined in grains per gallons. If the
analysis report is in terms of parts per million or milligrams per liter (these are equal), divide
H9-7
09-09
Softeners
Section H
by 17.1 to convert to grains per gallon.
4. Water Usage
When the flow rate is constant, multiply the flow rate (gpm) by minutes on line. For
example, 50 gpm for 480 minutes (8 hours) = 24,000 gallons. When the flow rate is not in
constant use, use actual gallons used, or calculate gallons used based on boiler make-up
rates.
5. Exchange Capacity
Exchange rate is expressed in grains, and varies with salt dosage as follows:
15 pounds of salt per cu-ft = 30,000 grains capacity (best water quality, least efficient).
10 pounds of salt per cu-ft. = 25,000 grains capacity (good water quality, medium
efficiency).
6 pounds of salt per cu-ft. = 20,000 grains capacity (poorest water quality, most efficient).
For boiler make-up water, the higher water quality - 15 pounds salt dosage per cu-ft. - is
recommended.
Sizing Calculations
l. Single Softener. (Water usage per day x water hardness = capacity required.) For example:
10,000 gallons per day x 15 gpg hardness = 150,000 grains per day capacity required.
Select a Model (SSE 150) from the literature. Then select the pipe size to meet flow rate
requirements.
2. Alternating Twin Softeners
Flow rate x hardness x minutes on line = capacity required. For example:
Flow rate = 40 gpm. Hardness = 15 gpg. 40 x 15 x 480 minutes on line = 288,000 grains.
Select a Model (SSE 300) from the literature. Then select pipe size based on flow rate
requirements. When the gallons of make-up is not known, use Figure H9-5 to calculate
softener capacity required per hour. When less than 6 hours is expected between
regeneration of a twin softener, two brine makers are required.
H9-8
09-09
Section H
Softeners
C
B
BRINE
FRONT VIEW OF 36" TANK

SHOWN REDUCED
F
PLAN VIEW
TREATED
WATER
RAW
WATER
C
A
B
D
RIGHT SIDE VIEW
FRONT VIEW
Dimensions (next page) are given in inches.
Figure H9-1. SSE Models (Size 30-1200) Softener Dimensions - Page 1 of 2
H9-9
09-09
Softeners
Section H
MODEL
NUMBER
A
(in.)
SSE
B
(in.)
D
(in.)
C
(in.)
***
SINGLE
TWIN
E
(in.)
TRIPLE
QUAD
SINGLE
TWIN
F
(in.)
TRIPLE
QUAD
QUAD
SINGLE
TWIN
TRIPLE
INLET/
OUTLET (in.)
DRAIN
SIZE
(in.).
**
30-1
10
40
46
18
18
40
40
32
46
60
74
3/4*
60-1
12
52
58
18
18
40
40
35
75
47
83
3/4*
14
66
72
18
24
40
41*
36
54
82
100
90-1
90-11/
1
2
120-11/2
72
18
66
120-2
150-1
150-11/2
210-11/2
24*
41
41
46
68
90
112
66
77
77
24
41
41
46
68
90
112
24
24
50
50
52
80
108
136
66
300-2
450-2
77
24
24
50
50
52
80
108
136
66
450-3
30*
50
39
48
50*
65
48
80
99
133
71
600-3
1 1 /2
167
1*
1*
1 1/2*
3
2
82
36
11/2
3/4
2
30
86
600-2
11/2
77
30
3/4*
72
24
11/2
1
24
72
24
3/4*
2
72
18
210-2
300-11/2
77
24
11/
39
86
120
160
200
1 1/2
3
900-3
42
71
86
39
39*
48
48*
85
131
177
223
1200-2
48
71
86
52
52*
60
60*
104
156
212
268
* Recommend two (2) brine tanks on quad systems.

** When using two brine tanks on quad systems, add the diameter of the brine tank plus 4 inches to the overall length.
*** Total height of the unit will increase when using ASME code tanks. All ASME tanks (18-inch diameter through 48inch diameter) are 70-1/2 inches in height plus the height of the control valve.
Figure H9-1. SSE Models (Size 30-1200) Softener Dimensions - Page 2 of 2
H9-10
09-09
Section H
Softeners
BRINE
TREATED
WATER
RAW
WATER
A
C
B
D
E
FRONT VIEW
RIGHT SIDE VIEW
Figure H9-2. (1 of2) Model FSE (Size 30-600) Softener Dimensions
H9-11
09-09
Softeners
Section H
MODEL
NUMBER
D
(in.)
A
(in.)
B
(in.)
C
(in.)
FSE
E
(in.)
F
(in.)
PIPE SIZE (in.)
TRIPLE
QUAD*
SINGLE
TWIN
TWIN
TRIPLE
QUAD*
SINGLE
TWIN
TRIPLE
QUAD**
SINGLE
INLET/ DRAIN
OUTLET SIZE
30-1
48
54
18
18
40
40
31
44
57
70
3/
60-1
12
52
59
18
18
40
40
34
50
66
82
3/
3/
3/
3/
90-1
90-11/2
120-11/2
1
14
65
71
18
17
72
72
24
24*
40
41*
36
54
82
100
24
41
41
45
66
87
100
120-2
210-11/2
72
24
41
41
45
66
87
100
24
24
50
50
52
80
108
136
82
24
72
87
72
24
24
50
50
52
80
108
136
87
30
72
36
72
92
1 1 /2
30
30*
50
50
64
98
132
166
39
39*
48
48
79
119
159
199
1 1 /2
2
92
96
11/2
82
24
600-2
600-3
24
84
300-2
450-2
80
17
210-2
300-11/2
1 1 /2
2
150-1
150-11/2
11/2
1
1
2
3
1 1 /2
* Recommend using two (2) brine tanks on quad systems.

** When using two (2) brine tanks on quad systems, add the diameter of the brine tank plus 4-inches to the overall
length.
Figure H9-2. (2 of 2) Model FSE (Size 130-600) Softener Dimensions
H9-12
09-09
Section H
Softeners
BRINE
TANK
F
PLAN VIEW
RAW
TREATED
WATER
WATER
C
B
RIGHT SIDE VIEW
FRONT VIEW
MODEL
NUMBER
PIPE SIZE (in.)

A
(in.)
B
(in.)
C
(in.)
D
(in.)
E
(in.)
F
(in.)
CRS
INLET/
OUTLET
DRAIN
30-1
48
54
18
40
46
3/
60-1
12
52
59
18
40
52
3/
3/
90-1
14
65
71
18
120-11/2
16
65
72
150-11/2
17
72
80
90-11/2
210-11/
40
54
24
41
67
1 1 /2
3/
24
41
68
1 1 /2
3/
11/2
24
72
82
24
50
80
11 /
300-11/2
24
72
82
24
50
80
1 1 /2
Figure H9-3. CRS Crossover Twin Dimensions (Size 30-300)

H9-13
09-09
Softeners
Section H
1
MODEL NUMBER
HEIGHT
(IN)
SMR-150-1
WIDTH
(IN)
SINGLE
LL1
TWIN
L2
TRIPLE
L3
50
88
126
54
96
138
60
108
156
66
114
162
81
135
189
81
135
189
90
150
218
98
158
218
29
SMR-150-1 1/4
30
72
SMR-150-1 1/2
30
SMR-150-2
34
SMR-210-1 1/4
32
SMR-210-1 1/2
32
73
SMR-210-2
36
SMR-210-2 1/2
37
SMR-300-1 1/2
38
SMR-300-2
42
76
SMR-300-2 1/2
43
SMR-300-3
44
SMR-450-1 1/2
38
SMR-450-2
42
82
SMR-450-2 1/2
43
SMR-450-3
44
SMR-600-1 1/2
44
SMR-600-2
48
89
SMR-600-2 1/2
49
SMR-600-3
50
SMR-750-2
48
SMR-750-2 1/2
101
SMR-750-3
50
SMR-900-2
SMR-900-2 1/2
49
54
94
55
SMR-900-3
56
SMR-1050-2
54
SMR-1050-2 1/2
SMR-1050-3
106
55
56
Figure H9-4. SMR Dimensions (Size 150-1050)

H9-14
09-09
Section H
Softeners
Table H9-1. SSE Water Softener Ratings Polybond Lined Steel
MODEL
NUMBER
EXCHANGE
CAPACITY
RESIN
QYT
CONT
SERV
FLOW
PRESS
DROP
PEAK
SERV
FLOW
BACKPRESS WASH
DROP FLOW
SSE
MAX GR
MIN
GR
CU-FT
GPM
PSI
GPM
PSI
GPM
30-1
30,000
20,000
12
10
60-1
60,000
40,000
16
10
24
20
21
15
29
25
90,000
60,000
90-1
90-1-1/2
120-1-1/2
120,000
80,000
150-1-1/2
100,000
210,000
140,000
300,000
200,000
450-2
300,000
600-2
400,000
1200-3
900,000
48
22
48
12
40
13
52
25
60
11
45
15
60
25
84
15
45
15
58
25
15
107
25
87
15
118
25
15
200
25
94
15
125
25
(in.)
(lbs)
400
12x52
18x40
400
14x66
18x40
400
1
1-1/2
20
140
(in.)
18x40
15
77
SOFR BRINE
10x40
15
56
SALT
STORAGE
CAPACITY
7
40
FLOW
SENSOR
SIZE
(in.)
7
32
MANIF
PIPE
SIZE
(in.)
18x66
18x66
24x66
24x66
30x66
36x71
160
15
240
25
30
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1 1 /2
1-1/2
1 1 /2
24x41
700
24x41
700
24x50
24x50
30x50
25
20
600-3
900-3
12
15
450-3
600,000
32
10
300-2
450,000
16
210-2
300-11/2
36
150-2
210-11/2
120-2
150,000
24
TANK
DIMENSIONS
1,000
1,000
1,500
39x48
2,500
600,000
30
200
15
270
25
40
42x71
39x48
2,500
1,200,000 800,000
40
210
15
280
25
50
48x71
52x60
4,500
Flow rates and resin capacities are based on a single tank.
H9-15
09-09
Softeners
Section H
Table H9-2. FSE Water Softener Ratings, Fiberglass Softeners

MODEL
NUMBER
EXCHANGE
CAPACITY
RESIN
QYT
CONT
SERV
FLOW
PRESS
DROP
PEAK
SERV
FLOW
BACKPRESS
DROP WASH
FLOW
FSE
MAX GR
MINGR
CU-FT
GPM
PSI
GPM
PSI
GPM
30-1
30,000
20,000
12
10
60-1
60,000
40,000
16
10
24
20
21
15
29
25
90,000
60,000
90-1
90-1-1/2
120-1-1/2
120,000
80,000
210,000
140,000
300,000
200,000
12
48
22
32
48
12
40
13
52
25
40
60
16
45
15
60
25
7
56
84
15
45
15
58
25
10
450,000
300,000
15
600,000
400,000
20
600-2
600-3
9X48
18x40
400
12x52
18x40
400
14x65
18x40
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
16X65
17X72
15
77
15
107
25
87
15
118
25
20
94
15
125
25
25
160
15
240
25
SALT
STORAGE
CAPACITY
(lbs)
15
300-2
450-2
32
FLOW
SENSOR
SIZE
(in.)
(in.)
210-2
300-11/2
16
150-2
210-11/2
36
SOFR BRINE
MANIF
PIPE
SIZE
(in.)
(in.)
150-1-1/2
100,000
120-2
150,000
24
TANK
DIMENSIONS
24x72
24x72
400
700
24x41
24x41
700
24x50
1,000
24x50
30x72
30x50
36x72
39x48
30
1,000
1,500
2,500
Table H9-3. CRS Water Softener Ratings, Fiberglass Softeners with Crossover Controls
MODEL
NUMBER
EXCHANGE
CAPACITY
RESIN
QYT
CONT
SERV
FLOW
PRESS
DROP
PEAK
SERV
FLOW
PRESS BACKWASH
DROP FLOW
CRS
MAX GR
MINGR
CU-FT
GPM
PSI
GPM
PSI
GPM
30-1
30,000
20,000
12
10
60-1
60,000
40,000
16
10
24
90-1
90,000
60,000
21
15
90-11/2
90,000
60,000
24
12011/2
120,000
80,000
150-11/2
150,000
100,000
210-11/2
210,000
300-11/2
300,000
TANK
DIMENSIONS
SOFR BRINE
MANIF
PIPE
SIZE
(in.)
FLOW
SENSOR
SIZE
(in.)
SALT
STORAGE
CAPACITY
(lbs)
(in.)
(in.)
9x48
18x40
400
20
12x52
18x40
400
29
25
14x65
18x40
400
36
16
14x65
18x40
1 1 /2
1 1 /2
400
32
12
48
22
16x65
24x41
1 1 /2
1 1 /2
700
40
13
52
25
17x72
24x41
1 1 /2
1 1 /2
700
140,000
45
15
60
25
15
24x72
24x50
1 1 /2
1 1 /2
1,000
200,000
10
45
15
58
25
15
24x72
24x50
1 1 /2
1 1 /2
1,000

(CRS Crossover Systems Are Only Available In Twin Alternating Configurations.)
H9-16
09-09
Section H
Softeners
Table H9-4. SMR Water Softener Ratings

MODEL
NUMBER
SMR
150-1
150-1-1/4
150-1-1/2
150-2
EXCHANGE
CAPACITY
MAX
GR
MIN
GR
RESIN
MANIF
PIPE
SIZE
CONT
SERV
FLOW
PEAK
SERV
FLOW
BACKWASH
FLOW
IN.
GPM
GPM
GPM
1
1-1/4
1-1/2
2
32
43
55
69
42
57
70
97
1-1/4
1-1/2
2
2-1/2
41
64
80
115
57
86
110
160
1-1/2
2
2-1/2
3
65
82
140
165
92
125
190
230
CU-FT
TANK
DIMENSIONS
SALT
CAPACITY
BRINE MAKER
(LBS)
SALT PER
REGEN
MAX
LBS
MIN
LBS
700
75
30
24x50
600
105
42
30x54
24x60
600
150
60
SOFR BRINE
(in.)
(in.)
10.0
20x54
24x50
15
24x54
20.0
1-1/4
1-1/2
2
2-1/2
1-1/2
2
2-1/2
3
1-1/2
2
2-1/2
3
90
120
1-1/2
2
2-1/2
3
1 1/2
300
375
150
2
2-1/2
3
1 1/2
1700
1900
450
180
2
2-1/2
3
42x60
2300
525
210
2
2-1/2
3
50x60
210,000 140,000
300,000 200,000
10
450-1-1/2
450-2
450-2-1/2
450-3
450,000 300,000
15
1-1/2
2
2-1/2
3
63
82
120
140
90
115
170
190
20.0
30x60
30x60
1000
225
600-1-1/2
600-2
600-2-1/2
600-3
600,000 400,000
20
1-1/2
2
2-1/2
3
72
110
140
175
94
125
190
250
30.0
36x60
39x60
1900
750-2
750-2-1/2
750-3
750,000 500,000
25
2
2-1/2
3
90
140
160
116
190
230
30.0
36x72
39x60
900-2
900-2-1/2
900-3
900,000 600,000
30
2
2-1/2
3
105
150
188
133
218
274
45.0
42x60
35
2
2-1/2
3
95
145
175
124
210
259
45.0
42x72
1050-2
1050-2-1/2
1050-3
1050K
700K
(in.)
300-1-1/2
300-2
300-2-1/2
300-3
DRAIN
PIPE SIZE
(in.)
1
1-1/4
1-1/2
2
150,000 100,000
210-1-1/4
210-1-1/2
210-2
210-2-1/2
REC
WATER
METER
SIZE
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.
H9-17
09-09
Softeners
Section H
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 makeup 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 required for each hour of generator operation from line C.
3. Calculate the hardness removal required each day by multiplying the value obtained in step 2 by the
hours operated each day.
NOTE: In situations where softened water is required for loads in addition to boiler requirements, the total
gpm flow for the softener is the total of both requirements. Then using lines B and E, the required grain
removal per hour can be determined.
EXAMPLE
10,000 lbs steam/hour
15% make-up
8 hours daily operation
Water hardness 10 grains per gallon
FROM NOMOGRAPH
Feedwater make-up is 3 gpm.
Hardness removal required is 1800 grains per hour.
Hardness removal required each day - 8 x 1800 - 14,400 grains.
SOFTENER SELECTION
Select a softener that will meet both flow rate and exchange requirements. For 24 hour operation and to
provide a continuous supply of soft water, a twin unit is required. For the above example, an SSE-60-1 Twin
could be used to provide 24 hour operation. This model would provide 1 day operation between regeneration periods. To provide 8 hour a day operation, the SSE-60-1 single unit would permit 3 days between regeneration periods.
Figure H9-5. Water Softener Sizing Chart

H9-18
09-09
Section H9
Softeners (SSE/FSE)
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-20
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-20
Tanks 10 Through 36 Diameter (Steel Polybond: Standard SSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-20
Tanks 9 Through 36 Diameter (Fiberglass Reinforced Plastic: Standard FSE) . . . . . . . . . . . . . . . . . . H9-21
Tanks 20 Through 42 Diameter (SMR Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-21
Distribution System - Models SSE & FSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-21
Main Operating Valve SSE / FSE 30 to 1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-22
Brine System and Salt Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-22
Resin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-22
Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-22
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-23
Gauge and Sample Valve Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-23
Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-23
Duplex Twin Alternating Units EDT Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-23
Variable Flow Multiple Tank Systems VF Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-24
Cross Over Twin Units CSR Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-25
Time Clock Units TC Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-25
Flowsensors 1 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-25
Flowsensors 1.5 x 2 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-26
Flowsensors 3 and Larger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-26
EXECUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-26
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-26
Time Clock Units TC Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-27
Flowsensors 1 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-27
Flowsensors 1.5 x 2 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-27
Flowsensors 3 and Larger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-27
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-27
Skid Mounting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-28
Steel Softeners Model 30 to 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-28
Steel Softeners Model 450 to 600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-28
Steel Softeners Model 750 to 1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-28
Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-28
SAMPLE SPECIFICATIONS (SSE/FSE)

The following sample specifications are provided to you by Cleaver-Brooks to assist you in meeting your customers
requirements.
H9-19
09-09
Softeners
Section H
PART 1 GENERAL
11
GENERAL
Furnish, install, and place in operation an Automatic Water Softener System similar or
approved equal to Cleaver-Brooks Model (SSE: lined steel tank/ FSE: fiberglass
reinforced plastic tank)_______________, having ______tank(s) with ______cu-ft. of
ion exchange resin per tank. Soft water output to be ___________gallons (cu-meters)
per tank per regeneration with______lbs(kg) of salt, based on _______ grains per gallon
compensated hardness. Service flow rate per tank_______ gpm (lpm) at a pressure loss
through softener system not exceeding _______ psig (bar).
PART 2 PRODUCTS
21
EQUIPMENT
A. Tanks 10 Through 36 Diameter (Steel Polybond: Standard SSE)
1. Softener tanks shall be made of butt-welded industrial grade
carbon steel designed for a working pressure of 125 psi (____bar)
dynamic and hydrostatically tested at 50% excess of the working
pressure. Each tank shall be _______ m) diameter with a _______
m) overall tank height. Tank support(s) shall be of a skirt-ring type
welded to the tank(s) lower head. The tank(s) shall be equipped
with a resin loading port and a drain/resin removal port (14 and
larger).
2. Steel tank(s) shall be provided with a 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.
3. Steel tank linings shall be tested for lining integrity by a 2,500-volt
spark test, and the test certified with the shipping papers for the
system (if requested at the time of order). The spark test shall be
capable of detecting the most minute imperfection. The tank(s),
with linings in place, shall be water tested under pressure for
leaks.
4. 2.1 Tanks 42 Through 48 Diameter (Steel Polybond: Standard
SSE)
5. Softener tanks shall be made of butt-welded industrial grade
carbon steel designed for a working pressure of 100 psi (____bar)
dynamic and hydrostatically tested at 50% excess of the working
pressure. Each tank shall be _______ m) diameter with a _______
m) overall tank height. Tank support(s) shall be strap-type steel
legs permanently welded to the lower tank head. The tank(s) shall
be equipped with a resin loading port and a drain/resin removal
port.
H9-20
09-09
Section H
Softeners
6.
B.
C.
D.
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.
7. Steel tank linings shall be tested for lining integrity by a 2,500-volt
spark test, and the test certified with the shipping papers for the
system if requested at the time of order. The spark test shall be
capable of detecting the most minute imperfection. The tank(s),
with linings in place, shall be water tested under pressure for leaks.
Tanks 9 Through 36 Diameter (Fiberglass Reinforced Plastic:
Standard FSE)
1. Softener tank(s) shall be made of fiberglass reinforced ABS
plastic. The exterior sideshell shall be reinforced by a continuous
roving glass filament overwrap of the same color as the tank shell.
The tank(s) shall be supported by a molded polypropylene
structural base. Including the base, each vessel shall have the
dimensions of _______ inches diameter and _______ inches
height.
Tanks 20 Through 42 Diameter (SMR Standard)
1. Option - Pressure vessels shall be provided in accordance with
ASME Section VIII. Working pressure will be 100, 125 or 150
psig and hydrotested to 150% of stamped and certified rating.
2. Option - Provide tank with high temperature internal epoxy lining
at 8-10 mil DFT. Exterior tank surface will be cleaned and coated
with a corrosion-resistant zinc-rich primer suitable for epoxy
coating in the field.
3. Option - Provide tank with a baked phenolic internal epoxy lining
at 8-10 mil DFT. Exterior tank surface will be cleaned and coated
with a corrosion-resistant zinc-rich primer suitable for epoxy
coating in the field.
4. Option - Provide tank with an external coating of a high gloss
epoxy paint 2-4 mil DFT.
Distribution System - Models SSE & FSE
1. The soft water collector and backwash water distributor shall be
non-clogging design with slot size slot 0.010 inch in width. Single
point and hub radial laterals will be used to ensure adequate
distribution of flow during service, backwash and regeneration.
Laterals will be made of Schedule 80 PVC and designed for low
pressure drop-in service.
2. The distributor system will be fully covered by a minimum of 2
inches of quartz underbedding. The quartz shall be washed and
dried to remove debris and fines, and screened not to exceed 16
mesh size by 3/16-inch particle size.
H9-21
09-09
Softeners
Section H
E.
F.
G.
H.
Main Operating Valve SSE / FSE 30 to 1200

1. The control valve shall have _______inch _______ cm) NPT
(BSP) inlet and outlet connections. It shall be a low lead brass
mechanically-actuated, hydraulically-balanced, self-cleaning
piston six-position type to accomplish the regeneration steps of
backwash, brine draw, slow rinse, fast rinse, and refill. Separate
rinse and timed refill positions will be provided to reduce
regeneration water use. The valve shall contain fixed orifice
eductor nozzle and self-adjusting backwash flow control. The
valve will be capable of being manually stepped through
regeneration without electrical power.
Brine System and Salt Storage
1. The brine system shall be designed to minimize possible overflow
conditions by eliminating line pressure to the salt storage tank at
all times except during refill. Timed tank refill will be used to
utilize salt and regeneration water efficiently and the regeneration
salt dosage shall be adjustable from 5 to 20 lbs _______ to___ kg)
per cubic ft. (m) from the system control without the need for
emptying salt tanks or moving fill plugs.
2. A combination salt storage tank with cover and brine tank well
shall be supplied as part of the system. The tank shall be sufficient
size to hold salt for at least _______ regenerations between refills.
The tank(s) shall be made of corrosion-free one-piece molded
polyethylene or fiberglass reinforced plastic material. The tank(s)
shall have a nominal diameter of _______ inches (_____cm) and a
height of _______ inches (_____cm) and have a storage capacity
of ______lbs (kg). All brine systems will include a float operated
plastic brine pick up designed to provide positive shut off to
prevent air from entering the system.
3. Option - A pressurized brine control system will be provided to
introduce brine into the softener vessels. A timed brine controller,
non-corrosive self-adjusting flow controls and pilot-operated
diaphragm valve will be provided for integration into the facilities
pressurized brine source. Salt dosage shall be field adjustable
through the timed brine module.
Resin
1. Each softener tank shall be provided with _______ cubic feet of
high capacity sulphonated styrene divinylbenzene based synthetic
ion exchange resin having a minimum exchange capacity of
30,000 grains per cubic foot when regenerated with 15 pounds of
salt per cubic foot. The resin shall be solid, with uniform particle
size, clean and free of dirt and extraneous matter that might
interfere with flow of water through the resin or that might
interfere with the ion exchange process. All resin shall be FDA
compliant under the Code of Federal Regulation No.21 paragraph
173.25.
Flow Control
1. Automatic backwash and brine refill flow control shall be
provided to maintain proper backwash, rinse and brine flow rates
over wide fluctuations of operating pressure. The controller will
contain no moving parts and require no field adjustment. All flow
controls will be connected for ease of removal for inspection and
H9-22
09-09
Section H
Softeners
I.
J.
K.
L.
service as needed.
Piping
1. Contractor shall furnish and install all interconnecting pipe and
isolation valves. Drain connections from the control valve shall
have an air gap conforming to local codes and to permit
observation and sampling of backwash and regeneration water.
Gauge and Sample Valve Option
1. Manufacturer shall provide two pressure gauge and sample valve
assemblies or contractor installation in the inlet and outlet piping.
Pressure gauges and sample valves will be stainless steel or other
non-corrosive design.
Control Options
1. Single Units EDS Control
a. The softener system will be controlled by a single computerbased demand (meter) initiated controller. The controller
shall be capable of operating either 1 or 2 units in single, twin
alternating, or parallel configurations allowing easy
expansion as soft water demand increases without the need
for rewiring or adding additional controllers. The control will
utilize alphanumeric, self-prompting programming for simple
start up. EEPROM memory shall store program data
eliminating need for battery back-up or configuration input
after power loss. The control shall be pre-wired and includes
twist lock electrical end connectors for installation ease.
b. The controller will constantly monitor current operating
condition and be capable of displaying instantaneous flow
rate through the system. A resettable totalizing flow counter
will be included to measure total water processed.
c. The control shall be self-diagnostic and capable of emitting
an audible signal and error specific messages if it detects a
system problem. Control diagnostics can be transmitted over
telephone lines for troubleshooting or review of historical
operational data to allow system optimization through
evaluation of actual water usage. Valve and control operation
will be 24V, 60Hz, 1ph A suitably sized UL/CSA listed
transformer(s) will be provided to convert 120V, 60Hz, 1ph
power for system operation. Control printed wiring
assemblies will be conformally coated to MIL specifications
suitable for use in humid environments. A water-tight
enclosure will be used to house he control.
Duplex Twin Alternating Units EDT Control
1. The softener system will be controlled by a single computer-based
demand (meter) initiated controller. The controller shall be capable
of operating 2 units in twin alternating, or parallel configurations
allowing the units to easily both be put on-line to handle peak start
up flows and returned to alternating operation during normal use
periods without the need for rewiring, or extensive reprogramming
or adding additional controllers. Although the control will allow
two units to be put on-line simultaneously, a built-in lockout
prevents both units from regenerating at the same time. The control
will utilize alphanumeric, self-prompting programming for simple
H9-23
09-09
Softeners
Section H
M.
start up. EEPROM memory shall store program data eliminating

need for battery back-up or configuration input after power loss.
The control shall be pre-wired and includes twist lock electrical
end connectors for installation ease.
2. The controller will constantly monitor current operating condition
and be capable of displaying instantaneous flow rate through the
system. A resettable totalizing flow counter will be included to
measure total water processed.
3. The control shall be self-diagnostic and capable of emitting an
audible signal and error-specific messages if it detects a system
problem. Control diagnostics can be transmitted over telephone
lines for trouble shooting or review of historical operational data
to allow system optimization through evaluation of actual water
usage. Valve and control operation will be 24V, 60Hz, 1ph A
suitably sized UL/CSA listed transformer(s) will be provided to
convert 120V, 60Hz, 1ph power for system operation. Control
printed wiring assemblies will be conformally coated to MIL
specifications suitable for use in humid environments. A watertight enclosure will be used to house the control.
Variable Flow Multiple Tank Systems VF Control
1. The system will be supplied with a single computer-based demand
(meter) initiated controller capable of operating systems with 2 to
4 units. In addition to traditional parallel or alternating operating
conditions, the control can operate in a variable flow mode which
has the ability to bring units on and off-line depending on current
service flow. The control will utilize alphanumeric, self-prompting
programming for simple start-up. EEPROM memory shall store
program data eliminating need for battery back-up or
configuration input after power loss. It is pre-wired and includes
twist lock electrical end connectors for installation ease.
system. On multiple vessel systems flow and operational data for
each unit shall be independently displayable. A resettable
totalizing flow counter will be included to measure total water
processed.
3. The control shall be self diagnostic and capable of emitting an
audible signal and error-specific messages if it detects a system
lines for troubleshooting or review of historical operational data to
allow system optimization through evaluation of actual water
usage. If an error is detected the controller will be capable of
automatically readjusting the operating program to place the
maximum number of tanks on-line and recalculate regeneration
frequency to provide optimum treatment flow capacity until
service is provided. Valve and control operation will be 24V,
60Hz, 1ph A suitably sized UL/CSA listed transformer(s) will be
provided to convert 120V, 60Hz, 1ph power for system operation.
Control printed wiring assemblies will be conformally coated to
MIL specifications suitable for use in humid environments. A
water tight enclosure will be used to house the control.
H9-24
09-09
Section H
Softeners
4.
N.
O.
P.
Q.
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.
Cross Over Twin Units CSR Control
1. The softener system will be supplied with a computer-based
demand (meter) initiated controller. The control will utilize
alphanumeric, self-prompting programming for simple start-up.
EEPROM memory shall store program data eliminating need for
battery back-up or configuration input after power loss.
audible signal and error specific messages if it detects a system
usage.
4. Valve and control operation will be 24V, 60Hz, 1ph A suitably
sized UL/CSA listed transformer(s) will be provided to convert
120V, 60Hz, 1ph power for system operation. Control printed
wiring assemblies will be conformally coated to MIL
specifications suitable for use in humid environments. The control
will be mounted directly in the valve cover. Electrical installation
will only require plugging in the transformer and connecting the
flowsensor cable.
Time Clock Units TC Control
1. The softener(s) will be provided with a 7 day timer allowing
recharge to occur at a user adjustable time of day or night. The
timer shall be capable of being set to skip one or more days
between regenerations. Electrical operation is 120V, 60Hz, 1ph.
Flowsensors 1 Models
1. _______ 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 selflubricated shaft riding on a sapphire bearing. The sensor shall be
made in such a way that it can be installed and removed with
simple hand tools. Pipe size of the sensor(s) shall be 1 inch
(_______cm). It shall have a minimum flow of 1 gpm (___lpm),
and a peak flow of 40 gpm (____lpm). Flow rate normal range is 1/
2 to 30 gpm. The flowmeter housing shall be brass.
Flowsensors 1.5 x 2 Models
simple hand tools. Pipe size of the sensor(s) shall be 1.5 inch
(_______cm) x 2 inch _______ cm). It shall have a minimum flow
of 2 gpm, flow rate normal range is 1-1/2 to 60 gpm (____lpm),
H9-25
09-09
Softeners
Section H
R.
PART 3 EXECUTION
3.1
and a peak flow of 125 gpm (_____lpm). The flowmeter housing

shall be brass.
Flowsensors 3 and Larger
1. _______ Hall effect paddle wheel flow sensor(s) will be provided.
These sensor(s) shall be made with no packing glands or rotating
shaft seals and will be solid state proximity transducer type with a
self lubricated PVDF paddlewheel riding on a titanium shaft The
sensor shall be made in such a way that it can be installed and
removed with simple hand tools. Pipe size of the sensor(s) shall be
3 inch (_______cm). It shall have a minimum flow of 7 gpm
(____lpm), and a peak flow of 230 gpm (_____lpm) [for 3 "].
Flow rate for 3" - normal range is 7 to 200 gpm, _____12 gpm
(____lpm), 395 gpm (_____lpm) [for 4"]. Flow rate for 4" normal range is 12 to 350 gpm. 25 gpm (____lpm) 999 gpm
(_____lpm) [for 6"].3
EXECUTION
A. Instructions
1. The softener system will be supplied with a computer-based
demand (meter) initiated controller. The control will utilize
alphanumeric, self-prompting programming for simple start-up.
EEPROM memory shall store program data eliminating need for
battery back-up or configuration input after power loss.
audible signal and error specific messages if it detects a system
usage.
4. Valve and control operation will be 24V, 60Hz, 1ph A suitably
sized UL/CSA listed transformer(s) will be provided to convert
120V, 60Hz, 1ph power for system operation. Control printed
wiring assemblies will be conformally coated to MIL
specifications suitable for use in humid environments. The control
will be mounted directly in the valve cover. Electrical installation
will only require plugging in the transformer and connecting the
flowsensor cable.
B. Time Clock Units TC Control
1. The softener(s) will be provided with a 7 day timer allowing
recharge to occur at a user adjustable time of day or night. The
timer shall be capable of being set to skip one or more days
between regenerations. Electrical operation is 120V, 60Hz, 1ph.
C. Flowsensors 1 Models
made in such a way that it can be installed and
H9-26
09-09
Section H
Softeners
D.
E.
F.
G.
H.
(___lpm), and a peak flow of 40 gpm (____lpm). Flow rate normal
range is 1/2 to 30 gpm. The flowmeter housing shall be brass.
Flowsensors 1.5 x 2 Models
simple hand tools. Pipe size of the sensor(s) shall be 1.5 inch
(_______cm) x 2 inch _______ cm). It shall have a minimum flow
of 2 gpm, flow rate normal range is 1-1/2 to 60 gpm (____lpm),
and a peak flow of 125 gpm (_____lpm). The flowmeter housing
shall be brass.
Flowsensors 3 and larger
1. _______ Hall effect paddle wheel flow sensor(s) will be provided.
These sensor(s) shall be made with no packing glands or rotating
shaft seals and will be solid state proximity transducer type with a
self lubricated PVDF paddlewheel riding on a titanium shaft The
sensor shall be made in such a way that it can be installed and
(____lpm), and a peak flow of 230 gpm (_____lpm) [for 3 "]. Flow
rate for 3" - normal range is 7 to 200 gpm, _____12 gpm
(____lpm), 395 gpm (_____lpm) [for 4"]. Flow rate for 4" normal range is 12 to 350 gpm. 25 gpm (____lpm) 999 gpm
(_____lpm) [for 6"].3
Instructions
1. A complete set of instructions for installation and operation of the
softener system will be included.
Skid Mounting Options
1. The softener system will be provided skid-mounted with all units
pre-piped by the manufacturer. Each unit will be isolatable and a
system bypass valve shall come installed in the plumbing header.
Inlet and outlet connections will terminate in convenient locations
near the skid edge. All plumbing shall be supported by Unistrut or
equivalent anchors and members.
2. Inter-tank hydraulic tubing and fittings will be installed as part of
the skid package. All mineral tanks will be bolted to the skid
members to allow removal. Permanent mounting or welding is not
acceptable. All skids will be completely assembled, and
hydraulically and electrically tested before shipment. Prior to
shipping, the system will be drained before packaging. Partial
disassembly may be required for shipment. All assemblies will be
marked to allow simple reconnection.
Steel Softeners Model 30 to 300
1. Tanks 10 to 24 diameter will be mounted on a 4 channel iron
skid (5.4 lb. per foot, ASTM grade A-36) The skid will be crossbraced with similar 4 channel or angle iron. All steel surfaces will
be cleaned and painted with a high gloss epoxy top coat matching
H9-27
09-09
Softeners
Section H
I.
J.
K.
the softener vessel color.

skid (8.2 lb. per foot, ASTM grade A-36) The skid will be crossbraced with similar 6 channel or angle iron. All steel surfaces will
be cleaned and painted with a high gloss epoxy top coat matching
the softener vessel color.
skid (8.2 lb. per foot, ASTM grade A-36) The skid will be crossbraced 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.
Guarantee
1. Attrition loss of mineral is guaranteed not to exceed 3% per year
for a period of 3 years.
2. All mechanical equipment is guaranteed for 1 year against any
defects in workmanship or materials. All EDS, EDT, and VF
controls are guaranteed for 1 year against M & W. Consult specific
product warranty for mineral and brine tank information.
3. The manufacturer guarantees that under actual operating
conditions, the mineral shall not be washed out of the system
during service or backwash cycles when operated under the
instructions and guidelines set forth in the operation manual.
H9-28
09-09
Section H9
Softeners (SMR)
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-30
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-30
Regeneration Initiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-31
SAMPLE SPECIFICATIONS (SMR)

requirements.
H9-29
09-09
Softeners
Section H
PART 1 GENERAL
1.1
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.
PART 2 PRODUCTS
2.1
EQUIPMENT
2.1 Tanks
Softener tank(s) shall be of welded construction of tank quality carbon steel. Each tank
shall be _______ diameter with a _______ straight side shell height. The tank(s) shall
have threaded openings for pipe connections and an 11" x 15" manhole in the top head
(for tanks 30" diameter and smaller; two 4 x 6 handholes should be provided in the top
head and lower side shell). The tank(s) shall be rated for 100 psig working pressure and
150 psig test pressure. Support legs will be the strap-type permanently welded to the
lower tank head. The tank(s) shall have their exterior and interior protected with a hot
dipped galvanized application after fabrication. A minimum freeboard of 50% shall be
provided for backwash expansion above the normal ion exchange resin bed level.
2.2 Tank Option
Provide pressure vessel in accordance with ASME Section VIII. Working pressure to be
100, 125 or 150 pounds, hydrotested to 150, 187.5, or 225 psig, stamped and certified.
2.3 Tank Option
Provide cold-set epoxy internal lining 10-12 mils DFT, with rust resistant prime coat,
external coating 2-3 mils DFT.
2.4 Tank Option
Provide baked phenolic internal lining 4-5 mils DFT, with rust resistant prime coat,
external coating 2-3 mils DFT.
2.5 Tank Option
Provide Safety Blue epoxy finish paint 6-8 mils DFT over exterior tank and valve
surfaces. To be applied on channel iron surface if applicable.
2.6 Upper Distributor
The upper distribution system shall be a single point baffle constructed of Schedule-40
galvanized steel pipe and fittings.
2.7 Lower Distributor
The lower distribution system shall be of the hub end radial type constructed of PVC
with slotted full flow non-clogging replaceable ABS strainers and covered with a subfill
of 1/8 x 1/16 washed gravel.
2.8 Main Operating Valves
The main operating valves shall be a nest of individual diaphragm valves. The valves
shall have cast iron bodies with Buna-N diaphragm and stainless steel and brass internal
parts. The valves shall be slow opening and closing, and free of water hammer. There
shall be no contact of dissimilar metals within the valves and no special tools shall be
required to service the valves. Valves can be operated either hydraulically or
pneumatically.
2.9 Brine System
H9-30
09-09
Section H
Softeners
The brine system shall be platform type with dry salt storage compartment, sufficient for
at least four regenerations at full salting and a saturated brine compartment. The tank
shall be of polyethylene construction. It shall be equipped with a float operated plastic
brine valve and allow for simple adjustment of salt dosage without removing the brine
valve. It shall be _______ diameter x _______ shell height and have a storage capacity
of lbs of salt.
2.10 Resin
Resin shall be of a premium grade high capacity synthetic sulfonated styrene
divinylbenzene type, to be furnished in the sodium form. It shall be stable over the entire
pH range, have good resistance to bead fracture, and be insoluble in all common
solvents. The resin shall be capable of 30,000 grains per cubic foot capacity when
regenerated with 15 lbs NaCl.
2.11 Flow Control
An automatic backwash control shall be provided to maintain a proper backwash and fast
flush flows over wide variations of operating pressure. Controller to contain no moving
parts, and requires no field adjustment.
2.12 Piping
The main operating valves and manifold piping shall be Schedule 40 galvanized steel.
Galvanized fittings shall be standard class 150 threaded malleable iron.
PART 3 EXECUTION
3.1
REGENERATION INITIATION
A. Control
1. A NEMA 12rated factory mounted and wired electrical enclosure
with all timing and sequencing controls for each softener shall be
manufactured and provided by the same vendor providing the
water treatment hardware.
2. The controls shall include an automatic regeneration sequencer
having the capability of providing site adjustable regeneration
steps of backwash brine injection, brine displacement, flush and
return to service. An indicator on the pilot stager points to the cycle
of operation at all times. Complete function and control of all
regeneration steps can be performed by manual operation of the
pilot stager.
3. The 12-Day electrical time clock controller shall be fully
adjustable to initiate regeneration at any hour of the day and any
day of the week.
B. Control Option
1. Single Automatic Reset Meter and Alternator (Twin Softeners
Only)
2. The twin water softener shall be equipped with a single _______
(disc) (turbo) water meter, AWWA rated, in the common outlet
header. At a pre-set gallonage the automatic reset head of the meter
will send a 120 volt signal to an alternator that will direct the signal
to regenerate the unit presently on-stream. Upon completion of
regeneration, that softener will remain off stream in the stand-by
position. This sequence will repeat on an alternating basis each
time the preset gallonage of soft water has passed through the
meter. A lockout shall be provided to allow only one unit to
regenerate at any one time.
H9-31
09-09
Softeners
Section H
C.
D.
E.
Control Option
1. MX Electronic Programmable Controls (Two or Three Tanks)
2. The system will operate with two or three media tanks each having
a dedicated paddle wheel type flow sensor and operate in either of
these modes, one of which will be on-line while the other is
regenerated and user selected modes.
a. Alternating One media tank will be in the standby or
regeneration and one (1) or two (2) media tanks will be online. At a user specified volume the standby tank will go on
line and the exhausted tank will go into regeneration. After
regeneration this tank will go into standby until its rotation to
go back on-line
b. Parallel - All media tanks are on-line simultaneously. As
each media tanks user specified volume is reached it shall
immediately be taken off-line, regenerated, and placed
immediately back on-line.
c. Additive Flow - One (1) media tank, designated as the
primary, will remain on-line at all times. Variation of treated
water flow demand shall automatically cause (one additional
media tank) (up to two additional media tanks) to change
status from standby to on-line and back to standby as needed.
3. When the primary media tank regenerates the next media tank in
sequence shall become the primary.
4. As each media tanks user set volume is reached it will
immediately be taken off-line, regenerated, and placed
immediately back on-line or standby depending on treated water
flow demand.
5. The controller shall be capable of continuously determining the
exhaustion rate of each media tank thus automatically avoiding the
possibility of a simultaneous regeneration attempt. Simultaneous
regenerations are not possible.
6. The exchange capacity of each softener can be the same or
different. Flow or peak flow rate indication shall be continuously
displayed for each unit. The continuous flow range is 0-999 flow
units per minute (gallons, cu.ft., liters, cu-m, etc.). Cumulative
volume totalization to eight (8) digits shall be continuously
displayed for each unit.
Instructions - A complete set of installation instructions and operating
instructions shall be furnished.
Skid Mounting (Pre-pipe and Pre-wire)
1. Mineral Tank skid mount Option.
H9-32
09-09
Section H
Softeners
2.
F.
The softener mineral tanks shall be shall be mounted on a 4"

channel iron skid (7.25 lbs per foot, ASTM grade A-36). The skid
shall be cross-braced with a 4" channel or angle iron,. All steel
surfaces shall be prime coated. All interconnecting piping shall be
the same material as the valve nest manifold piping and shall be
assembled by the manufacturer. This shall include inlet and outlet
bronze isolation valves for each tank, and a bronze system bypass
valve. Inlet and outlet headers shall be installed and terminate at
the skid edge. All piping shall be suitably supported by Unistrut
supports anchored to the skid. Electric wiring, where applicable,
shall be complete between all inter unit controls and require only a
single power source connection. The inter unit wiring shall be
contained in Flextite flexible, waterproof conduit. All inter-tank
hydraulic or pneumatic tubing shall be installed as part of the skid
package. The mineral tanks are to be bolted to the skid. Permanent
attachment, or welding, will not be acceptable. The entire skid
mounted system shall be both leak and electrically tested as a unit
by the manufacturer before shipment
Guarantee
1. Attrition loss of mineral is guaranteed not to exceed 3% per year
for a period of 3 years.
2. All mechanical equipment is guaranteed for 1 year against any
defects in workmanship or materials. Any part proving defective
will be replaced or repaired within this period.
3. The manufacturer guarantees that under actual operating
conditions the mineral shall not be washed out of the system
during the service run or backwashing period; that the turbidity
and color of the effluent, by reason of passing through the softener
system, shall not be greater than that of the incoming water; and
that the under-drain system, gravel and mineral shall not become
fouled, either with turbidity or by dirt, rust, or scale from the
softening system, or present in the soft water, while operating as
noted on manufacturers instructions.
H9-33
09-09
Softeners
Section H
Notes
H9-34
09-09
Section H10
DEALKALIZERS
CONTENTS

DIMENSIONS, RATINGS AND SIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sizing Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H10-3
H10-3
H10-4
H10-4
H10-4
H10-4
H10-5
H10-9
ILLUSTRATIONS
Figure H10-1. Dealkalizer Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-6

TABLES
Table H10-1. Automatic Dealkalizer Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-4

Table H10-2. Dealkalizer Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-7
H10-1
09-09
Dealkalizers
Section H
Information in this section applies directly to Cleaver-Brooks dealkalizers ranging from 10,000 to 980,000 grain
capacity.
Cleaver-Brooks chloride cycle dealkalizers are similar to water softeners except that, instead of cation resin, they use a
strong anion resin to remove selective negatively charged ions from the raw water supply.
Dealkalizers require use of softened water, and are installed down stream from the water softener, and before the
deaerator. Dealkalizers remove more than 90% of the bicarbonate alkalinity from the softened water supply. This
effectively controls formation of carbon dioxide in the boiler, the major cause of condensate line corrosion.
Dealkalization reduces the need for neutralizing chemicals by as much as 90%, and cuts fuel costs by minimizing
blowdown.
H10-2
09-09
Section H
Dealkalizers

Reduces Bicarbonate Alkalinity, Thereby Minimizing CO2 Production:
Decreased chemical consumption.
Decreased condensate line corrosion.
Lower blowdown rates.
Reduces fuel consumption.
Increased cycles of concentration.
Uses a Strong Base Anion Resin With a Combination of

Salt/Caustic Soda Regeneration:
Produces a higher operating capacity and a more consistent effluent quality.
Provides some silica reduction.
Increases feed water pH.
PRODUCT OFFERING
Information in this section applies directly to Cleaver-Brooks dealkalizers ranging from
10,000 to 980,000 grain capacity (Table H10-1).
Cleaver-Brooks chloride cycle dealkalizers are similar to water softeners except that,
instead of cation resin, they use a strong anion resin to remove negatively charged ions
from the raw water supply. Dealkalizers replace bicarbonate, sulfate, nitrate, and silica
with chloride ions.
Dealkalizers require use of softened water, and are installed down stream from the water
softener, and before the deaerator. Dealkalizers remove more than 90% of the
bicarbonate alkalinity from the softened water supply. This effectively controls
formation of carbon dioxide in the boiler, the major cause of condensate line corrosion.
Dealkalization reduces the need for neutralizing chemicals by as much as 90%, and cuts
fuel cost by minimizing blowdown.
Dealkalizers offer best payback when:
1.
2.
3.
4.
Cycles of concentration in the boiler can be doubled.

Chloride content is below 120 ppm.
Sulfate count is below 50% of total exchangeable anions.
Bicarbonate alkalinity is 100 ppm or more.
Dealkalizers are regenerated with salt brine and sodium hydroxide and have an operating
temperature range of between 40 and 120 F.
Optional equipment includes:
ASME code tank construction.
Water meter for automatic or semi-automatic regeneration.
Skid mounting.
NEMA 12 or 4 control panels.
External corrosion protection.
Operating requirements include a continuous source of softened water at 30 to 100 psig,

40 F to 100 F. Electrical service, 120 Vac, 60 Hz, 5A.
H10-3
09-09
Dealkalizers
Section H
DIMENSIONS, RATINGS AND SIZING

Dimensions
Dealkalizer dimensions are shown in Figure H10-1.
Ratings
Dealkalizer ratings are shown in Table H10-2.
Sizing
Five things are required to size a dealkalizer:

1. Flow rate/pressure loss - because of a slower rate of exchange than softeners,
dealkalizers should be operated at a flow rate not exceeding 2 gpm per cubic foot of
resin. Peak flow could exceed this for very short periods of time without affecting
capacity or water quality.
2. Time on line - Single dealkalizers should be sized to stay on line for at least one day.
For continuous usage when an alternating twin dealkalizer is used, each tank should be
sized to stay on line for 8 - 12 hours.
3. Water analysis - In addition to alkalinity, a dealkalizer will remove sulfate, nitrate, and
carbon dioxide from water and these must all be considered to determine the total load.
The alkalinity, sulfite, nitrate, and carbon dioxide should be reported as CaCO3. To
correct an analysis from the ion to CaCO3 equivalents use the following conversion
factors:
Bicarbonate HCO3 = ______ x .82 =_________ as CaC03
Sulfate SO4 = _________ x 1.04 = __________ as CaCO
Table H10-1. Automatic Dealkalizer Selection Chart
MODEL
NUMBER
PIPE
SIZE
RESIN
CAPA
Resin
Tank
Size
FLOW
RATE
NORM
FLOW
RATE
B
MAX
BACKWASH
RATE
BRINE
TANK
SIZE
ACC-DAB-
IN.
CU-FT
GR
IN
GPM
GPM
GPM
IN.
LBS
10-3/4
3/4
10000
9x48
1.0
18x31
20-1
20000
12x54
1.4
30-1
30000
14x60
12
40-1-1/4
1-1/4
40000
16x60
50-1-1/4
1-1/4
50000
20x54
80-1-1/4
1-1/4
80000
140-1-1/2
1-1/2
14
200-2
250-2
CAUSTIC
REGEN
WATER
METER
C
SIZE
LBS
LBS
IN.
200
.4
3/4
18x31
200
.8
3/4
2.0
18x31
200
12
1.2
3/4
16
2.4
22x36
375
16
1.6
10
20
4.3
22x36
375
20
2.0
24x54
16
32
6.5
22x36
300
32
3.2
140000
30x60
28
56
10.0
24x54
550
56
5.6
1-1/2
20
200000
36x60
40
80
15.0
24x60
700
80
8.0
1-1/2
25
250000
36x72
50
100
15.0
24x60
600
100
10.0
1-1/2
330-3
33
330000
42x72
66
132
20.0
30x60
900
132
13.2
2T
420-3
42
420000
48x72
88
176
25.0
39x60
1800
168
16.8
2T
550-3
55
550000
54x72
110
220
32.0
39x60
1500
220
22.0
2T
680-3
68
680000
60x72
136
272
40.0
42x60
1800
272
27.2
3T
98
980000
72x72
196
300
60.0
50x60
3000
392
39.2
3T
980-4
SALT
SALT
CAP
REGEN
BRINER
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.
H10-4
09-09
Section H
Dealkalizers
Nitrate NO3 = __________ x .81 = __________ as CaCO
Carbon Dioxide CO2 = ______ x 1.14 =_______ as CaCO
The total of the above is the total load on the dealkalizer. If the total is in terms of parts
per million or milligrams per liter, convert to grains per gallon by dividing by 17.1.
4. Water usage - when the flow rate is constant, multiply the flow rate in gpm x minutes
on line. For example: 50 gpm x 480 minutes (8 hours) = 24,000 gallons. When the flow
rate is not constant, use actual gallons used or calculate gallons based on boiler make-up
rates.
5. Exchange capacity - does not vary with salt usage like a water softener. Use a capacity
of 10,000 grains per cubic foot and regenerate consumption of 4 pounds salt and 0.4
pounds caustic per cubic foot.
Sizing Calculations
Single Dealkalizer - Water usage per day x total load = capacity required. For example:
10,000 gallons per day x 20 gpg total load = 200,000 grain capacity required. Select a
Model ACC-DAB 200 from the literature. Then select the pipe size to meet the flow rate
required.
Notice
Check to assure the continuous flow rate does not exceed 2 gpm per cubic foot of resin.
H10-5
09-09
Dealkalizers
Section H
MODEL NO.
DS
DB
L1
ACC-DAB-10-3/4
18
37
54
22
61
88
ACC-DAB-20-1
12
18
43
60
22
64
94
ACC-DAB-30-1
14
18
49
66
22
66
98
ACC-DAB-40-1-1/4
16
22
49
66
22
72
106
ACC-DAB-50-1-1/4
20
22
43
76
30
76
114
ACC-DAB-80-1-1/4
24
22
43
79
34
80
122
ACC-DAB-140-1-1/2
30
24
43
85
41
88
136
ACC-DAB-200-2
36
24
43
91
45
94
148
ACC-DAB-250-2
36
24
43
103
45
94
148
ACC-DAB-330-3
42
30
43
106
53
106
166
ACC-DAB-440-3
48
39
38
98
64
112
178
ACC-DAB-550-3
54
39
39
99
70
126
198
ACC-DAB-680-3
60
42
40
101
76
132
210
ACC-DAB-980-4
72
48
42
105
90
148
238
Figure H10-1. Dealkalizer Dimensions
H10-6
09-09
Section H
Dealkalizers
Table H10-2. Dealkalizer Ratings

RESIN TANK DATA
MODEL
NO
TANK
PIPE RESIN FRRE GRAVEL
(ACCBOARD 1/8X1/16
SIZE
SIZE
FT3
DAB) (DIA X HT) (IN.)
(IN.)
(LBS)
FLOW RATES
BACK
SERVI CAPACITY
WASH
(GPM) (GRAINS)
(GPM)
BRINE TANK DATA
SLOW
RINSE
(GPM)
FAST
RINSE
(GPM)
TANK
SIZEA
CAUSTIC DATA
SALT SALT/ BRINE NaOH/ NaOH

CAP. REGN RATE REGN RATE
(LBS) (LBS) (GPM) (LBS) (GPM)
10
9x48
3/4
16
15
2
5
10000
8000
1.0
0.71
2.0
18x31
225
0.17
0.4
0.42
20
12x54
18
30
4
10
20000
16000
1.4
0.99
2.8
18x31
225
0.22
0.8
0.54
30
14x60
21
45
6
15
30000
24000
2.0
1.38
4.4
18x31
225
12
0.30
1.2
0.76
40
16x60
1-1/4
20
60
8
20
40000
32000
2.4
1.95
5.9
22x36
375
16
0.43
1.6
1.08
50
20x54
1-1/4
25-1/2
100
10
25
50000
40000
4.3
2.38
7.5
22x36
375
20
0.52
2.0
1.33
80
24x54
1-1/4
20-1/2
200
16
40
80000
64000
6.5
3.45
12.0
22x36
375
32
0.76
3.2
1.88
140
30x60
1-1/2
14
23
300
28
70
140000
112000
10
6.90
21.5
24x50
550
56
1.52
5.6
3.77
200
36x60
20
24-1/2
400
40
100
200000
160000
15
8.5
30
24x60
650
80
1.87
8.0
4.72
250
36x72
25
28
400
50
125
250000
200000
15
13.9
40
24x60
650
100
3.05
10.0
7.85
330
42x72
33
29
600
66
165
330000
264000
20
15.5
50
30x60
850
132
3.4
13.2
8.91
420
48x72
42
29
1000
88
210
420000
336000
25
21.4
65
38x60
1650
168
4.7
16.8
12.18
550
54x72
55
27-1/2
1300
110
275
550000
440000
32
30
85
38x60
1350
220
6.6
22.0
17.3
680
60x72
68
27-1/2
1800
136
340
680000
544000
40
37.5
100
42x60
1700
272
8.3
27.2
21.4
980
72x72
98
27-1/2
2600
196
490
980000
784000
60
53.4
150
48x60
2200
392
10.0
39.2
26.4
A. Tank size = diameter x height.
H10-7
09-09
Dealkalizers
Section H
NOTES
H10-8
09-09
Section H10
Dealkalizers
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-10
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-10
Tanks 9" Through 16" Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-10
Tanks 20" Through 42" Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-10
Tanks 48" Through 72" Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-10
Tank Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-11
Tank Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-11
Tank Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-11
Upper Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-11
Lower Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-11
Main Operating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-11
Brining System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-11
Caustic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-11
Resin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-12
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-12
Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-12
Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-12
Automatic Reset Register Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-12
Single Automatic Reset Meter and Altwinator (Twin Dealkalizers Only) . . . . . . . . . . . . . . . . . . . . . . . H10-13
Two Tanks - Alternating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-13
(Two) (Three) Tanks - Parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-13
EXECUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-14
Test Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-14
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-14
Skid Mounting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-14
Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-15
requirements.
H10-9
09-09
Dealkalizers
Section H
PART 1 GENERAL
1.1
GENERAL
A. Furnish, install, and place in operation an Automatic Chloride Cycle
Dealkalizer system, similar or approved equal to Cleaver-Brooks Model
ACC-DAB ________, having tank(s) with ________ cu-ft of ion
exchange resin per regeneration with ________ lbs of salt and
________ lbs of caustic, based on grains per gallon total anion load.
B. Service flow rate per tank ________ gpm at a pressure loss through the
dealkalizer system not exceeding _______ psig. The dealkalizer shall be
supplied by a boiler manufacturer that will be responsible for the total
boiler room system.
PART 2 PRODUCTS
2.1
EQUIPMENT
A. Tanks 9" Through 16" Diameter
1. Dealkalizer tank(s) shall be of welded construction, tank quality
carbon steel. Each tank shall be _______ " diameter with a
_______ " straight side shell height. The tank(s) shall have
reinforced openings for pipe connections and a 4" diameter access
opening in the top head. The tank(s) shall be rated for 100 psig
working pressure and 150 psig test pressure. Tank support(s) shall
be of a skirt ring type design, welded to the tank(s) lower head.
The tank(s) shall have the exterior protected with a finish coat of
polyurethane and the interior protected with an epoxy-polyamide
coating. A minimum freeboard of 50% shall be provided for
backwash expansion above the normal ion exchange resin bed
level.
B. Tanks 20" Through 42" Diameter
carbon steel. Each tank shall be __________ " diameter with a
___________" straight side shell height. The tank(s) shall have
reinforced openings for pipe connections and an 11" x 15"
manhole in the top head (for tanks 30" diameter and smaller; two
3" spin off handhole should be provided in the top head and lower
sideshell). The tank(s) shall be rated for 100 psig working pressure
and 150 psig test pressure. Support legs will be the strap type
permanently welded to the lower tank head. The tank(s) shall have
the exterior prime coated and the interior protected with an epoxy
lining 4-6 mils DFT after fabrication. A minimum freeboard of
50% shall be provided for back wash expansion above the normal
ion exchange resin bed level.
C. Tanks 48" Through 72" Diameter
carbon steel. Each tank shall be _______ " diameter with a
________ " straight side shell height; the tanks shall have
reinforced openings for pipe connections and 12" x 16" manhole
in the top head. The tank(s) shall be rated for 100 psig working
pressure and 150 psig test pressure. Support legs will be the
adjustable jack type. The tank(s) shall have the exterior protected
with a rust inhibiting primer and the interior shall have an epoxy
lining 4-6 mils DFT, prior to shipment. A minimum freeboard of
50% shall be provided for backwash expansion above the normal
ion exchange resin bed level.
H10-10
09-09
Section H
Dealkalizers
D.
E.
F.
G.
H.
I.
J.
K.
Tank Option
1. Provide pressure vessel in accordance with ASME Section VIII.
Working pressure to be 100, 125 or 150 pounds, and hydrotested to
150, 187.5 or 225 psig, stamped and certified.
Tank Option
1. Provide high-temperature epoxy internal lining 10-12 mils DFT,
with rust resistant prime coat, external coating 2-3 mils DFT.
Tank Option
1. Provide baked phenolic internal lining 4-5 mils DFT, with rust
resistant prime coat, external coating 2-3 mils DFT.
Upper Distributor
1. The upper distribution system shall be a single point baffle or fourpoint cross-arm type (9" through 60" diameter, single point), (66"
through 72" diameter, four point), constructed of Schedule-40
galvanized steel pipe and fittings.
Lower Distributor
1. The lower distribution system shall be of a single fine slotted PVC
lateral design with a single layer of washed 1/8" x 1/16" gravel
sub-fill to support the resin bed (9" through 16" diameter).
2. The lower distributor system be the Hub and Radial type or headerlateral 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).
Main Operating Valve
1. Each Dealkalizer shall have an automatic multiport diaphragm
type, slow opening and closing, and free of water hammer. The
valve shall consist of five (5) individual diaphragm valves housed
in a compact casing. These valves are to be pressure actuated by an
external pilot valve, automatically or manually. The valves shall be
manufactured by the same manufacturer as the entire dealkalizer
system. The valve guides, seats and diaphragm shall be constructed
of Noryl plastic. The valve shall have inlet and outlet pressure
gauges and sample cocks.
Brining System
1. The brining system shall be Flexi-trol type with dry salt storage
compartment, sufficient for at least six regenerations at full salting
and a saturated brine compartment. It shall be equipped with a float
operated plastic fitted brine valve and allow for simple adjustment
of salt dosage without removing the brine valve. The tank shall be
of polyethylene construction. It shall be _______ " diameter x
______ " shell height, and have storage capacity of lbs of salt.
Caustic System
1. The caustic system shall be designed to pump directly from
customer-purchased drums or carboys of 50% liquid caustic soda
with no caustic handling necessary.
2. Components of the caustic system shall be as follows:
a. One (1) caustic feed metering pump
b.
One (1) moveable pump stand
H10-11
09-09
Dealkalizers
Section H
c.
d.
L.
M.
N.
2.2
One (1) pressure switch

One (1) 30 minute automatic reset timer mounted in
protective box
e.
One (1) blend valve for adjustment of concentration
3. The metering pump shall be of the diaphragm type for corrosion
resistance and have a capacity of _______ gallons per minute.
Resin
1. Resin shall be of a premium grade high capacity synthetic
quaternary ammonium devinylbenyene type, to be furnished in the
chloride form. It shall be stable over the entire pH range, have
good resistance to bead fracture, and be insoluble in all common
solvents. The resin shall be capable of 10,000 grains per cubic foot
capacity when regenerated with 4 lbs of NaCl and 0.4 lbs of
NaOH.
Piping
1. Manufacturer to furnish dealkalizer tank, with assembled valve
manifold piping. Contractor shall furnish and install
interconnecting piping. Drain shall have an air gap conforming to
local codes to permit observation of discharge backwash water and
manufacturer shall provide a valved drain at the lowest point of
the dealkalizer system.
Flow Control
1. An automatic backwash control shall be provided to maintain a
proper backwash and fast flush flows over wide variations of
operating pressure. Controller to contain no moving parts and
requires no field adjustment. The flow controls shall be
manufactured by the same manufacturer as the entire dealkalizer
system.
CONTROL OPTIONS
A. Regeneration shall be controlled by a fully automatic time clock control
which is fully adjustable or can be controlled by a remote manual
controller. For fully automatic operating the regeneration shall be
initiated by calendar clock. A pointer indicates the cycle of operation at
all times.
1. Standard Gallon Register Meter - Each Dealkalizer tank shall be
equipped with a ______ " (disc), or (turbo), standard gallon
register meter to record the amount of dealkalized water produced.
The time clock will initiate the regeneration sequence.
2. Signal Register Meter - Each dealkalizer tank shall be equipped
with a _________ " (disc), or (turbo) meter with a signal register
head. The head shall send a ___ volt electrical signal to an audible
alarm upon reaching the hand set gallonage. The signal will
continue until reset by the operator. Regeneration will be initiated
by a push-button on the cycle controller of the exhausted unit.
B. Automatic Reset Register Meters
1. Each dealkalizer tank shall be equipped with a _____ " (disc), or
(turbo) meter with automatic reset head. The head shall send a 120
volt signal to the dealkalizer cycle controller to initiate
H10-12
09-09
Section H
Dealkalizers
C.
D.
E.
regeneration at a preset gallonage. The head will automatically

reset to this gallonage.
Single Automatic Reset Meter and Altwinator (Twin Dealkalizers Only)
1. The twin chloride cycle dealkalizer shall be equipped with a single
_____ " (disc), or (turbo) water meter in the common outlet header.
At a preset gallonage the automatic reset head of the meter will
send a 120 volt signal to an altwinator that will direct the signal to
regenerate the unit presently on stream. Upon completion of
regeneration, that dealkalizer will remain off stream in the standby
position. This sequence will repeat on an alternating basis each
time the preset gallonage of dealkalized water has passed through
the meter.
Two Tanks - Alternating
1. The system will operate with two media tanks each having a
dedicated flow sensor, one of which will be on-line while the other
is regenerated and standing by. Each tank can regenerate several
times per day. The on-line media tank shall regenerate immediately
upon reaching a user specified volume of treated water.
Simultaneous regenerations are not possible.
2. The exchange capacity of each dealkalizer can be the same or
different.
3. Flow rate indication shall be continuously displayed for each unit.
The flow range is 0-999 flow units per minute (gallons, cu-ft,
liters, cu-m, etc.).
4. Cumulative volume totalization to eight (8) digits shall be
continuously displayed for each unit.
(Two) (Three) Tanks - Parallel
1. The system shall consist of (two) (three) media tanks each having a
dedicated flow sensor, configured for parallel flow and operate in
either of these user selected modes:
a. All media tanks are on-line simultaneously. As each media
tank s user specified volume is reached it shall immediately
be taken off-line, regenerated, and placed immediately back
on-line.
b. One (1) media tank, designated as the primary, will remain
on-line at all times. Variation of treated water flow demand
shall automatically cause (one additional media tank) (up to
two additional media tanks) to change status from standby to
on-line and back to standby as needed.
2. When the primary media tank regenerates the next media tank in
sequence shall become the primary. As each media tank user set
volume is reached it will immediately be taken off-line,
regenerated, and placed immediately back on-line or standby
depending on the treated water flow demand.
3. The networked controls shall be capable of continuously
determining the exhaustion rate of each media tank, thus
automatically avoiding the possibility of a simultaneous
regeneration attempt. Simultaneous regenerations are not possible.
4. The exchange capacity of each dealkalizer can be the same or
different.
H10-13
09-09
Dealkalizers
Section H
5.
6.
PART 3 EXECUTION
3.1
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
feedwater recovery.
EXECUTION
A. Test Kit
1. A test kit shall be furnished to measure the dealkalizer
performance. It shall be of the methylorange type to detect
alkalinity.
B. Instructions
1. A complete set of installation instructions and operating
instruction shall be furnished.
C. Skid Mounting Options
1. The dealkalizer system shall be completely skid mounted. Tanks
9" through 16" diameter shall be mounted on a 3" channel iron
skid (9 lbs per foot, ASTM Grade A-36). The skid shall be crossbraced with 3" channel or angle iron, and the entire skid covered
with a 1/4" steel plate. All steel surfaces shall be prime coated.
2. Tanks 20" through 30" diameter shall be mounted on a 3" channel
iron skid (9 lbs per foot, ASTM Grade A-36). The skid shall be
cross-braced with a 3" channel or angel iron, and the entire area
under the polyethylene briner shall be covered with a 1/4" steel
plate. All steel surfaces shall be prime coated.
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
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
5. All interconnecting piping shall be assembled by the
manufacturer. This shall include inlet and outlet isolation valves
for each tank and a system bypass valve. Inlet and outlet headers
shall be installed and terminate at the skid edge. All piping shall be
suitably supported by Unistrut supports anchored to the skid.
Electric wiring, where applicable, shall be complete between all
inter unit controls and require only a single power source
connection. The inter unit wiring shall be contained in Flextite,
flexible, waterproof conduit.
6. All inter tank hydraulic or pneumatic tubing shall be installed as
part of the skid package.
7. All polyethylene briners shall be supported on the skid by a 12"
high steel band welded to the skid.
H10-14
09-09
Section H
Dealkalizers
8.
D.
The mineral tanks are to be bolted to the skid. Permanent

attachment, or welding, will not be acceptable.
9. Lifting lugs, rings, etc., will be suitably located for single point
lifting of the entire skid mounted system.
10. The entire skid mounted system shall be both hydro and
electrically tested as a unit by the manufacturer before shipment.
The system shall be completely drained after hydro testing.
Guarantee
1. The manufacturer of the dealkalizer equipment shall guarantee his
equipment as follows:
a. All parts found defective in material or workmanship within
a period of one year after installation shall be repaired or
replaced.
b. The dealkalizer shall reduce the alkalinity of the water to 10
ppm or to 10% of the influent alkalinity.
c. Loss of resin by attrition shall not exceed 3% per year for 3
years.
2. The manufacturer of the dealkalizer equipment must have been
engaged in the manufacturing of this size equipment for a period of
not less than five (5) years and be able to furnish locations of likesized equipment installed and operating in the general area of this
job. A complete set of operating instructions covering the
installation, care and operation of the dealkalizer system shall be
furnished in bound booklet form.
H10-15
09-09
Dealkalizers
Section H
Notes
H10-16
09-09
Section H11
BLOWDOWN SEPARATORS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H11-3

PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H11-3
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H11-11
ILLUSTRATIONS
Figure H11-1. Blowdown Separator Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H11-4

Figure H11-2. Automatic Drain Water Aftercooler (18DF) Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . .H11-7
Figure H11-3. Automatic Drain Water Aftercooler (20AO) Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .H11-7
Figure H11-4. Model 5D Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H11-8
Figure H11-5. Separator Floor Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H11-9
Figure H11-6. Separator Wall Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H11-10
TABLES
Table H11-1. Boiler Blowdown Separator Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H11-4

Table H11-2. Cooling Water Line and Valve Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H11-8
This section contains information on blowdown separators, which are used to provide safe and economical flash
purification to enhance blowdown effectiveness.
H11-1
09-09
Blowdown Separators
Section H
Notes
H11-2
09-09
Section H
Blowdown Separators

Fast, Safe, Low-Cost Way to Separate Steam and Water and Remove Harmful
Dissolved Solids.
Protects boiler surfaces from severe scaling or corrosion problems.
Economical Flash Purification Process for Enhancing Blowdown Effectiveness.
Reduce drain water temperature to meet state and local requirements.
The Design is Quiet, with Noise Levels Held Below 90 dBA, so no Exhaust Head is
Required.
CB Blowdown Separators are Compact, and Can Be Quickly Installed with Few
Connections.
Stainless steel striking plate greatly extends separator life.
Momentum of Water is Speeded by Spiral Baffle Centerwise to Drain. Drain is

Completely Filled - No Center Void.
Tangential inlet and small diameter prompt high velocity spinning for release of
steam.
All Interior Surfaces Slant Toward Drain, Making Unit Self- Draining, Self-Drying for
Longer Life.
Proven Performance.
Demonstrated Durability.
Universal Adaptability.
PRODUCT OFFERING
Boilers that supply steam for power, process or heating applications require periodic and
more often, frequent, blowdowns to prevent buildup of harmful solids. Blowdown
protects boiler surfaces from severe scaling or corrosion problems that would otherwise
result.
Cleaver-Brooks blowdown separators use a safe, economical flash purification process
for enhancing blowdown effectiveness. Steam is rapidly separated from blowdown water
and vented out the top of the blowdown separator in a cyclonic spinning action. Water
and dissolved solids are flushed out the bottom drain.
The design is quiet, with noise levels held below 90 dBA, so no exhaust head is required.
Internal pressures do not exceed 5 psig. Blowdown water is cooled to 120 F by a drain
tempering device, designed to meet state and local codes.
Cleaver-Brooks blowdown separators are compact, and can be quickly installed with few
connections. Accessories include leg or wall brackets, drain tempering fitting, strainer,
temperature regulating valve, thermometer, pressure gauge and flanges.
Pressure ranges:
0 to 300 psig, standard.
301 to 1600 psig, special.
Available with ASME U stamp.

H11-3
09-09
Blowdown Separators
Section H
Inspection Port
"V" Vent
"A" +/- 1/4"
SS Wear Plate
"I" Inlet
9"
MODEL NO.
A20B
A34B
A56B
H Dimension
22
34
56
A Dimension
10
10-1/4
11
"H" +/- 1/2"
"PL"
A
14"
I Inlet size Determined by blowdown valve size.

:V Vent size Select from Table H11-1.
D Drain size Select from Table H11-4.
PL Plate size 5/16 or 3/8. May be determined by
codes.
"D" Drain
Section A-A
HEADS
Model No. ________ MAWP

250 PSIG at 450 F
SA 516-70
SHELL
SA 53B
COUPLINGS
SA 105
WEAR PLATE
SA 240-304
BAFFLES
SA 240-304
NOZZLES
SA 53B, SA 106-B
FINISH
RED OXIDE PRIMER
Figure H11-1. Blowdown Separator Dimensions

Table H11-1. Boiler Blowdown Separator Sizing
Generator
Op psig
0-15
16-50
51-100
101-125
126-150
151-175
176-200
201-225
226-300
14
20
20
34
34
34
34
34
56
1
1
1
1
1
1
1
1
1
2
2
3
3
3
3
3
4
4
2-1/2
2-1/2
2-1/2
3
3
4
4
4
4
20
20
34
34
34
34
34
56
56
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
3
3
4
4
4
4
4
4
4
4
4
4
4
4
4
5
5
5
20
34
34
34
34
34
56
56
56
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
3
3
4
4
4
4
5
5
5
4
4
4
4
5
5
5
5
6
20
34
34
34
56
56
56
56
56
2-1/2"
2
2
2
2
2
2
2
2
2
4
4
5
5
5
5
6
6
6
5
5
5
5
6
6
6
6
8
Model H
1-1/2"
Model H
1-1/4"
Model H
Model H
Separator
Dim.
1"
Model H
VALVE
SIZE
34
34
34
56
56
56
56
56
56
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
5
5
6
6
6
6
6
8
8
6
6
6
6
6
8
8
8
8
251-300 psig U. Symbol Construction and Stamping is required.

To use this chart:
1.Select separator size from this table by matching operating pressure and blow-down valve size.
2.Select Plate Thickness (PL) as local regulations require or as desired for maximum pressure stamped on Separator 3/16", 150 psig,
5/16", 225 psig, 3/8", 250 psig.
3.If local regulations require, indicate ASME or Standard. Separator size is now determined and discharge piping may follow these sizes with
no calculation necessary. Separators are designed to exhaust at less than 5 psig.
H11-4
09-09
Section H
Standard and
Optional Equipment
Selection
Blowdown Separators
For dimensions and sizing of blowdown separators, refer to Figure H11-1 and Table
H11-1
For manual drain water tempering, use Aftercooler model 5D and specify drain diameter.
For automatic control of drain water temperature, use 18DF___ or 20AO___ Aftercooler.
20AO Aftercooler is required in some areas to automatically regulate the temperature of
the water to the drain. Check local codes to ascertain if it is required in your area.
A temperature regulating valve should be used when the blowdown temperature going to
the drain needs to be less than 212 F. (See Table H11-2 to select cooling water line and
valve size.)
Use a solenoid valve and thermostat when the cooling water pressure exceeds 80 psig.
1. Model 18 DF Aftercooler (Figure H11-2). Nonclogging automatic drain tempering
fitting with stainless steel mixing tongue (on 4" and larger) to provide thorough mixing
of influent cold water with drain water. The middle flange permits rotation for various
pipe fitting requirements and also serves as a dismantling flange. Two bulb-wells for
mounting control valve and thermometer are furnished. When ordering, state cold water
inlet size.
2. Model 20AO Jacket Type After Cooler (Figure H11-3). Required in some areas. Has
mixing holes corresponding to the cold water inlet size. The lower portion is designed
with wells to accommodate automatic control bulb and thermometer. When ordering
state cold water inlet size.
3. Temperature Regulator Valves Figure H11-2 and Figure H11-3). Automatically control
the flow of cold water by responding to temperature changes at the thermostatic bulb.
The 6" capillary tube allows installation in the cold water line while the 11" bulb is
mounted in the lower portion of the aftercooler. The valve size should correspond to the
cold water inlet.
4. Thermometer. Bi-metal, drawn steel case, rust resistant and finished in oven baked
enamel. Six inch brass stem with 1/4" NPT bushing provided for use with Model 18 DF
and Model 20 AO Aftercoolers.
5. Solenoid Valve. Automatically controls cooling water to aftercooler. Non-magnetic
stainless steel body; micro-finished, hardened pilot valve ball. Has two-wire control
circuit (120/60). Well immersion hot water control provided for actuating solenoid valve.
6. The Model 5D Drain Tempering Fitting (Figure H11-4). Simple type of aftercooler for
adding cooling water with manual control. It has cold water inlet for adding cooling
water to drain for tempering to 120 F. Inlet is sized for minimum influent water
conditions of 60 F water at 40 psig pressure with 100 sq-ft of supply. When ordering,
state Model 5 D (Drain Diameter); i.e. for 4" drain use Model 5D 4.
7. Armstrong Strainer. Cast iron with .045 stainless steel screen. Install in cold water line
to protect temperature regulator valve or solenoid valve shown in adjacent column.
8. Separator Floor Stand (Figure H11-5). Provides and excellent means for supporting
separators. Constructed of sturdy angle iron. They come attached to the separator to
provide an easy and expedient means of installation. Standard height raises separator 18
inches from floor, or when aftercoolers are provided, additional height is provided.
9.Separator Wall Brackets (Figure H11-6). For wall mounting where floor space is
limited, or where desired installation is at a level higher than leg height of 18 inches.
H11-5
09-09
Blowdown Separators
Section H
H11-6
09-09
Section H
Blowdown Separators
CWI
2
2
2-1/2
3
3
4
4
5
5
6
6
20
20
20
20
20
20
20
20
20
20
20
3
3
3
3-1/2
3-1/2
3-1/2
3-1/2
3-1/2
3-1/2
4
4
1/2
3/4
3/4
3/4
1
1
1-1/4
1-1/4
1-1/2
1-1/2
2
C
C
CWI - COLD WATER INLET - NPTF
STAINLESS STEEL MIXING
TONGUE SUPPLIED ON
MODELS 18DF4 AND LARGER
1/4 NPTF CONNECTION TO
ACCOMODATE BIMETALLIC
THERMOMETER
NOTES:
1. Temperature regulator valve bulb is installed in
lower section of the aftercooler so that the bulb
senses mixed water temperature. Valve is modulating
so that the right amount of cold water is added to
cool the drain water to the desired temperature set
on the valve. Valve range is 115 to 180 F.
1/2, 3/4, OR 1 NPTF

CONNECTION TO ACOMODATE
REGULATOR VALVE SENSING
BULB
2. Regulator Valve has composition seat to ensure

tight shut-off when not blowing down. Valve should
be protected with C.1. Strainer with .045 mesh.
3. CWI = cold water inlet size.
Figure H11-2. Automatic Drain Water Aftercooler (18DF) Dimensions
CWI
2
2
2-1/2
3
3
4
4
5
5
6
6
3
3
4
4
4
5
5
6
6
8
8
1/2
3/4
3/4
3/4
1
1
1-1/4
1-1/4
1-1/2
1-1/2
2
CWI COLD WATER INLET NPTF
5-1/4 D2
1/4 NPTF CONNECTION TO

ACCOMODATE BIMETALLIC
THERMOMETER
1/2, 3/4, OR 1 NPTF

CONNECTION TO ACOMODATE
REGULATOR VALVE SENSING
NOTES:
1. Temperature regulator valve bulb is installed in lower BULB
section of the aftercooler so that the bulb senses mixed
water temperature. Valve is modulating so that the right
amount of cold water is added to cool the drain water to
the desired temperature set on the valve. Valve range
is 115 to 180 F.
D2
20
D1
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 H11-3. Automatic Drain Water Aftercooler (20AO) Dimensions

H11-7
09-09
Blowdown Separators
Section H
Table H11-2. Cooling Water Line and Valve Sizing
SEPARATOR
INLET SIZE
COOLING
WATER
PRESS. (PSIG)
40
1-1/4"
50
60
40
50
1-1/2
60
40
50
2"
60
40
50
2-1/2"
60
40
50
60
1-1/2
2
2
2-1/2
2-1/2
2-1/2
2-1/2
1-1/2
2
2
2-1/2
2-1/2
2-1/2
2-1/2
1-1/2
2
2
2
2
2
2-1/2
2
2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2
2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
1-1/2
2
2
2
2-1/2
2-1/2
2-1/2
GENERATOR OPERATING PRESSURE (50 TO 70 F COOLING WATER TEMPERATURE)

0-50
51-100
101-125
126-175
176-225
226-250
251-300
1/2
1
1
1
1
1-1/4
1-1/4
1/2
3/4
3/4
1
1
1-1/4
1-1/4
1/2
3/4
3/4
1
1
1-1/4
1-1/4
1
1
1
1-1/4
1-1/4
1-1/4
1-1/4
1
1
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
1
1
1
1-1/4
1-1/4
1-1/4
1-1/4
1
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
1
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/2
2
2
2
2
2
1-1/4
1-1/2
2
2
2
2
2
1-1/4
1-1/4
1-1/2
2
2
2
2
GENERATOR OPERATING PRESSURE (71 TO 80 F COOLING WATER TEMPERATURE)

0-50
51-100
101-125
126-175
176-225
226-250
251-300
3/4
1
1
1
1
1-1/4
1-1/4
1/2
3/4
1
1
1
1-1/4
1-1/4
1/2
3/4
3/4
1
1
1-1/4
1-1/4
1
1
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/2
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
2
1
1
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
2
1
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/2
1-1/4
2
2
2
2
2-1/2
2-1/2
1-1/4
2
2
2
2
2-1/2
2-1/2
1-1/4
1-1/2
2
2
2
2
2
Use the chart as follows:

1. Depending upon the temperature of the cooling water used, locate the section of the chart which applies, 50-70 F or
71 - 80 F.
2. At the top of chart locate Separator inlet size and in left column under the section selected in step one, locate Boiler
Operating pressure. You now have a selection of three valve sizes.
3. From the top of chart select the cooling water line pressure either 40, 50 or 60 and read the desired valve and line size.
CWl
3/4
2-1/2
3/4
3-1/2
3-1/2
1-1/4
3-1/2
1-1/2
COLD WATER
INLET - NPTF
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 temperature. Valve is modulating so that the right amount of cold water is added to cool the drain water to the desired temperature set on the valve. Valve range is 115 to 180 F.
2. Regulator Valve has composition seat to ensure tight shut-off when not blowing down. Valve
should be protected with C.1. Strainer with .045 mesh.
4. 16DS Same as 18DF Without Flanges.
Figure H11-4. Model 5D Dimensions
H11-8
09-09
Section H
Blowdown Separators
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
22
2-1/2
23
24
25
30
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
28
2-1/2
30
31
32
33
35
Figure H11-5. Separator Floor Stand
H11-9
09-09
Blowdown Separators
Section H
1 STRAP
13
TYPICAL
12-1/2
SEPARATOR WALL BRACKET 2 X 2 X 1/4" ANGLE
USE MODEL 20 W/20" SEPARATOR
MODEL
20
20
14
13
34
20
14
56
35
28
14
NOTE:
1. DIMENSION C IS FOR MODEL 56 ONLY.
2. DIMENSION D IS FOR MODEL 20 ONLY.
Figure H11-6. Separator Wall Bracket
H11-10
09-09
Section H11
Blowdown Separators
PART 1 GENERAL
1.1
GENERAL
customers requirements.
PART 2 PRODUCTS
2.1
EQUIPMENT
A. Blowdown Separaator
1. Furnish and install Cleaver-Brooks Model _____ blowdown
separator with I=______, D=_____, V=______, and _______ plate
thickness.
2. The separator shall be manufactured in accordance with ASME
Code for 250 psig design and tested to 375 psig.
3. Provide separator with National Board stamping and "U" symbol.
(Necessary in Michigan and Utah, optional elsewhere.)
4. The separator shall be furnished with ______________ (screwed,
weld bevel, 150# flanged or 300# flanged) connections.
5. The separator shall include a stainless steel striking plate at the
point of inlet impingement and shall be furnished by CleaverBrooks.
B. Accessories
1. Provide a ________ solenoid valve to automatically control the
flow of cold water by responding to temperature changes sensed at
the thermostatic bulb in the aftercooler fitting.
2. Furnish a bi-metal thermometer with necessary adaptor bushing for
use with _________ (18DF or 20AO) aftercooler.
3. Furnish a ______ cast iron strainer with .045 stainless steel screen
ahead of the ________ (TRV or solenoid valve) to protect said
valve against foreign matter.
4. Furnish and install an automatic drain water aftercooler, Model
________ (18DF or 20AO) with a ______ cold water connection
for a _________________ (TRV or solenoid valve and thermostat)
(See Figure H10-2 or Figure H10-3).
5. Provide a ___________ temperature regulator valve to
automatically control the flow of cold water by responding to
temperature changes sensed at the thermostatic bulb in the
aftercooler fitting.
6. The accessory separator floor stand and wall mounting bracket are
shown in Figure H10-5 and Figure H10-6.
H11-11
09-09
Blowdown Separators
Section H
NOTES
H11-12
09-09
Section H12
BLOWDOWN HEAT RECOVERY SYSTEMS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BHR-S and BHR-M Series (High Pressure Steam Applications) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BHR-S and BHR-M Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H12-3
H12-3
H12-3
H12-3
H12-13
ILLUSTRATIONS
Figure H12-1. Blowdown Heat Recovery System Selection and Payback (Sheet 1 of 3) . . . . . . . . . . . . . .
Figure H12-2. Model BHR-S Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure H12-3. Model BHR-S Ratings/Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure H12-4. Model BHR-M Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure H12-5. Model BHR-M Ratings/Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H12-5
H12-8
H12-9
H12-10
H12-11
H12-1
09-09
Blowdown Heat Recovery Systems
Section H
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.
H12-2
09-09
Section H

BHR-S and BHR-M Series (High Pressure Steam Applications)
Integrated System Automatically Adjusts to Changing Demands:
Recovers 90% of heat normally lost.
Automatically controls surface blowdown flow to maintain the desired concentration

of dissolved solids within the boiler.
Automatically controls boiler dissolved solids.
Compact Size for Convenient Placement:
Removable Shell for Easy Inspection and Cleaning:
Significant Fuel Savings for Any Size Boiler:

It transfers the blowdown heat to the make-up, thereby decreasing fuel costs.
Saves chemical costs by reducing blowdown.
Blowdown is Cooled Before Discharging Into the Sewer:
Complies with discharge water codes.
PRODUCT OFFERING
BHR-S and BHR-M Series
Continuous boiler surface blowdown is the most effective method of purging destructive
solids from any steam boiler system. However, this protective procedure also results in a
constant and costly heat loss, unless a blowdown heat recovery system is used.
Cleaver-Brooks blowdown/heat recovery systems adjust automatically to changing
system demands, and recover 90% or more of the heat normally lost during boiler
surface blowdown operation.
The blowdown/heat recovery systems will usually result in a payback in a few short
months from fuel savings alone. Refer to Figure H12-1 for selection and payback
calculations.
The Cleaver-Brooks Packaged Blowdown Heat Recovery System serves two primary
functions.
1. It automatically controls the surface blowdown to maintain the desired level of total
dissolved solids (TDS) in the boiler, reducing the amount of blowdown to a minimum.
2. It recovers the heat from the high temperature blowdown, and transfers it to the
incoming cold make-up water, maximizing boiler efficiency. Use of BHR also improves
deaerator efficiency by reducing surges caused by adding large amounts of cold make-up
water to the system.
The control valve within the unit performs two functions. The valve senses the flow of
make-up, and positions itself to maintain the desired ratio of blowdown and make-up
flows. As a result, the dissolved solids concentration within the boiler is maintained
automatically.
H12-3
09-09
Section H
The proportioning control also provides for very effective heat recovery since hot
blowdown flows only when there is a corresponding flow of cold water (make-up).
Model BHR-M Systems for multiple boiler installations include a flow control valve for
each boiler. This allows for proportioning the overall system blowdown between
different boilers, which may be operating at different loads. A strainer and sampling
valve are also provided for each boiler, with a sample cooler mounted on the system.
Thus, all boilers can be sampled at one convenient location.
The heavy duty blowdown heat exchangers are uniquely designed to handle the
blowdown on the tube side. This allows many tube side passes, which ensures maximum
heat transfer, and maintains high fluid velocities preventing scaling and fouling. Due to
the severe service, tubes are stainless steel, and because of the abrasive nature of the
fluid, return bends are fabricated of extra thick material. Since vibration is a common
problem with blowdown exchangers, hold down devices are provided to clamp the tube
bundle in place.
Each system is equipped with a blowdown outlet thermometer so that performance can
be monitored. By logging data regularly, a cleaning schedule can be established for each
exchanger.

Dimensions and ratings for Model BHR-S are shown in
Figures H12-2 and H12-3.
Dimensions and ratings for Model BHR-M are shown in
Figures H12-4 and H12-5.
.
H12-4
09-09
Section H
Notes:
H12-5
09-09
Section H
Figure H12-1. Blowdown Heat Recovery System Selection and Payback (Sheet 1 of 3)
H12-6
09-09
Section H
H12-7
09-09
Section H
H12-8
09-09
Section H
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
20-1/2
20-1/2
23-1/2
23-1/2
33
C REF
10
10
12-1/2
D
REF
28
64
64
100
100
E REF
9-1/8
9-1/8
11-1/8
F EF
5-1/2
5-1/2
5-1/2
5-1/2
7-1/2
7-1/2
9-1/2
H + 1/8
16-1/2
38-1/2
38-1/2
64-1/2
64-1/2
J REF
22-3/4
22-3/4
33-1/2
31-1/2
35-3/4
62-5/8
62-5/8
107-1/2
105
33
60
60
105
96-1/2
4-1/2
4-1/2
4-3/8
4-3/8
16-1/2
16-1/2
19-1/2
19-1/2
24-1/2
7-1/2
1/2
1/2
3/4
S + 1/8
7-1/8
7-1/8
9-1/8
CONNECTIONS
1
1-1/2 FPT
1-1/2 FPT
2 FPT
2 FPT
3FLG
1-1/2 FPT
1-1/2 FPT
2 FPT
2 FPT
3 FPT
3/4 FPT
3/4 FPT
3/4 FPT
3/4 FPT
1 FPT
3/4 FPT
3/4 FPT
3/4 FPT
3/4 FPT
1 FPT
Figure H12-2. Model BHR-S Dimensions

H12-9
09-09
Section H
MAXIMUM CAPACITIES (GPM)

Model No.
Blowdown
Make up
BHR-2S
48
BHR-4S
48
BHR-9S
130
BHR-14S
14
130
BHR-22S
22
180
Figure H12-3. Model BHR-S Ratings/Capacities
H12-10
09-09
Section H
MODEL BHR-M SERIES DIMENSIONS

MODEL
BHR-2M
BHR-4M
BHR-9M
BHR-14M
BHR-22M
MAX NO.OF BOILERS
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
9-1/8
9-1/8
11-1/8
F REF
5-1/2
5-1/2
5-1/2
5-1/2
7-1/2
7-1/2
9-1/2
H + 1/8
16-1/2
38-1/2
38-1/2
64-1/2
64-1/2
J REF
22-3/4
22-3/4
33-1/2
31-1/2
35-3/4
62-5/8
62-5/8
107-1/2
105
33
60
60
105
96-1/2
4-1/2
4-1/2
4-3/8
4-3/8
14
14
16
16
20
13-1/2
13-1/2
15-1/2
15-1/2
21
11-1/2
11-1/2
11-1/2
11-1/2
11-1/2
20-1/2
20-1/2
23-1/2
23-1/2
33
T + 1/8
7-1/8
7-1/8
9-1/8
25-1/2
61-1/4
61-1/4
92-1/4
95-3/4
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
1-1/2 FPT
1-1/2 FPT
2 FPT
2 FPT
3 FPT
3/4 FPT
3/4 FPT
3/4 FPT
3/4 FPT
3/4 FPT
3/4 FPT
3/4 FPT
3/4 FPT
3/4 FPT
1 FPT
1/4 FPT
1/4 FPT
1/4 FPT
1/4 FPT
1/4 FPT
Figure H12-4. Model BHR-M Dimensions

H12-11
09-09
Section H
MAXIMUM CAPACITIES (GPM)

MODEL
BLOWDOWN
MAKE-UP
BHR-2M
48
BHR-4M
48
BHR-9M
130
BHR-14M
14
130
BHR-22M
22
180
Figure H12-5. Model BHR-M Ratings/Capacities
H12-12
09-09
Section H12
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-14
BHR-S Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-14
BHR-M Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-14
H12-13
09-09
Section H
PART 1 GENERAL
1.1
GENERAL
specifying your customers requirements.
PART 2 PRODUCTS
2.1
BHR-S SERIES
A. Furnish ______ Cleaver-Brooks Model BHR-S Package blowdown heat
recovery system designed to handle a maximum blowdown rate of
_______ gpm (2 to 22) and a maximum make-up rate of _______ gpm
(48 to 180).
B. The heat recovery system shall be designed for a boiler of _______ hp
(150 - 1500), hp operating at _______ psig (35 to 250). The unit shall be
designed to cool the blowdown to within 30 F of the make-up water
temperature. The unit shall have a 250 psig rating at 400 F.
C. The heat recovery system shall consist of a differential temperature
control valve that shall automatically regulate the blowdown of makeup flow. The flow of blowdown shall be regulated by the thermal
expansion of the inner brass tube pressing against a valve seat. The
inner tube will contract only when cold make-up water passes through
the brass jacketed steel outer tube shell, allowing the blowdown to cool
and go out the exchanger.
D. The system shall also have a heat exchanger, including a removable Utube bundle manufactured of 19 gauge, 304 stainless steel tubes and
steel sideshell with hold down clamps to stop tube bundle vibration. The
vessel shall be ASME code stamped for 250 psig at 400 F. The system
shall have interconnecting piping of steel and stainless steel. The
exchanger shall have a minimum sq-ft of surface area. The flow of the
blowdown make-up shall flow in opposite directions for a maximum
heat transfer efficiency of _______ percent.
E. A heat treated stainless steel valve seat and plunger shall manually
control the blowdown flow by a handwheel.
F. A blowdown thermometer Weksler Type 152 shall be furnished at the
blowdown outlet.
G. The entire system shall be supported by steel channel legs with 3/4"
diameter holes for customer-supplied 5/8" diameter anchor bolts.
H. The system will be painted with a hard enamel coating.
2.2
BHR-M SERIES
A. The following sample specifications are provided by Cleaver-Brooks to
assist you in specifying your customers requirements.
B. Furnish ______ Cleaver-Brooks Model BHR-M package blowdown
heat recovery system designed to handle a maximum blowdown rate of
_______ gpm (2 to 22) and a maximum make-up rate of _______ gpm
(48 to 180).
C. The heat recovery system shall be designed for boilers of ______ hp
(250 - 1500), hp operating at _______ psig (35 to 250). The unit shall be
designed to cool the blowdown to within 30 F of the make-up water
temperature. The unit shall have a 250 psig rating at 400 F
H12-14
09-09
Section H

D.
E.
F.
G.
H.
I.
J.
The heat recovery system shall consist of a differential temperature

control valve that shall automatically regulate the blowdown and makeup 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 Utube 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 means of a handwheel. A blowdown
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.
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 finish coating.
H12-15
09-09
Section H13
FLASH TANK HEAT EXCHANGERS
CONTENT

PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13-3
ILLUSTRATIONS
Figure H13-1. Model AHR Flash Tank Heat Exchanger Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13-4
This section contains information on Cleaver-Brooks Flash Tank Heat Exchangers. Flash tank heat exchangers are used
on applications when operating pressures exceed 25 psig and continuous blowdown heat recovery is desired.
H13-1
09-09
Flash Tank Heat Exchangers
Section H

Flashing:
Hot, high-pressure blowdown water from each boiler is piped to individual flow
control valves on the inlet manifold. Pressure drops across the flow control valve to
5-20 psig, causing the blowdown water to flash into a mixture of steam and water.
Separation Steam/Water:
An entrainment baffle directs the mixture around the inside of the tank in a
centrifugal motion. Efficient baffling separates the dirty blowdown water from the
clean steam.
Discharge:
Steam then rises through the top of the flash tank and is piped to the feedwater
heater, or wherever low pressure steam is required. The remaining hot, dirty water
flows out the bottom of the flash tank to a heat exchanger for additional heat
recovery, or to a blow-off tank or sewer.
Heat Recovery:
In addition to the heat recovered as flashed steam, the heat exchanger will transfer
the remaining heat normally lost during blowdown, to the cold make-up water as it
flows to the feedwater heater.
PRODUCT OFFERING
Flash tank heat exchangers are used when operating pressures exceed 25 psig and
continuous blowdown heat recovery is desired for cost savings. They consist of an
ASME approved and stamped flash tank and a blowdown heat exchanger. Water from
continuous blowdown enters the tank and separates into steam and water. The steam,
normally at 5 psig, can be returned to the deaerator to help meet heating needs. Hot
water leaves the flash tank at temperatures of 220 F, or more. It goes into the heat
exchanger, where it heats cold makeup water entering the system.
The systems quickly pay for themselves with fuel savings resulting from recycled heat
that would otherwise be wasted.
The Model AHR (Figure H13-1) is available in sizes ranging from 3 to 30 gpm
blowdown and 9 to 150 gpm makeup. The model AHR is a coil type flash tank heat
exchanger. It is a compact, low cost alternative to the shell and tube design. The basic
difference is the heat exchanger, constructed of stainless steel, is integral with the ASME
approved flash tank. The space saving system includes floor supports, liquid level
control, three indicating thermometers, and a safety valve as standard equipment.
Standard Offering
Flash separator with stainless steel coil heat exchanger.
Floor supports.
Liquid level controller.
Liquid level indicator, brass body Michigan gauge.
H13-2
09-09
Section H
Temperature control panel with three indicating thermometers (drain temperature,

make-up inlet, make-up outlet).
Safety Valve.
ASME Code Construction (150# Design).
Major Components
Blowdown system.
Flashtank.
Heat exchanger.
Stand.
Optional Equipment
Drain valve and level control.
Sample coolers and assembly.
Flow control valve and assembly.
Manifold.
Safety valve.
Gauge glass.
Pressure gauge.
Gauge panel.
Level alarm.
Level alarm control panel.
Thermometers for exchanger operation.
H13-3
09-09
Section H
MODEL
BLOWDOWN
(GPM)
MAKEUP
(GPM)
ACC-AHR-39
ACC-AHR-315
ACC-AHR-612
ACC-AHR-630
ACC-AHR-1020
ACC-AHR-1050
ACC-AHR-2040
ACC-AHR-3060
ACC-AHR-20100
ACC-AHR-30150
3
3
6
6
10
10
20
30
20
30
9
15
12
30
20
50
40
60
100
150
96
97
110
111
100
106
140
172
140
132-1/2
44
50
49
53
44
50
67
76
67
67
44-1/4
36
50
46
42
44
62
85
62
52-1/2
8
10
10
12
16
16
18
18
18
24
1
1
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
2-1/2
2-1/2
3
3
4
4
6
6-8
6
6-8
1
1
1
2
2
2
2
2
2
2
3/4
1
3/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
2
2-1/2
NOTE: Dimensions in inches.
Figure H13-1. Model AHR Flash Tank Heat Exchanger Dimensions
H13-4
09-09
Section H13
Sample Specifications: Model AHR
H13-5
09-09
Section H
PART 1 GENERAL
1.1
GENERAL
The following sample specification is provided by cleaverbrooks to assist you in
specifying your customers requirements.
PART 2 PRODUCTS
1.2
MODEL AHR
A. Geneal
1. Furnish Cleaver-Brooks Model ACC-AHR ____ packaged flash
tank coil type heat exchanger system, designed to handle a
maximum blowdown rate of ____ gpm (3 to 30) and a maximum
makeup rate of _____ gpm (9 to 150).
2. The system shall be designed for boilers of (130-2200) hp
operating at (0-600) psig. The unit shall be designed to cool the
blowdown to within 30 F of the makeup water temperature. The
unit shall have a 150 psig rating at 365 F.
3. The systems flash tank shall have an ASME code design pressure
of 150 psig and an internal flash pressure of ____ psig (5 to 15).
The flash tank shall be ____" diameter and ____" high and shall
be complete with a ______" tangential blowdown inlet, stainless
steel wear plate, steam outlet, ball type float trap with all working
parts constructed of stainless steel, tank stand, brass-bodied
Michigan site glass, and a safety relief valve set at 150 psig. The
flash tank shall have a flanged bottom section for quick access to
the sludge area and to the coil.
4. The system shall also have a vertical coil-type heat exchanger. The
exchanger shall be constructed of stainless steel and shall be
integral with the flash tank. The coil shall be complete with
______" threaded connections for the makeup water inlet and
outlet.
5. A gauge panel shall be furnished and shall include dial
thermometers for indicating makeup inlet temperature, makeup
outlet temperature and blowdown outlet temperature. The gauge
panel shall be prepiped and mounted on the unit.
6. The entire system shall be supported by steel legs with 3/4"
diameter holes for customer-supplied 1/2" diameter bolts. The
system will be painted with Cleaver-Brooks blue finish paint.
B. Optional Equipment
1. A SC-325 Sample Cooler with isolation valves and
interconnecting piping shall be supplied for a single boiler
application. With each additional boiler, a sample valve assembly
shall be added and manifolded to the sample cooler.
C. Multiple Boiler Operation
1. A manifold assembly shall be necessary for multiple boiler
installations and shall consist of the necessary piping with
threaded connections for the customer-supplied continuous
blowoff valves.
H13-6
09-09
Section H14
SAMPLE COOLERS
CONTENTS

H14-3
H14-3
H14-4
H14-4
H14-7
ILLUSTRATIONS
Figure H14-1. Sample Cooler (SC-22) Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure H14-2. Performance Curves for Hot Water Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure H14-3. Sample Cooler (SC-42) Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure H14-4. Performance Curves for Steam Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H14-5
H14-5
H14-6
H14-6
TABLES
Table H14-1. Sample Cooler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H14-4
H14-1
09-09
Sample Coolers
Section H
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.
H14-2
09-09
Section H
Sample Coolers

Heavy Duty All Stainless Steel Wetted Parts:
SC-22 cools hot water samples up to 635 F and 2000 psig.
SC-42 cools steam or water samples up to 1000 F and 5000 psig.
True Counterflow Cooling:
Effective baffling on the shell side produces full counter flow with high cooling
water flow and minimum pressure drop, vibration and scaling.
Proper temperature achieved.
Compact Design:
SC-22 3-9/16" square x 5-1/2" long compact size. Easily mounted in cooling water
piping without using brackets or special supports.
SC-42 3-9/16 square x 11-1/4 long mounted in cooling water piping without using
brackets or special supports.
Stainless Steel Coil:
Single continuous tube with no joints assures long, maintenance free operation.
Removable Shell:
Shell can be easily removed for inspection and/or cleaning without disconnecting
sample water lines.
Lowest Cost:
Largest heat transfer surface per unit of cost of any sample coolers.
PRODUCT OFFERING
The sample cooler is a low-pressure-drop system for monitoring boiler water quality
without shutting down the boiler system. The Model SC-22 sample cooler is simple,
compact and designed to cool boiler samples with minimum disturbance to system
pressure. The 316 stainless steel tubing is a continuous, jointless, coil arrangement. The
tubing is maintenance-free, rated for 635 F at 2000 psig. The shell is also 316 stainless
steel, rated at 450 F, 250 psig.
The design has baffling on the shell side to achieve high cooling water flow which
minimizes pressure drop, vibration and scaling. The shell can be easily removed for
inspection and/or cleaning without disconnecting sample or water lines.
Notice
The Model SC-22 Sample Cooler is not generally recommended for steam samples. Use
SC-42 for steam sample cooler information.
H14-3
09-09
Sample Coolers
Section H

Dimensions for Model SC-22 are shown in Figure H14-1, and in Figure H14-3 for
Model SC-42. Ratings are shown in Table H14-1.
ENGINEERING DATA
Refer to Figure H14-2 (hot water) and Figure H14-4 (steam) for performance curves.
For example, the hot water samples show the relationship of outgoing sample
temperature to incoming cooling water temperature for various sample temperatures
(diagonal lines) and flow rates (Scale at left). Example: If the water sample is 1/4 gpm
(946 cc/min) at 400 F and is to be cooled to less than 100 F and the cooling water is 95
F. Follow the dotted line at 0.25 gpm to 400 F inlet temperature. Read 18 F
temperature approach. Sample pressure drop will be approximately 6.5 psig. Sample
will cool to 88 F, (70 F coolant + 18 F approach).
Table H14-1. Sample Cooler Ratings

MODEL
NO.
SHELL
DESIGN
TUBE
DESIGN
TUBE
MATERIAL
SHELL & HEAD

MATERIAL
AREA
WEIGHT
SC-22
250 psig @
450oF
2000 psig @
635oF
1/4" OD SSA
304 Stainless
1.2 sq-ft
9 lbs
SC-42
450 psig @
o
650 F
5000 psig @
o
1000 F
1/4 OD
316 SS
304 SS
2.4 sq-ft
12 lbs
A. Tubing is 300 series stainless steel with chemical and physical properties equal to, or better
than T304.
H14-4
09-09
Section H
Sample Coolers
Figure H14-1. Sample Cooler (SC-22) Dimensions
MODEL SC-22 (2.4 SQ-FT)

3 GPM COOLING WATER
1PSIG PRESSURE DROP
SAMPLE
PRESS.
DROP
(PSIG)
APPROACH TEMPERATURE F
Figure H14-2. Performance Curves for Hot Water Samples
H14-5
09-09
Sample Coolers
Section H
Figure H14-3. Sample Cooler (SC-42) Dimensions
SAMPLE DATA
LB/
GPM HR
CC/
MIN
MODEL SC-42
3 GPM COOLING WATER
1 PSIG PRESSURE DROP
SAMPLE
PRESS.
DROP
(PSIG)
APPROACH TEMPERATURE F
Figure H14-4. Performance Curves for Steam Samples
H14-6
09-09
Section I1
BOILER SELECTION CONSIDERATIONS
CONTENTS
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-2
BOILER TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4
Scotch Marine - The Classic Firetube Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4
Firebox boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-5
Commercial Watertube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-5
Industrial Watertube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-5
Flexible Watertube (Bent Tube) Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6
Membrane Watertube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6
Cast Iron Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6
Electric Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6
BOILER SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7
Heating Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10
Process Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10
Combination Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10
Defining Load Variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10
System Load Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-11
Load Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-11
Back-Up Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-11
Type of Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-12
Downtime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-12
Boiler Turndown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-12
Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-14
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-14
Combustion Efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-15
Thermal Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-15
Boiler Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-15
Fuel-to-Steam Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-15
Stack Temperature and Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-15
Excess Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-16
Radiation and Convection Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-16
Heating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-16
Flue Gas Passes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-16
Integral Boiler/Burner Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-16
Replacement Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-16
PAYBACK ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-17
ILLUSTRATIONS
Figure I1-1. Annual Gas Cost as a Function of Gas Use and Unit Price . . . . . . . . . . . . . . . . . . . . I1-21
Figure I1-2. Annual Gas Cost as a Function of Gas Use and Unit Price (Expansion of Figure I1-1) . . I1-22
Figure I1-3. Annual Fuel Oil Cost as a Function of Fuel Oil Use and Unit Price . . . . . . . . . . . . . . . I1-23
Figure I1-4. Annual Fuel Oil Cost as a Function of Fuel Oil Use and Unit Price
(Expansion of Figure I1-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I1-24
I1-1
09-09
Boiler Selection Considerations
Section I
Figure I1-5. System Efficiency Improvement as a Function of Incremental Component Efficiency GainI1-25
Figure I1-6. Annual Savings as a Function of Annual Fuel Cost and System Efficiency Improvement I1-26
Figure I1-7. Annual Savings as a Function of Annual Fuel Cost and System Efficiency Improvement
(Expansion of Figure I1-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-27
TABLES
Table I1-1. Common Boiler Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4
Table I1-2. Considerations for Selecting a Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7
Table I1-3. Load Demand Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9
Typical Firetube Boiler Fuel Consumption Rates - N0. 6 Oil (gal/hr . . . . . . . . . . . . . . . . . . . . . . . . )I1-13
Table I1-4. Typical Firetube Boiler Fuel Consumption Rates - No. 2 Oil (gal/hr) . . . . . . . . . . . . . . . I1-13
Table I1-5. Typical Firetube Boiler Fuel Consumption Rates - Natural Gas (MM/Btu/hr) . . . . . . . . . I1-14
Perhaps no other piece of equipment is more important to a facility than the boiler. Proper boiler selection, to
meet the needs of the application, is a critical factor in the design of any steam or hot water system.
This section provides information to consider when selecting a boiler. This information is divided into three main
subsections:
1. Boiler Types
Typical boiler types are defined, including: firetube, firebox, industrial watertube, and commercial watertube
boilers. General information is provided on the differences in boiler types (sizes, ranges, pressures, etc.). For
more detailed information on boiler products, refer to the specific boiler product section.
2. Boiler Selection
Provides information on codes and standards; when to use steam or hot water boilers; defines load
requirements; defines the number of boilers needed; discusses performance issues; and addresses special
requirements.
3. Payback Analysis
There are many factors that affect the decision to purchase a particular piece of boiler room equipment. This
section addresses economic considerations only, and provides a procedure that can be applied to individual
equipment selection or evaluation of alternative systems.
Definitions
To assist with understanding information in this section, it will be necessary to understand the following
definitions.
Boiler horsepower(BHP) is a measure of boiler energy output. One boiler horsepower (from and at 212 F):
BHP = 34.5 lbs/hr
BHP = 33,472 Btu/hr
BHP = 9.8 kW
BHP should not be confused with other horsepower measurements.
Boiler Trim: Accessories added to the boiler, such as auxiliary low water cutoff, special tappings, special gas
trains, etc.
Btu: Amount of energy required to raise one pound of water one F.
Input: Total amount of fuel input to the burner in Btu/hr.
Output: Total amount of energy released from a steam or hot water boiler measured in boiler horsepower, lbs/hr
of steam, or Btu/hr.
I1-2
09-09
Section I
For additional definitions, refer to the glossary at the end of The Boiler Book.
I1-3
09-09
Section I
BOILER TYPES
The boilers discussed in this book are packaged boilers. This concept has been
around for more than 60 years. The packaged boiler originated with CleaverBrooks, when a pre-engineered assembly was supplied to a customer to eliminate
his need to purchase separate components, and then try to make them work
together. The packaged boiler has proven to be a successful concept - with more
than 150,000 Cleaver-Brooks units around the world.
There are many types of packaged boilers available. Table I1-1 compares common
boiler types and their features.
The following is an overview of different types of boilers.
Scotch Marine - The Classic Firetube Boiler
The Scotch Marine style of boiler has become so popular in the last 40 years that it
frequently is referred to simply as a firetube boiler. Firetube boilers are available
for low or high pressure steam, or for hot water applications. Firetube boilers are
typically used for applications ranging from 15 to 1500 horsepower. A firetube
boiler is a cylindrical vessel, with the flame in the furnace and the combustion
gases inside the tubes. The furnace and tubes are within a larger vessel, which
contains the water and steam.
The firetube construction provides some characteristics that differentiate it from
other boiler types. Because of its vessel size, the firetube contains a large amount of
water, allowing it to respond to load changes with minimum variation in steam
pressure.
Steam pressure in a firetube boiler is generally limited to approximately 350 psig.
Table I1-1. Common Boiler Types
CAST
IRON
MEMBRANE
WATERTUBE
ELECTRIC
FIREBOX
FIRETUBE
Efficiency
Low
Medium
High
Medium
High
Medium
Medium
Low/Medium
Floor Space
Required
Low
Very Low
Very Low
Medium
Medium/
High
Low
High
Very Low
Medium
Medium/High
Low
Low
Medium
High
Low
Maintenance Medium/High
FLEXIBLE INDUSTRIAL
WATERTUBE WATERTUBE
VERTICAL
FIRETUBE
Initial Cost
Medium
Low/Medium
High
Low
Medium/
High
Low/Medium
High
Low
No. of Options
Available
Low
Medium
Medium
Low/Medium
High
Medium
High
Low
Pressure
Range
HW/LPS
HW/LPS
HW/LPS
HW/LPS
High Temp
HW
HW/LPS
HPS to 150
psig
HW/LPS HPS HW/LPS HPS

to 600 psig
to 900 PSIG
HPS to 350
psig
HPS to 900
psig
Typical Sizes
To 200 hp
To 250 hp
To 300 hp
To 300 hp
To 1500 hp
To 250 hp
Typical
Applications
Heating/
Process
Heating/
Process
Heating/
Process
Heating
Heating/
Process
Heating
Comments
Field
Erectable
Field
Erectable
I1-4
09-09
To 100 hp
Process
Heating/
Process
Section I

To achieve higher pressure, it would be necessary to use very thick shell and tube
sheet material. For this reason, a watertube boiler is generally used if pressure
above 350 psig design is needed.
Firetube boilers are usually built similar to a shell and tube heat exchanger. A large
quantity of tubes results in more heating surface per boiler horsepower, which
greatly improves heat transfer and efficiency.
Firetube boilers are rated in boiler horsepower (BHP), which should not be
confused with other horsepower measurements.
The furnace and the banks of tubes are used to transfer heat to the water.
Combustion occurs within the furnace and the flue gases are routed through the
tubes to the stack outlet. Firetube boilers are available in two, three and four pass
designs. A single pass is defined as the area where combustion gases travel the
length of the boiler. Generally, boiler efficiencies increase with the number of
passes.
Firetube boilers are available in either dryback or wetback design. In the dryback
boiler, a refractory-lined chamber, outside of the vessel, is used to direct the
combustion gases from the furnace to the tube banks. Easy access to all internal
areas of the boiler including tubes, burner, furnace, and refractory, is available from
either end of the boiler. This makes maintenance easier and reduces associated
costs.
The wetback boiler design has a water cooled turn around chamber used to direct
the flue gases from the furnace to the tube banks. The wetback design requires less
refractory maintenance; however, internal pressure vessel maintenance, such as
cleaning, is more difficult and costly. In addition, the wetback design is more prone
to water side sludge buildup, because of the restricted flow areas near the turn
around chamber.
For more information on specific firetube boiler products, refer to Section A.
Firebox boilers
The firebox boiler uses similar tube attachment techniques as the firetube boiler. Its
combustion chamber is not round, like the firetubes cylindrical furnace. The firebox
boiler is typically manufactured to low pressure steam or hot water applications.
The firebox boiler is a compact, economical unit and serves as a good fit for
seasonal use and when efficiency is not the driving factor. Sizes range from 12 to
337 horsepower.
Commercial Watertube Boilers
Commercial watertube boilers typically produce steam or hot water for commercial,
or modest-size applications. There are a wide variety of types, sizes, capacities, and
design pressures available. Commercial watertube boilers can be membrane type,
straight tube, modular, etc. They can be either atmospherically fired or utilize power
burners.
For more information on commercial watertube boilers, refer to Section B.

The industrial watertube boiler typically produces steam or hot water primarily for
industrial process applications, and is used less frequently for heating applications.
I1-5
09-09
Section I
In the watertube design, tubes contain steam and/or water and the products of
combustion pass around the tubes. Typically, watertube designs consist of multiple
drums. A steam drum (upper) and mud drums (lower) are connected by the tubes,
which form both the convection section and the furnace area.
Packaged industrial watertube boilers are typically rated in pounds of steam per
hour output at operating conditions and range from 10,000 to 134,000 lbs/hr.
Industrial watertube boilers are noted for their fast steaming capability. Steam is
generated very rapidly because of the relatively low water content. This allows them
to respond quickly to changing load demands.
The industrial watertube boiler design makes it capable of generating either
saturated or superheated steam. When applications dictate superheated steam
usage, large or fluctuating steam loads, or high pressures (greater than 350 psig),
an industrial watertube boiler should be considered.
For more information on industrial watertube boilers, refer to Section C.
Flexible Watertube (Bent Tube) Boilers
Flexible watertube boilers are a common type of boiler used for heating applications
because of their resistance to thermal shock. Flexible watertube boilers are
available in size ranges from 2 to 9 MMBtu/hr input. Flexible watertube boilers are
available for low pressure steam or hot water applications. Field erectable packages
are also available.
For more information on flexible watertube boilers, refer to Section B.
Membrane Watertube Boilers

The membrane watertube boiler is available for low or high pressure steam or hot
water applications. High outputs are available in a compact design and should be
considered where space is limited. Sizes range from 34 to 143 horsepower.
For more information on membrane type commercial watertube boilers, refer to
Section B.
Cast Iron Boilers
Cast iron boilers are limited to low-pressure steam or hot water applications, and
typically range in size from 25 to 200 horsepower. One advantage of the cast iron
boiler is its modular design, which includes sections for field erection.
For more information on cast iron boiler products, contact your local Cleaver-Brooks
Electric Boilers
Electric boilers are noted for being clean, quiet, easy to install, and compact.
Because there are no combustion considerations, an electric boiler has minimal
complexity (no fuels or fuel handling equipment) with easily replaceable heating
elements.
An electric boiler may be the perfect alternative to supply low or high pressure
steam or hot water where the customer is restricted by emission regulations. In
areas where the cost of electric power is minimal, the electric boiler could be the
I1-6
09-09
Section I

Table I1-2. Considerations for Selecting a Boiler
High Efficiency
X
XA
X
X
FLEXTUBE
Boiler Operator Factor
Low Maintenance
High Turndown
Field Erectable
X
X
Fuel Limitations
VERTICAL
FIREBOX
XA
Low Cost
Low Operating Cost
OHIO
SPECIAL
Space Factor
Emissions Factor
COMMERCIAL
WATERTUBE
ELECTRIC
CAST IRON
REQUIREMENT OR
APPLICATION
WATERTUBE
FIRETUBE
BOILER SELECTION
X
X
Low Usage, No Stack
High Pressure, Over

350 psig, or Superheat
A. With Flue Gas Recirculation/ Model CB (LE) Option.
best choice. Sizes range from 9 kW to 3,375 kW output.

For more information on electric boilers, refer to Section B.
BOILER SELECTION
Six criteria should be considered when selecting a boiler to meet the application
needs. The criteria are:
1. Codes and standards requirements
2. Steam or Hot Water
3. Boiler load
4. Number of boilers
5. Performance considerations
6. Special considerations
Codes and
Standards
There are a number of codes and standards, laws, and regulations covering boilers
and related equipment that should be considered when designing a system.
Regulatory requirements are dictated by a variety of sources and are all focused
primarily on safety. For more information on how the various rules affect boiler
selection and operation, you may want to contact your local Cleaver-Brooks
authorized representative. Here are some key rules to consider:
The boiler industry is tightly regulated by the American Society of Mechanical

Engineers (ASME) and the ASME Codes, which governs boiler design,
inspection, and quality assurance. The boilers pressure vessel must have an
ASME stamp. (Deaerators, economizers, and other pressure vessels must also
be ASME stamped).
I1-7
09-09
Section I
The insurance company insuring the facility or boiler may dictate additional
requirements. Boiler manufacturers provide special boiler trim according to the
requirements of the major insurance companies. Special boiler trim items
usually pertain to added safety controls.
Some industries, such as food processing, brewing, or pharmaceuticals, may also

have additional regulations that have an impact on the boiler and the boiler room.
A UL, ULC, cUL, CSA or CGA listing, or Canadian Registration Number (CRN)
may be required. State, local, or provincial authorities may require data on the
boiler controls or basic design criteria.
Most areas have established a maximum temperature at which water can be

discharged to the sewer. In this case, a blowdown separator aftercooler is
required.
Most state, local or provincial authorities require a permit to install and/or

operate a boiler. Additional restrictions may apply in non-attainment areas
where air quality does not meet the national ambient air quality standards and
emission regulations are more stringent.
For all new boilers with inputs over 10 MMBtu/hr, U.S. Federal emission
standards apply, including permitting and reporting procedures.
Limits on fuel sulfur content are frequently set at 0.5% maximum.
A full-time boiler operator may be required. Operator requirement depends on

the boilers size, pressure, heating surface or volume of water. Boilers can be
selected which minimize the requirements, either by falling under the
requirements and being exempt or with special equipment that gives the
operator more freedom in the facility.
Most states or provinces require an annual boiler inspection. There may be other
requirements on piping as well.
Before beginning the selection process, refer to Table I1-2, which shows multiple
considerations for selecting a packaged boiler.
Steam or Hot Water
Now that you have a general overview of the types of boilers and code and
standards requirements, its time to look at the facilitys application in order to see
how the boiler will be used. Keep in mind, the primary purpose of the boiler is to
supply energy to the facilitys operations - for heat, manufacturing process, laundry,
kitchen, etc. The nature of the facilitys operation will dictate whether a steam or hot
water boiler should be used.
Hot water is commonly used in heating applications with the boiler supplying water
to the system at 180 F to 220 F. The operating pressure for hot water heating
systems usually is 30 psig to 125 psig. Under these conditions, there is a wide
range of hot water boiler products available. If system requirements are for hot
water of more than 240 F, a high temperature water boiler should be considered.
For more information on application considerations for hot water boilers and hot
water systems, refer to Hot Water Systems, Section I2.
Steam boilers are designed for low pressure or high pressure applications. Low
pressure boilers are limited to 15 psig design, and are typically used for heating
applications. High pressure boilers are typically used for process loads and can have
an operating pressure of 75 to 700 psig. Most steam boiler systems require
saturated steam.
I1-8
09-09
Section I

Steam and hot water boilers are defined according to design pressure and operating
pressure. Design pressure is the maximum pressure used in the design of the boiler
for the purpose of calculating the minimum permissible thickness or physical
characteristics of the pressure vessel parts of the boiler. Typically, the safety valves
are set at or below design pressure. Operating pressure is the pressure of the boiler
at which it normally operates. The operating pressure usually is maintained at a
suitable level below the setting of the pressure relieving valve(s) to prevent their
frequent opening during normal operation.
Some steam applications may require superheated steam. It should be noted that
superheated steam has a high enthalpy, so there is more energy per pound of steam
and higher (drier) steam quality. One example of an application where superheated
steam may be required is with a steam turbine. The turbines blades require very
dry steam because the moisture can destroy the blades. When very high pressure or
superheated steam is required, an industrial watertube boiler should be selected.
For more information on application considerations for steam boilers and steam
systems, refer to Section I3, Steam Systems.
System Load
In addition to the system load considerations provided in this section, many

excellent reference manuals are available to help further define specific load details
and characteristics. For more information, refer to the ABMA Firetube Engineering
Guide, the ASHRAE Handbook, or contact your local Cleaver-Brooks authorized
representative.
System load is measured in either Btus or pounds of steam (at a specific pressure
and temperature). When discussing the system load, we will include references to
both steam and hot water. However, not all situations or criteria apply to both. It
would be nearly impossible to size and select a boiler(s) without knowing the
system load requirements. Knowing the system load provides the following
information:
The boiler(s) capacity, taken from the maximum system load requirement.
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 requirements.
I1-9
09-09
Section I
The boiler(s) turndown, taken from the minimum system load requirement.
Conditions for maximum efficiency, taken from the average system load
requirement.
Determining the total system load requires an understanding of the type(s) of load in
the system. There are three types of loads: heating, process, and combination.
Heating Load
A heating load is typically low pressure steam or hot water, and is relatively simple
to define because there is not a great deal of instantaneous changes to the load.
And, once a heating load is computed, the number can easily be transferred into the
equipment size requirements. A heating load is used to maintain building heat.
Cooling loads, using steam to run an absorption chiller, also are included when
computing a heating load. Characteristics of a heating load include large seasonal
variations but small instantaneous demand changes. The boiler should be sized for
the worst possible weather conditions, which means that true capacity is rarely
reached.
Process Load
A process load is usually a high pressure steam load. A process load pertains to
manufacturing operations, where heat from steam or hot water is used in the
process. A process load is further defined as either continuous or batch. In a
continuous load, the demand is fairly constant - such as in a heating load. The
batch load is characterized by short-term demands. The batch load is a key issue
when selecting equipment, because a batch-type process load can have a very large
instantaneous demand that can be several times larger than the rating of the boiler.
For example, based on its size, a heating coil can consume a large amount of steam
simply to fill and pressurize the coil. When designing a boiler room for a process
load with instantaneous demand, a more careful boiler selection process should take
place.
Combination Load
Many facilities have a mixture of loads - different types of process loads and
combinations of heating and process loads. The information just given on heating
and process loads should be taken into consideration when dealing with a
combination load.
Defining Load Variations
Loads vary and a power plant must be capable of handling the minimum load, the
maximum load, and any load variations. Boiler selection is often dictated by the
variation in load demand, rather than by the total quantity of steam or hot water
required.
There are three basic types of load variations: seasonal, daily, and instantaneous.
Seasonal Variations. For a heating system, seasonal variations can mean no demand
in the summer, light demand in the fall and spring, and heavy demand in the winter.
Manufacturing operations often have seasonal variations, because the demand for
production may vary. When selecting boiler equipment, the minimum and maximum
load for each season should be determined.
Daily Variation. Daily variation can occur due to
I1-10
09-09
Section I

variations in the work hours, or the heat required at various times of the day or
weekend. Minimum and maximum seasonal variations mentioned earlier may
already reflect these changes if they occur daily. If not, the minimum and maximum
daily loads should be included.
The seasonal and daily variations define the size of the load that the boiler(s) must
handle. Seasonal and daily variations also help define the number of boilers and
turndown requirements.
Instantaneous Demand. Instantaneous demand is a sudden peak load change that
is usually of short duration. These types of loads are sometimes hidden. Many
machines or processes are rated in pounds of steam per hour or Btu/hr as running
loads, under balanced operating conditions, and there is no recognition given to
cold startup, peak or pickup loads. The instantaneous load demand is
important to consider when selecting a boiler to ensure that these load variations
are taken into account. If the instantaneous demand is not included in the system
load calculations, the boiler(s) may be undersized.
System Load Summary
The load demand matrix shown in Table I1-3 can be used as a work sheet in
determining the minimum, maximum, and average system loads.
Load Tracking
Load tracking is the ability of a boiler to respond to changes in steam or hot water
demand. Most often associated with process loads, load tracking focuses on the
boilers ability to supply a constant volume of steam at the required pressure.
The ability of the boiler to track a variable load depends on the boiler type, burner
turndown capability, feedwater valve control, and combustion control design. If the
analysis of the load shows highly variable load conditions, a more complex control
package may be necessary. This type of control is achieved with sophisticated boiler
management systems. For more information on these types of systems, refer to
Controls, Section D, or contact your local Cleaver-Brooks authorized representative.
If the application has instantaneous load demands, whereby a large volume of
steam is required for a short period of time, a boiler with a large energy storage
reserve, such as a firetube, should be considered. If the application dictates large
variances in load demand, where the load swings frequently for long periods of
time, the best choice is probably a watertube type boiler, because it contains less
water and can respond to the variances more rapidly.
In all cases, operation of the burner should be taken into account in selecting a
boiler(s) to meet system demand. The burner will require proper operating controls
that can accurately sense the varying demands and be capable of the turndown
requirements. The boiler feedwater valve and control design are also critical if load
swings are expected.
Number of Boilers
Back-Up Boilers
When selecting the boiler(s), consideration should be given to back-up equipment
to accommodate future expansion, emergency repairs, and maintenance. There are
a number of considerations for a backup boiler.
I1-11
09-09
Section I
Type of Load
Heating systems and non-critical loads that do not result in a sudden loss of
production generally have little or no backup. While this is not recommended, it is
still common practice. These types of applications rely on the ability to make repairs
quickly to reduce downtime. The risk involved in having no backup is a total loss of
heat when the boiler is not in service.
When process or heating loads use multiple boilers during peak times, and one
boiler during most other times, the availability of an additional boiler to provide full
backup during maximum demand should be considered.
In applications with critical steam or hot water requirements, laws or codes may
require a backup. Even if laws or codes do not require a backup, there are many
cases where the operation cannot tolerate downtime. For example, a hotel uses hot
water 24 hours a day, seven days a week. During periods of maintenance or in an
emergency, a backup boiler is required.
Downtime
Another way to determine whether a backup boiler is a wise decision is to compute
the cost of downtime to the owner or the user, as shown in the following three
examples:
A chemical company manufactures dry cell battery compound in a batch
process. The process temperature must be maintained within 2 degrees. The
boiler shuts down on a flame failure. They have 20 minutes to recover steam or
the batch is scrap. The value of the product is $250,000.
A Midwestern insurance company building has comfort heat supplied by one
boiler. There are over 2000 workers in the building. The boiler shuts down due
to a failed gas valve. Outside, its 11F. Inside, the temperature continues to
drop and, at 1:30 in the afternoon, all 2,000 workers are sent home.
A meat processing company makes its entire packaged ham line in a Southern
plant. It operates 24 hours a day, every day. A single boiler provides heat for
curing, sterilizing, and cleaning. The boiler goes down due to a lack of
feedwater. Each hour of steam loss results in four hours of lost production.
Boiler Turndown
Boiler turndown is the ratio between full boiler output and the boiler output when
operating at low fire. Typical boiler turndown is 4:1. For example, a 400 horsepower
boiler, with a 4:1 turndown burner, will modulate down to 100 horsepower before
cycling off. The same boiler with a 10:1 turndown burner will modulate down to 40
horsepower.
The ability of the burner to turn down reduces frequent on and off cycling. Fully
modulating burners are typically designed to operate down to 25% of rated capacity.
At a load that is 20% of the rated capacity, the boiler will turn off and cycle
frequently.
A boiler operating at low load conditions can cycle as frequently as 12 times per
hour, or 288 times per day. With each cycle, pre- and post-purge air flow removes
heat from the boiler and sends it out the stack. The energy loss can be eliminated by
keeping the boiler on at low firing rates. Every time the boiler cycles off, it must go
through a specific start-up sequence for safety
I1-12
09-09
Section I

Table I1-4. Typical Firetube Boiler Fuel Consumption Rates - N0. 6 Oil (gal/hr)A
AVERAGE
OUTPUT
BOILER EFFICIENCY
86%
84%
82%
80%
78%
76%
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
BHP
A. Based on 150,000 Btu/gallon.
Table I1-5. Typical Firetube Boiler Fuel Consumption Rates - No. 2 Oil (gal/hr)A
AVERAGE
OUTPUT
BOILER EFFICIENCY
86%
84%
82%
80%
78%
76%
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
BHP
A. Based on 140,000 Btu/gallon.
assurance. It requires about one to two minutes to place the boiler back on line.
And, if theres a sudden load demand, the start-up sequence cannot be accelerated.
Keeping the boiler on line assures the quickest response to load changes. Frequent
cycling also accelerates wear of boiler components. Maintenance increases and,
more importantly, the chance of component failure increases.
As discussed earlier, boiler(s) capacity requirement determined by many different
types of load variations in the system. Boiler over-sizing occurs when future
I1-13
09-09
Section I
Table I1-6. Typical Firetube Boiler Fuel Consumption Rates - Natural Gas (MM/Btu/hr)
AVERAGE
OUTPUT
BOILER EFFICIENCY
86%
84%
82%
80%
78%
76%
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
BHP
expansion and safety factors are added to assure that the boiler is large enough for
the application. If the boiler is oversized, the ability of the boiler to handle minimum
loads without cycling is reduced. Therefore, capacity and turndown should be
considered together for proper boiler selection to meet overall system load
requirements.
Performance
Considerations
Three important considerations pertain to fuels, emissions, and efficiency. All three
have important impact on boiler performance, and can affect long-term boiler
operating costs.
Fuels
Remember, from an operating perspective, fuel costs typically account for
approximately 10% of a facilitys total operating budget. Therefore, fuel is an
important consideration. Normally, the fuels of choice are natural gas, propane, or
light oil. Increasingly stringent emission standards have greatly reduced the use of
heavy oil and solid fuels such as coal and wood. Of the fossil fuels, natural gas
burns cleanest and leaves less residue; therefore less maintenance is required.
It can be advantageous to supply a boiler with a combination burner that can burn
two fuels independently - for example, oil or natural gas. A combination burner
allows the customer to take advantage of peak time rates, which substantially
reduces the costs of a therm of gas when operating off peak by merely switching
to the back up fuel. Dual fuel capability also is beneficial if the primary fuel supply
must be shut down for safety or maintenance reasons.
Some waste streams can be used as fuel in the boiler. In addition to reducing fuel
costs, firing an alternate fuel in a boiler can greatly reduce disposal costs. Waste
streams are typically used in combination with standard fuels to ensure safe
operation and to provide additional operating flexibility.
Emissions
Emission standards for boilers have become very
I1-14
09-09
Section I

stringent in many areas, because of the new clean air regulations. The ability of the
boiler to meet emission regulations depends on the type of boiler and burner
options. For more information, refer to Emissions, Section E.
Efficiency
Efficiency is used in the measure of economic performance of any piece of

equipment. In the boiler industry, there are four common definitions of efficiency,
but only one true measurement. Following are the definitions and how to measure
efficiency.
Combustion Efficiency
Combustion efficiency is the effectiveness of the burner only and relates to its ability
to completely burn the fuel. The boiler has little bearing on combustion efficiency. A
well- designed burner will operate with as little as 15 to 20% excess air, while
converting all combustibles in the fuel to thermal energy.
Thermal Efficiency
Thermal efficiency is the effectiveness of the heat transfer in a boiler. It does not
take into account boiler radiation and convection losses - for example, from the
boiler shell, water column piping, etc.
Boiler Efficiency
The term boiler efficiency is often substituted for combustion or thermal
efficiency. True boiler efficiency is the measure of fuel-to-steam efficiency.
Fuel-to-Steam Efficiency
Cleaver-Brooks guaranteed boiler efficiencies are fuel-to- steam efficiencies.
Fuel-to-steam efficiency is the correct definition to use when determining boiler
efficiency. Fuel-to-steam efficiency is calculated using either of two methods, as
prescribed by the ASME Power Test Code, PTC 4.1. The first method is inputoutput. This is the ratio of Btu output divided by Btu input x 100.
The second method is heat balance. This method considers stack temperature and
losses, excess air levels, and radiation and convection losses. Therefore, the heat
balance calculation for fuel-to-steam efficiency is 100 minus the total percent stack
loss and minus the percent radiation and convection losses.
Stack Temperature and Losses
Stack temperature is the temperature of the combustion gases (dry and water
vapor) leaving the boiler. A well-designed boiler removes as much heat as possible
from the combustion gases. Thus, lower stack temperature represents more
effective heat transfer and lower heat loss up the stack. The stack temperature
reflects the energy that did not transfer from the fuel to steam or hot water. Stack
temperature is a visible indicator of boiler efficiency. Any time efficiency is
guaranteed, predicted stack temperatures should be verified.
Stack loss is a measure of the amount of heat carried away by dry flue gases
(unused heat) and the moisture loss (product of combustion), based on the fuel
analysis of the specific fuel being used, moisture in the combustion air, etc.
I1-15
09-09
Section I
Excess Air
Excess air provides safe operation above stoichiometric conditions. A burner is
typically set up with 15 to 20% excess air. Higher excess air levels result in fuel
being used to heat the air instead of transferring it to usable energy, increasing stack
losses.
Radiation and Convection Losses
Radiation and convection losses will vary with boiler type, size, and operating
pressure. The losses are typically considered constant in Btu/hr, but become a larger
percentage loss as the firing rate decreases.
Boiler design factors that also impact efficiencies of the boiler are heating surface,
flue gas passes, and design of the boiler and burner package.
Heating Surface
Heating surface is one criterion used when comparing boilers. Boilers with higher
heating surface per boiler horsepower tend to be more efficient and operate with
less thermal stress. Many packaged boilers are offered with five square feet of
heating surface per boiler horsepower as an optimum design for peak efficiency.
Flue Gas Passes
The number of passes that the flue gas travels before exiting the boiler is also a good
criterion when comparing boilers. As the flue gas travels through the boiler it cools
and, therefore, changes volume. Multiple pass boilers increase efficiency because
the passes are designed to maximize flue gas velocities as the flue gas cools.
Integral Boiler/Burner Package
Ultimately, the performance of the boiler is based on the ability of the burner, the
boiler, and the controls to work together. When specifying performance, efficiency,
emissions, turndown, capacity, and excess air all must be evaluated together. The
efficiency of the boiler is based, in part, on the burner being capable of operating at
optimum excess air levels. Burners not properly designed will produce CO or soot at
these excess air levels, foul the boiler, and substantially reduce efficiency. In
addition to the boiler and burner, the controls included on the boiler (flame
safeguard, oxygen trim, etc.) can enhance efficiency and reduce overall operating
costs for the customer. A true packaged boiler design includes the burner, boiler, and
controls as a single, engineered unit.
Special
Considerations
Replacement Boilers
If the boiler is to be placed in an existing facility, there are a number of
considerations:
Floor space required.
Total space requirements.
Access space for maintenance.
Size and characteristics of the boiler to be replaced, including location of

existing piping, the boiler stack and utilities.
Boiler weight limitations.
I1-16
09-09
Section I
With little or no access to the boiler room, the cast iron boiler and some benttube type boilers can be carried into the boiler room in sections or pieces and
easily assembled, with no welding required.
Electric boilers should also be considered, especially since they do not require a
stack.
Vertical firetube boilers have a small floor space requirement.
PAYBACK ANALYSIS
There are many factors that affect the decision to purchase a particular piece of
boiler room equipment. This subsection addresses some of the economic
considerations in the decision process. The procedure presented can be applied to
equipment selection and the economic evaluation of alternative systems.
The effect of a single piece of equipment can be a significant part of the overall
transfer of energy from the fuel burned to the thermal energy of the steam or hot
water delivered. The performance of equipment, such as the boiler, stack gas
recovery systems (economizers), condensate recovery systems (deaerators, etc.),
oxygen trim systems, and blowdown heat recovery systems, should be considered.
Efficiency gains from each piece of equipment need to be evaluated individually in
the context of the overall system to determine the incremental fuel cost savings.
Savings from efficiency gains are used to evaluate the payback potential of the
equipment. Payback simply refers to the time period that will elapse before the
cumulative cost savings will equal the incremental capital cost of the equipment
selected.
In summary, this section provides a procedure and a set of tables and figures to
assist in assessing the economic justification of purchasing higher performance
equipment or additional energy savings equipment (e.g., economizers, oxygen trim
controls, etc.). This procedure may also be used to evaluate the operating cost
impact of different system configurations.
The tables and figures provided are not unique to Cleaver- Brook products.
Therefore, the procedures may be applied to any thermal energy consuming system.
Before proceeding, product related information (e.g., efficiency and fuel
consumption rates) should be obtained for each specific product.
Having defined a basic system configuration, and having identified equipment that
would yield incremental performance improvement (and investment), the payback
analysis sequence is straight forward and can be summarized as follows:
1. Estimate boiler fuel consumption rate.
2. Estimate annual fuel use.
3. Estimate annual fuel cost.
4. Determine potential incremental efficiency improvement.
5. Estimate potential annual fuel savings.
6. Determine the payback period for the investment.
7. Refine the analysis.
The remainder of this section outlines the step-by-step procedure to be used in
conjunction with the figures and tables.
I1-17
09-09
Section I
Remember, the lowest cost product is not necessarily the most economic choice. In
fact, most often it is not the best choice!
Step 1: Boiler Fuel Consumption Rate
Use Table I1-4,Table I1-5, andTable I1-6 to compare the fuel consumption rates of
two boiler configurations with different fuel-to-steam efficiency or, as a base fuel
rate for a given boiler configuration. Find the appropriate boiler size and the
efficiency on the table to find the associated fuel consumption.
Step 2: Annual Fuel Usage
Multiply the hourly fuel consumption rates by the annual hours of operation to
determine the annual fuel usage rate.
Step 3: Annual Fuel Cost
Figure I1-1 and Figure I1-2 are used to determine annual fuel cost for natural gas
based on annual gas use (billion Btu/yr) and gas cost ($/MMBtu). Figure I1-2
provides a more detailed graph for lower gas usage applications. Save the annual
fuel cost value for Step 5.
(Note that the figures referenced in this discussion are located at the end of this
section.)
Figure I1-3 and Figure I1-4 are used to determine annual fuel cost for oil fuels
based on annual oil use (thousand gal/yr) and oil cost ($/gal). Figure I1-4 provides
a more detailed graph for lower oil usage application. Save the annual fuel cost
value for Step 5.
Step 4: Incremental Efficiency Improvement
If an improvement is being added to a boiler (economizer, oxygen trim, etc.) that is
designed to improve the efficiency of the boiler by x percent (incremental
efficiency gain). Use Figure I1-4 to take the base system efficiency (bottom) and the
incremental efficiency gain (right side) to determine the actual improvement in the
system efficiency to be used for the cost savings in Step 5.
Step 5: Annual Fuel Savings
Use Figure I1-6 to determine the annual fuel savings based on the annual fuel cost
and system efficiency improvement (right side of graph). Figure I1-7 provides for a
more detailed graph for lower fuel cost applications.
Step 6: Payback Period
The payback period is the years required to recover the capital investment. To
determine payback simply divide the capital cost of the equipment by the annual
savings.
To determine the amount of capital available based on a known payback period,
multiply the annual savings by the payback period required.
Step 7: Refine the Analysis
It should be recognized that the tools provided herein are intended to provide a
quick mechanism to focus on an appropriate equipment configuration and scope.
The graphs provided should permit you to quickly identify candidate equipment
options that economically qualify and, therefore, merit more serious evaluation.
I1-18
09-09
Section I

Additional economic issues (maintenance, necessity of equipment, etc.) should be
considered by final conclusions are reached.
Contact your local Cleaver-Brooks authorized representative for additional
information.
Example
Consider the following payback analysis example. Assume that a project requires a
three-year payback for any incremental capital investment. Also assume that an
800 hp firetube boiler firing No. 2 oil and operating at 85% efficiency has a cost of
$1/gal. Assume the average load is 50% of rated capacity for the anticipated 5000
hours per year of operation. The questions are:
What is the yearly savings attributable to adding an oxygen trim control system
designed to improve efficiency 1.3% to the boiler?
How much capital may be allocated to purchase this equipment and fall within the
three-year payback guideline?
Step 1: Estimate Boiler Fuel Consumption Rate
Using Figure I1-4, an average output of 400 hp at 85% efficiency will use
approximately 112.5 gal/hr (interpolated between 86% at 111 gal/hr and 84% at
114 gal/hr) of No. 2 fuel oil.
Step 2: Estimate Annual Fuel Use
112.5 gal/hr x 5000 hr/yr = 562,500 gal/yr annual fuel consumption or
approximately 560,000 gal/yr
Step 3: Estimate Annual Fuel Cost
Refer to Figure I1-5 and find the intersection of 560,000 gal/yr (bottom scale) and
the $1.40/gal fuel price line (right scale). Looking to the left, the annual fuel cost
(left scale) is shown to be $784,000.
Step 4: Determine Potential Incremental Efficiency Improvement
Based on an average efficiency improvement attributable to the trim control of 1.3%
for No. 2 oil. Refer to Figure I1-3and find the intersection of the boiler system base
efficiency of (85%) and the 1.3% incremental efficiency gain curve (right scale).
Referring to the left scale, the system efficiency improvement is shown to be 1.6%.
Step 5: Estimate Potential Annual Fuel Savings
Refer to Figure I1-7and find the intersection of $784,000 annual fuel cost (bottom
scale) and the 1.6% system efficiency improvement (right scale) identified in Step
4. Looking across to the left scale, annual savings are shown to be approximately
$12,000.
Step 6: Determine the Payback Period for the investment (or the Allowable
Incremental Capital)
Multiply $12,000 times the three years required to get $36,000.
Step 7: Refine the Analysis
If there are other economic factors to be considered as a result of adding oxygen trim
controls, add these savings (or costs) to the $12,000 annual fuel savings
determined in Step 5. Then repeat Step 6 with the combined savings figure.
I1-19
09-09
Section I
Assuming there are no other economic factors to be considered, the analysis has
shown that the project payback criteria can be met provided the installed oxygen
trim control will cost no more than $36,000. Clearly, purchase of the added control
is this example would be a good investment. The equipment purchase cost would
be recouped in less than three years and the customer would enjoy $12,000
annual savings thereafter that will grow with fuel price increases and escalation.
I1-20
09-09
ANNUAL GAS COST - Dollars/Year
Section I
$15,000,000
$15.00/MM Btu
$13,500,000
$13.50/MM Btu
$12,000,000
$12.00/MM Btu
$10,500,000
$10.50/MM Btu
$9,000,000
$9.00/MM Btu
$7,500,000
$7.50/MM Btu
$6,000,000
$6.00/MM Btu
$4,500,000
$4.50/MM Btu
$3,000,000
$1,500,000
$0
0
100
200
300
400
500
600
700
800
900
1000
ANNUAL GAS USE - Billion Btu/Yr.
Figure I1-1. Annual Gas Cost as a Function of Gas Use and Unit Price
I1-21
09-09
Section I
$4,800,000
$15.00/MM Btu
$4,200,000
ANNUAL GAS COST - Dollars/Year
$3,600,000
$12.00/MM Btu
$3,000,000
$9.00/MM Btu
$2,400,000
$1,800,000
$6.00/MM Btu
$1,200,000
$600,000
$0
0
100
200
300
ANNUAL GAS USE - Billion Btu/Yr.

Figure I1-2. Annual Gas Cost as a Function of Gas Use and Unit Price (Expansion of Figure I1-1)
I1-22
09-09
Section I
$30,000,000
$2.40/Gal
$28,000,000
$24,000,000
$2.00/Gal
$20,000,000
ANNUAL FUEL OIL COSTS - Dollars/Year
$1.60/Gal
$16,000,000
$1.20/Gal
$12,000,000
$0.80/Gal
$8,000,000
$0.40/Gal
$4,000,000
$0
0
2,000
4,000
6,000
8,000
10,000
12,000
FUEL OIL CONSUMPTION - Thousands of Gallons/Year

Figure I1-3. Annual Fuel Oil Cost as a Function of Fuel Oil Use and Unit Price
I1-23
09-09
Section I
$8,000,000
$2.40/MM Btu
$7,000,000
ANNUAL FUEL OIL COST - Dollars/Year
$6,000,000
$2.00/MM Btu
$5,000,000
$1.60/MM Btu
$4,000,000
$1.20/MM Btu
$3,000,000
$0.80/MM Btu
$2,000,000
$0.40/MM Btu
$1,000,000
$0
0
1.000
2,000
3,000
ANNUAL FUEL OIL CONSUMPTION - Thousands of Gallons/Year
Figure I1-4. Annual Fuel Oil Cost as a Function of Fuel Oil Use and Unit Price (Expansion of Figure I1-3)
I1-24
09-09
Section I
10.00%
9.00%
SYSTEM EFFICIENCY IMPROVEMENT - PERCENT
8.00%
Incremental
Efficiency
Gain
7.00%
6.00%
5%
5.00%
4.00%
4%
3.00%
3%
2.00%
2%
1.00%
1%
0.00%
50%
55%
60%
65%
70%
75%
80%
85%
90%
95% 100%
REFERENCE BASE SYSTEM EFFICIENCY - PERCENT
Figure I1-5. System Efficiency Improvement as a Function of Incremental Component Efficiency Gain
I1-25
09-09
Section I
5.00%
$750,000
4.50%
ANNUAL SAVINGS - Dollars
$600,000
4.00%
3.50%
$450,000
3.00%
2.50%
$300,000
2.00%
1.50%
$150,000
1.00%
0.50%
$0
0
1.5
3.0
4.5
6.0
7.5
9.0
10.5 12.0 13.5 15.0
ANNUAL FUEL COST - $MM
I1-26
09-09
Section I
$240,000
5.00%
$210,000
$180,000
4.00%
ANNUAL SAVINGS - Dollars
$150,000
3.00%
$120,000
$90,000
2.00%
$60,000
1.00%
$30,000
$0
0
1.5
3.0
4.5
ANNUAL FUEL COST - $MM

(Expansion of Figure I1-6)
I1-27
09-09
Section I
Notes
I1-28
09-09
Section I2
HOT WATER SYSTEMS
CONTENTS
MECHANICAL CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-3

Code Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-3
Boiler Selection Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-3
Air Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4
Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4
Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-8
Domestic Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-8
Heating/Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-9
Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-9
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-10
High Temperature Water Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-10
CONTROL CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-11
Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-11
Lead/Lag Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-12
Temperature Setbacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-15
Heat Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-16
WATER CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-18
Water Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-18
Chemical Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-19
Make-up Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-19
Ethylene Glycol as Heat Transfer Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-19
SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-21
ILLUSTRATIONS
Figure I2-1. Typical Expansion Tank Piping Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-5

Figure I2-2. Typical Pump Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-5
Figure I2-3. Pressure Temperature Chart for Firetube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-7
Figure I2-4. Plug Cock or Gate Valve (Manual Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-14
Figure I2-5. Two-Position Valve (Electric or Pneumatic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-14
Figure I2-6. Throttling or Modulating Valve (Electric or Pneumatic) . . . . . . . . . . . . . . . . . . . . . . . I2-14
Figure I2-7. Three-Way Mixing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-14
Figure I2-8. Three-Way Mixing Valve (By-Pass Arrangement) . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-15
Figure I2-9. Three-Way Diverting Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-15
Figure I2-10. Intermittent Secondary Pump Operation (On-Off) . . . . . . . . . . . . . . . . . . . . . . . . . . I2-15
Figure I2-11. Water Temperature Constant Thru Zone Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-15
Figure I2-12. Continuous Secondary Pump Operation with Two-Position Valve (Valve Open) . . . . . . I2-16
I2-1
09-09
Hot Water Systems

Figure I2-13.
Figure I2-14.
Figure I2-15.
Figure I2-16.
Figure I2-17.
Figure I2-18.
Figure I2-19.
Section I
Continuous Pump Operation with Two-Position Valve (Valve Closed) . . . . . . . . . . . .

Primary Loop Circuit, Constant Speed Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary Loop Circuit with Secondary Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . .
Individual Zone Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary Loop Circuit with Three-Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Four-Way Valve System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multiple Boiler Lead/Lag, Primary/Secondary Pumping . . . . . . . . . . . . . . . . . . . . .
I2-16
I2-22
I2-23
I2-24
I2-25
I2-26
I2-27
TABLES
Table I2-1. Circulation Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-6

Table I2-2. Pressure drop across firetube hot water boilers (standard size nozzles) . . . . . . . . . . . . I2-9
This section provides design considerations for boiler applications in hot water systems. The information
provided is intended to create an awareness of the various considerations that should be evaluated to ensure a
successful installation and long boiler life.
I2-2
09-09
Section I
Hot Water Systems
MECHANICAL CONSIDERATIONS
Code
Considerations
Boilers constructed in accordance with Section IV, Heating Boilers, of the ASME
Boiler and Pressure Vessel Code can be operated with water temperature up to 250
F with a maximum design pressure of 160 psig.
Boilers for operation over 250 F or 160 psig must be constructed in accordance
with Section I, Power Boilers, of the ASME Boiler and Pressure Vessel Code.
Due to limitations of control and safety settings, desired operating temperatures
between 240 F and 250 F may require the use of a Section I boiler. System
operating pressure must not exceed 90% of the relief valve pressure setting.
Consideration should be given to system piping to ensure it meets all applicable
codes. For example, when Section I boilers are used, the piping must be in
accordance with B31.1 ASME Power Piping Code.
Boiler Selection
Considerations
When a hot water system is laid out, all of the components must be selected to
work together to achieve the design intent. The design intent could include criteria
such as: system flexibility, maximum efficiency, heating/cooling, domestic hot water,
heat storage, fuel capability, etc. Selection and operation of the boiler(s) in relation
to the other system components, and in support of the design intent, are important
considerations.
Selection of a boiler to support the design intent of the hot water system is
dependent on several site-specific variables, such as those just listed. In addition,
one of the most important selection factors is the maximum continuous rating of the
boilers, which is dependent on the load imposed by the heat users and the nature
of the load. For example, consider an installation with a maximum load of
10,300,900 Btu/hr. Of this, 9,300,900 Btu/hr are the peak winter heating load
and 1,000,000 Btu/hr are domestic hot water load, which are provided through
means of a heat exchanger.
Based on the maximum load conditions just described, consideration might be given
to a 310 horsepower firetube boiler (1 boiler horsepower = 33,472 Btu/hr).
However, to ensure system flexibility, and to provide some degree of stand-by for
unscheduled outage, common practice would dictate the installation of two units,
each with a capacity of 65% of the maximum load. That is; two 200 horsepower
units, or 6,695,000 Btu/hr each.
Based on the example just mentioned, it is apparent that boiler capacity selection,
based on peak loading, is fairly straight forward.
Specific load mix, often caused by early fall or late spring heating loads, can require
additional considerations. When the minimum heating load is 10% of the maximum
heating load, the heating load is: 9,300,900Btu/hr.
Heating Load @ 10% = 930,090Btu/hr
Domestic Water = 1,000,000Btu/hr
TOTAL LOAD = 1,930,090Btu/hr
When the light heating load only is imposed, the demand on the boiler is only 14%
of its rated capacity. A third, smaller unit should be considered for light load
conditions, unless the boiler has a burner with a 10:1 turndown ratio.
When multiple boilers are used, care must be taken to assure proper proportional
flow through each of the units. If flow is not properly balanced, wide variations in
I2-3
09-09
Hot Water Systems
Section I
boiler firing rates can occur and, in extreme cases, the resulting outlet water
temperatures may not be at the desired point.
In summary, the seasonal and daily variations define the size of the load that the
boilers must handle. The maximum load will be used, along with backup
requirements, to set the plant capacity. Seasonal and daily variations are used to
help select the number of boilers and turndown requirements. In some applications,
there is a mixture of loads. These may be different types of process loads or
combinations of heating and process loads. It is usually best to analyze them
individually, and then combine them for each season.
Air Removal
Air removal in a hot water boiler is important for two main reasons. Air contains
oxygen, which can cause corrosion of metal surfaces. And, air acts as an insulator
and can affect heat transfer as well the operation of temperature controls.
All Cleaver-Brooks hot water outlet connections include a dip tube, which extends 2
to 3 inches into the boiler. The dip tube does not allow any air, which may be
trapped at the top of the drum, to get back into the system.
Because any oxygen or air which is released in the boiler will collect or be trapped
at the top of the boiler drum, the air vent tapping on the top center line of the boiler
should be piped into the expansion or compression tank or fitted with an automatic
air vent valve. Any air that is trapped at the top of the boiler will find its way out of
the boiler through this tapping.
Dip tube assemblies furnished for external mounting into the boiler return
connection, or system air separators, may also be equipped with an air vent
tapping. These devices will remove air from the system, however, they do not
remove air from the top of the boiler. To avoid trapped air at the top of the boiler
drum, it is still necessary to pipe the boiler air vent into the expansion or
compression tank or into an automatic air vent valve.
Expansion Tank
An expansion tank serves one primary function in a hot water system. It provides a
means for the system water to expand, as it is heated, without significantly
increasing system pressure.
Expansion tanks are also often used as the receiver for the air removed from the
boiler. This is convenient if the expansion tank does not have a bladder or
diaphragm. If the expansion tank has a bladder or diaphragm, the air from the
boiler must be removed by an automatic type air vent piped directly to the air vent
tapping on the top of the boiler.
Proper expansion tank design will account for the desired system pressure and
changes in the specific volume of water from 60 F (ambient temperature) to the
maximum operating temperature of the boiler and related system. To design the
expansion tank, you must first know the total volume of water in the flooded boiler
and system. For flooded values for a Cleaver-Brooks boiler, refer to the boiler
products section. You will need to estimate the water volume in the system by
considering the diameter and length of system piping and including the volume of
water contained in system heat exchangers.
Expansion tanks are usually charged with air or an inert gas such as nitrogen.
Nitrogen is often used in high temperature water applications due to its low
corrosive nature. Regardless of the charging media, expansion tanks are charged at
a pressure slightly higher than the static pressure on the tank with the system at
ambient temperature. As the water in the system is heated, the air or gas cushion in
I2-4
09-09
Section I
Hot Water Systems
Figure I2-1. Typical Expansion Tank Piping Arrangement
Figure I2-2. Typical Pump Curve
I2-5
09-09
Hot Water Systems
Section I
the expansion tank compresses, allowing the water to expand without significant
variations to the system pressure.
For more information on sizing expansion tanks, refer to the ASHRAE Guide Book,
or contact your local Cleaver-Brooks authorized representative.
A typical expansion tank piping arrangement is shown in Figure I2-1.
Pumping Equipment
Pump Type
Centrifugal type pumps are typically used for system circulating pumps, because of
their proven durability, efficiency, and ability to pump the required flow and
pressure.
Although there are many types of centrifugal pumps available with varying
characteristics, most applications use a pump with a curve similar to Figure I2-2.
When using this type of pump curve, draw a horizontal line at the feet-of-head
requirement for the system (2.31 feet of water at 60 F = 1 psig). At the point
where the line intersects the pump curve, draw a vertical line to determine the
gallon per minute flow the pump will pump at the given feet-of-head. Select a pump
that meets both the flow and feet of head requirements for the system. The
operating or design point of the pump is the point at which the vertical and
horizontal lines intersect the pump curve. This point is also commonly referred to as
the duty point.
Table I2-1. Circulation Rates

SYSTEM TEMPERATURE DROP - DEGREES F
BOILER
OUTPUT
(X 1000)
BTU/HR
10
15
500
100
50
33
25
20
17
14
20
670
134
67
45
33
27
22
19
30
1005
200
100
67
50
40
33
40
1340
268
134
89
67
54
50
1675
335
168
112
84
60
2010
402
201
134
70
2345
470
235
80
2680
536
100
3350
125
BOILER
HP
90
100
12
11
10
17
15
13
29
25
22
20
45
38
33
30
27
67
56
48
42
37
33
101
80
67
58
50
45
40
157
118
94
78
67
59
52
47
268
179
134
107
90
77
67
60
54
670
335
223
168
134
112
96
84
75
67
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
20
30
40
50
60
70
80
Note: Applications with design temperature drops over 50 degrees F require review by Cleaver-Brooks.
I2-6
09-09
Section I
Hot Water Systems

Pump Location
It is recommended that the system circulating pumps take suction from the outlet
connection on the boiler and that they discharge to the system load in order to put
the boiler and the expansion tank on the suction side of the pump. This location is
preferred because it decreases potential for air entry into the system and does not
impose the system head on the boiler.
It is common practice to install a standby system circulating pump, to
accommodate scheduled pump maintenance without shutting the system down.
Usually, both the main and standby circulating pumps are located adjacent to the
boilers in the boiler room.
Pump Operation
Pumps are normally started and stopped by manual switches. It is also desirable to
interlock the pump with the burner so that the burner cannot operate unless the
circulating pump is running.
Pump Capacity
Table I2-1 can be used to determine the maximum gpm circulating rate in relation
to full boiler output and system temperature drop. Knowing the boiler size and
expected system temperature drop, the maximum circulation rate can be selected.
Circulation
The system should be piped and the controls configured to ensure continuous flow
of system water through the boiler under all operating conditions. Constant
Figure I2-3. Pressure Temperature Chart for Firetube Boilers

I2-7
09-09
Hot Water Systems
Section I
circulation through the boiler results in a more even water temperature and
eliminates the possibility of stratification within the boiler and system. Constant
circulation reduces the possibility of thermal stresses to the boiler and subsequent
pressure vessel failure.
Minimum Circulation
As a rule of thumb, the minimum continuous circulation rate through the boiler
under operating conditions is one gallon per minute per boiler horsepower.
Maximum Circulation
The maximum circulation in gallons per minute through the boiler is based on
system design temperature drop, and maximum Btu output rating of the boiler.
Table I2-1 shows the maximum circulation rates for firetube boilers. For information
on specific boiler circulation rates, refer to the boiler products section.
Pressure Drop
When sizing the system circulating pump, it is necessary to account for the system
line losses. Proper sizing will allow the pump to overcome the system pressures in
order to deliver the proper flow through the system. The boiler is part of the system
pressure drop calculation. As a rule of thumb, there is a pressure drop of less than
3 feet of head (1 psi = 2.31 feet of head) through Cleaver-Brooks boilers.
Table I2-2 shows pressure drop curves for firetube boilers with standard size
nozzles. To determine the pressure drop for a particular application, find the flow
rate in GPM on the y-axis and read across the graph to the boiler HP. The resulting
x value will be the head loss in feet of water (note: scale is log-log).
Pressure Requirements
In a hot water boiler, the pressure/temperature relationship is critical. Unlike a
steam boiler, where the pressure and temperature relationship corresponds to the
laws of nature, a hot water boiler design purposely prevents the water from turning
to steam. To prevent steaming, a certain amount of over pressure is required to
keep the water from flashing to steam. Figure I2-3 shows a typical pressure/
temperature relationship for Firetube and Model 4 hot water boilers. Similar charts
are provided in the specific boiler product sections. To use the chart, locate the
maximum system operating temperature (High Limit Control Setting) on the bottom
line. Draw a straight line to the minimum recommended boiler operating pressure
curve. At the point where the lines intersect, draw a horizontal line to the left of the
chart and find the necessary pressure.
Domestic Hot Water
Hot water systems are often used as the energy source to provide domestic hot
water. The hot water for personal washing (showers, laundry, etc.) and, in some
cases, light industrial process, is often provided through the incorporation of a heat
exchanger in the system.
Physically, the heat exchanger provides a separation of the hot water system water
from the domestic water which, in turn, allows the fluids to be of different chemical
make-up. This provides integrity and proper water treatment for the hot water
system, and proper water treatment, while providing potable water in the secondary
loop.
Space requirements for the domestic water heat exchanger vary considerably based
on specific application. However, typically, the required space is quite small. For
I2-8
09-09
Section I
Hot Water Systems
9.0
10.0
5.0
6.0
7.0
8.0
4.0
3.0
2.0
Table I2-2. Pressure drop across firetube hot water boilers (standard size nozzles)
I2-9
09-09
Hot Water Systems
Section I
example, Cleaver-Brooks can provide domestic water coils integral to the boiler that
require no additional floor space, and only need room for the associated domestic
water loop piping. In this type of system, typically, there is a low volume of domestic
water stored. The heat exchanger system must be sized to maintain minimum
desired temperature at maximum load conditions. This is an excellent application
for fairly continuous domestic water loads.
In many cases, domestic hot water can, and should, be provided by including a
shell and tube (or plate and frame) heat exchanger as part of the hot water system.
Isolation and services of the heat exchanger can be performed without removing the
hot water heating system from service.
When it is apparent that large domestic water demands are required for a short
period of time, consideration should be given to incorporating a storage tank in the
domestic water loop. In most applications of this type, the heat exchanger is
incorporated into the storage tank and the hot water system fluid is pumped through
the tube side of the exchanger and the domestic hot water is on the shell side.
Domestic water heat exchangers provide physical separation of the two media and,
therefore, considerable flexibility with respect to flow and temperature. Such
systems, however, are not trouble free. Scaling or fouling of the heat exchanger
surface can occur, process controls can fail, etc. To maintain optimum operating
efficiency of the domestic water circuit, serviceability of the equipment should
always be considered during system design.
Heating/Cooling
Heating/cooling systems are often called single pipe systems. In a single pipe
system, the water is either heated by a boiler or cooled by a chiller to meet the
comfort demand.
Special care and consideration must be given to system design when the heating
(hot water) and cooling (chilled water) systems share common distribution piping.
The type of boilers selected; control systems for both heating and cooling; and type
of load - heat in the morning, cooling in the afternoon - are critical issues of design
consideration that will dictate success or failure of the installation.
The overall system design intent must be the comfort heating, or cooling, of the
individuals who occupy the building. However, if either the boiler or chiller cannot
be used because they are being repaired, the system intent has failed.
Why would a boiler or chiller fail? With respect to the boiler, consider a scenario
where heating is required in the early morning and early evening. During the day,
cooling is required. To meet the demand, the boiler is maintained in a hot stand-by
mode. When the system demands heat, the pumps and control valves shift to send
boiler water to the system. What comes back to the boiler is the chilled water
(relatively cold) from the system. The result - THERMAL SHOCK. It is assumed that
a similar, but opposite, phenomenon exists within the chiller.
What can the system designer do to minimize the potential problem when single
pipe systems are designed?
Provide slow acting valves that slowly bleed the system water into the boiler
during the cooling/heating mode changeover.
Specify boilers that minimize problems resulting from Thermal Shock. Refer to
the Cleaver-Brooks Flextube Boiler product section, Section B1.
I2-10
09-09
Section I
Accumulators
Hot Water Systems
Select and specify boiler operating controls and system controls that maximize
equipment protection without sacrificing the heating/cooling comfort needs of
the individuals.
Possibly include accumulator tanks into the system.
Hot water systems inherently have considerable energy capacity. Once the heating
system is on-line, the flywheel affect has a tendency to smooth out the minor
spikes and valleys that occur during the typical heating load. However, some
systems dictate the requirement for load, or heat shedding, to maximize operating
efficiency or the availability of additional heat to satisfy load demand peaks. When
load shedding or heat storage needs exist within the same system, an accumulator
tank or heat accumulator, is an ideal fit.
When hot water systems include large demand heat users that are brought into
service quickly through controls and valving, the increased load demand is
immediately realized by the boiler. To minimize the impact of the condition and to
add to the total available energy for the system, accumulators or storage tanks can
be used. Proper sizing of accumulator tanks requires careful analysis of the load
peaks that are to be addressed and the minimum/maximum temperature swings
that can be tolerated in the system.
The control system, including circulating pumps, will be dependant on the specific
application of the accumulator and the design of the storage tank, such as
stratification tanks and baffle tanks.
Although accumulators are not common in most heating systems, they do provide
heat storage capacity and equipment protection and should be considered in
complex hydronic system designs.
Safety
The highest level of consideration in any system design should be the safety of
personnel. Good safety practices are essential in hot water, as well as in steam
systems. For example, consideration for safe discharge of water from the relief
valves is important. For hot water heating boilers (ASME Section IV; 160 psig/250
F maximum) a flexible connection between the safety valve and the discharge pipe
is recommended. The discharge piping must be properly arranged and supported so
that its weight does not bear upon the valve.
High Temperature
Water Boilers
As required by ASME Boiler and Pressure Vessel Code, boilers for operation over
250 F or 160 psig must be constructed in accordance with ASME Section I, Power
Boilers. Due to limitations of control and safety settings, an operating temperature
above 240 F will require the use of a Section I boiler.
Design pressures above 125 psig will require Cleaver-Brooks review, regardless of
operating temperature. Use Figure I2-3 for the operating temperature and
recommended minimum boiler operating pressure. Also, please ensure that there is
continuous water flow trough the boiler.
Depending on horsepower requirements, operating temperature, design pressure,
and water flow rate, there could be some limitations that affect recommended boiler
size or maximum Btu rating. Cleaver-Brooks is in a better position to review and
comment on the design criteria if the evaluation is performed at the design stage of
the project. Contact your local Cleaver-Brooks authorized representative on any high
temperature water applications. Provide the following details for review:
Supply and return temperatures.

I2-11
09-09
Hot Water Systems
Section I
Flow rate (is it constant or variable?).
Operating pressure.
Describe load characteristics.
Provide detail of system and sequence of operation.
If a system schematic is available, forward a copy to your local CleaverBrooks authorized representative.
CONTROL CONSIDERATIONS
Temperature Control
Boiler Water Temperature Control

As with all pieces of mechanical equipment, rapid changes in temperature will
cause thermal stress to a boiler pressure vessel. The degree of stress and
subsequent failure is directly related to the frequency and degree at which the
thermal stresses are applied. Also, in hot water applications, too low of a boiler
water outlet temperature can cause condensation of flue gases and subsequent
fireside corrosion. In order to avoid these types of problems, certain parameters
must be considered when designing a hot water control system.
1. Minimum Outlet Temperature
Fireside corrosion occurs when flue gases are cooled below the dew point.
Cooling of the flue gases occurs when hot flue gases come in contact with cool
pressure vessel surfaces. To prevent this, minimum operating temperatures
must be maintained to keep the flue gases above the dew point. The minimum
water outlet temperature is typically 170 F. The minimum return water
temperature is typically 150 F. For exact temperatures refer to the specific
boiler section. Maintaining minimum outlet temperatures will help prevent
harmful condensing of flue gases.
2. Maximum Outlet Temperature
The maximum temperature rating for all Cleaver-Brooks ASME Section IV

boilers is 250 F. Due to limitations of control and safety settings, desired
operating temperatures above 240 F may require the use of a Section I boiler
and a high temperature hot water system. For high temperature water, ASME
Section I, the boilers maximum outlet temperature depends upon its design
pressure. For information on high temperature water applications, contact your
local Cleaver-Brooks authorized representative for further information.
3. Temperature Drop Across the Boiler
The maximum temperature drop from supply to return is directly related to the
circulation rate through the boiler and boiler capacity. These factors must be
evaluated to ensure they meet the intent of the system design. Refer to Table I21 for flow rate versus temperature drop charts.
Even though design temperature drops can be up to 100 F, care must be taken
when applying boilers into these systems. At no time should the system
temperature drop provide return water at a temperature that could cause flue
gas condensation and subsequent fireside corrosion.
4. Boiler Warm-up
The controls that maintain the boiler water temperature should be designed and
set in such a way as to allow a slow warm-up of a cold boiler. To prevent
I2-12
09-09
Section I
Hot Water Systems

damage to the pressure vessel and refractory, a warm-up from a cold (ambient)
boiler to operating temperature is normally accomplished through manual
operation at the low-fire rate. Automatic operation from a cold start is not
recommended without proper control sequencing, as is available with the CBHAWK control.
In multiple boiler installations when a second cold boiler is being brought into
the system, a means should be provided to slowly introduce flow of system
water into the return. The boilers temperature should not be increased any
quicker than 1 F per minute. Even when the boiler has reached return water
temperature, a means must be provided for a slow warm-up of the boiler from a
stand-by to an operational condition. This will provide proper warm-up of the
refractory within the boiler as well as ensure that the pressure vessel is at
operating temperature. Under these conditions, a means should be provided to
hold the burner in the low-fire position a minimum of 30 minutes if the burner
has not operated within the last 4 hours.
5. Rapid Replacement of Boiler Water
The most common causes of cold water slugs returning to a boiler are: 1) cycling
of individual zone pumps and, 2) the main circulating pump cycling off, allowing the
boiler to continue to operate. These situations cause a boiler that is operating
between 170 and 250 F to experience high flow rates of possibly ambient
temperature water, thus causing excessive thermal stress. To determine the rate at
which cold water can be introduced into an operating boiler, refer to the specific
boilers temperature drop/flow rate charts.
6. One additional item that must be considered when deciding upon boiler outlet
water temperatures is boiler auxiliaries, which may require certain temperatures. For
example, a hot water boiler firing a No. 6 fuel oil may require temperatures in
excess of 200 F, when heating the oil in an oil preheater with boiler water. The
operating temperatures needed will depend upon the fuel oil temperatures required
for proper atomization of the fuel. If water temperatures cannot be maintained at the
required levels, an electric preheater must be sized accordingly to provide the
additional heat.
System Temperature Control
Since the minimum outlet temperature for a boiler is limited, it is sometimes
desirable to regulate the water temperature going to the heat users. This is normally
done by regulating the temperature of the main supply and/or the water temperature
at the heat users.
The most common way to vary the system supply temperature is through the use of
a three- or four-way control valve. These control valves will blend a portion of return
water with boiler supply water to maintain the desired system supply temperature.
When applying these types of valves, care must be taken to ensure that the
minimum flow requirements for the boiler will be met at all times. These valves
must be slow moving to ensure that rapid temperature changes are not taking place
in the boiler return water temperature.
Temperature control at the heat users is normally accomplished through diverting or
two-position valves controlled by a room or duct thermostat. Temperature control of
heat users will be discussed in more detail later in this section.
I2-13
09-09
Hot Water Systems

Lead/Lag Systems
Section I
A Lead/Lag system sequences the on-off firing and modulation of multiple boilers to
meet the system load demand.
The key to the design of a lead/lag control in a hot water system is the realization
that temperature changes in a hot water system are inherently slow. This also
means that a change in boiler output does not result in immediate changes in
overall system temperature. The control system must be designed to take into
account the lag times and allow for fine tuning.
Lead/lag systems are available in two basic types. Lead/lag start - unison
modulation and lead/lag start - lead/lag modulation. Please refer to Controls, Section
8, for a more detailed description of these two systems.
In general, with hot water systems, lead/lag start - unison modulation would be the
most practical system. This is due to the fact that with hot water boilers, the load
imposed on a particular boiler is directly related to the rate of water flow through it.
If the flow rate through two boilers is equal, they must have the same Btu output to
maintain a constant supply header temperature. The following example illustrates
the problem associated with not having unison modulation with two equally sized
boilers in a lead/lag sequence.
Boiler #1
Boiler #2
200hp
200hp
Flow = 500gpm
Flow = 500gpm
Firing rate = 100%
Firing rate = 25%
Return temperature = 160 F

Required header temperature = 190 F
The Btu output of a 200hp boiler at 100% firing rate is 6,695,000 Btu/hr. The
same boilers output at 25% is 1,673,750 Btu/hr. Each boiler has a flow of 500
gpm or 4071 lb/min. Since it takes 1 Btu to change 1 pound of water 1 F, we can
determine the outlet temperature of each boiler.
Boiler #1
6,695,000 Btu/hr 60 min/hr = 111,583 Btu/min
111,583 Btu/min output divided by the 4071 lbs/min flow rate yields a
temperature rise of 27.4 F.
Boiler #2
1,673,750 Btu/hr 60 min/hr = 27,895 Btu/min
27,895 Btu/min output divided by the 4071 lbs/min flow rate yields a temperature
rise of 6.9 F.
With a return temperature to both boilers at 160 F, it can be seen that the outlet
temperature of boiler #1 would be approximately 187 F and the outlet temperature
of boiler #2 would be almost 167 F. Since the flow through both boilers is equal,
the mixed temperature to the header would be approximately
177 F.
This scenario becomes even further complicated when more than two boilers are in
a system, and when they are of varying sizes. When the boilers are different sizes,
the flow through the boilers must be proportional to the capacity and firing rate of
the boilers. For example, the load on a smaller boiler
may exceed rated capacity while the larger boiler is
I2-14
09-09
Section I
Hot Water Systems
Figure I2-6. Throttling or Modulating Valve

(Electric or Pneumatic)
Figure I2-4. Plug Cock or Gate Valve

(Manual Operation)
Figure I2-5. Two-Position Valve

(Electric or Pneumatic)
Figure I2-7. Three-Way Mixing Valve
cycling off, resulting in inefficiencies and potential thermal shock damage to the
pressure vessel and refractory. To ensure the flow through a particular boiler is
proportional to its size and firing rate, controls and motorized valves should be
incorporated. The control system required to perform this can become quite
sophisticated; however, reliable operation and a savings in repair and maintenance
costs will be realized.
The stand-by boiler must be kept in mind when designing a system with lead/lag
operation. If there is continuous flow through all boilers, regardless of whether or
not they are firing, the stand-by boiler will have an outlet temperature equal to the
return temperature. This, again, will create a situation where a blended temperature
is getting to the common supply header. This is normally avoided by installing a
motorized valve at the outlet or return to each boiler. The position of the valve is
dictated by the status of the boiler. The valve will generally have two positions.
When the boiler is at header temperature and supplying hot water to the system,
the valve would be at its position for maximum design flow through the boiler.
When the boiler is in stand-by, the valve would be positioned for the minimum flow
rate required by the boiler. Maintaining the minimum flow rate will prevent
stratification of temperatures within the boiler. The valve positions become more
I2-15
09-09
Hot Water Systems
Section I
complicated and numerous when boilers of unequal sizes are applied in the same
system. Keep in mind, flow through the boilers must be proportional to the output of
the boilers.
Provisions should be made in the lead/lag control system to maintain a boiler in a
hot standby condition. This normally requires intermittent firing at low fire to
maintain a set point slightly lower than the main supply set point.
To ensure that refractory as well as the pressure vessel are at a proper operating
temperature, all lead/lag controls must ensure that the burners return to low fire
prior to turning the burners off. It is recommended that once a boiler is brought into
the system after being off for a period of time (standby hot condition), that it be
operated at its lowest firing rate for a minimum of 30 minutes.
Temperature
Setbacks
In the interest of conserving energy, it is sometimes desirable to set back the system
supply temperatures based on time of day, day of week, or outdoor air temperature.
Since the boiler water temperature requires that a minimum outlet temperature be
maintained, resetting the boiler temperature is normally not practical. Resetting the
supply water temperature is normally accomplished through a three- or four-way
control valve. One important item to keep in mind when setting back temperatures,
is how the control valve reacts when returning the system to the higher temperature.
Figure I2-8. Three-Way Mixing Valve (By-Pass

Arrangement)
Figure I2-10. Intermittent Secondary Pump Operation

(On-Off)
Figure I2-9. Three-Way Diverting Valve
Figure I2-11. Water Temperature Constant Thru Zone

Bypass
I2-16
09-09
Section I
Hot Water Systems

Control valve operation should not be instantaneous. It is extremely important to
ensure that the valve does not travel from a fully closed to a fully open position
instantaneously. This would cause high flow rates of relatively cold water to return
to the boiler, causing thermal stress and possible pressure vessel damage.
Individual zones should not normally be set back by turning off individual
circulating pumps. In determining whether or not this practice would be acceptable,
the flow rate of the zone versus the entire system flow rate must be considered. If
the zone has a high flow rate compared to other zones, cycling of pumps can cause
serious problems with cold slugs of water being returned to the boiler, resulting in
thermal stress and subsequent pressure vessel failure.
Heat Users
Selection of the type, size, quantity and location of heat users is job specific, and is
usually determined by the project design engineer.
Typical load groupings are shown on the hot water system layouts shown in Figure
I2-14 thru Figure I2-19. The groupings will naturally be varied, depending on
actual job layout and the individual load and temperature requirements.
The following heat users are most commonly used in hot water heating systems:
1. Radiators
2. Convectors
3. Coils in Ducts
4. Fin Coils
5. Blast Coils
6. Unit Heaters
7. Unit Ventilators
8. Unit Ventilators with Face and Bypass Dampers
9. Radiant Panel - Inside
10. Process Heating
Figure I2-12. Continuous Secondary Pump

Operation with Two-Position Valve (Valve Open)
Figure I2-13. Continuous Pump Operation with TwoPosition Valve (Valve Closed)
I2-17
09-09
Hot Water Systems
Section I
Manufacturers installation recommendations should be closely followed to avoid
special problems such as coil freeze- up, water hammer, and noise factors.
Control of Water Flow Through Heat Users
Common methods of controlling water flow through heat users are shown on the hot
water layouts found later in this section and are described later.
Plug Cock or Gate Valve (Manual Operation)
Figure I2-4 is the simplest form of control and is directly related to physical comfort
in the area adjacent to the heat user. It is commonly used on radiators, convectors,
unit heaters or ventilators, and blast coils. It is sometimes used on coils and unit
ventilators with face and by-pass dampers.
Sometimes an orificed gate valve is used in a non-critical area. The orificed gate
valve is recommended to ensure flow to the heat user, because it allows flow back to
the boiler under all system conditions.
Two-position Valve (Electric or Pneumatic)
Two-position (fully open or fully closed) valves are commonly used to control water
flow to all types of heat users. See Figure I2-5. The electric or pneumatic signal to
the valve is usually controlled by a room thermostat or manual on-off switch in the
area adjacent to the heat user.
The room thermostat or manual on-off switch in the area adjacent to the heat user
will also start the fan on devices such as unit heaters.
Throttling or Modulating Valve (Electric or
Pneumatic)
Throttling or modulating valves are used to control water flow to heat users such as:
blast coils, unit heaters, and unit ventilators. See Figure I2-6. Throttling or
modulating valves are preferred to two-position valves since they provide more
uniform heating and a relatively constant flow of return water.
Three-way Mixing Valve
Three-way mixing valves (two inlets, one outlet) are used to control water
temperatures going to inside radiant panels or process loads. See Figure I2-7. If a
pump is used, its capacity governs the quantity of water flowing through the heat
user. The pump usually operates (on-off) in response to a high limit room thermostat
(without heat anticipation feature).
When used on inside radiant panels, the three-way valve is usually controlled by a
room thermostat or by the temperature of the water going to the panel.
When used on process loads, the three-way valve is usually controlled by the
temperature of the process itself.
Three-way Mixing Valve (By-pass Arrangement)
The three-way mixing valve with bypass arrangement (Figure I2-8) is commonly
used on fin coils, coils, panels, and process loads and is preferred to the three-way
mixing valve arrangement, since it assures a flow of return water. When fin coils or
coils are controlled by a three-way valve, a room or duct thermostat usually operates
the valve.
I2-18
09-09
Section I
Hot Water Systems

Three-way Diverting Valve
A three-way diverting valve (one inlet, two outlets) arrangement can be used in the
same manner as the three-way mixing valve (by-pass arrangement). See Figure I29. In either case, the position of the valve allows more or less water to flow through
the coil or through the by-pass. Either position of the valve assures return water
flow to the boiler.
Primary-Secondary Pumping
1. Intermittent Secondary Pump Operation (on-off)
The secondary pump operates in response to a high limit room thermostat (without
heat anticipation feature), a duct thermostat, or actual temperature of the water
entering or leaving the heat user. See Figure I2-10.
A tee can actually be used as a mixing valve with this system. Also, wide ranges
and good control of temperature drops are available to the designer. (In the example
just given, there is a 60 degree drop from supply to return, but only a 20 degree
drop across the heat user). When the pump is off, there is no flow in the secondary
zone. The amount of water entering the zone by-pass flows through the zone bypass to the return header.
In Figure I2-11, the 5 gpm at 250 degrees entering the zone by-pass leaves the
zone by-pass at approximately the same temperature. If desired, the supply water
temperature could be varied with an indoor-outdoor system.
2. Continuous Secondary Pump Operation (with 2-position valve)
In Figure I2-12, when the 2-position valve is open (admits 250 F water), the 5
gpm at 250 F mixes with the 10 gpm at 190 F to supply 15 gpm at 210 F to the
pump and the heat users.
Notice
There is 0 gpm in the common piping and the return water (5 gpm) is at 190 F.
Thus, there is a 60 degree drop from supply to return, and a 20 degree drop across
the heat user.
The 2-position valve could be controlled by a room thermostat or by the
temperature of the water entering or leaving the heat user.
When the 2-position valve is closed, (Figure I2-13) the continuously operating
secondary pump is circulating 15 gpm at approximately 210 F. As long as this
satisfies the load requirements, the valve remains closed.
The 5 gpm at 250 F entering the zone by-pass line leaves the zone by-pass at
approximately the same temperature.
Continuous secondary pump operation provides continuous controlled heat input
into each zone.
WATER CONSIDERATIONS
Water Conditioning
Boiling Out: Initial Cleaning

Every new system will have certain harmful substances which remain in the boiler
and piping after construction. It is common to find oils, greases, weld slag, and
I2-19
09-09
Hot Water Systems
Section I
other contaminates within the system. If the foreign materials remain, the boiler
could be affected by loss of heat transfer on heat exchanger surfaces and/or an
acidic water condition. Boiler life may be reduced as a result of an unclean system.
Your authorized Cleaver-Brooks representative or water treatment company will be
able to recommend a chemical cleaning or boil-out procedure. Also, refer to the
boiler operating and instruction manual for more details.
Chemical Treatment
It is recommended that chemical treatment be provided for the initial fill of the
system. Generally, chemicals will be required to prevent scale formation, promote
elimination of dissolved gases and control pH.
Most hot water boilers operate in a closed system and are considered to require
little attention for water treatment. Experience has shown, however, few systems
can be considered completely closed. Loss of water can occur from pump packing,
glands, air venting devices, and threaded or flanged pipe connections. A means
must be provided to chemically treat the raw water make-up. This is generally
accomplished through the use of a shot-type chemical feeder. For information on
shot type chemical feeders refer to Section 19.
Make-up Water
It has been generally accepted in system design that hot water boilers are in a
closed system and, therefore, no make-up water is needed. This is not always the
case. Untreated make-up water is a leading cause for failures of hot water boilers.
In the design stage of a hot water system, provisions must be made for properly
introducing, metering, and treating make-up water.
Introducing Make-up Water
A recommended means for introducing make-up water to a hot water system is
shown in Figure I2-1. This method ensures all air is removed from the make-up
water. It also ensures the water temperature is tempered prior to being introduced
to the boiler, thus reducing the risk of thermal shock.
Metering Make-up Water
The purpose of metering the make-up water to a hot water system is to prevent
potential problems that can tend to damage an otherwise well planned installation.
Figure I2-1 shows the recommended location for a water meter, which is used to
measure the amount of make-up water used by the system. The meter is necessary,
as it may be the only means to identify a system loss of water. Knowledge of makeup water usage will alert the operator to investigate the cause of the system water
loss. This allows the operator to fix the problem and properly treat the make-up
water prior to experiencing any additional problems.
In some cases, depending on the preference of the customer, no automatic means
for make-up water is provided. Instead, a low water alarm is used in the expansion
tank to alert the operator of a loss in system water and a need for system make-up.
The operator can then diagnose the system loss and properly treat the make-up
water. A low water alarm is only practical where full- time operators are employed.
Ethylene Glycol as
Heat Transfer
Medium
on applications requiring freeze protection, a mixture of ethylene glycol and water

is commonly used.
When using ethylene glycol certain design limitations are important, due to the
characteristics of the fluid versus the characteristics of water. These characteristics
I2-20
09-09
Section I
Hot Water Systems

are: Elevated saturation temperature, decreased thermal conductivity and specific
heat, and increased viscosity and density. In addition, ethylene glycol degrades
when it is heated above the manufacturers specified maximum film temperature.
The following design parameters must be considered when operating with ethylene
glycol solutions. For industrial watertube boiler parameters, or for conditions not
covered in the following, contact your local Cleaver-Brooks authorized
representative.
1. Maximum Glycol Concentration
Firetube:60%
Flexible Watertube: 60%
Model 4 Watertube: 50%
2. Maximum Outlet Temperature
Firetube: up to 300 F
Flexible Watertube: 200 F
Model 4 Watertube: 200 F
3. Internal Circulation
A. For firetube boilers, the size of the supply and return connections are decreased
based on the design temperature drop and the system pump gpm.
B. A minimum continuous gpm flow rate through the boiler corresponding to a 40 F
system drop is recommended. For firetube boilers operating between 250 300 F, use a flow rate based on a 30 F system drop.
4. Expansion Tank
a. An inert gas pressurizing blanket is preferred due to the over-pressure
requirements.
5. Over-Pressure Required:
A. Firetube
170 - 250 F operating temperature - recommend 40 psig minimum operating
pressure.
250 - 300 F operating temperature - recommend 100 psig minimum operating
pressure.
B. Flexible Watertube - recommend 50 psig minimum operating pressure.
C. Model 4 Watertube - recommend 50 psig minimum operating pressure.
6. Depending upon the application, process boilers may need to be sized to limit
continuous duty to 80% of maximum boiler rating. As a general rule, fireside boilers
up to 350 horsepower and a maximum operating temperature of 200 degrees F, can
be operated without consideration of Btu de-rating.
Notice
Generally, Firetube boilers up to 350 horsepower and a maximum operating
temperature of 200 F can be operated without consideration of Btu de-rating.
1. On applications requiring freeze protection, a mixture of ethylene glycol and water is
commonly used.
I2-21
09-09
Hot Water Systems
Section I
7. A means should be provided to routinely monitor the condition of the system
fluid. Frequent analysis during the first six months of operation and semi-annual
checks thereafter are recommended.
8. Excessive use of inhibitors can create precipitation of solids causing reduced
circulation and reduced heat transfer.
9. Always alert your local Cleaver-Brooks authorized representative of a system to
be designed for glycol mix. Additional product modifications may be necessary,
based on size, boiler model and operating temperature.
10. The temperature rating of the glycol is also important. In general, use a product
with a minimum temperature rating of 175 degree F above the boiler operating
temperature.
SYSTEM DIAGRAMS
Hot Water System Layout Schematics:
The system layouts (Figure I2-14 through Figure I2-19) are intended to be used
as a general guide for use with Cleaver- Brooks products. Many system layout
combinations have not been shown.
Typical load groupings have been shown and will naturally vary, depending on
actual job layout and individual load temperature requirements.
Reverse returns are shown, since they help equalize the paths of water flow and
simplify balancing of the circuits.
Centrifugal system circulating pumps are shown. It is assumed that these

pumps are manually started and stopped and that they are electrically
interlocked with the burner control circuit. The boiler cannot fire unless the
circulating pumps are running.
Balancing cocks are shown in the supply lines from each boiler to the pumps in
order to help equalize or proportion flow through the boilers.
The number and location of balancing cocks, shutoff valves, etc., to be used in
the system will vary with the particular application.
A make-up water meter must be installed in any raw water feed to the system.
A means for introducing chemicals to the system water must be provided.
Individual expansion tanks are shown for clarity. One expansion tank for
multiple boilers is typically sufficient when sized properly.
Notice
When working with individual zone circuits, where one zone may have a large
quantity of water, and where the zone circulating pump has a high gpm compared
to other zones, cooling down of the water can cause a serious problem in rapid
replacement of boiler water when the pump is started. For this reason, it is
recommended that all circulating pumps run continuously to permit constant
circulation through the relief or bypass device.
I2-22
09-09
Section I
Hot Water Systems
Figure I2-14. Primary Loop Circuit, Constant Speed Pumps
I2-23
09-09
Hot Water Systems
Section I
Figure I2-15. Primary Loop Circuit with Secondary Pumping

I2-24
09-09
Section I
Hot Water Systems
Figure I2-16. Individual Zone Circuits
I2-25
09-09
Hot Water Systems
Section I
Figure I2-17. Primary Loop Circuit with Three-Way Valve

I2-26
09-09
Section I
Hot Water Systems
Figure I2-18. Four-Way Valve System
I2-27
09-09
Hot Water Systems
Section I
Figure I2-19. Multiple Boiler Lead/Lag, Primary/Secondary Pumping
I2-28
09-09
Section I3
STEAM SYSTEMS
CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-3
THE STEAM-GENERATING FACILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-3
Type of Application/Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5
Operating Conditions, Requirements and Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5
Codes and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-7
Other Federal, State, Provincial and Local Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-7
EQUIPMENT CONSIDERATIONS AND HARDWARE DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-7
Steam Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-8
Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-10
Boiler Piping and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-13
Boiler Feed Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-16
Water Treatment Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-21
Economizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-24
Blowdown Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-24
SYSTEM INTEGRATION AND
OPTIMIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-26
EXAMPLE - STEAM SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-26
Boiler Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-29
Condensate Return And Feedwater System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-30
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-31
Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-31
Efficiency Enhancement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-31
System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-31
ILLUSTRATIONS
Figure I3-1. Typical Steam System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-4
Figure I3-2. Schematic Diagram of a Generic Steam-Generating Facility . . . . . . . . . . . . . . . . . . . . I3-4
Figure I3-3. Summary of Application/Energy-Use Audit Items . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-6
Figure I3-4. Recommended Safety Valve Discharge Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-12
Figure I3-5. Example of System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-31
TABLES
Table I3-1. Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table I3-2. Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table I3-3. Recommended Non-Return Valve Size (High Turndown). . . . . . . . . . . . . . . . . . . . . . .
Table I3-4. Removal of Harmful Elements with Various Types of Equipment . . . . . . . . . . . . . . . . .
Table I3-5. Makeup Water Impurities, Limits and Treatment Methods . . . . . . . . . . . . . . . . . . . . .
Table I3-6. Recommended Limits for Total Suspended Solids . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table I3-7. Water Test Results and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I3-11
I3-11
I3-12
I3-15
I3-15
I3-20
I3-26
I3-1
09-09
Steam Systems
Section I
Notes
I3-2
09-09
Section I
Steam Systems
INTRODUCTION
A steam system consists of a steam-supply/generating facility, a steam and
condensate return/water piping system, and a steam-use facility (Figure I3-1). In
this section, the discussion is focused on the integration of the various equipment
within the steam-generating facility. Information is offered which need be
considered when designing a steam-supply system. A general guideline is provided
which identifies major issues to be addressed, leading to the evaluation of system
solutions and ultimately to equipment considerations for selection and design.
Finally, an example of an audit and system design are provided for demonstration
purposes.
The reader is encouraged to review the specific product sections for additional
information. The discussion in this section applies primarily to new systems and
new boiler installations. When modifying existing systems, other considerations
may apply.
THE STEAM-GENERATING FACILITY

The steam-generating facility, located in the boiler room, consists of boilers,
feedwater systems, heat exchangers (e.g., economizers), boiler and system controls,
fuel and gas handling equipment (e.g., fuel trains, stacks), and steam/water
treatment equipment and piping (Figure I3-2). The purpose of the steam-generating
facility is to provide energy (in the form of thermal energy of the steam) to drive
other processes in the steam-use facility. In turn, typical steam-use facilities are
designed to meet various industrial and commercial needs such as comfort heating,
food processing, paper corrugation, etc.
Steam-generating facility design is unique to the specific application and it is
dictated by good engineering practice, the ASME code, applicable national, state,
provincial and local codes, and utility and insurance requirements. System design
and selection depend on job specific operating requirements, boiler room structure
and venting, fuel storage, and utility service considerations. There is therefore no
simple mathematical expression to correlate steam boiler room design and
application. However, there are several characteristics which help define the
application and its relevant requirements. For a steam-generating facility, these
characteristics include:
Type of Application/Load
Operating Conditions, Requirements and Constraints
Facility Requirements and Limitations
Codes and Standards
Other Federal, State, Provincial and Local Requirements
Many of these characteristics have been thoroughly discussed in other sections of
The Boiler Book. The objective here is to draw from that information in order to
address design of integrated steam systems. Ultimately, the objective is to design a
steam-generating facility which is economically optimal for the demands of the
steam-use facility.
The following is a step-by-step procedure which assists in the design of steamgenerating facilities for industrial and commercial use. These items are typically
addressed during an application/energy-use audit of the facility.
I3-3
09-09
Steam Systems
Section I
STACK GASES
STEAM-SUPPLY/GENERATING FACILITY
FUEL AND
COMBUSTION
AIR
BOILERS
CONTROLS
STACKS
ECONOMIZERS
FUEL TRAINS
HEAT EXCHANGERS
STEAM
FEEDWATER SYSTEMS
SEPARATORS
BLOWDOWN SYSTEMS
WATER TREATMENT
PUMPS
STEAM AND CONDENSATE

RETURN PIPING SYSTEM
COMMERCIAL
AND INDUSTRIAL HEATING,
PROCESS, AND
COMBINATION
APPLICATIONS
PIPING
STEAM TRAPS
PUMPS
CONDENSATE
RETURN
MAKE-UP WATER
Figure I3-1. Typical Steam System
STACK GAS
MAKE-UP WATER
ECONOMIZER
STEAM
WATER
TREATMENT
SYSTEM
FEEDWATER
SYSTEM
STEAM-USE
FACILITY
BOILER(S)
BLOWDOWN
SYSTEM
BOILER FEEDWATER
CONTROLS
CONDENSATE RETURN
TO SEWER
Figure I3-2. Schematic Diagram of a Generic Steam-Generating Facility
I3-4
09-09
STEAM-USE
FACILITY
Section I
Type of Application/
Load
Operating
Conditions,
Requirements and
Constraints
Steam Systems
1. Categorize the application and load as heating/cooling, process or combination
(see Section I1, System Load). There are a number of institutional applications
which demand not only heating/cooling, but other steam or hot water
requirements for the purpose of cooking, washing, etc. Generally speaking,
these institutional loads are classified as heating applications since the
requirement typically deals with heating and cooling of air and potable-water.
2. At this juncture, a determination is made whether the boiler should be steamor hot water-generating (see Section I1). For the remainder of this section, it is
assumed that a steam- generating facility is appropriately chosen. (For more
information on application considerations for hot water boilers and hot water
systems, please refer to Section I2, Hot Water Systems.)
Steam
1. Determine the desired operating pressure. For existing steam-use facilities, the
operating pressure has typically been set in the past and now acts as a
constraint on the system design at hand. For new facilities, slightly more
flexibility exists and yet operating characteristics of equipment in the steam-use
facility either set or limit the range of operating pressure of the boiler.
2. Determine the steam load characteristics and ultimately the profile of the
steam-use facility in its entirety (see Section I1). It is important to understand
both the steady-state load profile as well as the transient and instantaneous
demands.
3. Determine the desired or necessary steam quality (dryness) or degree of
superheat. Steam quality ranges from 0 to 100% and is defined as the ratio of
the amount of saturated steam vapor to the total steam amount (which may
consist of both saturated steam vapor and liquid). A 100% steam quality
translates to zero amount of saturated steam liquid and, in this condition, the
steam is termed to be dry.
4. The degree of superheat refers to the amount of thermal energy (heat) added to
the steam relative to the saturated steam vapor point of reference, typically
expressed in units of degrees Fahrenheit. For example, a degree of superheat of
50 oF means that an additional amount of heat has been added to the steam so
that the final steam temperature is 50 oF greater than the saturation
temperature of the steam at the given operating pressure.
Condensate Return/Make-up Water
1. Determine the condensate return conditions, primarily focusing on temperature,
pressure and flow rate (% return).
2. Calculate the make-up water requirement based on the percentage of
condensate return.
3. Determine the water charges for the specific facility under analysis.
Water Discharge
1. Determine the maximum temperature for water discharge, which is usually
mandated by the local environmental governing authorities.
2. Determine the sewer charges for the specific facility under analysis.
Fuel
1. Determine the type(s) of fuel to be combusted within the boiler. Generally
speaking, the fuels are limited to natural gas, propane, and fuel oil (although
some other alternate fuels may be used).
I3-5
09-09
Steam Systems
Section I
2. Obtain a composition analysis for each fuel, which will be necessary for
calculating fuel usage for a given load.
3. Determine the fuel costs; this is necessary for the economical optimization of
boiler room design. For new boiler(s) installation into an existing system, a twothree year history of fuel billing data would be helpful in the eventual design of
the steam-generating facility.
Combustion Air
1. Determine the ambient air conditions in the boiler area and determine current
fresh air supply (e.g., louvre area). Primarily, the intention is to understand
typical air temperatures and humidity and their variance during the necessary
time of boiler operation.
Stack Gas
1. Determine any temperature limitations imposed on the stack gas.
2. Understand the local emission requirements, which will affect the allowable
stack gas composition.
3. Determine the physical lengths and flow areas of stack/breeching, most
importantly any constraints imposed in this area. These physical attributes will
affect the stack gas pressure which can, in turn, have an impact on combustion
characteristics and firing rates.
Electrical Power
1. Understand the electrical power overall demand and seasonal profiles.
2. Determine the electrical power costs for the facility. A review of 2-3 year
historical data of electric power billing from the local power company will assist
in this area. It is important to understand the demand charges separate from
the actual electrical energy charges.
STACK GAS
14. TEMPERATURE LIMITATIONS
15. EMISSION REQUIREMENTS
16. STACK/BREECHING PHYSICAL ATTRIBUTES
COMBUSTION AIR
13. TEMPERATURE
HUMIDITY
VARIANCE
FUEL
STEAM
STEAM-GENERATING
FACILITY
17. ELECTRICAL POWER DEMANDS
AND PROFILE
18. ELECTRICAL COSTS
19. PHYSICAL LIMITATIONS
20. NOISE LEVEL REQUIREMENTS
10. TYPE(S) OF FUEL

11. COMPOSITION ANALYSIS
12. FUEL COSTS
2. OPERATING PRESSURE
3. LOAD PROFILE
4. QUALITY/DEGREE OF SUPERHEAT
STEAM-USE
FACILITY
1. TYPE OF APPLICATION/LOAD
CONDENSATE RETURN
5. TEMPERATURE
PRESSURE
PERCENT RETURN
WATER DISCHARGE
MAKE-UP WATER
8. MAXIMUM TEMPERATURE
9. SEWER CHARGES
6. PERCENT MAKE-UP
7. WATER CHARGES
Figure I3-3. Summary of Application/Energy-Use Audit Items

I3-6
09-09
Section I
Steam Systems
Facility Requirements and Limitations
1. In regard to boiler room design, understand the physical limitations of the
facility. This understanding should include floor space or footprint for both
installation and maintenance considerations as well as height limitations for
equipment sizing.
2. Determine noise level requirements.
These twenty audit items are summarized in Figure I3-3.
Codes and
Standards
Various Codes and Standards govern the design, fabrication and installation of many
of the boiler room components. Of primary importance is the American Society of
Mechanical Engineers' (ASME) Boiler and Pressure Vessel Code. The different
sections of this Code specify the rules by which steam boilers, pressure vessels and
connecting piping are to be designed, constructed and installed.
Section I of the ASME Code contains rules for Power Boilers which, for the case of
steam boilers, are boilers designed for a maximum allowable operating pressure
(MAWP) greater than 15 psig. Section IV of the ASME Code would provide rules for
steam boilers with a MAWP of 15 psig or lower. B31.1 Power Piping Code provides
rules for most of the piping systems involved in a typical steam plant, but has
special significance relative to Section I in that it contains Certification and
Stamping requirements for boiler external piping (BEP). BEP is defined as piping
from the first circumferential joint leaving the boiler up to and including the required
stop valve or valves. Most, if not all, of the piping included with a packaged boiler
is within the scope of BEP. This generally includes steam, feedwater, blowdown,
water column and instrument piping. Section VIII of the ASME Code contains rules
for unfired pressure vessels, which may apply to deaerators, blowdown separators,
etc.
Other Federal, State,

Provincial and Local
Requirements
There are many other Codes and Standards which apply to other aspects of the
design and installation of steam room equipment. For a listing of standards
organizations of relevance to the design of steam systems, please refer to Section I4.
Local jurisdictions, insurance companies and individual contracts often impose
special requirements above and beyond Code requirements, or may require
compliance with special Codes and Standards. It is essential that those responsible
for the planning of a boiler room installation be familiar with such requirements.
EQUIPMENT CONSIDERATIONS AND HARDWARE DESIGN

Having defined the application and obtained an understanding of the requirements
and constraints of the steam system, it is now important to consider basic
equipment needs and hardware design. Here the concern deals with potential
equipment problems of the steam-generating facility in terms of performance and
life. Specifically, the issues to be addressed when designing and integrating
equipment into a workable system are: (1) equipment capacity, (2) operating
characteristics and constraints of equipment, (3) maintenance issues and the
tradeoff with design/initial cost, and (4) the operational effects of each piece of
hardware on the overall system operation.
The following is a discussion concerning considerations given to each subsection of
the overall system, categorized as: steam boilers, boiler piping and valves,
feedwater systems, water treatment systems, heat exchangers and economizers,
and blowdown systems. Stacks and controls are not discussed since the intention
here is to concentrate on the steam side of the system. For information concerning
I3-7
09-09
Steam Systems
Section I
controls and stacks, please refer to sections D and F, respectively. Considerations
concerning sizing of piping, steam traps, etc. are also not covered in this section;
those items are considered as a part of the steam/condensate return handling and
piping system design and many references concerning these issues are available.
Steam Boilers
The boiler selection process is based on an evaluation of the system and load
requirements as described above, and a comparison with the different boiler types
that are available. This section defines a process and the considerations that can
be used to select a boiler for a steam system application, based on the
requirements discussed in Section I1.
The steam-use facility will have certain operating requirements that are used to
establish the boiler design pressure. For example, heating systems often operate at
low pressure (a steam pressure of 8 - 10 psig), and would use a boiler that is
designed for 15 psig. The boiler design pressure must be higher than the operating
pressure, and is usually based on common design pressures. Steam quality, or the
moisture content in the steam, may also be a requirement of the facility.
The first step in determining the required boiler size is to determine the number of
boilers. Multiple boilers can be used to divide a seasonal load into more
manageable segments, even using different boiler sizes to better match the load.
Additional boilers can be used to provide backup and minimize potential down
time. Hospitals usually require a substantial amount of backup capability.
Increasing the number of boilers also adds to the initial cost, on-going maintenance
costs and complexity of the system.
Once the number of boilers have been selected, the capacity of the boilers can be
determined. This task should not be limited to matching the peak load and the
total capacity of the boilers. For example, the base capacity or number of boilers
should be increased if there can be a high instantaneous demand. Some
consideration should also be given to how multiple boilers are cycled to minimize
the cycling and number of units in use at any one time.
Increasing the number of boilers will:
Minimize down time and maximize reliability.
Provide the highest efficiency by matching load to boiler capacity.
Increase the total installed cost of the boiler room.
Allow the use of smaller boilers and support components.
Increase maintenance cost.
Increase the size and complexity of the boiler room.
Minimizing the number of boilers will:
Decrease total installed cost.
Reduce overall efficiency because of low-load operation.
Minimize maintenance costs.
Provide a less complex and smaller boiler room.
Different sized boilers can be used for the large variation in seasonal loads.
Total boiler capacity should include future expansion considerations.
Emission regulations may require special controls above a certain total capacity.
I3-8
09-09
Section I
Steam Systems
At this stage of the selection process, some boiler types can be eliminated based on
the operating pressure and capacity requirements. (Table I1-1 in Section I1 can be
used as a guide in this process). In addition, the load type may also impact the
selection process. For example, watertube boilers are better suited to swing loads
while firetube boilers are better for loads with upset conditions. Also, bent tube
boilers can be used when quick warm up is required.
Watertube boilers are the preferred choice for pressures above 350 psig.
Higher turndown rates improve the boiler load response because the boiler
remains on line at low loads.
Bent tube and electric boilers can provide quick warm-up without thermal
shock.
Steam superheat is generally only available on the IWT boiler.
There are numerous regulatory requirements in the boiler industry. Many boilers are
listed by Underwriters Laboratories or a similar agency, which has tested the
product to ensure that it meets their minimum standards for safety and
performance. Emission regulations have become more common in recent years.
Finally, there may be other organizations that will mandate requirements for an
installation, such as the city, state or insurance carrier. These requirements may
prevent the use of some boiler types.
Check insurance carrier for requirements.
A Package listing helps insure boiler/burner compatibility.
Construction and operating permits are usually required by local authorities.
Federal NSPS regulations, permits and recording applies over 200 hp.
The final stage in the selection process will be the consideration of the operating
features and efficiency of the boilers. Initial cost is always a factor, but it should not
be the only factor. For example, the boiler efficiency, turndown and maintenance
requirements can result in much higher or lower operating costs, and can easily
change the cost analysis. Some common considerations that impact overall
efficiency and fuel costs are:
Multiple fuel capabilities, including future conversions.
More flue gas passes in a firetube boiler will increase heat transfer.
Heating surface area, usually 5 square feet per boiler hp in a firetube boiler.
Higher turndown increases boiler efficiency and provides quicker load response.
Lower excess air operation increases boiler efficiency.
Economizers can be added to most boilers, which will increase efficiency.
Maintenance and down time can be important considerations in the boiler selection.
Using multiple boilers helps reduce the potential for loss of steam generating
capability.
Higher turndown reduces component wear and failure due to on-off cycling.
Critical operations should include controls to keep the standby boiler hot.
Always use duplex pumps and filters to allow maintenance without shut down.
Consider rental boilers as potential backup, and include required piping in the
plant.
Generally boilers with large water volumes and surface areas are more tolerant
of feedwater treatment variations and load surges.
I3-9
09-09
Steam Systems
Section I
The moisture content in steam from a steam generator is normally very small.
There are conditions that can upset the normal operation and result in some
relatively high amounts of water carry-over.
In addition, there are some
applications which require extremely dry steam for proper operation. There are
some guidelines for maintaining high quality steam, and methods to improve the
steam quality.
Feedwater quality is the single most important element in steam quality. General
feedwater guidelines are given in this book and others. Special considerations need
to be given to the type of boiler. There may be additional requirements based on the
boiler type and the conditions of the local water supply. A water specialist should
be consulted for specific requirements of an installation.
The steam quality from a boiler can be improved by adding an external separator or
an equalizing line similar to a Hartford Loop. Such special steam piping
arrangements are sometimes used on low pressure steam boilers with small steam
chambers.
The industrial watertube boiler offers some additional options for improving the
steam quality. One option uses special drum components to further remove solids,
resulting in higher steam quality. The other option is to add a superheater to
provide superheated steam.
Water maintenance programs can help insure reliable steam quality.
Boiler concentrations may need to be adjusted for best steam quality.
Special steam piping can be used with some boilers (such as the cast iron
boiler) to reduce carry-over.
An external separator will typically remove 90% of the moisture in a steam line.
Superheated steam and special steam dryers are available on industrial

watertube boilers.
Steam Nozzle Size
Minimum steam nozzle size is important to maintain an acceptable steam velocity

as steam exits the boiler. Standard nozzle sizes are usually based on the design
pressure of the boiler, so it is important to determine when a nozzle change is
recommended. Use Table I3-1 as a reference when selecting the steam nozzle on a
firetube boiler.
Non-Return Valves
Table I3-3 gives non-return valve sizes for standard applications. Table I3-3 gives
non-return valve sizes for high turndown applications.
I3-10
09-09
Section I
Steam Systems
Table I3-1. Recommended Steam Nozzle Size
RECOMMENDED STEAM NOZZLE SIZE WHEN
OPERATING AT VARIOUS PRESSURES
TO MAINTAIN 5000 FPM NOZZLE VELOCITY MAXIMUM.
- FIRETUBE BOILERS BOILER HORSEPOWER
Operating
Pressure
PSI
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
175
200
225
250
15
20
30
40
50
60
70
80
100 125 150 175
200
225
250
300
350
400
500
600
700
750
4
2
2
2
2
2
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
4
2.5
2.5
2
2
2
2
2
2
2
2
2
2
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
4
3
3
2.5
2.5
2.5
2.5
2.5
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
6
4
3
3
3
3
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
6
4
4
4
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2
2
6
4
4
4
4
4
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2
2
6
6
4
4
4
4
4
4
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2
2
6
6
6
4
4
4
4
4
4
4
3
3
3
3
3
3
3
3
3
3
3
3
3
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2
2
8
6
6
6
6
6
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
3
2.5
2.5
2.5
2.5
2.5
2.5
2
2
10
8
8
8
8
6
6
6
6
6
6
6
6
6
6
6
6
6
4
4
4
4
4
4
4
4
4
4
4
4
3
3
10
8
8
8
8
8
6
6
6
6
6
6
6
6
6
6
6
6
6
6
4
4
4
4
4
4
4
4
4
4
3
3
10
8
8
8
8
8
8
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
4
4
4
4
4
4
4
4
12
10
10
8
8
8
8
8
8
8
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
4
4
4
4
12
10
10
10
8
8
8
8
8
8
8
8
8
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
4
4
4
12
10
10
10
10
10
8
8
8
8
8
8
8
8
8
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
4
4
12
12
12
10
10
10
10
10
10
8
8
8
8
8
8
8
8
8
8
8
8
8
8
6
6
6
6
6
6
6
6
6
12
12
12
12
12
10
10
10
10
10
10
10
8
8
8
8
8
8
8
8
8
8
8
8
8
8
6
6
6
6
6
6
12
12
12
12
12
12
12
10
10
10
10
10
10
10
10
8
8
8
8
8
8
8
8
8
8
8
8
8
6
6
6
6
12
12
12
12
12
12
12
12
10
10
10
10
10
10
10
10
8
8
8
8
8
8
8
8
8
8
8
8
8
6
6
6
8
6
6
6
6
6
6
6
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
3
3
3
3
3
2.5
2.5
2.5
2.5
8
8
6
6
6
6
6
6
6
6
6
4
4
4
4
4
4
4
4
4
4
4
4
4
4
3
3
3
3
3
3
3
8
8
8
6
6
6
6
6
6
6
6
6
6
6
4
4
4
4
4
4
4
4
4
4
4
4
4
4
3
3
3
3
Note
Shaded area denotes that special surge load baffles must be installed.
Standard nozzle sizes are listed for 15 and 125 psi operating pressures.
Request standard nozzle size to be changed per this table.
Table I3-2. Recommended Non-Return Valve Size

BOILER HP
BOILER CAPACITY (LBS/

HR)
50
75
100
100
125
150
200
250
300
350
400
500
600
700
800
3450
4313
5175
6900
8625
10350
12025
13800
17210
20700
24150
27600
2-1/2
3
3
3*
4
4
4
5
6
6
6
6
2-1/2
2-1/2
3
3
3*
4
4
4
5
6
6
6
NA
2-1/2
2-1/2
3
3
4
4
4
5
5
6
6

125
150
NA
2-1/2
2-1/2
3
3
3*
4
4
4
5
5
6
NA
NA
2-1/2
3
3
3
4
4
4
5
5
6
175
200
250
NA
NA
2-1/2
2-1/2
3
3
3*
4
4
4
5
5
NA
NA
NA
2-1/2
3
3
3
4
4
4
5
5
NA
NA
NA
2-1/2
3
3
3
3*
4
4
4
5
Valve sizes (300# flange) given in inches. Standard non-return valve selection limited to a maximum 2 to 1 turndown (50% of boiler output).
Selection based on typical valve sizing recommendations. For final valve selection contact your authorized C-B representative.
I3-11
09-09
08-08
3450
100
Turndown
Drop (psig)
125
Turndown
Drop (psig)
150
Turndown
Drop (psig)
200
Turndown
Drop (psig)
250
Turndown
Drop (psig)
300
Turndown
Drop (psig)
350
Turndown
Drop (psig)
400
Turndown
Drop (psig)
500
Turndown
Drop (psig)
600
Turndown
Drop (psig)
700
Turndown
Drop (psig)
750
Turndown
Drop (psig)
800
Turndown
Drop (psig)
I3-12
09-09
Low pressure applications:

Contact MKE Sales for valve selection,
performance, and price.
2" (2S)
10 to 1
3.5
2.5" (2S)
10 to 1
2
2.5" (2S)
10 to 1
3
4" (1S)
9.8 to 1
5.3
4" (1S)
10 to 1
8.8
5" (1S)
7.4 to 1
3.7
5" (1S)
7.6 to 1
5.1
5" (1S)
9.8 to 1
6.9
5" (1S)
10 to 1
12
6" (1S)
8.4 to 1
6.3
6" (1S)
9.8 to 1
9
8" (1S)
8.2 to 1
3.2
8" (1S)
8.8 to 1
3.6
2.5" (1A)
8.8 to 1
1.5
2.5" (1A)
10 to 1
2.5
2.5" (1A)
10 to 1
3.6
3" (1A)
10 to 1
4.5
4" (1A)
10 to 1
3.3
4" (1A)
10 to 1
5
4" (1A)
10 to 1
7.2
5" (1A)
9.4 to 1
2.6
5" (1A)
10 to 1
4.3
5" (1A)
10 to 1
6.6
6" (1A)
9.4 to 1
3.4
6" (1A)
10 to 1
3.9
6" (1A)
10 to 1
4.6
2" (2S)
10 to 1
2.7
2" (2S)
10 to 1
4.3
2.5" (2S)
10 to 1
2.3
2.5" (2S)
10 to 1
4.2
2.5" (2S)
10 to 1
7.1
4" (1S)
10 to 1
9.9
5" (1S)
8.6 to 1
3.9
5" (1S)
8.7 to 1
5.2
5" (1S)
9.5 to 1
8.5
6" (1S)
7.5 to 1
4.8
6" (1S)
8.7 to 1
6.7
6" (1S)
9.3 to 1
7.8
6" (1S)
10 to 1
9
2" (2S)
10 to 1
2.2
2" (2S)
10 to 1
3.5
2" (2S)
10 to 1
5.2
2.5" (2S)
10 to 1
3.4
2.5" (2S)
10 to 1
5.5
4" (1S)
10 to 1
7.9
4" (1S)
10 t o 1
11
5" (1S)
7.9 to 1
4.2
5" (1S)
10 to 1
6.8
5" (1S)
10 to 1
10
6" (1S)
7.9 to 1
5.4
6" (1S)
8.5 to 1
6.3
6" (1S)
9 to 1
7.2
2" (2A)
10 to 1
5.8
2.5" (1A)
9 to 1
1.6
2.5" (1A)
10 to 1
2.8
2.5" (1A)
10 to 1
4.2
3" (1A)
10 to 1
4.4
4" (1A)
10 to 1
3
4" (1A)
10 to 1
4.1
4" (1A)
10 to 1
5.6
5" (1A)
10 to 1
2.6
5" (1A)
10 to 1
3.8
5" (1A)
10 to 1
5.4
5" (1A)
10 to 1
6.3
5" (1A)
10 to 1
7.3
2" (2S)
10 t o 1
1.8
2" (2S)
10 to 1
2.9
2" (2S)
10 to 1
4.3
2.5" (2S)
10 t o 1
2.8
2.5" (2S)
10 to 1
4.6
4" (1S)
10 to 1
6.6
4" (1S)
10 to 1
9.1
4" (1S)
10 to 1
12
5" (1S)
9.2 to 1
5.7
5" (1S)
10 to 1
8.4
5" (1S)
10 to 1
12
6" (1S)
7.8 to 1
5.3
6" (1S)
8.4 to 1
6
Operating Pressure (Psig)
2" (2A)
10 to 1
7.4
2.5" (1A)
10 to 1
1.9
2.5" (1A)
10 to 1
2.8
2.5" (1A)
10 to 1
5.2
4" (1A)
10 to 1
2.5
4" (1A)
10 to 1
3.7
4" (1A)
10 to 1
5.2
4" (1A)
10 to 1
7.1
5" (1A)
10 to 1
3.2
5" (1A)
10 to 1
4.8
5" (1A)
10 to 1
6.9
5" (1A)
10 to 1
8.2
6" (1A)
10 to 1
3.4
Notes:
- Above valve selections rated to a maximum turndown of 10 to 1 (10% of full boiler output).
- Number in parentheses designates the specific valve selction and Price Book pricing.
- Straight pattern valves must be installed in the horizontal position.
27600
25875
24150
20700
17210
13800
12025
10350
8625
6900
5175
4313
Boiler
Boiler
Steam Boilers Recommended Non-Return Valve Size - High Turn Down
2" (2A)
10 to 1
4.7
2" (2A)
10 to 1
7.6
2.5" (1A)
10 to 1
1.9
2.5" (1A)
10 to 1
3.5
3" (1A)
10 to 1
3.7
4" (1A)
10 to 1
2.5
4" (1A)
10 to 1
3.4
4" (1A)
10 to 1
4.6
4" (1A)
10 to 1
7.5
5" (1A)
10 to 1
3.2
5" (1A)
10 to 1
4.5
5" (1A)
10 to 1
5.2
5" (1A)
10 to 1
6
2" (2S)
10 to 1
1.6
2" (2S)
10 to 1
2.5
2" (2S)
10 to 1
3.7
2.5" (2S)
10 to 1
2.4
2.5" (2S)
10 to 1
3.9
4" (1S)
10 to 1
5.7
4" (1S)
10 to 1
7.8
4" (1S)
10 to 1
10
5" (1S)
8.6 to 1
4.9
5" (1S)
10 to 1
7.2
5" (1S)
10 to 1
10
5" (1S)
10 to 1
12
6" (1S)
7.8 to 1
5.2
2" (2A)
10 to 1
4.1
2" (2A)
10 to 1
6.4
2.5" (1A)
9.5 to 1
1.7
2.5" (1A)
10 to 1
3
2.5" (1A)
10 to 1
4.8
3" (1A)
10 to 1
4.7
4" (1A)
10 to 1
3
4" (1A)
10 to 1
3.9
4" (1A)
10 to 1
6.3
5" (1A)
9.9 to 1
2.8
5" (1A)
10 to 1
3.8
5" (1A)
10 to 1
4.4
5" (1A)
10 to 1
5.1
2" (2S)
10 to 1
1.4
2" (2S)
10 to 1
2. 2
2" (2S)
10 to 1
3. 2
2" (2S)
10 to 1
5.9
2.5" (2S)
10 to 1
3.4
4" (1S)
9.8 to 1
5
4" (1S)
10 to 1
6.8
4" (1S)
10 to 1
9.1
5" (1S)
8 to 1
4.3
5" (1S)
9.7 to 1
6.3
5" (1S)
10 to 1
8.7
5" (1S)
10 to 1
10
5" (1S)
10 to 1
12
2" (2A)
10 to 1
3.6
2" (2A)
10 to 1
5.5
2.5" (1A)
8.9 to 1
1.5
2.5" (1A)
10 to 1
2.7
2.5" (1A)
10 to 1
4.2
3" (1A)
10 to 1
4.1
4" (1A)
10 to 1
2.6
4" (1A)
10 to 1
3.5
4" (1A)
10 to 1
5.5
5" (1A)
9.3 to 1
2.4
5" (1A)
10 to 1
3.4
5" (1A)
10 to 1
3. 9
5" (1A)
10 to 1
4.4
2" (2S)
10 to 1
1.1
2" (2S)
10 to 1
1.8
2" (2S)
10 to 1
2.6
2" (2S)
10 to 1
4.7
2.5" (2S)
10 to 1
2.8
3" (1S)
10 to 1
8.5
4" (1S)
10 to 1
5. 5
4" (1S)
10 to 1
7.3
4" (1S)
10 to 1
12
5" (1S)
8.8 to 1
5.1
5" (1S)
10 to 1
7
5" (1S)
10 to 1
8.1
5" (1S)
10 to 1
9.2
2" (2A)
10 to 1
3
2" (2A)
10 to 1
4.4
2" (2A)
10 to 1
6.3
2.5" (1A)
10 to 1
2.2
2.5" (1A)
10 to 1
3.4
3" (1A)
10 to 1
3.3
3" (1A)
10 to 1
4. 5
4" (1A)
10 to 1
2.8
4" (1A)
10 to 1
4.4
4" (1A)
10 to 1
6.5
5" (1A)
9.8 to 1
2.7
5" (1A)
10 to 1
3.1
5" (1A)
10 to 1
3.6
Steam Systems
Section I
Table I3-3. Recommended Non-Return Valve Size - High Turndown
Section I
Boiler Piping and
Valves
Steam Systems
This section contains information on boiler piping and valve requirements for low
and high pressure boilers.
Relevant highlights of the ASME Code are included. However, for complete details,
the reader should review the applicable section of the ASME Code. In addition to
the ASME Code, the reader should determine whether there are any special, local
insurance or regulatory requirements.
Low Pressure Boilers
The ASME Code contains many recommendations for low pressure steam systems.
Here are excerpts that apply to design consideration.
Steam Line Expansion - Provisions shall be made for the expansion and
contraction of steam and hot water mains connected to boilers by providing
substantial anchorage at suitable points, and by providing swing joints when boilers
are installed in batteries, so there will be no undue strain transmitted to the
boilers. para. HG-703.1
Stop Valves for Single, Multiple, and Steam Boilers
Steam Boilers - When a stop valve is used in the supply pipe connection of a single
steam boiler, there shall be one used in the return pipe connection.para. HG710.1
Multiple Boiler Installations - A stop valve shall be used in each supply and return
Figure I3-4. Recommended Safety Valve Discharge Piping

I3-13
09-09
Steam Systems
Section I
pipe connection of two or more boilers connected to a common system. para. HG710.3
Shutoff Valves - No shutoff of any description shall be placed between the safety
relief valve and the boiler, nor on discharge pipes between such valves and the
atmosphere. para. HG-701.5
Safety and Safety Relief Valves - Safety and safety relief valves shall not be
connected to an internal pipe in the boiler. para. HG-701.4
Safety Valve Discharge Piping - A discharge pipe shall be used. Its internal crosssectional area shall be not less than the full area of the valve outlet or of the total of
the valve outlets discharging there into and shall be as short and straight as possible
and so arranged as to avoid undue stress on the valve or valves. When an elbow is
placed on a safety or safety-relief valve discharge pipe, it shall be located close to
the valve outlet. The discharge from safety or safety-relief valves shall be so
arranged that there will be no danger of scalding attendants. Para. HG-701.6 Refer
to Figure I3-4.
Bottom Blowoff - Each boiler shall have a bottom blowoff or drain pipe connection
fitted with a valve or cock connected with the lowest water space practicable. The
discharge piping shall be full size to the point of discharge. para. HG-715
High Pressure Boilers
The ASME Code provides many recommendations for high pressure steam boilers.
Here are some excerpts that apply to design considerations.
Steam Line Expansion - Provisions shall be made for the expansion and
contraction of steam mains connected to boilers, by providing substantial anchorage
at suitable points, so that there shall be no undue strain transmitted to the boiler.
para. PG-59.1.2
Steam Stop Valves - Each boiler discharge outlet, except safety valves or safety
relief valves, or preheater inlet and outlet connections, shall be fitted with a stop
valve located at an accessible point in the steam-delivery line and as near the boiler
nozzle as is convenient and practicable. When such outlets are over NPS2, the valve
or valves used on the connection shall be of the outside-screw-and-yoke rising-stem
type so as to indicate from a distance, by the position of its stem whether it is closed
or open, and the wheel may be carried either on the yoke or attached to the stem.
para. 122.1.7 (A.1) (ASME B31.1)
When boilers are connected to a common header, the connection from each boiler
having a manhole opening, shall be fitted with two stop valves having an ample
free-blow drain between them. The discharge of this drain shall be visible to the
operator while manipulating the valve. The stop valves shall consist preferably of
one automatic non-return valve (set next to the boiler) and a second valve of the
outside-screw-and-yoke type or two valves of the outside-screw-and-yoke type shall
be used. Para. 122.1.7 (A.2) (ASME B31.1)
Stop-Check Valves (Non-Code Recommendations) - A problem confronting the
power piping designer is the selection of the best size of stop check valve for his
service conditions. This type valve usually has a floating disc member, hence it is
important that the valve be sized to provide full disc lift under flow conditions
prevailing during the major portion of the service life of the installation. If the valve
is too large for flow conditions, the disc will float in a partially open position; this
may result in fluttering of the disc and rapid wear of
I3-14
09-09
Section I
Steam Systems
Table I3-4. Removal of Harmful Elements with Various Types of Equipment
DISSOLVED
CONSTITUENT
SOFTENER
CLORIDE CYCLE
DEALKALIZER
FILTERS
DEAERATORS
Calcium CaB
98-100%
Must have soft water
No Change
No Change
Magnesium MgB
98-100%
No Change
No Change
HardnessA
98-100%
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
100%
No Change
No Change
No Change
No Change
No Change
No Change
Suspended SolidsA
Must Be Removed
Must be removed
Down to 10
Micron
No Change
Dissolved GasesA
No Change
Free CO2 Only
See Filter
Section
To.005 cc/liter of O2
Soluble Iron Fe
Total Dissolved SolidsA
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 I3-5. Makeup Water Impurities, Limits and Treatment Methods

MAKE-UP WATER TEST
TYPICAL IMPURITIES
TYPICAL LIMITS
TREATMENT METHOD
Oxygen
6 ppm
<.007
Hardness
86 ppm
<1.0 ppmA
Softener
Suspended Matter
0.1 ppm
0.15 ppmA
Blowdown
6.87
7.0-10.5A
Chemical
Silica
10 ppm
<150 ppmB
Blowdown
Alkalinity
100 ppm
<700 ppmB
Blowdown/Dealkalizer
500 -mho/cm
<7000 mho/cmB
Blowdown
pH
Dissolved Solids
ppmA
Deaeration/Chemical
A. Limits for feedwater.

B. Limits of boiler.
valve parts. Conversely, if the valve is too small for flow conditions encountered,
pressure drop will be excessive.
Safety Valves - No valve of any description shall be placed between the required
safety valve or valves and the boiler, nor the discharge pipe between the safety
valve and the atmosphere. When a discharge pipe is used, the cross-sectional area
shall be not less than the full area of the valve outlet or the total of the areas of the
valve outlets discharging there into and shall be as short and straight as possible
and so arranged as to avoid undue stresses on the valve or valves. All safety valve or
relief valve discharges shall be so located or piped as to be carried clear from
running boards or platforms. Ample provision for gravity drain shall be made in the
I3-15
09-09
Steam Systems
Section I
discharge pipe at or near each safety valve or safety relief valve, and where water of
condensation may collect. Each valve shall have an opening gravity drain through
the casing below the level of the valve seat. For iron-and-steel bodied valves
exceeding 2-1/2 inch size, the drain hole shall be tapped not less than 3/8 inch pipe
size. Para PG-71.3 Refer toFigure I3-4, Recommended Safety Valve Discharge
Piping.
Safety Valve Mounting - When a boiler is fitted with two or more safety valves or
safety relief valves on one connection, this connection to the boiler shall have a
cross-sectional area not less than the combined area of inlet connections of all the
safety valves with which it connects and shall also meet the requirements of
Paragraph PG-71.3. Para. PG-71.5
Blowoff Valves - The blowoff valve or valves, the pipe between them, and the boiler
connection shall be of the same size except that a larger pipe for the return of
condensate may be used.
For all boilers... with allowable working pressure in excess of 100 psig, each bottom
blowoff pipe shall have two slow-opening valves, or one quick-opening valve or
cock; at the boiler nozzle followed by a slow-opening valve. A slow-opening valve is
a valve which requires at least five 360 degree turns of the operating mechanism
from fully closed to fully opened. On a boiler having multiple blowoff pipes, a single
master valve may be placed on the common blowoff pipe from the boilers, in which
case only one valve on each individual blowoff is required. In such a case, either the
master valve or the individual valves or cocks shall be of the slow-opening type.
Para. 122.1.7 (ASME B31.1)
Feedwater Valves - The feedwater piping for all [steam] boilers ... shall be provided
with a check valve... between the check valve and the boiler. Para 122.1 (B1)
(ASME B31.1)
When two or more boilers are fed from a common source, there shall also be a
globe or regulating valve in the branch to each boiler located between the check
valve and the source of supply. Para. 122.1.7 (B.5) (ASME B31.1)
Boiler Feed Systems
The transfer of heat from steam, regardless of process usage, will create
condensate. The quantity of collectable condensate varies with the type of
application. For instance, with humidification, the steam is released to the
environment and the condensate is considered uncollectible. In industrial
applications, condensate can typically be collected in large quantity.
An important factor in the condensate return and water make-up system is to ensure
that contaminated condensate does not return to the boiler room and its associated
equipment. Condensate contaminated with oil, dye, soap, etc. must be disposed of
in a safe manner. Contaminated condensate will cause problems such as foaming,
priming, unstable water level, and it will increase blowdown requirements.
The collection of clean steam condensate is desirable for several economic reasons.
Condensate generally is capable of being collected at temperatures higher than the
temperature of raw water make-up. This results in significant fuel cost savings and
improved overall system efficiency. Since condensate is formed from steam, it
contains little or no dissolved solids. Therefore, using collected condensate reduces
chemical usage and associated costs as well.
Additionally, the cost of raw water make-up will be reduced by collecting condensate
because the demand for raw water is limited. When considering installation costs,
the expected condensate return may allow for down-
I3-16
09-09
Section I
Steam Systems
sizing of the raw water make-up supply system and other components.
Unfortunately, condensate flow from the system may be unpredictable.
Unpredictability of returning condensate causes a problem for the boiler, since it
should have a continuous and immediately available supply of water. However,
there are several ways to collect and store condensate so it is readily available.
A collection or storage tank can be incorporated to act as a reservoir. Products
which serve this purpose include boiler feedwater systems, surge tanks, and
deaerators.
The function of these products in the overall condensate return and raw water
make-up system is as follows. For further information on this equipment, refer to
the specific product sections in The Boiler Book.
Boiler Feed System
Boiler feedwater systems help maintain maximum efficiency and prolong the life of
the boiler, when investment in a deaerator cannot be justified. Consisting of one or
more feed pumps and a corrosion resistant receiver tank, the system automatically
supplements condensate with make-up water to replace system losses. When
equipped with an automatic preheater, feedwater temperatures can be maintained
at temperatures up to 210 F (maximum). At this temperature, substantial amounts
of oxygen and carbon dioxide are released, reducing the amount of chemicals
required to protect the boiler and system from corrosion. Preheating is
recommended if the return condensate constitutes 50% or less of the required
feedwater.
Boiler feed systems typically combine one or more boiler feed pumps with a tank to
store condensate and make-up water. These components are typically furnished as
a complete package with level, temperature, and pressure controls. Additional
features such as deaeration hardware and more sophisticated controls may be
considered.
The purpose of the boiler feed system is to provide a reservoir with sufficient surge
capacity to accommodate intermittent condensate flowrates, and to provide stable
suction conditions for the boiler feed pump(s). The selection of a boiler feedwater
system is primarily driven by surge capacity. For this reason, it is necessary to
accurately estimate peak condensate flowrates from the steam-use facility,
considering also factors due to transient conditions such as equipment startups,
piping hydraulics, and system interactions. Once this information is obtained and
understood, a boiler feed tank of sufficient size may be selected.
The operating characteristics of the boiler and steam-generating system have an
impact on the type of controls and features included in the boiler feed system. In
particular, those factors influencing pump selection will also have an effect on the
height of the boiler feedwater system, the level control system, and suction piping
design. The characteristics of the returning condensate should also be considered
when selecting feedwater system components, corrosion resistant linings, and
pressure/temperature controls.
There are many cost/benefit tradeoffs available when configuring a boiler feed
system. A partial list includes:
Feedwater Preheat reduces thermal shock.
Premium Lining/Galvanizing reduces corrosion.

I3-17
09-09
Steam Systems
Section I
Premium Level Control reduces overflow losses.
Code Rated Pressure Tank reduces flash steam losses.
Deaeration Hardware reduces corrosion and thermal shock.
Each of these options has a direct benefit on the long-term operating costs of the
system. Their increased initial costs must be balanced against the overall capital
cost and the expected life of the system. For more information on boiler feed
systems, please refer to Section H5.
Surge Tanks (Condensate Receiver Tanks)
Surge tanks can greatly reduce dependence on cold, untreated raw water to replace
boiler system losses by collecting condensate by gravity return for re-use in the
boiler feed system. Surge tanks are required when no other storage exists or when
intermittent peak loads of condensate can exceed the storage capacity of the
deaerator. Integrated control automatically introduces makeup water to supplement
condensate only when necessary to meet boiler demand. Refer to Section H4 for
more detailed information.
Deaerators
Deaeration is widely recognized as the most acceptable method for removing oxygen
and carbon dioxide from makeup water and condensate. Without deaeration, the
dissolved gases can cause serious corrosion in the boiler and other system
hardware.
Deaerators are considered essential for:
All boiler plants operating at 75 psig or more.
All boiler plants with little or no standby capacity.
All boilers plants where production depends on continuous operation.
All boiler plants operating with makeup water of 25% or more.
In addition to removing oxygen and carbon dioxide, deaerators also heat boiler
feedwater. The large storage capacity provides an effective means for recovering
heat from exhaust steam and hot condensate. With a deaerator, further savings
result from the reduced need for oxygen-scavenging chemical treatment. For further
information, refer to Sections H1, H2, and H3.
Pumps
There are five design criteria that must be considered before the proper boiler feed
pump can be selected.
1.
2.
3.
4.
5.
Will the pump run continuously or intermittently?

What is the temperature of the water being pumped?
What is the pump capacity requirement in gpm?
What is the pump discharge pressure requirement?
What is the NPSH (net positive suction head) required?
Continuous or Intermittent Operation - Continuous or intermittent operation of a

pump is determined by the critical nature of the desired water level control. The
water level control requirements are primarily based on the type of boiler, but are
also affected by the load, operating pressure, and feed water temperature.
Continuous operation provides better water level control, but adds cost and
components to the system.
Boiler types with a relatively low water volume, such
I3-18
09-09
Section I
Steam Systems
as watertube boilers, require more precise water level control than boiler types with
a large water volume, such as firetubes. This is due to the relationship between
drum (vessel) size and gallons of water content. For example, a fifty gallon change
in a watertube boiler might represent a one inch change in water level, while the
same fifty gallon change in a firetube boiler might only represent a fraction of an
inch change in water level.
Frequent load swings will require more accurate water level control to ensure the
feedwater flow matches the steam flow requirement. Frequent load swings may
require continuous feedwater control to maintain proper water level.
The relationship between operating pressure and feedwater temperature can make
water level control more critical if the temperatures vary or if there is a large
differential between saturation temperature and feed water temperature. Large
temperature differentials could result in a reduction in boiler water level when feed
water is added. The reduction is caused by a quenching effect, which lowers the
boiler water temperature slightly, reducing the steam/water volume, thereby
lowering the water level. This type of water level reduction is generally more
common on smaller, low pressure boilers.
Selection of Pump Type (Centrifugal or Turbine) - Once the criteria for water level
control is determined, the type of feed pump can be selected.
Highly accurate water level control can be achieved with a centrifugal type pump,
running continuously, in conjunction with a modulating feed water valve on the
boiler.
An effective but less precise means of water level control can be provided using a
turbine type pump, with intermittent (on- off) operation. With intermittent
operation, larger swings in water level control will result.
Although not common, turbine pumps have been used in conjunction with a
modulating feedwater valve to provide water level control. In this application, a
relief device must be included to discharge water back to the feedwater tank to
protect the pump from dead head pressures. Dead head pressures can cause
overheating, cavitation, and subsequent pump damage. A concern of this design is
the use of a relief device as a control valve, and the inherent performance and
reliability factors.
Pump Water Temperature - The temperature of the pumped water must be
specified to ensure proper design and construction. Pumps use packing or
mechanical seals to seal the area between the pump shaft and the pump casing.
These seals have temperature limitations and, if misapplied, the seals will fail.
Standard pump seals are adequate up to temperatures of approximately 215 F.
Higher temperature seals are available for temperatures up to 250 F and, for
temperatures above 250 F, external water cooling is usually employed to protect
the seals. For applications above 250 F, contact your local Cleaver-Brooks
Pump Capacity Requirements - Determining pumping capacity requirements
involves slightly different criteria for centrifugal and turbine type pumps. For both
pump types, the maximum boiler capacity must be determined. The maximum
boiler capacity, or evaporation rate, is usually calculated in pounds of steam per
hour, and should be converted to gallons per minute, and have blowdown added to
I3-19
09-09
Steam Systems
Section I
it for pump selection purposes. For assistance in this calculation, contact your local
The pump capacity for turbine pumps, with intermittent operation, should be equal
to 2 times the maximum evaporation rate of the boiler.
The pump capacity for centrifugal pumps, with continuous operation, is equal to:
evaporation rate times 1.15 (safety factor), plus by-pass flow requirement (in gpm)
for the pump. The by-pass flow is usually regulated through a fixed orifice, and is of
sufficient quantity to prevent cavitation within the pump under dead head
conditions. The by-pass orifice must be located between the pump discharge and
the modulating feedwater valve to allow water to recirculate back to the storage
tank.
Pump Discharge Pressure Requirements - Pump discharge pressure requirements
are calculated by determining the boiler operating pressure and calculating the line
losses between the pump and the boiler. The pump discharge pressure needs to
overcome the piping line losses, and boiler pressure in order to get water into the
boiler.
All calculations need to be converted to feet of head for pump selection purposes.
Therefore, convert boiler operating pressure to feet of head, and add to that value
the equivalent length (in feet of head) of the piping and associated valves between
the pump discharge and the boiler.
Net Positive Suction Head (NPSH) - Every pump design has a certain requirement
for net positive suction head. This is the amount of liquid in feet that must be above
the pump suction centerline in order to prevent cavitation and to provide proper
pump operation.
Net positive suction head required (NPSH-R) by the pump must be exceeded by the
net positive suction head available (NPSH-A) from the system.
Calculation: NPSH-A = HP + HZ - HF - HVP
NPSH-A - Available NPSH expressed in feet of fluid.
HP - Absolute pressure on the surface of the liquid at the pump suction location,
expressed in feet. This could be atmospheric pressure or vessel pressure
(pressurized tank).
HZ - Static elevation of the liquid above, or below the centerline of the impeller,
Table I3-6. Recommended Limits for Total

Suspended Solids
OPERATING
PRESSURE
PSIG
TOTAL
SOLIDS
PPM
SUSPENDED
SOLIDS
PPM
0-300
3500
300
301-450
3000
250
451-600
2500
150
601-750
2000
100
751-900
1500
60
901-1000
1250
40
I3-20
09-09
Section I
Steam Systems
expressed in feet.
HF - Friction and entrance head loss in the suction piping, expressed in feet.
HVP- Absolute vapor pressure of the fluid at the pumping temperature, expressed in
feet.
Cleaver-Brooks makes selections that are based on pumps having the lowest
possible NPSH-R. This is done to provide the lowest stand height and the lowest
overall height of the tank. There are some sacrifices which must be accepted in
order to have low NPSH-R. Usually a selection with a low NPSH-R is a pump that
is larger and usually requires a greater horsepower drive. Generally speaking,
however, it is more important to keep the overall height to a minimum than to select
a pump with a higher NPSH-R.
Pumps (General) - The design criteria for transfer pumps (pumps which pump
water to a deaerator) is the same as the criteria just covered for boiler feed pumps.
Cleaver-Brooks and our authorized representatives provide a full line of pumps, and
pump selection services for application in both steam and hot water systems. For
assistance, contact your local Cleaver-Brooks authorized representative.
Water Treatment
Systems
Harmful elements are contained in surface and well water. Surface and well water
are also called raw water. A sample of the raw water should be analyzed early in
the equipment planning stage. The analysis provides a clear definition of the
particular threats posed by the water source. Your Cleaver-Brooks representative
can assist you in defining the harmful elements, and can help in planning a water
treatment program and in selecting the proper treatment equipment.
The following is a discussion of the elements commonly found in raw water.
Surface water usually has high suspended solids and dissolved gases and low
dissolved solids. Well water normally has high dissolved solids and low suspended
solids and dissolved gases.
Suspended solids represent the undissolved matter in water, including dirt, silt,
biological growth, vegetation, and insoluble organic matter.
When minerals dissolve in water, ions are formed. The sum of all minerals or ions in
the water is the total dissolved solids or TDS.
Iron can be soluble or insoluble. Insoluble iron can clog valves and strainers and
can cause excessive sludge build up in low lying areas of a water system. It also
leads to boiler deposits that can cause tube failures. Soluble iron can interfere in
many processes, such as printing or the dying of cloth. In domestic water systems,
porcelain fixtures can be stained by as little as 0.25 ppm of iron.
Water hardness is the measure of calcium and magnesium content as calcium
carbonate equivalents. Water hardness is the primary source of scale in boiler
equipment.
Silica in boiler feedwater can also cause hard dense scale with a high resistance to
heat transfer.
Alkalinity is a measure of the capacity of water to neutralize strong acid. In natural
waters, the capacity is attributable to bases, such as bicarbonates, carbonates, and
hydroxides; as well as silicates, borates, ammonia, phosphates, and organic bases.
I3-21
09-09
Steam Systems
Section I
These bases, especially bicarbonates and carbonates, break down to form carbon
dioxide in steam, which is a major factor in the corrosion of condensate lines.
Alkalinity also contributes to foaming and carryover in boilers.
pH is a measure of the degree of acid or base of a solution. The pH scale is from 0
to 14, with 0 being the most acidic and 14 being the most basic or alkaline.
Dissolved oxygen is the amount of oxygen gas dissolved in the raw water and is
caused by the solubility of atmospheric oxygen. Dissolved oxygen is not related to
the combined oxygen contained in the water molecule H2O. All surface and rain
water contain dissolved oxygen, because of their contact with the atmosphere. With
enough contact, the dissolved oxygen content will reach saturation for the
corresponding temperature. The solubility of oxygen is affected by solid content.
Water with a higher solid content will contain less oxygen than distilled water.
Surface water usually contains more oxygen than well water. As the raw water
temperature rises, dissolved oxygen is released and can cause corrosion of iron and
steel. Therefore, the problem caused by dissolved oxygen in boiler systems is
corrosion in the boiler feedwater piping, economizer, boiler, and steam and
condensate return piping.
Hence, the generation of steam from naturally occurring water sources can be
complicated by the presence of various chemical constituents in the water supply.
The American Society of Mechanical Engineers has published guidelines on boiler
water and boiler feedwater quality for steam boilers. Most boiler installations will
require some form of water treatment in order to conform to these guidelines. A few
methods of treatment are depicted in Table I3-4 and ITable I3-5.
The Objectives of Feedwater Treatment
Proper boiler feedwater treatment is an absolute necessity! Unless the boiler
receives water of proper quality, the boilers life will be shortened. The water supply
for a steam system may originate from rivers, ponds, underground wells, etc. Each
water supply source requires a specific analysis. Depending upon the analysis,
various pretreatment methods may be employed to prepare make-up water for the
boiler feedwater system.
The objectives of boiler water treatment in general are as follows:
1. Prevent hard scale deposits or soft sludge type deposits which would, if present,
impair the rate of heat transfer and possibly result in overheating and damage
to the pressure vessel.
2. Prevent general corrosion or pitting to assure maximum life of the boiler at the
lowest maintenance cost.
3. Prevent intercrystalline cracking or caustic embrittlement of boiler metal.
4. Prevent carryover to assure high quality steam at an economical rate of
continuous and intermittent blowdown.
The accomplishment of these objectives will, in all cases, involve several forms of
treatment including:
Pretreatment of the make-up water before it enters the boiler feedwater

system.
Chemical treatment of the boiler water internally in the boiler.
In addition, the selection of pretreatment methods will depend upon the chemistry
of the raw water and the plant operating
I3-22
09-09
Section I
Steam Systems
characteristics. In most cases, pretreatment becomes more critical as the
percentage of make-up to the system increases.
Raw Water Make-up
Impurities in raw water make-up can be removed and controlled either chemically
or mechanically with various equipment. Mechanical means of removing or
controlling impurities will result in less chemicals being added to the boiler and
system. However, mechanical means will not remove or control all impurities.
Chemicals will still be required to provide the desired results.
The following are descriptions of feedwater pretreatment equipment and a
discussion of their functions in the overall feedwater pretreatment cycle. For further
information on equipment, refer to the specific product sections.
Filters
The need for special filter equipment to remove impurities can be readily
determined by a raw water analysis. Filters should be considered in order to remove
sand, iron, chlorine, and some dissolved organics and sediments. Refer to Section
H7.
Water Softeners
Water softeners should be used whenever raw water hardness exceeds 5 ppm. A
softener removes calcium and magnesium and exchanges them with highly soluble
sodium ions. Removing hardness prevents scale buildup on heat transfer surfaces
and helps maintain peak boiler efficiency. A water softener also is the base for many
sophisticated pretreatment processes that require the control of water hardness for
proper operation. Refer to Section H8.
Dealkalizers
Dealkalizers use softened water and remove negatively charged ions of bicarbonate,
carbonate, sulfate nitrate, and silica. They are replaced with chloride ions. Removal
of bicarbonate alkalinity controls formation of carbon dioxide and reduces the
corrosion of condensate piping. Dealkalization reduces the need for neutralizing
chemicals by as much as 90% and cuts fuel costs by minimizing blowdown. Refer
to Section H9.
Chemical Feed Systems
Chemical feed systems treat feedwater, boiler water, and condition blowdown
sludge where an additional measure of protection against corrosion and scaling is
required. Refer to Section H6.
In summary, the benefits of water treatment equipment include improved boiler
efficiency, corrosion reduction and therefore component life, and improved steam
purity. The selection and sizing of water treatment equipment is dictated by the
capacity of the steam system, the chemical constituents in the make-up water
supply, and the operating characteristics of the overall system. Generally speaking,
the greater the treatment load (in units of lb/hr removal), the larger the equipment.
It is important when designing a water treatment system that a detailed water
analysis be available as a guide.
The design of the water treatment system is influenced by cost/benefit tradeoffs in
equipment selection. These influences may include:
Chemical Feed Systems which have low initial costs, but significant
I3-23
09-09
Steam Systems
Section I
operating costs.
Component Duplexing which tends to ensure uninterrupted operation.
Chloride Cycle Dealkalizers which reduce blowdown losses.
Filters which also reduce blowdown losses and maintenance.
Skid Mounting which decreases installation costs.
Premium Regeneration Controls which may decrease operating costs.
These equipment selection economic tradeoffs are influenced by size, criticality, and
operating environment of the steam system.
Economizers
During boiler operation in typical commercial and industrial applications,

approximately 10-20% of the heating value of fuel is expelled with the stack gases
to the atmosphere. Stack economizers are designed to recover significant amounts
of this stack gas energy loss, thereby vastly improving boiler system efficiency, as
shown in Section G, Tables G-5 and G-6.
There are several considerations when selecting an economizer:
Gas-side Pressure Drop. Added back-pressure on the boiler stack affects the
combustion air fan throughput capability. The economizer and combustion
air fan(s) must be sized properly in order to assure a suitable system
operation and capacity.
Feedwater Temperature. The feedwater to the economizer must be

deaerated and the temperature setpoint minimally at 220oF to prevent tube
corrosion.
Water-side Pressure Drop. Feedwater pumps must be sized to accommodate

the economizer pressure drop. Additionally, a continuous modulating
feedwater system is required to ensure proper flow rates through the
economizer.
A full product line description of Cleaver-Brooks Boilermate Economizers, including

sizing and performance information, is offered in Section G.
Blowdown Systems
A number of factors determine the need for boiler blowdown. As mentioned earlier,
the amount of total dissolved solids (TDS) is one. The American Boiler
Manufacturers Association (ABMA) has developed recommended limits for total and
suspended solids for different boiler operating pressures. Refer to Table I3-6 for
recommended limits for total and suspended solids.
Other controlling factors for determining blowdown requirements are alkalinity,
suspended solids, and other chemical factors. In boilers operating over 600 psig,
silica content could be the limiting factor.
I3-24
09-09
Section I
Steam Systems
Solids are brought into the boiler by the feedwater. Even though the water is
treated, either mechanically or chemically, neither means of treatment is capable of
removing all substances. A small amount of crystallized solids will be present in the
boiler water, which can tend to encrust surfaces.
That is, solids become less soluble in the high temperature of the boiler water and
tend to crystallize and concentrate on heating surfaces. Internal chemical treatment
is therefore required in order to keep harmful scale and sludge from forming.
Scale has a low heat transfer value and acts as an insulating barrier. Insulation
retards heat transfer, which not only results in lower operating efficiency but, more
importantly, can cause overheating of boiler metal. Overheating of boiler metal
results in tube failure or other pressure vessel metal damage.
Scale is caused primarily by calcium and magnesium salts, silica, and oil. Any
calcium and magnesium salts, along with organic materials in the boiler water, are
generally precipitated by the use of sodium phosphate in order to maintain these
precipitates or sludge in a fluid form.
Solids, such as sodium salts and suspended dirt, do not readily form scale.
However, as boiler water boils, forming relatively pure steam, the remaining water
becomes increasingly thicker with solids. If the concentration is permitted to
accumulate, foaming and priming will occur and the sludge can cause harmful
deposits that potentially result in overheating of the metal. Therefore, lowering or
removing concentrated solids requires the use of boiler water blowdown.
Types of Blowdown
There are two principal types of blowdown: manual (intermittent) bottom blowdown
and surface (continuous) blowdown.
Manual (Intermittent) Bottom Blowdown - Bottom blowdown is necessary for the
proper operation of the boiler. Bottom blowdown removes sludge and controls the
level of TDS. On a manual system, the blowdown tappings are located at the
bottom or lowest part of the boiler, so that the dissolved solids in the boiler water
are lowered, and a portion of the sludge that accumulates in the lower portion of
the boiler is removed.
Surface (Continuous) Blowdown - Surface blowdown involves a continuous, low
flow of boiler water extracted from the surface of the water level in order to skim off
sediment, oil and other impurities. The blowdown is regulated by a flow control
valve, which is adjusted as needed to control the TDS level. The surface blowdown
opening is on the top center line of the pressure vessel and is provided with an
internal collecting pipe terminating slightly below the working water level.
A controlled orifice valve is used to allow a continual, yet controlled, flow of
concentrated water. Periodic adjustments are made to the valve in order to increase
or decrease the amount of blowdown in accordance with test analysis.
There are a few considerations when designing a blowdown system:
Local Code Requirements: If necessary, a blowdown aftercooler should be

incorporated to bring the blowdown water temperature to a level acceptable
to the sewer system and local code requirements.
Blowdown Heat Recovery: Since the blowdown water is discharged at the

saturated steam temperature, a significant amount of energy may be
I3-25
09-09
Steam Systems
Section I
expelled during blowdown. A well-designed blowdown heat recovery system
can control blowdown rates and dissolved solids concentration while
recovering heat for make-up water preheating.
When selecting a blowdown heat recovery system, two factors should be
considered: (1) tube materials and construction, and (2) blowdown flowrate
control. The high velocities and abrasive nature of blowdown water necessitates
quality construction materials such as stainless steel, as well as design for vibration
damping. Secondly, it is important to control blowdown rate so as to match makeup
water flow rates for optimal heat recovery.
In most cases, the intermittent nature of bottom blowdown will preclude recovery of
the blowdown energy losses. Moreover, the bottom blowdown can contain
suspended matter or sludge that will tend to clog a heat exchanger. With a
continuous blowdown system, heat may certainly be recovered, transferred to makeup water, before the blowdown is cooled and sent to sewer.
Flash Tank Heat Exchangers: Flash tank heat exchangers are also designed
to recover heat from blowdown water, but provide an added feature of
producing low-pressure steam for deaeration. The portion of blowdown
water which is not flashed either enters a blowdown heat recovery system
for make-up water preheating or is discharged to sewer.
SYSTEM INTEGRATION AND

OPTIMIZATION
The purpose of this section is to provide assistance in designing and integrating
various equipment into a workable system. A workable system is one that meets
the requirements and purposes of the system, has satisfactory life and maintenance
costs, and abides by all constraints such as pressures, temperatures, footprint,
noise, emissions, etc. In summary, a workable system performs the assigned duty,
given the imposed constraints and requirements.
System optimization, on the other hand, is the process of determining system
configuration and state point conditions which provide a maximization of some
objective such as the net present value of overall life costs. Optimized design may
offer the steam-user significant savings over the life of the steam-generating facility.
It is the design which maximizes profitability for the owner over time.
For a given application, there are many workable designs, but only one optimal
design. The discussion in this section entails a search method to approaching the
Table I3-7. Water Test Results and Limits
SUBSTANCE
TEST RESULT
LIMITS
Oxygen
6 ppm
<0.007 ppm
Hardness
86 ppm
<5.0 ppm
Suspended Matter
0.1 ppm
<0.15 ppm
pH
6.8
7.0-10.5
Silica
10 ppm
<150 ppm
Total Alkalinity
100 ppm
<700 ppm
Dissolved Solids
500 mho/cm
<7000 mho/cm
I3-26
09-09
Section I
Steam Systems
optimal design. Components/equipment are added arbitrarily and evaluated for
effect on system performance and ultimately cost/benefit to the steam system
owner. A complete discussion of optimum system design is beyond the scope of this
publication
EXAMPLE - STEAM SYSTEMS

The following is an example of a relatively simple low pressure steam heating
system. The entire steam-generating facility of an existing heating system is
evaluated for replacement. An application/energy-use audit results in the following
information.
1. Type of Application/Load: Heating
2. Nominal Steam Pressure: 10 psig
3. Steam Load Characteristics/Profile:
The steam system operates 5 months/year.
During 3 months (2160 hours)
Minimum load: 0
Maximum load: 5,600 kBtu/hr
Average load:650 kBtu/hr
8100 kBtu
hour
hp hour
) = 241 hp
( 33.475
kBtu
Next, approximate fuel costs are calculated using the following:2

total load =
(loadi) (hoursi)
total load = 2160 hrs 650 kBtu/hr. + 1440 2500 kBtu/hr.

= 5,004,000 kBtu
total fuel cost =
(total load) ($/MMBtu)
where = system efficiency (decimal)

1
$4.50
(5,004,000 MBtu) 0.6
MMBtu
( ) = $37,530
During 2 months (1440 hours)

Minimum load: 0
Maximum load: 8,100 kBtu/hr
Average load: 2,500 kBtu/hr
Transient loads, instantaneous demand, and sudden load swings do not exist.
4. Steam Quality Requirements: 98% steam quality at boiler pressure vessel exit
5. Condensate Return Conditions:
Temperature: 200 F
I3-27
09-09
Steam Systems
Section I
Pressure: 2 psig
% Return: 90%
6. Make-up Water Requirement: 10%
7. Water Charges:
$68.04/month service charge
$0.833/ccf consumption charge
8. Water Discharge Max. Temp: 120 F
9. Sewer Charges:
$13.72/month service charge
$0.573/ccf use charge
10. Types of Fuel:
Natural Gas
Light Oil considered as a back-up
11. Fuel Analysis:
Natural Gas
Methane: 86.0% (vol.)
Ethane: 7.2% (vol.)
Nitrogen: 6.8% (vol.)
SG: 0.619
HHV: 21,100 Btu/lb (1000 Btu/scf)
No. 2 Oil
Carbon: 85.8% (wt.)
Hydrogen: 12.7% (wt.)
Sulfur: 0.2% (wt.)
HHV: 19,420 Btu/lb
12. Fuel Costs:
Natural Gas: $4.50/MMBtu ($3.50 MMBtu interruptible)
No. 2 Oil: $4.20/MMBtu
13. Combustion Air Conditions:
Avg Temp1: 80 F
Rel Hum: 60%
14. Stack Gas Temperature Limits: N/A
15. Emission Regulations:
There are none currently, but requirements are in the expected future. Site is
located in a non-attainment zone.
16. Stack/Breeching Physical Attributes:
A new single stack is to be designed by the boiler supplier.
17. Electrical Power Demand: Not applicable in this case
I3-28
09-09
Section I
Steam Systems
18. Electrical Power Costs:
$0.0345/kWhr on-peak
$0.0245/kWhr off-peak
19. Physical Limitations of Facility: None
20. Noise Level Requirements: <90 dBA
When designing a steam generating facility, necessary system capacity and
approximate fuel costs need to be considered. This will for allow both qualitative
and quantitative economic analyses of different installation alternatives.
First, required system capacity should be calculated. This is the maximum load.
A total capacity of 241 horsepower is required for this application.
Boiler Selection
As this steam generating facility is replacing an existing one, pressure is already set
at 10 psig. This system operating constraint allows the use of a 15 psi boiler which
falls under Section IV of the ASME code. In addition to pressure requirements,
steam quality requirements need to be met. The customers system/application
requirement is 98%. Most boilers offer 98.5% steam quality at low pressure;
therefore this is not a limitation.
The large amount of idle time and low-load firing apparently suggest a two boiler
installation (boilers operate most efficiently near their rated capacity), with a large
boiler for winter and a smaller model for spring and fall. Reviewing the fuel bill,
however, indicates that an improvement in efficiency would not justify increased
installation, maintenance and capital costs that the customer wishes to minimize.
Furthermore, there is no need for back-up in this application. Therefore, the
recommendation is to install a single boiler. However, high- turndown would be
desirable to prevent excessive cycling.
With the necessary capacity calculated, and the number of boilers to be installed
decided, several boiler types can be ruled out immediately. Neither the Vertical
Firetube nor the Model 4 Watertube Boilers are available in sufficient size for this
system. At the opposite extreme, the load is far too small for an industrial
watertube boiler. Remaining boilers include the firebox, firetube, flextube, electric
and cast iron boilers. The cast iron boiler may be ruled out because of its higher
initial cost; the electric may be ruled out because of higher operating costs. The
remaining boilers, the firebox, firetube and flextube all are good choices for heating
loads requiring low pressure steam.
Instantaneous load is not an issue with a heating load. Likewise, there are no large
load swings to consider.
An application under federal emission regulations (NSPS) needs to be submitted
because this installation is capable of using over 10 MMBTU/hr. There are no
federal emissions requirements for this boiler because of the fuels selected. Local
permits for construction and operation will also be required. Furthermore, it is
desirable that the boiler be UL listed. There are no current local emission
requirements, although they are expected to occur in the near future as the site is
located in an ozone nonattainment area.
To minimize maintenance, a boiler with 5 square feet of heating area per
horsepower should be selected. The large water chamber and surface area reduce
I3-29
09-09
Steam Systems
Section I
the need for cleaning, and minimize upsets caused in water treatment. A turndown
capability increased from the standard 4-1 would further reduce maintenance and
prolong boiler life. A 10-1 turndown, standard on the CB and CB (LE) [low
emission] Firetube Boilers (250-800 hp), would result in significant fuel savings in
this application. In a heating system such as this, eight to twelve cycles per hour
are common. The 10-1 turndown drastically reduces such excessive cycling and
decreases purge energy losses and cycling wear on components.
Both the CB and CB (LE) Firetube Boilers guarantee steam quality above the system
requirements.
The certainty of a future tightening of emission regulations leads to a decision in
favor of the 60 ppm CB (LE) Firetube Boiler3. Although both the firebox and flextube
boilers may be retrofitted with low NOx burners, it is done at considerable cost. The
CB (LE) Firetube Boilers ability to meet all future emission regulations, along with
its fuel savings, 10-1 turndown, and low cost for emissions reduction, make it the
best choice.
The customer currently carries uninterruptable gas service, paying $4.50/MMBtu.
The customer has the opportunity for savings by switching to a dual fuel burner,
which would allow for interruptible service. With the gas cost reduced to $3.50/
MMBtu, and assuming that light oil at $4.20/MMBtu would be used 20% of the
time, the resultant fuel bill is $30,490, or a $7,040 savings.
The final choice in this example will be a 250 horsepower 60 ppm CB (LE) Firetube
Boiler with a dual fuel burner. As this is a heating load, and no expansion is
foreseen, the 20% oversizing used in boiler selection for some systems is not
necessary here. In this application, the CB (LE) Firetube Boiler was selected due to
high turndown capability and the ability to meet future emissions regulations. These
features compensate for the higher capital costs of other boiler choices which could
meet demand.
Condensate Return
And Feedwater
System
This system has 90% condensate return. This yields a make-up water requirement
of 10%. If we assume a constant specific heat, and a make-up water temperature
of 40 F, a direct mixing would result in a feedwater temperature of 184 F.
It must first be decided whether to use a boiler feed system or a deaerating system.
In either case, this system must consist of a water reservoir, a stand (to provide
sufficient net positive suction head for the pump) and a pump. In this system, the
percentage of make-up water is low, and the feedwater mix temperature is relatively
high. Oxygen in the system may be controlled by chemicals. These conditions,
coupled with an already low annual fuel cost, decide against additional spending for
a deaerating system.
A rule of thumb for tanks is to have a fifteen minute water supply for boiler feed
systems and a ten minute supply for deaerating systems. A larger tank may be used
for systems with high condensate return, and a smaller tank for systems with a high
percentage of make-up. In this system, a fifteen minute water supply corresponds
to 2100 lb, or 253 gallons. A 270 gallon tank will be specified, allowing for the
high percentage condensate return.
In a heating system with a firetube boiler there is neither a large load swing nor a
necessity for precise boiler water level control. Therefore, an intermittent operation
turbine style pump will be selected to minimize system cost. As the feedwater
temperature is well below 215 F, there is no need for high temperature pump seals.
I3-30
09-09
Section I
Steam Systems
Duplex pumps will be specified to minimize maintenance downtime.
Water Treatment
Water treatment options include chemical, deaeration, softening and filtering. A

test result yielded the results in Table I3-7
The limits for silica, alkalinity and dissolved solids are all limits for the boiler water
itself. These can be controlled through blowdown (described below). The decision
to control oxygen through chemicals has already been made. It will be necessary to
include a water softener in the water treatment system to remove hardness.
Blowdown
Manual bottom blowdown should be specified. The low fuel bills preclude the
option of continuous blowdown with heat recovery.
Additional equipment
necessary includes a bottom blowdown separator and aftercooler. These are
necessary to reduce the blowdown water temperature to the maximum 120F.
Efficiency
Enhancement
The small annual fuel bills rule out a reasonable return on investment for efficiency
enhancing equipment such as an economizer, oxygen trim or blowdown heat
recovery. On large systems selecting such options may be the wise economic
decision.
System Schematic
A schematic of the resulting system in shown in Figure I3-5.
I3-31
09-09
Steam Systems
Section I
MAKE-UP WATER
90% CONDENSATE RETURN
200
STACK
WATER
SOFTENER
10 PSIG STEAM
STEAM HANDLING, HEATING

AND CONDENSATE RETURN
SYSTEMS
250 HP
CB (LE) BOILER
PACKAGED
BOILER FEED
SYSTEM
BOTTOM BLOWDOWN
CHEMICAL
FEED SYSTEM
COLD WATER
SUPPLY
STEAM
SEPARATOR/
BLOWDOWN
AFTERCOOLER
TO DRAIN
Figure I3-5. Example of System Configuration
I3-32
09-09
Section I4
General Engineering Data
CONTENTS
STEAM PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NATURAL GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL OIL PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EQUIVALENT LENGTHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FACTORS OF EVAPORATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMODYNAMIC PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STANDARD ASSOCIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ILLUSTRATIONS
Figure I4-1. Steam Pipe Chart - Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure I4-2. Pressure Drop for Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure I4-3. Oil Piping Pressure Drop (Viscosity = 100 SSU and Specific Gravity = 0.94) . . . . . .
Figure I4-4. Typical Stack Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure I4-5. Typical Stack Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure I4-6. Rain Cap Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure I4-7. Fuel Oil Viscosity and Temperature Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLES
Table I4-1. Gas Line Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table I4-2. Oil Piping Pressure Drop (Viscosity = 40 SSU and Specific Gravity = 0.9) . . . . . . . . .
Table I4-3. Oil Piping Pressure Drop (Viscosity = 100 SSU and Specific Gravity = 0.94) . . . . . . .
Table I4-4. Oil Piping Pressure Drop (Viscosity = 500 SSU and Specific Gravity = 0.94) . . . . . . .
Table I4-5. Oil Piping Pressure Drop (Viscosity = 1000 SSU and Specific Gravity = 0.96) . . . . . .
Table I4-6. Oil Piping Pressure Drop (Viscosity = 5000 SSU and Specific Gravity = 0.96) . . . . . .
Table I4-7. Equivalent Length of Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table I4-8. Single Boiler Vent or Stack Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table I4-9. Multiple Boilers - Common Breeching and Stack . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table I4-10. Pounds of Dry Saturated Steam per Boiler Horsepower . . . . . . . . . . . . . . . . . . . . . .
Table I4-11. Typical Units for Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table I4-12. Detailed Requirements for Fuel Oils - Properties of Fuel Oil . . . . . . . . . . . . . . . . . . .
Table I4-13. Detailed Requirements for Fuel Oil Grade of Fuel Oil . . . . . . . . . . . . . . . . . . . . . .
I4-3
I4-3
I4-4
I4-4
I4-10
I4-10
I4-13
I4-14
I4-14
I4-15
I4-20
I4-21
I4-32
I4-45
I4-5
I4-6
I4-8
I4-12
I4-12
I4-12
I4-19
I4-7
I4-8
I4-8
I4-8
I4-9
I4-9
I4-10
I4-13
I4-13
I4-14
I4-15
I4-16
I4-17
I4-1
09-09
Section I
Table I4-14. Thermal Properties of Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table I4-15. Saturated Steam Properties, Temperature Table (Sheet 1 of 7) . . . . . . . . . . . . . . . .
Table I4-16. Saturated Steam Properties, Pressure Table (Sheet 1 of 5) . . . . . . . . . . . . . . . . . . .
Table I4-17. Temperature Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table I4-18. Conversion Factors (Sheet 1 of 9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table I4-19. pH Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table I4-20. Salinity Indicating Readings Conversion Tables . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table I4-21. Useful Physical Constants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table I4-22. Conversions Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table I4-23. Approximate Common Equivalents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table I4-24. Conversions Accurate to Parts per Million . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I4-20
I4-21
I4-28
I4-33
I4-34
I4-42
I4-42
I4-42
I4-43
I4-44
I4-44
This section consists of four primary areas. The first includes information to assist in sizing of steam, water,
natural gas, and fuel oil piping. It also provides information on stacks.
The second area, entitled Thermodynamic Properties, contains information on fuel oils, water, and steam, and
covers viscosities, thermal properties of water, and steam tables covering the saturated region.
The third area is Unit Conversion, which includes extensive unit conversion factors as well as an discussion of the
difference between absolute and gauge pressure.
Finally, the fourth area provides a list of standard associations.
I4-2
09-09
Section I
STEAM PIPING
Figure I4-1 allows pressure drop to be calculated given saturated steam pressure,
flow rate and pipe diameter. Although the example covers calculating pressure
drop, it is possible to work backwards to calculate pipe size, given pressure drop.
Example for Steam Pipe Chart, Pounds per Minute to Pressure Drop
A 500 hp boiler at 125 psig has a capacity of 17210 lbs/hr. Pressure drop will be
found through 100 feet of 5" inside diameter pipe.
First, convert pounds/hr to pounds/min by dividing by 60:
17210 60 = 285
Next, convert psig to absolute pressure by adding 14.7:
125 + 14.7 = 139.7
Now, plot 140 (the pressure) on its corresponding axis. This gives point A. Draw a
line from A through B, which is the pipe diameter. Continue this line to the axis, X.
This gives point C.
A new line is plotted from point C, through the pounds of steam per minute axis
(point D). This line ends at the pressure drop axis, for a drop of slightly more than
2.5 psi per 100 feet of pipe.
Example for Steam Pipe Chart, Pounds per Minute to Feet per Minute
The same specifications will be used from the previous example.
For this chart, begin with pounds/min. This gives point A. Draw the line through
the proper point (in this case, point B) on the diameter axis to the X axis (point C).
Next, plot from the X axis through the appropriate pressure (point D) to get steam
velocity. In this example, that corresponds to 3200 feet per minute.
Btu
500 hp x 33475 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
WATER PIPING
Figure I4-2 allows pressure drop in psi or ft. of water to be calculated for a given
flow and pipe size. Like Figure I4-1, working backwards will allow pipe size to be
calculated for a target pressure drop. This figure will work with either water flow in
a hot water system boiler or feedwater to a steam boiler. This assumes a constant
viscosity and density for water over this range of temperatures, but should not
cause significant error.
Hot Water Boiler Example
In this example, pressure drop will be calculated for a 500 hp hot water boiler with
a 20 F temperature differential. This corresponds to approximately 1700 gpm.
The system will use 10" nominal size schedule 40 pipe. These two figures are
plotted on their respective axis, giving points A and B. A line is drawn through these
two points and the remaining two axis, giving a pressure drop of.57 psig (1.3 ft. of
water) and a 6.4 feet per second velocity.
I4-3
09-09
Section I
Feedwater Example
Now consider a 500 hp steam boiler. This requires approximately 40 gallons per
minute of feedwater. A 2" nominal schedule 40 pipe will be used. Plotting these
figure yields points C and D. Drawing a line through the points as before gives us a
pressure drop of 2 psig, or 4.6 feet of water.
NATURAL GAS PIPING

Table I4-1 shows capacity of a natural gas line for a given initial pressure with a 5%
pressure drop. For example, consider a 500 hp boiler, which requires 20,925 cu.ft. / hr. A 5 psi initial pressure is available for 100 ft. of pipe. To find the correct
pipe size, go to the line for initial gas pressure reading 5 pounds. Now move to the
right, until a number larger than 20,925 appears. In this case, the first greater
number is 30,500. The number at the top of that column shows the appropriate
pipe size, in this case 4". Table I4-1 assumes gas at 60 F, 1000 Btu/cu.-ft., and a
specific gravity of 0.619.
FUEL OIL PIPING

Table I4-2 through Table I4-6 show pressure drop for liquids with specific gravities
and viscosities in the ranges found for numbers 2 through 6 fuel oils.
To use these tables, select the table with the appropriate viscosity for the oil that is
being used. (An oil viscosity chart is provided later in this section in Figure I4-6.)
Select the line corresponding to the required flow, and the column corresponding to
the nominal pipe size. The intersection will give the pressure drop in psi per 100
feet of equivalent pipe length.
For example, a typical No. 2 fuel oil has a viscosity 40 SSU. A 500 hp boiler
requires up to 115 gallons per hour of No. 2 oil. Using Table I4-2, and specifying a
1-inch nominal pipe size, gives 0.1 psi pressure drop at 100 gph, and 0.2 at 150
gph. Linear interpolation gives 0.13 psi pressure drop per 100 equivalent feet of
pipe. Note that heavy oils require a return line, which increases total flow
requirements.
I4-4
09-09
Figure I4-1. Steam Pipe Chart - Pressure Drop
Section I
I4-5
09-09
Section I
Figure I4-2. Pressure Drop for Water
I4-6
09-09
Section I
Table I4-1. Gas Line Capacities

INITIAL
GAS
PRESSURE
TOTAL
PRESS
DROP
GAS LINE CAPACITIES (CU-FT/HR THROUGH 100 FT LENGTH)

DIAMETER OF PIPE IN INCHES
1/2
3/4
1-1/4
1-1/2
2-1/2
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
Multiplier
10
15
25
50
100
150
200
250
300
350
400
500
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
09-09
Section I
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
1.5
2.5
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.
Figure
Table I4-3.
I4-1. Oil
Oil Piping
Piping Pressure
Pressure Drop
Drop (Viscosity
(Viscosity =
= 100
100 SSU
SSU and
and Specific
Specific Gravity
Gravity =
= 0.94)
0.94)
FUEL OIL FLOW
RATE (GPH)

0.5
0.75
1.5
2.5
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
1.5
2.5
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
09-09
Section I
FUEL OIL FLOW
RATE (GPH)
0.5
0.75
1.5
2.5
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
1.5
2.5
25
80
26
10
0.3
0.1
0.05
50
160
52
20
0.6
0.3
0.09
75
240
78
30
1.0
0.4
0.14
100
320
104
40
1.3
0.5
0.18
150
480
156
59
11
1.9
0.8
0.27
200
641
208
79
14
2.6
1.1
0.36
250
801
260
99
18
3.2
1.4
0.46
300
961
312
119
21
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
09-09
Section I
EQUIVALENT LENGTHS
Table I4-7 shows equivalent lengths of pipe for various plumbing fittings. Find the
nominal pipe size being used in the leftmost column. For each fitting, read the
value under the appropriate heading and add this to the length of piping. This
allows total system pressure drop to be calculated. (This is valid for any fluid.)
STACKS
Notice
For boilers over 800 hp, consult your local Cleaver-Brooks authorized representative.
Why Used
The only purpose of a vent stack on Cleaver-Brooks boilers is to conduct the
products of combustion to a point of safe discharge (atmosphere). Forced draft
design eliminates the need for a stack designed to create a draft.
Stack Draft on CB Boilers
Depending on the boiler model, draft variations of as much as 1/2 inch W.C. at the
boiler vent outlet will have no appreciable effect on the Model CB burner operation.
This is due to the high pressure drops which are taken from the burner inlet to the
boiler vent outlet. See individual boiler sections for specific limitations on stack/
breeching size criteria. Other typical pressure drops for the Model CB Boilers are as
follows:
A. A 4 inch to 12 inch WC drop is taken across the burner in order to provide
high turbulence, good mixing of fuel and air, and high CO2 readings for most
efficient combustion,
B. A 2 inch to 6 inch WC drop is taken through the four (4) gas passes of the
boiler in order to maintain high flue gas velocities and thus increase heat
transfer.
For other boiler types, the draft variation could be similar. Consult you local CleaverBrooks authorized representative.
Table I4-7. Equivalent Length of Pipe
EQUIVALENT LENGTH OF STRAIGHT PIPE (FEET)
PIPE SIZE
STANDARD STANDARD
ELBOW
TEE
GATE
GLOBE
ANGLE
VALV E VALVE FULL VALVE FULL
FULL OPEN
OPEN
OPEN
1-1/2
0.9
41
21
11
1.2
54
27
2-/1/2
13
1.4
64
32
16
1.6
80
40
3-1/2
18
2.0
91
45
11
21
2.2
110
55
13
26
2.8
140
70
16
32
3.4
155
81
20
42
4.5
210
110
10
25
55
5.5
270
140
12
30
65
6.5
320
160
14
35
75
8.0
370
190
This table contains the number of feet of straight pipe usually allowed for standard
fittings and valves.
I4-10
09-09
Section I

If the stack height is over 150 feet or if an extremely large breeching and stack
combination cause excessive draft, a simple barometric damper can be located in
the breeching close to the stack or chimney. This damper should only be considered
after burner adjustment problems have been experienced and are serious enough to
warrant corrective action.
Automatic or special draft controls are not required and are not recommended for
use with Cleaver-Brooks boilers.
Stack Location
An off-set type stack connection to the stub vent on the boiler is preferred and
recommended. A direct vertical connection can also be made, if required. A typical
stack location diagram is shown in Figure I4-3.
Stack Condensation
The amount of condensation in the stack will vary with the type of fuel and with the
stack gas temperature. Normally, the temperature of the flue gas leaving the boiler
is higher than the temperature of the steam or the water in the boiler.
Stack condensation is most likely to occur on heating boiler installations where light
loads and intermittent firing cause a cool stack condition, which results in
condensation of the water vapor in the flue gas. This condensed water accelerates
corrosion of steel stacks or breechings.
The following items should be considered when planning to keep stack
condensation to a minimum:
A. The boiler should be sized as close as possible to the true heat load.
Oversized boilers should be avoided.
B. Masonry stacks have better heat holding characteristics than steel stacks.
C. When steel stacks are used, stack insulation will help prevent heat loss.
D. An off-set stack (recommended) with bottom clean-out and drain connection
will prevent any condensed water from draining back into the boiler.
Stack Weight
Boiler vent outlets will withstand a maximum direct vertical load of 2,000 pounds.
This loading must include the effect of wind and guy wires.
Stack Construction
The stack can be terminated several feel above the top of the roof. (State and local
codes may govern the stack height above the roof.) If down drafts are unavoidable,
the stack outlet can be provided with a ventilator such as the Breidert Air-X-Hauster
or equivalent. See Figure I4-4 for typical stack construction details.
Stack Material
Minimum 12 gauge steel is recommended for stack sections. If the stack will be
inaccessible, the use of a non-corrosive material (e.g. glass lining) should be
considered.
A rain cap or hood should be used at the top of the stack to minimize the entrance
of rain or snow. See Figure I4-5 for typical rain cap details.
I4-11
09-09
Section I
STACK TIGHT-SEAL
CLEANOUT
STACK
CLEANOUT
DRAIN CONNECTION
VERTICAL STACK CONNECTION
OFFSET STACK CONNECTION (RECOMMENDED)
Figure I4-3. Typical Stack Locations
RAIN CAP
B
C
2-0 MIN
AS REQUIRED
BY LOCAL CODE
D
A
TOP OR ROOF
B
A
STACK DIA.
STACK
DIA
STACK
DIAMETER (IN.)
A (IN.)
B
(IN.)
C
(IN.)
15-20
15
15
12
25-40, 50A
20
20
16
50-60
10
25
25
20
70-100A, 125A
12
30
30
125-200
16
40
250-350
20
400-800
24
BOILER HP
STACK
DIAMETER
(IN.)
A (IN.)
B
(IN.)
C
(IN.)
D
(IN.)
15-20
12
25-40, 50A
16
50-60
10
20
24
70-100A, 125A
12
24
40
32
125-200
16
12
32
50
50
40
250-350
20
15
40
10
10
60
60
48
400-600
24
18
48
12
12
700-800
24
21
48
12
12
BOILER HP
Figure I4-5. Rain Cap Details
Figure I4-4. Typical Stack Construction
I4-12
09-09
Section I

Stack/Breeching Size Criteria
The design of the stack and breeching system must provide a draft at the boiler
outlet(s) which is within the required limits. Consideration must be given to
operation variations (including number of boilers), purge cycles, outside wind and
air conditions, and the impact of other variables that may impact draft conditions.
Safe and reliable burner performance requires good stack design.See Table I4-8 and
further detail in the individual boiler sections.
Stack and breeching sizes should always be provided by a reputable stack supplier
who will design the stack and breeching system based on the required system
layout. Your local Cleaver-Brooks authorized representative is capable of assisting in
your evaluation of the stack/breeching design.
FACTORS OF EVAPORATION
The factor of evaporation is used to adjust rated boiler output (from and at 212 F)
to actual job or operating conditions. Available feedwater temperature and expected
boiler operating pressure (psig) affect the boiler output ratings which are based on
from and at 212 F.
Example: A boiler is to have an output of 3060 pounds of steam per hour when
operating at 10 psig with feedwater at 100 F. What should the boiler rating be on
the basis of from and at 212 F.
Referring to Table I4-10, at 100 F and 10 psig, the following factors can be
obtained: 30.6 pounds of steam per boiler horsepower. This factor is used to
convert the from and at 212 F rating basis:
3060 30.6 = 100 hp rated boiler should be selected.
Table I4-9. Multiple Boilers - Common Breeching

and Stack
Table I4-8. Single Boiler Vent or Stack Diameter

BOILER HP
STACK DIAMETER
Same as Boiler Vent Outlet
Size (Inches OD)
15-20
25-40, 50A
50-60
10
70-100, 100A,
125A
12
125-200
16
250-350
20
400-800
24
MINIMUM RECOMMENDED STACK

DIAMETERA
NUMBER OF BOILERS
BOILER HP
2
100
FT
200
FT
100
FT
200
FT
100
FT
200
FT
9"
10"
10"
12"
11"
12"
25-40
11"
12"
13"
14"
14"
16"
50A, 50-60
13"
14"
15"
16"
17"
18"
70-100.
100A
16"
17"
19"
20"
21"
23"
125-200
21"
22"
24"
26"
28"
30"
250-350
26"
28"
32"
34"
34"
40"
400-600
32"
34"
38"
40"
421"
46"
700-800
38"
42"
44"
48"
48"
52"
15-20
Notes:
A. No barometric damper required.
I4-13
09-09
Section I
THERMODYNAMIC PROPERTIES
Fuel Oils
The purpose of this section is to provide technical information on the various grades
of fuel oils commonly used in the generation of steam and hot water. The American
Society for Testing and Materials (ASTM) has established numerous tests to identify
fuel oil properties and specifications that allow the fuel to be identified by a grade,
which can be No. 1, 2, 4, 5, or 6.
Grades No. 1 and No. 2 are considered distillate oil, while grades No. 4 through No.
6 are considered residual oils. Distillate oils have a low viscosity and are relatively
easy to burn. Residual oils have a high viscosity and often require heating to pump
and atomize. Residual oils will also have much higher emission levels, and their use
is frequently regulated because of this.
The viscosity ranges of fuel oils are shown in Figure I4-6.
Table I4-10. Factor of Evaporation
30.0
33.8
I4-14
09-09
Section I
Fuel Oil
Specifications

The limits on fuel oil properties are shown in Table I4-11, Table I4-12, and Table
I4-13. Definitions of these properties are discussed next.
Ultimate Analysis - Ultimate analysis is a statement of the quantities of the various
elements of which a substance is composed. For fuel oils, this will likely state
higher heating values and specific gravity in addition to the percentages by weight
of each element.
Flash Point - The flash point of a fuel oil is an indication of the maximum
temperature at which it can be stored and handled without serious fire hazard. The
minimum permissible flash point is usually regulated by federal, state or municipal
laws and is based on accepted practice in handling and use.
Pour Point - The pour point is an indication of the lowest temperature at which a fuel oil can be
stored and still be capable of flowing under very low forces. The pour point is prescribed in
accordance with the conditions of storage and use. Higher pour point fuels are permissible
where heated storage and adequate piping facilities are provided. An increase in
pour point can occur when residual fuel oils are subjected to cyclic temperature
variations that can occur in the course of storage or when the fuel is preheated and
returned to storage tanks. To predict these properties, Test Method D 3245 may be
required.
Water and Sediment - Appreciable amounts of water and sediments in a fuel oil
tend to cause fouling of facilities for handling it, and cause trouble in burner
mechanisms. Sediment may accumulate in storage tanks and on filter screens or
burner parts, resulting in obstructions to flow of oil from the tank to the burner.
Water in distillate fuels can cause corrosion of tanks and equipment, and can cause
emulsions in residual fuels.
Carbon Residue - The carbon residue of a fuel is a measure of the carbonaceous
material left after all the volatile components are vaporized in the absence of air. It
is a rough approximation of the tendency of a fuel to form deposits in vaporizing
burners, such as pot-type and sleeve burners, where the fuel is vaporized in an airdeficient atmosphere.
To obtain measurable values of carbon residue in the lighter distillate fuel oils, it is
necessary to distill the oil to remove 90% of it in accordance with Section 9 of Test
Method D 524, and determine the carbon residue concentrated in the remaining
10% bottoms.
Ash - The amount of ash is the quantity of noncombustible material in an oil.
Excessive amounts can indicate the presence of materials that cause high wear of
burner pumps and valves, and contribute to deposits on boiler heating surfaces.
Table I4-11. Typical Units for Fuels
GROSS HEATING
VALUES
ITEM
No. 2 Oil
140,000 Btu/gal.
No 5 Oil
148,000 Btu/gal.
No. 6 Oil
150,000 Btu/gal.
1 Therm
100,000 Btu
1 kW
3,413 Btu
I4-15
09-09
Section I
Table I4-12. Detailed Requirements for Fuel Oils - Properties of Fuel Oil
FUEL OIL GRADE
PROPERTY
Flash Point C min

Water and sediment,% vol max
Distillation temperature C
ASTM TEST
METHOD B
No. 1
No. 2
No. 4
(Light)
No. 4
No 5
(Light)
No. 5
(Heavy)
No. 6
D 93
38
38
38
55
55
55
60
0.05
0.05
(0.50)C
(0.50)C
(1.00)C
(1.00)C
(2.00)C
D 1796
D 85
10% vol recovered, max
215
90% vol recovered, min
282
max
288
338
D 445
Minimum viscosity
1.3
1.9
1.9
>5.5
Maximum viscosity
2.1
3.4
5.5
24.0D
5.0
9.0
15.0
14.9D
50.0D
Kinematic viscosity at 40 C mm2/s
Kinematic viscosity at 100 C mm2/s

Minimum viscosity
8.9D
Ramsbottom carbon residue on 10%

distillation residue% mass, max
D 524
0.15
0.35
Ash,% mass, max
D 482
0.05
0.15
0.10
0.15
Sulfur,% mass, maxE
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/m3
D 1298
Minimum density
>876F
Maximum density
850
876
D 97
-18
-6
-6
-6
Maximum viscosity
Pour Point C, maG

A
It is the intent of these classifications that failure to meet any requirement of a given grade does not automatically place an oil in
the next lower grade unless in fact it meets all requirements of the lower grade. However, to meet special operating conditions
modification of individual limiting requirements may be agreed upon among purchaser, seller, and manufacturer.
B The test methods indicated are the approved referee methods.
C The amount of water by distillation by Test Method D 95 plus the sediment by extraction by Test Method D 473 shall not exceed
the value shown in the table. For Grade No.6 fuel oil, the amount of sediment by extraction shall not exceed 0.50 mass%, and a
deduction in quantity shall be made for all water and sediment in excess of 1.0 mass%.
D Where low sulfur fuel oil is required, fuel oil falling in the viscosity range of a lower numbered grade down to and including No. 4
can be supplied by agreement between the purchaser and supplier. The viscosity range of the initial shipment shall be identified
and advance notice shall be required when changing from one viscosity range and another. This notice shall be in sufficient time
to permit the user to make the necessary adjustments.
E Other sulfur limits may apply in selected areas in the United States and in other countries.
F This limit assures a minimum heating value and also prevents misrepresentation and misapplication of this product as Grade
No. 2.
G Lower or higher pour points can be specified whenever required by conditions of storage or use. When a pour point less than
-18 C is specified, the minimum viscosity at 40 C for grade No. 2 shall be 1.7 MM.2/S. and the minimum 90% recovered 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
09-09
Section I

Table I4-13. Detailed Requirements for Fuel Oil Grade of Fuel Oil
DISTILLATION
TEMPERATURES, F
FLASH
POINT F
MIN
POUR
POINT
F MAX
WATER &
SEDIMENT
% MAX
CARBON
RESIDUE
ON 10%
RESIDUUM
% MAX
ASH%
MAX
1. Distillate oil intended for

vaporizing pot-type burners
and other burners requiring
this grade.
100
or
legal
trace
0.15
2. A distillate oil for general

purpose domestic heating for
use in burners not requiring
No. 1.
100
or
legal
20
0.10
4. An oil for burner installations

not equipped with preheating
facilities.
130
or
legal
20
5.A residual type oil for burner

installations equipped with preheating facilities.
130
or
legal
6.An oil for use in burners

equipped with preheaters permitting a high viscosity fuel,
130
or
legal
GRADE OF FUEL OIL
10%
POINT
MAX
90%
POINT
MAX
END
POINT
MAX
420
625
0.35
675
0.50
0.10
1.00
0.10
2.00
Distillation - The distillation test shows the volatility of a fuel and the ease with
which it can be vaporized. The test is of greater significance for oils that are to be
burned in vaporizing type burners than for the atomizing type. For example, the
maximum 10% and 90% distilled temperatures are specified for grade No. 1 fuel.
The limiting10% value assures easy starting in vaporizing type burner and the 90%
limit excludes heavier fractions that would be difficult to vaporize.
The limits specified for grade No. 2 heating oil define a product that is acceptable
for burners of the atomizing type in household heating installations. Distillation
limits are not specified for fuel oils of grades No. 4, 5, and 6.
Viscosity Limits for Grades Nos1214 1 and 2 - The viscosity of an oil is a measure
of its resistance to flow. In fuel oil it is highly significant since it indicates both the
relative ease with which the oil will flow or can be pumped and the case of
atomization.
Viscosity limits for No. 1 and No. 2 grades are specified to help maintain uniform
fuel flow in appliances with gravity flow, and to provide satisfactory atomization and
constant flow rate through the small nozzles of household burners. For the heavier
grades of industrial and bunker fuel oils, viscosity is of major importance, so that
adequate preheating facilities can be provided to permit them to be pumped to the
burner and to provide good atomization. However, it is equally important that the
maximum viscosity under the existing conditions be such that the oil can be
pumped satisfactorily from the storage tank to the preheater.
Density - Density alone is of little significance as an indication of the burning
characteristics of fuel oil. However, when used in conjunction with other properties,
I4-17
09-09
Section I
it is of value in mass-volume relationships and in calculating the specific energy

(heating value) of an oil.
Corrosion - The corrosion test serves to indicate the presence or absence of
materials that could corrode copper, brass, and bronze components of the fuel
system. This property is specified only for Nos. 1 and 2 distillate fuel oils.
Limited sulfur content of fuel oil can be required to meet federal, state, or local
legislation or regulations.
Nitrogen - Nitrogen oxide emission regulations have been imposed on certain
combustion facilities as a function of fuel nitrogen content. For purposes of these
regulations, distillate fuels, low nitrogen residual fuels, and high nitrogen residual
fuels have been defined by their nitrogen content. Installations are required to meet
different emission standards according to the classification of the fuel being used.
When regulations require such a distinction to be made, fuel nitrogen specifications
can be needed in the contractual agreement between the purchaser and the
supplier.
I4-18
09-09
Figure I4-6. Fuel Oil Viscosity and Temperature Curves
Section I
I4-19
09-09

Water
Section I
The relevant properties of water are shown in Table I4-14.

Table I4-14. Thermal Properties of Water
I4-20
09-09
Section I

Steam properties are shown in Table I4-15 and Table I4-16.
Steam
Table I4-15. Saturated Steam Properties, Temperature Table (Sheet 1 of 7)

ABS. PRESSURE
TEMP
F
t
PSIA
p
IN. HG
p
SPECIFIC VOLUME (ft.3/lb)

SAT.
LIQUID
vf
EVAP.
vfg
SAT.
VAPOR
vg
ENTHALPY (Btu/lb)
SAT.
LIQUID
hf
EVAP.
hfg
ENTROPY (Btu/lb,F)
SAT.
VAPOR
hg
SAT.
LIQUID
sf
EVAP.
sfg
SAT.
VAPOR
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
I4-21
09-09
Section I

ABS. PRESSURE
TEMP
F
PSIA
IN. HG

SAT.
LIQUID
EVAP.
EVAP.
ENTROPY (Btu/lb,F)
SAT.
VAPOR
sfg
SAT.
VAPOR
hf
hfg
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
09-09
sf
EVAP.
I4-22
hg
SAT.
LIQUID
0.4443
vf
vg
ENTHALPY (Btu/lb)
SAT.
LIQUID
76
vfg
SAT.
VAPOR
sg
Section I

ABS. PRESSURE
TEMP
F
PSIA
IN. HG

SAT.
LIQUID
EVAP.
ENTHALPY (Btu/lb)
SAT.
VAPOR
SAT.
LIQUID
EVAP.
ENTROPY (Btu/lb,F)
SAT.
VAPOR
sf
EVAP.
sfg
SAT.
VAPOR
vfg
vg
hf
hfg
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
vf
hg
SAT.
LIQUID
sg
I4-23
09-09
Section I

ABS. PRESSURE
TEMP
F
t
PSIA
p
IN. HG
p

SAT.
LIQUID
vf
EVAP.
vfg
SAT.
VAPOR
ENTHALPY (Btu/lb)
SAT.
LIQUID
vg
hf
EVAP.
hfg
ENTROPY (Btu/lb,F)
SAT.
VAPOR
hg
SAT.
LIQUID
sf
EVAP.
sfg
SAT.
VAPOR
sg
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
I4-24
09-09
Section I

ABS. PRESSURE
TEMP
F
PSIA
IN. HG

SAT.
LIQUID
EVAP.
SAT.
VAPOR
ENTHALPY (Btu/lb)
SAT.
LIQUID
hfg
hg
SAT.
LIQUID
sf
EVAP.
sfg
SAT.
VAPOR
vfg
vg
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
vf
hf
EVAP.
ENTROPY (Btu/lb,F)
SAT.
VAPOR
sg
I4-25
09-09
Section I

ABS. PRESSURE
TEMP
F
PSIA
IN. HG

SAT.
LIQUID
vf
EVAP.
SAT.
VAPOR
ENTHALPY (Btu/lb)
SAT.
LIQUID
EVAP.
ENTROPY (Btu/lb,F)
SAT.
VAPOR
SAT.
LIQUID
EVAP.
SAT.
VAPOR
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
vfg
vg
hf
I4-26
09-09
hfg
hg
sf
sfg
sg
Section I

ABS. PRESSURE
TEMP
F
PSIA
IN. HG

SAT.
LIQUID
EVAP.
SAT.
VAPOR
ENTHALPY (Btu/lb)
SAT.
LIQUID
EVAP.
hg
SAT.
LIQUID
EVAP.
sf
sfg
SAT.
VAPOR
vf
vfg
vg
hf
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
0.0503
902.7
902.7
1.0580
1.0580
hfg
ENTROPY (Btu/lb,F)
SAT.
VAPOR
sg
I4-27
09-09
Section I
Table I4-16. Saturated Steam Properties, Pressure Table (Sheet 1 of 5)

ABS.
PRESS
TEMP
PSIA
SPECIFIC
VOLUME (ft.3/lb)
SAT.
LIQUID
vf
SAT.
VAPOR
vg
ENTHALPY (Btu/lb)
SAT.
LIQUID
hf
EVAP.
hfg
ENTROPY (Btu/lb,F)
SAT.
VAPOR
SAT.
LIQUID
hg
sf
EVAP.
SAT.
VAPOR
INTERNAL ENERGY (Btu/lb)

SAT.
LIQUID
sfg
sg
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
09-09
ufg
SAT.
VAPOR
14.696
I4-28
uf
EVAP.
ug
Section I

ABS.
PRESS
TEMP
PSIA
SPECIFIC
VOLUME (ft.3/lb)
SAT.
LIQUID
vf
SAT.
VAPOR
vg
ENTHALPY (Btu/lb)
SAT.
LIQUID
hf
EVAP.
hfg
ENTROPY (Btu/lb,F)
SAT.
VAPOR
hg
SAT.
LIQUID
sf
EVAP.
SAT.
VAPOR

SAT.
LIQUID
uf
EVAP.
ufg
SAT.
VAPOR
sfg
sg
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
ug
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
I4-29
09-09
Section I

ABS.
PRESS
TEMP
PSIA
SPECIFIC
VOLUME (ft.3/lb)
SAT.
LIQUID
vf
SAT.
VAPOR
vg
ENTHALPY (Btu/lb)
SAT.
LIQUID
hf
EVAP.
hfg
ENTROPY (Btu/lb,F)
SAT.
VAPOR
hg
SAT.
LIQUID
SAT.
VAPOR
SAT.
LIQUID
ufg
SAT.
VAPOR
sfg
sg
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
09-09
uf
EVAP.
113
I4-30
sf
EVAP.
ug
Section I

ABS.
PRESS
TEMP
PSIA
SPECIFIC
VOLUME (ft.3/lb)
SAT.
LIQUID
vf
SAT.
VAPOR
vg
ENTHALPY (Btu/lb)
SAT.
LIQUID
hf
EVAP.
hfg
ENTROPY (Btu/lb,F)
SAT.
VAPOR
hg
SAT.
LIQUID
sf
EVAP.
SAT.
VAPOR

SAT.
LIQUID
uf
EVAP.
ufg
SAT.
VAPOR
sfg
sg
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
ug
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
I4-31
09-09
Section I

ABS.
PRESS
PSIA
p
500
520
540
560
580
600
620
640
660
680
700
720
740
760
780
800
820
840
860
880
900
TEMP
F
t
467.01
471.07
475.01
478.85
482.58
486.21
489.75
493.21
496.58
499.88
503.10
506.25
509.34
512.36
515.33
518.23
521.08
523.88
526.63
529.33
531.98
SPECIFIC
VOLUME (ft.3/in2)
SAT.
LIQUID
vf
0.0197
0.0198
0.0199
0.0200
0.0201
0.0201
0.0202
0.0203
0.0204
0.0204
0.0205
0.0206
0.0207
0.0207
0.0208
0.0209
0.0209
0.0210
0.0211
0.0212
0.0212
EVAP.
vfg
0.9081
0.8717
0.8379
0.8065
0.7772
0.7497
0.7238
0.6995
0.6767
0.6553
0.6349
0.6156
0.5973
0.5800
0.5635
0.5478
0.5329
0.5186
0.5049
0.4918
0.4794
SAT.
VAPOR
vg
0.9278
0.8915
0.8578
0.8265
0.7973
0.7698
0.7440
0.7198
0.6971
0.6757
0.6554
0.6362
0.6180
0.6007
0.5843
0.5687
0.5538
0.5396
0.5260
0.5130
0.5006
ENTHALPY (Btu/lb)
SAT.
LIQUID
hf
449.4
454.1
458.6
463.0
467.4
471.6
475.7
479.8
483.8
487.7
491.5
495.3
499.0
502.6
506.2
509.7
513.2
516.6
520.0
523.3
526.6
EVAP.
hfg
755.0
750.1
745.4
740.8
736.1
731.6
727.2
722.7
718.3
714.0
709.7
705.4
701.2
697.1
692.9
688.9
684.8
680.8
676.8
672.8
668.8
SAT.
VAPOR
hg
1204.4
1204.2
1204.0
1203.8
1203.5
1203.2
1202.9
1202.5
1202.1
1201.7
1201.2
1200.7
1200.2
1199.7
1199.1
1198.6
1198.0
1197.4
1196.8
1196.1
1195.4
ENTROPY (Btu/lb,F)
SAT.
LIQUID
sf
0.6487
0.6536
0.6584
0.6631
0.6676
0.6720
0.6763
0.6805
0.6846
0.6886
0.6925
0.6963
0.7001
0.7037
0.7073
0.7108
0.7143
0.7177
0.7210
0.7243
0.7275
EVAP.
sfg
0.8147
0.8060
0.7976
0.7893
0.7813
0.7734
0.7658
0.7584
0.7512
0.7441
0.7371
0.7303
0.7237
0.7172
0.7108
0.7045
0.6983
0.6922
0.6862
0.6803
0.6744
SAT.
VAPOR
sg
1.4634
1.4596
1.4560
1.4524
1.4489
1.4454
1.4421
1.4389
1.4358
1.4327
1.4296
1.4266
1.4237
1.4209
1.4181
1.4153
1.4126
1.4099
1.4072
1.4046
1.4020
INTERNAL
ENERGY (Btu/lb)
SAT.
SAT.
VALIQUID
POR
uf
ug
447.6
1118.6
452.2
1118.4
456.6
1118.3
460.9
1118.2
465.2
1118.0
469.4
1117.7
473.4
1117.5
477.4
1117.3
481.3
1117.0
485.1
1116.7
488.8
1116.3
492.5
1116.0
496.2
1115.6
499.7
1115.2
503.2
1114.8
506.6
1114.4
510.0
1114.0
513.3
1113.6
516.6
1113.1
519.9
1112.6
523.1
1112.1
UNIT CONVERSIONS
Note that pressures are typically given in gauge pressure. This is the difference
between the absolute pressure in the boiler and the absolute pressure of the
surroundings. A gauge reads pressure differences (in most cases, the difference
between the pressure of the substance and that of the atmosphere). Therefore,
gauge pressure may be positive or negative (vacuum). Gauge pressures, in U.S.
(English Engineering) units, are referred to as psig (pounds per square inch gauge,
although the g is frequently omitted).
An absolute pressure is the pressure above zero pressure, which can only be
positive. Most thermodynamic tables are based on absolute pressure. In U.S. units,
absolute pressure is referred to as psia (pounds per square inch absolute).
Absolute pressure is calculated by adding the absolute pressure of the surroundings
(atmospheric pressure) to the gauge pressure. In general, for U.S. units (psig) to
convert gauge pressure to absolute pressure, add 14.696. Conversely, to convert
absolute pressure to gauge pressure, subtract 14.696.
The following information is included for your convenience.
Temperature Conversion
Conversions Factors 2
pH Values
Salinity Indicating Readings Conversion Table
Useful Physical Constants
Conversions Table
Approximate Common Equivalents
Conversions Accurate to Parts per Million
I4-32
09-09
Section I
I4-33
09-09
Section I
Table I4-17. Temperature Conversion
I4-34
09-09
Section I

Table I4-18. Conversion Factors (Sheet 1 of 9)
I4-35
09-09
Section I
Table I4-18. Conversions Factors (Sheet 2 of 9)
I4-36
09-09
Section I

I4-37
09-09
Section I
I4-38
09-09
Section I

I4-39
09-09
Section I
I4-40
09-09
Section I

I4-41
09-09
Section I
.Table I4-18. Conversions Factors (Sheet 7 of 9)
I4-42
09-09
Section I

I4-43
09-09
Section I
Table I4-20. Salinity Indicating Readings
Conversion Tables
Table I4-21. Useful Physical Constants
Table I4-19. pH Values
I4-44
09-09
Section I
Table I4-22. Conversions Table
I4-45
09-09
Table I4-23. Approximate Common

Equivalents
Section I
Table I4-24. Conversions Accurate to Parts per

Million
I4-46
09-09
Section I
STANDARD ASSOCIATIONS
American Gas Association (AGA)
1515 Wilson Blvd.
Arlington, VA 22209
703-524-2000
American National Standards Institute (ANSI)
11 West 42nd Street
New York, NY 10036
212-642-4900
ANSI acts as the national coordinating institution through which interested
organizations voluntarily cooperate in establishing, recognizing, and improving
standards.
American Society of Heating Refrigerating and Air Conditioning Engineers
(ASHRAE)
1791 Tullie Circle, NE
Atlanta, GA 30329
American Society of Mechanical Engineers (ASME)
345 East 47th Street
New York, NY 10017
212-705-8500
The ASME develops test codes for boilers and pressure vessels and for power
applications, and serves as a sponsor for ANSI in developing safety codes and
standards.
American Society for Nondestructive Testing
3200 Riverside Drive
Columbus, Ohio 43221
American Society for Testing and Materials (ASTM)
1916 Race Street
Philadelphia, PA 19103-1187
ASTM is the largest voluntary standards development system in the world
publishing standards for materials, products, systems and services.
Canadian Standards Association (CSA)
178 Rexdale Blvd.
Etobicoke, Ontario, Canada M9W 1R3
416-747-4044
CSA, a nonprofit nongovernmental body, which promotes nationwide standards for
product design, construction and performance for Canada. CSA is a recognized
testing agency.
Canadian Gas Association (CGA)
55 Scarsdale Road
Don Mils, Ontario M3B 2R3
416-447-6465
CGA, a nonprofit association of manufacturers of gas utilities, provides certification
service based on standards established by CSA.
I4-47
09-09
Section I
Factory Mutual System (FM)

1151 Boston-Providence Turnpike
Norwood, MA 02062
617-762-4300
FM is an association of 4 mutual insurance companies dedicated to minimizing loss
of insured property. Through its research arm, the Factory Mutual Research
Corporation, it investigates means of preventing and minimizing fire and other
losses. FM laboratories provide product testing and approval.
85 Woodland Street
Hartford, CT 06105
203-520-7412
IRI is composed of stock insurance companies providing indemnity for damage
caused by such perils as fire, explosion, and windstorm. To assist their
policyholders, IRI provides an advisory engineering service. Part of this service is
the development of recommendations which serve as standards for IRI itself and its
policyholders.
Kemper Insurance Company
1 Kemper Drive
Long Grove, IL 60049
708-320-2000
The HPR (Highly Protective Risk) Department of Kemper has developed a set of
recommendation for gas and oil fired boiler furnaces. These recommendations are
used to determine the underwriting acceptability of proposals and completed
installations.
National Board of Boiler and Pressure Vessel Inspectors
1055 Crupper Avenue
Columbus, OH 43229-1183
614-888-8320
The National Board is an organization comprised of Chief Inspectors of states and
cities of the US and provinces of Canada organized for the purpose of promoting
greater safety in the construction, installation, inspection and repair of boilers and
pressure vessels.
1 Batterymarch Park
Quincy, MA 02269-9101
The National Electric Code is a standard established for safe wiring procedures in
the interest of personal safety and fire protection. The code is adopted and
copyrighted by the NFPA (see National Fire Protection Association).
National Fire Protection Association (NFPA)
1 Batterymarch Park
Quincy, MA 02269-9101
NFPA develops and promotes standards for the purpose of advancing the science
and improving the methods of fire protection and prevention.
I4-48
09-09
Section I

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
I4-49
09-09
Section I
Notes:
I4-50
09-09
Section I5
Alternative fuels systems sales and technical guide
Section 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-2
Section 2:Digester and landfill gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-2
2.1 Definition and sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Characteristics of digester gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3. Digester/landfill gas system evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4. Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5. Control Schemes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
....
....
....
....
....
. . . I5-2
. . . I5-2
. . . I5-3
. . . I5-4
. . . I5-6
Section 3: Flammable Liquids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-8

3.1 Definition and sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-8
3.2. Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-8
3.3. Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-9
3.3.4 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-11
Section 4 Waste Oil Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-12

4.1. Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-12
4.2 Fuel Specification Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-12
4.3 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-13
4.4 Base System Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-14
4.5 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-14
Section 5 Fuels requiring special engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-15

Section 6 Unacceptable fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-15
I5-1
09-09
Alternative Fuel Systems
Section I
SECTION 1: INTRODUCTION
Cleaver-Brooks defines alternative fuel(s) as that which is other than standard
commercially available fuel; used with a burner/boiler combination. Standard,
commercially available fuels, include: natural gas, light and heavy oils. Hence, all
other fuels including but not limited to digester gas, landfill gas, solvents, waste
oils, hydrogen, town gas, or biogas are considered nonstandard, waste or,
alternative.
Over the years, Cleaver-Brooks has offered alternative fuel systems and gained
considerable experience in this field including custom designs, engineered around
specific, onsite requirements.
We have found too, the majority of the waste fuels available for boiler applications
can be grouped into three (3) categories: flammable liquids, digester (landfill) gas,
and waste oil. We have; therefore, standardized product offerings for these three
common alternative fuels. In addition, Cleaver-Brooks offers products for other
waste fuels, but these require up front engineering evaluation before design
begins
The purpose of this guide is to provide the reader with a working knowledge of the
characteristics of the most common alternative fuels (digester/landfill, flammable
liquids and waste oils), the features of our system(s), and the type of information
required for these projects.
You do not have to be an expert to be successful in promoting alternative fuels
systems. You do; however, have to know the basics concerning these fuels, features
of our system(s), ask the right questions, and assemble a complete information
package for each inquiry.
With the fuel prices almost tripling in the last 10 years, there is tremendous
opportunity in pursuing the alternative fuel business.
SECTION 2:DIGESTER AND LANDFILL GASES

2.1 Definition and sources
Digester gas typically refers to gas produced by the fermentation of organic matter
such as manure, wastewater sludge, municipal solid waste, or any other
biodegradable feedstock, under anaerobic (oxygen present) conditions. Digester
gas is also called biogas, swamp gas, landfill gas, sewer gas, landfill gas,
depending on where it is produced. Each variant has different levels of methane
and carbon dioxide with other minor gases. However; in general, the heating value
and composition of these gases is essentially known and; therefore, they can be
used as a fuel in Cleaver-Brooks boilers.
2.2 Characteristics of digester gas
Characteristics of digester gas vary depending on a source. Typical chemical
breakdown variations and properties are presented in the following tables.
I5-2
09-09
Section I

Table I5-1. Typical analysis of the digester gas
Component
Methane
Carbon Dioxide
Hydrogen Sulfide
Water Vapor
Other Gases
Chemical Formula
CH4
CO2
H2S
H2O
CO, N2, O2
% Vol
50-65
35-50
Trace 2
3-6
1-10
Table I5-2. Digester and natural gas comparison

Characteristic
Heating Value
Specific gravity (Air =
1.0)
Hydrogen Sulfide
Water Vapor
Temperature
Units
Btu/Scf
Digester Gas
500-600
Natural gas
950-1100
N/A
% Vol
% Vol
(F
0.85 0.95
Trace - 2
3 6 (Sturated)
75-120
Supply Pressure
IWC
6-15
0.6 0.64
None
None
Ambient
27.7 277 (1 10
PSIG)
2.3. Digester/landfill gas system evaluation.

2.3.1.1 Digester gas has only about half the heating value of natural gas, is heavier
than natural gas, and is typically supplied at a lower pressure than natural gas.
These facts create the need for a system that can handle high flow rates of gas with
minimum pressure drop.
2.3.1.2 The higher flow rates also have a major impact on burner design and
performance. A special burner should be used to provide adequate gas velocities for
good mixing but without excessive pressure drop.
2.3.1.3 Digester gas usually contains some hydrogen sulfide (H2S), and is
saturated with water. These characteristics create a corrosive environment for the
gas piping, valving, exhaust breeching and stack should condensation occur. We;
therefore, require (contact) components be resilient to these conditions, using
materials such as stainless steel; providing better corrosion resistance when
compared to carbon steel.
2.3.1.4 Digester gas systems are usually hot water or low pressure steam systems
because they are often used for heating at the site location. These boilers produce
low flue gas exit temperatures adding to the corrosive issues in the boiler system.
2.3.1.5 The digester gas supply is not always reliable and can be frequently
interrupted. Therefore, the boiler system must be capable of responding to
interruptions or inadequate supply of digester gas while continuing to meet the
plants heat demand.
2.3.1.6 Often natural gas is used as a primary backup when digester gas supply
interruptions occur. Normally, this is accomplished by the use of a dual canister gas
burner housing with a control system that can automatically change over to the
backup fuel.
I5-3
09-09
Section I
Figure I5-1. Dual Canister Burner

2.4. Components.
Sulfur in any gas can be combined with hydrogen in the combustion process
resulting in (corrosive) hydrogen sulfide. During cold startups, and if the
combustion gas is cooled below its dew point, condensation occurs and the
hydrogen sulfide condenses with the water vapor. This product is extremely
damaging to carbon steel as well as some gasket materials. Therefore, it is
imperative the correct materials are selected to ensure long life of the equipment.
2.4.1. Gas Train. Separate gas trains are supplied for natural gas and digester gas.
Corrosion resistive components are used for valves and switches on the digester gas
train. In addition, all digester gas trains are supplied with two automatic safety
shut off valves regardless of insurance requirements This, to ensure that the
corrosive gas does not leak into the boiler when not in use. These automatic shut
off valves have electric or pneumatic spring-return actuators.
2.4.2. Gas Pressure Regulator Since digester gas is usually supplied at relatively
low pressure (6-15 W.C.), the gas pressure regulator must be capable of operation
at high gas flow rates with minimum pressure drop. Since most regulator suppliers
sizing data is based on natural gas, a correction factor is used to properly size the
regulator.
2.4.3. Dual gas burner. For integral head firetube boilers firing digester gas with a
I5-4
09-09
Section I

backup gas, Cleaver-Brooks uses our patented dual canister housing burner (see
figure 1). The design of this burner system allows separate combustion control for
two gases with different fuel characteristics.
The dual canister burner components are sized such that the digester gas system
components are designed based on the digester gas fuel composition. The backup
fuel system is separately designed based on the backup fuel composition.
Hence, different materials may be used for each fuel to ensure long component life,
maximum burner efficiencies, and safety.
Figure I5-2. Dual Gas Train Schematic
Table 1:
Natural Gas
Tag #
TAG #
PCV-010
HV-010A
PSL-010
FV-010A
FV-010B
FV-010C
PSH-010
HV-010B
CV-010
NA
NA
Digester Gas
Tag #
Tag #
PCV-020
HV-020A
PSL-020A
FV-020A
FV-020B
FV-020C
PSH-020
HV-020B
CV-020
PSL-020B
T-020
Function
Function
Gas Pressure Regulator
Automatic Shut Off Valve
Vent valve
Automatic Shut Off Valve
Firing Rate Modulating Valve
Automatic Fuel Changeover Switch *
Flame Arrester with Check Valve*
* Optional components
I5-5
09-09
Section I
2.5. Control Schemes.

Over the years Cleaver-Brooks used many different control schemes when digester
gas was fired in a boiler. Most of these schemes were customized to the specific
customer needs. Control scheme selection can be based on a number of factors
including digester gas pressure, boiler size, number of boilers in a plant, and
availability of digester gas. The most common control schemes are described
below.
2.5.1. Automatic fuel changeover. The purpose of this control scheme is to
automatically switch a boiler fuel from digester gas to a back up fuel whenever
digester gas supply becomes insufficient to meet the control settings. This option
requires an automatic fuel changeover pressure switch, which is typically installed
prior to the digester gas pressure regulator. When the boiler demand exceeds
availability of the digester gas fuel, digester gas pressure drops tripping the
changeover pressure switch and the controls will modulate to the minimum firing
position. Once minimum burner position is proven, the burner shuts down and then
re-starts, firing the back up fuel. When digester gas pressure is restored, the
aforementioned sequence is reversed, and the burner re-starts, firing digester gas.
2.5.2. Preferential firing. The purpose of this control scheme is to fire all the
available digester gas available. In order for this control scheme to work, another
boiler is required to maintain adequate steam pressure (water temperature) when
the digester gas supply cannot meet heat/process load demand.
Figure I5-3. Preferential Firing Control Scheme

Pressure/Temperature controller PTC-030 receives boiler outlet temperature signal
I5-6
09-09
Section I

from temperature transmitter TT-040 and digester gas pressure signal from pressure
transmitter PT-020. Output to the firing rate control valve CV-020 is based on these
two signals. When digester gas pressure is above set point, firing rate is based on
the heat demand, i.e. boiler outlet water temperature. When digester gas pressure
drops below set point, firing rate signal is reduced to maintain digester gas pressure.
Hence the control scheme ensures that all available digester gas can be burned.
Automatic fuel changeover and low fire hold is incorporated into the control
algorithm of PTC-030.
2.5.3. Simultaneous Firing. This control scheme is used when there is a
requirement to burn all available digester gas, maintain steam pressure (water
temperature), and provide automatic fuel changeover without burner shutdown.
Figure I5-4. Simultaneous Firing

Temperature indicating controller TIC-040 receives boiler outlet temperature signal
from temperature transmitter TT-040. Control signal from TIC-040 is sent to
digester gas firing rate controller FC-020 and natural gas firing rate controller FC010. Firing rate controllers provide control signal to digester and natural gas firing
rate control valves CV-020 and CV-010.
Parallel positioning or full metered combustion control is incorporated in the
simultaneous firing control scheme. This control scheme can become quite complex
and requires PLC based control hardware.
I5-7
09-09
Section I
SECTION 3: FLAMMABLE LIQUIDS.

3.1 Definition and sources.
Flammable liquids are defined as having temperatures between 70 F and 140 F at
which they give off vapor in such a concentration that combined with air, a
flammable mixture is formed. Hence, they can be extremely hazardous since
inadequate ventilation can allow flash back from a source of ignition to the liquid.
These liquids can also be classified as halogenated or non-halogenated. Halogens
are elements like chlorine that will form corrosive compounds as products of
combustion, hence halogenated liquids are more difficult to handle and they require
that the burner and fuel train utilize materials that are corrosive resistant. Because
of the corrosive nature of halogenated liquids, most manufacturing companies try to
use non-halogenated flammable liquids. These are produced as a byproduct from
the manufacturing of printed circuit boards, pharmaceuticals, plastics, tobacco,
machined parts or textiles.
Flammable liquids include solvents, paint thinners, xylene, methanol, methyl ethyl
keytone, benzene, acetone, toluene, isopropanol, and mineral spirits.
Benefits of burning flammable liquids in lieu of other fuels include:
Fuel costs of the plant can be substantially reduced
Liability associated with off site disposal is reduced
Expansive waste hauling costs and paperwork are reduced or eliminated
Future uncertainty of off site disposal alternatives is reduced
3.2. Characteristics
Flammable liquids cover a wide range of types and therefore their compositions
vary greatly. However, they do share some characteristics such as:
Heating Value
As sampled (Typically 50,000 100,000

Btu/Gal
Flash PointL
Less then 140(F
Viscosity
30 100 SSU
Water
30% maximum
Chlorine/Halogens
0.4% maximum
Ash
1% maximum
Solids
1% maximum
Metals
50 ppm maximum
I5-8
09-09
Section I

)
3.3. Evaluation
3.3.1. Design concerns Using waste liquids as an alternate boiler fuel poses some
major design concerns that if not addressed properly, can lead to safety problems
and boiler equipment failures.
To understand these design concerns, the
characteristics of the waste fuel must be analyzed.
Typical characteristics that have an effect on combustion include:
Low lubricity can result in premature wear to pumps, seals, and valves
Low viscosity may require heating to properly flow through the fuel system
High or variable water content can cause combustion issues
Variable heating value can cause combustion issues
Contamination with dirt or solids can lead to plugging of components
Incompatibility with brass, buna or carbon steel due to corrosive nature of

the fuel
Typical problems resulting from firing flammable liquids without proper equipment
and controls include:
Flame stability problems
Fuel valve failure
Supply pump failure
Burner gun vapor lock
Variations in excess air level
Corrosion and sooting of the boiler
Poor control and adjustment of air/fuel ratios
Loss of steam supply without standard fuel backup
High potential for boiler occurances
The benefits of energy recovery are quickly lost if the system is not properly
designed to handle the specified flammable liquid. Therefore, it is critical that the
fuel characteristics are known; typically accomplished by analyzing a fuel sample.
3.3.2. Critical factors Many factors must be considered before a system can be
designed to burn flammable liquid fuels. In addition, decisions on project feasibility,
system options, and percent input ratio must be known. The following factors are
typically considered:
Halogens - Flammable liquids with high amounts of chlorine or other halogens

can cause corrosive damage to the boiler and accessory equipment and, may
require off gas pollution control equipment. Flammable liquids containing more
than 0.4% halogens can sometimes be handled at a reduced input ratio.
Therefore, for most applications, materials with halogens in excess of 0.4% are
not feasible as an alternate boiler fuel
Metals and Solids - Burning materials with high amounts of metals can pose air
pollution problems which can be a limiting factor for the project, and may
require a special permit. Handling materials with high amounts of solids
requires filtration and ash removal equipment to avoid plugging and/or erosion
I5-9
09-09
Section I
of components. This additional equipment increases the capital expense of the
project and adds to the maintenance requirements of the system. Accurate
information on metals, solids, and ash content will allow for the most
economical package to be quoted while ensuring longevity of the equipment.
Waste Fuel Variations - The base simultaneous fired system will allow for some
variations in heating value and other waste fuel contents. When large variations
are expected, additional controls to monitor composition of waste fuel can be
provided. These controls can include oxygen trim systems for boiler excess air
monitoring and control, heating value biasing systems to regulate the fuel flow
input if variations occur, and flow meters with annunciation and recorders.
These systems provide additional safety and reliability when an unreliable fuel
source is being fired. However, these control systems can be expensive. The
best way to reduce the cost and complexity of the system is to control the
consistency of the fuel stream.
Percent Input Ratio - The percent input ratio is the percent of heat that the
waste fuel contributes to total input of the boiler. Maximum waste fuel inputs
for the base system are 50% when fired with natural gas and 40% when fired
with oil. For each inquiry, the percent input of the waste fuel must be
determined. The lower the percent input, the less effect variations in the waste
fuel will have on combustion and excess air levels. The higher the percent
input, the greater amount of waste can be handled with the system. Therefore,
the quantity of waste being produced and the average firing rate and run time of
the boiler must be known to determine the optimum percent input of the waste
fuel.
Cost and Liability The liability associated with designing combustion and fuel
handling equipment to handle an unreliable fuel source is extremely high.
Therefore, when insufficient information is provided, the system must be
designed conservatively, and costs increase. Therefore, it is critical that
accurate and complete information is provided to ensure that the system is
designed safely and cost effectively.
3.3.3 Base System Features The base system is designed to handle consistent
liquid wastes within the listed fuel specification parameters. This base system
incorporates several features that provide safety and reliability including:
3.3.3.1 Simultaneous Firing The alternate fuel is fired simultaneously with natural
gas or oil to enhance stability and ensure complete combustion (see figure 4).
Natural gas is preferred as the supplemental fuel, due to greater flame stability and
burner configuration. When oil is used as the supplemental fuel, a dual burner gun
arrangement is supplied which ensures that the two fuels are not combined until
they enter the combustion chamber.
Simultaneous firing provides the following advantages:
Enhanced Flame Stability
Stable Combustion Temperature
Reduced Excess Air Variations
Safer Operation
I5-10
09-09
Section I

3.3.3.2 Separate Metering Control The practice of mixing alternative liquid fuels
with oil and utilizing a standard oil system for metering can be dangerous and is not
recommended.
Therefore, our base system is designed with a completely separate metering system,
fuel shut-off assembly, and pumping station for the waste fuel.
This feature provides separate control and adjustment of the waste fuel supply to
the burner. Steam production is maintained even if this fuel system is not
operational.
By isolating the waste fuel system from the standard fuel system, additional
monitoring and control options; compensating for waste fuel variations, can be
easily incorporated.
3.3.3.3 Materials of Construction The system utilizes special stainless steel pump
internals, fuel shut off valves, fuel metering valves, pressure switches and piping.
These special materials of construction provide extended life of the equipment and
enhance the safety of the system.
3.3.3.4 Pumps Pumping of these liquids at high pressure without pulsation
requires a positive displacement pump with close tolerances.
Special pump designs and materials of construction are provided, taking into
account the low lubricity of the liquid.
Even with the special designs, pump life can be a problem for these applications. If
the customer has had success with a specific pump for the waste material, we can
provide a similar pump or provide the system requirements to the customer so they
can supply the pump.
Regardless of who is responsible for providing the pump equipment, funds for spare
pumps should be identified as a required operating expense.
3.3.3.5 Reverse Purge The system utilizes a reverse purge system to prevent vapor
lock in the burner gun, rough light-off, and tip fouling.
The purge system pulls the flammable liquid out of the gun and back to the waste
fuel source at every boiler shutdown.
3.3.3.6. Control Panel The system is provided with PLC based control panel to
control, monitor and annunciate all waste fuel functions. The panel includes
Human Machine Interface (HMI) for easy identification of any system problem.
Retrofit systems are provided with revised wiring diagrams to show the waste fuel
system connection points.
3.3.4 Options The system may be provided with any of the following options
depending on the project requirements.
Automatic Change Over To The Standard Fuel Firing
Oxygen Trim System
Filtration Modules to remove contaminants and solids from the waste fuel
All Stainless Steel Wetted Parts
Flow Meters and Flow Totalization
I5-11
09-09
Section I
SECTION 4 WASTE OIL FUELS.

4.1. Definition.
Waste oils are heavy oils used for lubrication or hydraulic applications; discarded or
recycled due to contamination or loss of lubricity. Examples include machine oil,
fish oil, and transmission fluid.
Benefits of using waste oil to supplement a plants energy requirements include:
The fuel costs of the plant can be substantially reduced.
Liability associated with off-site disposal is reduced.
Expensive waste hauling costs and paperwork are reduced or eliminated.
Future uncertainty of recycling or off-site disposal alternatives is reduced.
4.2 Fuel Specification Parameters

The base system for waste oils is designed to handle waste streams that do not
exceed the following:
Heating Value
As sampled (Typical 100,000 150,000 Btu/Gal)
Flash Point
140( F or higher
Specific Gravity
As sampled (Typical 0.9 1.1)
Viscosity
Under 150 SSU @ 260( F
Water
5% Maximum
Total Halogens
1,000 ppm maximum
Ash
1% maximum
Solids
1% maximum
4.3 Evaluation
For each inquiry, the waste fuel specification and site conditions are evaluated.
Decisions on project feasibility, base system options, and percent input ratio are
based on the following critical factors.
Waste Fuel Variations
Key evaluation factors include the ability of the waste oil combustion system to
compensate for moderate variations in heating value, viscosity, and contaminant
level.
By utilizing simultaneous firing, batch blending, viscosity control, and additional
combustion controls, the Cleaver-Brooks system will allow for predictable variations
in the waste oil.
However, compensating for drastic variations in the waste fuel requires more
complex and expensive control packages.
Anything that can be done by the customer to maintain waste fuel consistency will
reduce the cost and complexity of the system.
I5-12
09-09
Section I

Contaminants - Waste oil will typically contain dirt and solids. Failure to remove
these contaminants can result in fouling of the fuel metering equipment and sooting
of the boiler.
Water is also a common contaminant found in waste oil. Although small quantities
of water mixed in an emulsion can help combustion, high quantities of water can
cause flame stability problems.
Viscosity - Maintaining adequate viscosity levels for proper atomization is a critical
factor when burning any oil. Waste oil usually has a higher viscosity/temperature
curve than conventional oils.
The common solution to this problem is to increase the setpoint on the oil heat
exchanger to reduce the viscosity to an acceptable level.
Metals and Halogens - The EPA has national standards regulating the quantities of
metals, halogens, and PCBs that can be present in waste oil used for energy
recovery.
Local standards pertaining to emissions of metals and acids also should be
investigated during the feasibility stage of each project.
Cleaver-Brooks will provide information on calculated emission levels based on the
waste fuel analysis.
However, the ultimate responsibility for permitting the project and control of the oil
content lies with the customer.
Boiler Size and Loads - Waste oil systems are only available on Cleaver-Brooks
boilers that utilize air or steam atomization (50 HP and above)
Consideration must also be given to the load demand on the boiler.
Frequent cycling of the boiler while firing waste oil can result in low oil and
combustion temperatures. This condition will usually result in sooting and fouling of
the boiler.
Therefore, as with any alternate fuel application, information on the boiler loading
and total boiler room steam demand is required with each inquiry.
Percent Input Ratio - The percent input ratio is the percent heat that the waste fuel
contributes to total input of the boiler compared to the percent heat of the
supplemental (standard) fuel.
Maximum waste fuel inputs for simultaneous fired systems are 50% when fired with
natural gas and 40% when fired with oil.
For each inquiry, the percent input of the waste fuel must be determined. The
lower the percent input, the less effect variations in the waste fuel will have on
combustion and excess air levels. Therefore, the quantity of waste being produced
and the average firing rate and run time of the boiler must be known to determine
the optimum percent input of the waste oil.
Cost and Liability - The liability and cost associated with designing combustion and
fuel handling equipment to handle an alternate fuel is relatively high. Therefore,
when insufficient information is provided, we must assume worst case conditions
and quote accordingly, and the price will escalate. Even with an accurate definition
of the project conditions, these systems are expensive. Without good information it
is very difficult to provide a reasonable and competitive price and package.
I5-13
09-09
Section I
4.4 Base System Features.

The base system alternate fuel system designed to handle waste oil fuels within the
listed fuel specification parameters, incorporates several features that provide safety
and reliability.
4.4.1 Simultaneous Firing with simultaneous firing, the alternate fuel is fired
simultaneously with natural gas or oil. Natural gas is preferred as the supplemental
fuel due to greater flame stability and reduced burner modification. When oil is
used as the supplemental fuel, a dual burner gun arrangement is supplied. The two
fuels are not combined until they enter the combustion chamber.
Simultaneous firing provides the following advantages:
- Enhanced Flame Stability
- Stable Combustion Temperature
- Reduced Excess Air Variations
- Safer Operation
Some waste oils (e.g. fish oil, recycled clean oil) can be burned by itself without
modifications to the standard fuel oil delivery system. However without the benefits
of simultaneous firing the risks associated with firing the waste oil are increased.
Therefore, formal documentation from the customer outlining his responsibility to
maintain a consistent waste fuel stream is required before a straight fired system
can be proposed.
4.4.2 Separate Metering Control In most cases the practice of mixing these types of
wastes with oil and utilizing a standard oil system for metering can be dangerous
and is not recommended.
Therefore, our system is designed with a completely separate metering system, fuel
shutoff assembly, and pumping station for the waste fuel.
This feature provides separate control and adjustment of the waste fuel to the
burner. Steam production is maintained even if the waste fuel system is not
operational.
By isolating the waste fuel system from the standard fuel system, additional
monitoring and control options to compensate for waste fuel variations can be easily
incorporated.
4.4.3. Viscosity Control One of the key features to the waste oil combustion system
is accurate viscosity control.
Standard heavy oil systems include an oil heat exchanger to preheat the oil to a set
point temperature. At these temperatures, the viscosity of the oil is reduced to an
adequate level for proper atomization.
The Cleaver-Brooks waste oil system automatically adjusts the oil temperature
when the oil viscosity changes. The system also monitors and controls oil
temperature throughout the metering system all the way to the burner gun tip.
I5-14
09-09
Section I

The burner gun is specifically designed to minimize heat losses and tip fouling.
With this automatic viscosity control system, many waste oils with high or variable
viscosity can now be successfully burned in Cleaver-Brooks boilers.
4.4.4. Filtration Module If required, system includes a filtration module to remove
solids, dirt from the waste oil.
Depending on the storage tank arrangement, a secondary recirculation pump in
conjunction with the filtration module may be required.
4.45 Control Panel The system is provided with a PLC based control panel to
control, monitor and annunciate all waste fuel functions. The panel includes
Human Machine Interface (HMI) for easy identification of any system problem.
Retrofit systems are provided with revised wiring diagrams to show the waste fuel
system connection points.
4.5 Options
The system may be provided with any of the following options depending on the
project requirements:
Automatic Change Over To The Standard Fuel Firing
Oxygen Trim System
Filtration Modules to remove contaminants and solids from the waste fuel
All Stainless Steel Wetted Parts
Flow Meters and Flow Totalization
SECTION 5. FUELS REQUIRING SPECIAL ENGINEERING.

The following is the list of fuels, which will require special engineering.
Hydrogen
Refinery gases
Contaminated air
Coke oven gas
SECTION 6 UNACCEPTABLE FUELS.

The following fuels will be unacceptable to be used in Cleaver-Brooks boilers.
Solid fuels
Acids
Radioactive material
Caustics
I5-15
09-09
Section I
Notes
I5-16
09-09
Section J
GLOSSARY
A
AMBIENT AIR - The air that surrounds the equipment. The standard
ambient air for performance calculations is air at 80 F, 60% relative
humidity, and a barometric pressure of 29.921 in. Hg, giving a specific humidity of 0.013 lb of water vapor per lb of dry air.
ABSOLUTE PRESSURE - Pressure above zero pressure; the sum of

the gauge and atmospheric pressures.
AMBIENT TEMPERATURE - The temperature of the air surrounding

the equipment.
ACCUMULATOR - (STEAM) A pressure vessel containing water and/or

steam, which is used to store the heat of steam for use at a late
period and at some lower pressure.
ANALYSIS - Quantitative determination of the constituent parts.
ACID CLEANING - The process of cleaning the interior surfaces of

steam generating units by filling the unit with dilute acid accompanied by an inhibitor to prevent corrosion, and subsequently draining,
washing and neutralizing the acid by a further wash of alkaline water.
ANALYSIS, ULTIMATE - Chemical analysis of solid, liquid or gaseous

fuels. In the case of coal or coke, determination of carbon, hydrogen,
sulfur, nitrogen, oxygen, and ash.
AQUASTAT - Water limit temperature control, a safety device often
used on boilers.
ACIDITY - Represents the amount of free carbon dioxide, mineral

acids and salts (especially sulphates of iron and aluminum) which
hydrolyze to give hydrogen ions in water and is reported as milliequivalents per liter of acid, or ppm acidity as calcium carbonate, or pH
the measure of hydrogen ions concentration.
ARRESTER - A device to impede the flow of large dust particles or

sparks from a stack, usually screening at the top.
AS-FIRED FUEL - Fuel in the condition as fed to the fuel burning
equipment.
ADIABATIC FLAME TEMPERATURE - The theoretical temperature

that would be attained by the products of combustion provided the
entire chemical energy of the fuel, the sensible heat content of the
fuel and combustion above the datum temperature were transferred
to the products of combustion. This assumes: No heat loss to surroundings and no dissociation.
ASH - The incombustible inorganic matter in the fuel.

ASH-FREE BASIS - The method of reporting fuel analysis, whereby
ash is deducted and other constituents are recalculated to total
100%.
AIR - The mixture of oxygen, nitrogen, and other gases, which with
varying amounts of water vapor, forms the atmosphere of the earth.
ASH PIT - A pit or hopper located below a furnace where refuse is

accumulated and from which refuse is removed at intervals.
AIR ATOMIZING OIL BURNER - A burner for firing oil in which the oil
is atomized by compressed air, which is forced into and through one
or more streams of oil which results in the breaking of the oil into a
fine spray.
ASME - The American Society of Mechanical Engineers.

ASPIRATING BURNER - A burner in which the fuel in a gaseous or
finely divided form is burned in suspension, the air for combustion
being supplied by bringing into contact with the fuel, air drawn
through one or more openings by the lower static pressure created by
the velocity of the fuel stream.
AIR DEFICIENCY - Insufficient air, in an air-fuel mixture, to supply the

oxygen required for complete oxidation of the fuel.
AIR-FREE - The descriptive characteristic of a substance from which
air has been removed.
AS-RECEIVED FUEL - Fuel in the condition as received at the plant.

ATMOSPHERIC AIR - Air under the prevailing atmospheric conditions.
AIR-FUEL RATIO - The ratio of the weight, or volume, of air to fuel.

ATMOSPHERIC PRESSURE - The barometric reading of pressure
exerted by the atmosphere. At sea level 14.7 lb per sq in. or 29.92
in. of mercury.
AIR INFILTRATION - The leakage of air into a setting or duct.

AIR, SATURATED - Air which contains the maximum amount of water
vapor that it can hold at its temperature and pressure.
ATOMIZER - A device by means of which a liquid is reduced to a very

fine spray.
AIR VENT - A valved opening in the top of the highest drum of a

boiler or pressure vessel for venting air.
AVAILABLE DRAFT - The draft which may be utilized to cause the

flow of air for combustion or the flow of products of combustion.
ALARM - A suitable horn, bell, light or other device which when operated will give notice of malfunction or off normal condition.
AVAILABILITY FACTOR - The fraction of time during which the unit is

in operable condition.
ALKALINITY - Represents the amount of carbonates, bicarbonates,

hydroxides and silicates or phosphates in the water and is reported as
grains per gallon, or ppm as calcium carbonate.
AXIAL FAN - Consists of a propeller or disc type of wheel within a cylinder that discharges air parallel to the axis of the wheel.
ALLOWABLE WORKING PRESSURE - See design pressure.
J-1
09-09
Glossary
BOOSTER FAN - A device for increasing the pressure or flow of a gas.
BREECHING - A duct that transports the products of combustion

between parts of a steam generating unit or to the stack.
BAFFLE - A plate or wall for deflecting gases or liquids.

BAFFLE TILE - A tile for deflecting gases.
BRIDGEWALL - A wall in a furnace over which the products of combustion pass.
BAFFLE-TYPE COLLECTOR - A device in gas paths utilizing baffles so

arranged as to deflect dust particles out of the gas stream.
BRITISH THERMAL UNIT (Btu) - The mean British Thermal Unit is 1/

180 of the heat required to raise the temperature of 1 lb of water from
32 F to 212 F at a constant atmospheric pressure. A Btu is essentially 252 calories.
BAG FILTER - A device containing one or more cloth bags for recovering particles from the dust laden gas or air which is blown through it.
BAG-TYPE COLLECTOR - A filter in which the cloth filtering medium
is made in the form of cylindrical bags.
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 maintains an air pressure sufficient for proper distribution and discharge of
secondary air.
BLIND NIPPLE - A nipple, or a short piece of pipe or tube, closed at

one end.
BURNER WINDBOX PRESSURE - The air pressure maintained in the

windbox or plenum chamber measured above atmospheric pressure.
BLOWDOWN - Boiler water that is removed from the boiler in order to

maintain the desired concentration levels of suspended and dissolved
solids in the boiler and removal of sludge.
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 - Carbon element, the principal combustible constituent of all fuels.
BLOWDOWN VALVE - A valve generally used to continuously regulate

concentration of solids in the boiler, not a drain valve. (Often called
continuous blowdown.)
CaCO3 - Calcium Carbonate.

CALORIE - The mean calorie is 1/100 of the heat required to raise the
temperature of 1 gram of water from Zero C to 100 C at a constant
atmospheric pressure. It is about equal to the quantity of heat
required to raise one gram of water 1 C. Another definition is: A calorie is 3600/860 joules.
BLOW-OFF VALVE - A specially designed, manually operated, valve

that connects to the boiler for the purpose of reducing the concentration of solids in the boiler or for draining purposes. (Often called bottom blowdown.)
CALORIMETER - Apparatus for determining the calorific value of a

fuel.
BLOWER - A fan used to force air under pressure.

BOILER - A closed vessel in which water is heated, steam is generated, steam is superheated, or any combination thereof, under pressure or vacuum by the application of heat from combustible fuels,
electricity or nuclear energy.
CAPACITY FACTOR - The ratio of the average load carried to the maximum design capacity.
CARBON - Element. The principal combustible constituent of all fuels.
BOILER EFFICIENCY - The term boiler efficiency is often substituted for combustion or thermal efficiency. True boiler efficiency is the
measure of fuel-to-steam efficiency.
CARRYOVER - The chemical solids and liquid entrained with the

steam from a boiler.
CASING - A covering of sheets of metal or other material such as fire
resistant composition board used to enclose all or a portion of a steam
generating unit.
BOILER HORSEPOWER - The evaporation of 34-1/2 lbs of water per

hour from a temperature of 212 F into dry saturated steam at the
same temperature. Equivalent to 33,475 Btu/hr.
CENTRAL STATION - A power plant or steam heating plant that generates power or steam.
BOILER RATING - The heating capacity of a boiler expressed in boiler

horsepower, Btu/hour, or pounds of steam/hour.
CENTRIFUGAL FAN - Consists of a fan rotor or wheel within a housing

that discharges air at a right angle to the axis of the wheel.
BOILER SHELL- The outer cylindrical portion of a pressure vessel.

BOILER WATER - A term construed to mean a representative sample
of the circulating boiler water, after the generated steam has been
separated and before the incoming feed water or added chemical
becomes mixed with it so that its composition is affected.
CHEMICAL ANALYSIS - Determination of the principal chemical constituents.

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

parts for the removal of oils, greases, etc.
CIRCULATION - The movement of water and steam within a steam

generating unit.
J-2
09-09
CONTROL - Any manual or automatic device for the regulation of a

machine to keep it at normal operation. If automatic, the device is
motivated by variations in temperature, pressure, water level, time,
light, or other influences.
CIRCULATION RATIO - The ratio of water entering a circuit to the

steam generated by that passes that circuit in a unit of time.
CIRCULATOR - A pipe or tube to pass steam or water between upper
boiler drums usually located where the heat absorption is low. Also
used to apply to tubes connecting headers of horizontal water tube
boilers with drums.
CONTROL VALVE - A valve used to control the flow of air, gas, water,
steam or other substance.
CONVECTION - The transmission of heat by the circulation of a liquid
or gas. It may be natural, with the circulation caused by buoyancy
affects due to temperature differences, or forced with circulation
caused by a mechanical device such as a fan or pump.
CLEANOUT DOOR - A door placed so that accumulated refuse may

be removed room a boiler setting.
CO - Carbon monoxide.
CO2 - Carbon dioxide.
CORROSION - The wasting away of metal due to chemical action. In

a boiler, usually caused by the presence of O2, CO2, or an acid.
COLLECTOR - A device used for removing gas borne solids from flue
gas.
CROWN SHEET - In a firebox boiler, the plate forming the top of the
furnace.
COLLOID - A finely divided organic substance which tends to inhibit

the formation of dense scale and results in the deposition of sludge, or
causes it to remain in suspension, so that it may be blown from the
boiler.
CRUDE OIL - Unrefined petroleum.

CSD-1 - Abbreviation for the ASME standard for Controls and Safety
Devices.
COMBUSTIBLE LOSS - The loss representing the unliberated thermal

energy occasioned by failure to oxidize completely some of the combustible matter in the fuel.
D
DAMPER - A device for introducing a variable pressure drop in a system used for regulating the volumetric flow of a gas, such as air.
COMBUSTIBLES - The heat producing constituents of a fuel.

COMBUSTION - The rapid chemical combination of oxygen with the
combustible elements of a fuel resulting in the release of heat.
DAVIT - The structure on large firetube boilers from which the front
and rear doors are suspended when opened.
COMBUSTION AIR - Air used in the combustion process. Air contains

oxygen which is required to combust fuel.
DEAERATION - Removal of air and gases from boiler feed water prior
to its introduction to a boiler.
COMBUSTION CHAMBER - See Furnace.
DEGASIFICATION - Removal of gases from samples of steam taken

for purity test. Removal of CO2 from water as in the ion exchange
method of softening.
COMBUSTION EFFICIENCY - The effectiveness of the burner to completely burn the fuel. A well designed burner will operate with as little
as 10 to 20% excess air, while converting all combustibles in the fuel
to useful energy.
DELAYED COMBUSTION - A continuation of combustion beyond the

furnace. (See also Secondary Combustion.)
COMPLETE COMBUSTION - The complete oxidation of all the combustible constituents of a fuel.
DESIGN LOAD - The load for which a steam generating unit is

designed, considered the maximum load to be carried.
CONCENTRATION - (1) The weight of solids contained in a unit

weight of boiler or feed water. (2) The number of times that the dissolved solids have increased from the original amount in the feedwater to that in the boiler water due to evaporation in generating steam.
DESIGN PRESSURE - The pressure used in the design of a boiler for

the purpose of calculating the minimum permissible thickness or
physical characteristics of the different parts of the boiler.
DESIGN STEAM TEMPERATURE - The temperature of steam for
which a boiler is designed.
CONDENSATE Condensed water resulting from the removal of latent

heat from steam.
DEW POINT - The temperature at which condensation starts.
CONDUCTION - The transmission of heat through and by means of

matter unaccompanied by any obvious motion of the matter.
DISENGAGING SURFACE - The surface of the boiler water from

which steam is released.
CONDUCTIVITY - (1) A material property relating heat flux (heat

transferred per unit area per unit time) to a temperature difference. In
American units, it is typically defined as the amount of heat (Btu)
transmitted in one hour through one square foot of material 1 inch
thick, with a temperature difference of 1F between the two surfaces
of the material.
DISSOCIATION - The process by which a chemical compound breaks

down into simpler constituents, as do CO2 and H2O at high temperature.
DISSOLVED SOLID - Those solids in water which are in solution.
DISTILLATE FUELS - Liquid fuels distilled usually from crude petroleum.
(2) The property of a water sample to transmit electric current under

a set of standard conditions. Usually expressed as microhms conductance.
DISTILLATION - Vaporization of a substance with subsequent recovery of the vapor by condensation. Often used in less precise sense to
refer to vaporization of volatile constituents of a fuel without subsequent condensation.
CONTINUOUS BLOWDOWN - The uninterrupted removal of concentrated boiler water from a boiler to control total solids concentration in
the remaining water.
J-3
09-09
Glossary
EQUIVALENT EVAPORATION - Evaporation expressed in pounds of
water evaporated from a temperature of 212 F to dry saturated steam
at 212 F.
DISTILLED WATER - Water produced by vaporization and condensation with a resulting higher purity.
DOWNCOMER - A tube or pipe in a boiler or waterwall circulating
system through which fluid flows downward.
EVAPORATION - The change of state from a liquid to a vapor.
DOWNTIME - Amount of time a piece of equipment is not operational.
EVAPORATION RATE - The number of pounds of water that is evaporated in a unit of time.
DRAFT - The difference between atmospheric pressure and some

lower pressure existing in the furnace stack or gas passages of a
steam generating unit.
EXCESS AIR - Air supplied for combustion in excess of that theoretically required for complete oxidation.
EXPANSION JOINT - The joint to permit movement due to expansion
without undue stress.
DRAFT DIFFERENTIAL - The difference in static pressure between

two points in a system.
EXPLOSION DOOR - A door in a furnace or boiler setting that is

designed to be opened by a pre-determined gas pressure.
DRAFT GAUGE -A device for measuring draft, usually in inches of

water.
EXTERNAL TREATMENT - Treatment of boiler feed water prior to its

introduction into the boiler.
DRAIN - A valved connection at the lowest point for the removal of all
water from the pressure parts.
DRUM - A cylindrical shell closed at both ends designed to withstand

internal pressure.
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 in air, and such water vapor, being a gas, is dry.
FAN PERFORMANCE - A measure of fan operation in terms of volume, 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 ordinates and the range of volumes as abscissa, all at constant speed and air density.
DRY GAS - Gas containing no water vapor.

DRY-GAS LOSS - The loss representing the difference between the
heat content of the dry exhaust gases and their heat content at the
temperature of ambient air.
FEED PUMP - A pump that supplies water to a boiler.

FEEDWATER - Water introduced into a boiler during operation. It
includes make-up and return condensate.
DRY STEAM - Steam containing no moisture. Commercially dry

steam containing not more than one half of one percent moisture.
FEEDWATER TREATMENT - The treatment of boiler feed water by the

addition of chemicals to prevent the formation of scale or to eliminate
other objectionable characteristics.
DUCT - A passage for air or gas flow.
FGR - Flue Gas Recirculation or the recirculation of flue gas with combustion air to reduce NOx emissions.
ECONOMIZER - Utilizes waste heat by transferring heat from flue

gases to warm incoming feedwater.
FILTER - Porous material through which fluids or fluid - and solid mixtures are passed to separate matter held in suspension.
EDR - Equivalent direct radiation is the rate of heat transfer from a

radiator or convector. It is equivalent to the square feet of surface area
necessary to transfer heat at the same rate at which it is produced by
a generator. A single boiler horsepower equals 140 ft2 EDR.
FIN - A fin is an extended surface, a solid, experiencing energy transfer by conduction within its boundaries, as well as energy transfer with
its surroundings by convection and/or radiation, used to enhance heat
transfer by increasing surface area.
EFFICIENCY - The ratio of output to input. See also Combustion,

Fuel-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 and removing that particle onto a collecting electrode.
FIRING RATE CONTROL - A pressure temperature or flow controller

which controls the firing rate of a burner according to the deviation
from pressure or temperature set point. The system may be arranged
to operate the burner on-off, high-low or in proportion to load demand.
ENTRAINMENT - The conveying of particles of water or solids from

the boiler water by the steam.
FIXED CARBON - The carbonaceous residue less the ash remaining in

the test container after the volatile matter has been driven off in making the proximate analysis of a solid fuel.
EQUALIZER - Connections between parts of a boiler to equalize pressures.
J-4
09-09
FLAME - A luminous body of burning gas or vapor.
GAS BURNER - A burner that uses gas or fuel.
FLAME DETECTOR - A device which indicates if a fuel (liquid, gaseous, or pulverized) is burning, or if ignition has been lost. The indication may be transmitted to a signal or to a control system.
GAS PRESSURE REGULATOR - A spring loaded, dead weighted or

pressure balanced device which will maintain the gas pressure to the
burner supply line.
FLAME PROPAGATION RATE - Speed of travel of ignition through a

combustible mixture.
GAUGE COCK - A valve attached to a water column or drum for

checking water level.
FLAME SAFEGUARD - A control that sequences the burner through

several stages of operation to provide proper air purge, ignition, normal operation, and shutdown for safe operation.
GAUGE GLASS - The transparent part of a water gauge assembly connected directly or through a water column to the boiler, below and
above 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 region of pressure lower than the saturation pressure that corresponds to the water temperature
GRADE - Oil classification according to quality, generally based on

ASTM specifications.
GRAINS PER CU-FT - The term for expressing dust loading in weight
per unit of gas volume (7000 grains equals one pound).
FLASH POINT - The lowest temperature at which, under specified

conditions, 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 million - ppm).
FLUE - A passage for products of combustion.

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; weight index of gaseous fuels as specific gravity
related to air under specified conditions; or weight index of solid fuels
as specific gravity related to water under specified conditions.
FOAMING - The continuous formation of bubbles which have sufficiently high surface tension to remain as bubbles beyond the disengaging surface.
FORCED CIRCULATION - The circulation of water in a boiler by

mechanical means external to the boiler.
HANDHOLE - An access opening in a pressure part usually not

exceeding 6" in its longest dimension.
FORCED-DRAFT FAN - A fan supplying air under pressure to the fuel

burning equipment.
HANDHOLE COVER - A handhole closure.
FOULING - The accumulation of refuse in gas passages or on heat

absorbing surfaces which results in undesirable restriction to the flow
of gas or heat.
HARDNESS - A measure of the amount of calcium and magnesium

salts 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

amount which require an excessive amount of soap to form a lather.
FREE ASH - Ash which is not included in the fixed ash.

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,

output and losses.
FUEL-AIR RATIO - The ratio of the weight, or volume, of fuel to air.

FUEL OIL - A liquid fuel derived from petroleum or coal.
HEAT EXCHANGER - A vessel in which heat is transferred from one

medium to another.
FUEL-TO-STEAM EFFICIENCY - The ratio of heat added to boiler

feedwater to produce the output steam to the amount of energy inputted with fuel.
FURNACE - An enclosed space provided for the combustion of fuel.
HEAT RELEASE RATE - Rate that describes the heat available per
square foot of heat-absorbing surface in the furnace or per cubic foot
of volume.
FURNACE PRESSURE - Pressure occurring inside the combustion

chamber; positive if greater than atmospheric, negative if less than
atmospheric, and neutral if equal to atmospheric.
HEATING SURFACE - Those surfaces which are exposed to products

of combustion on one side and water on the other. This surface is
measured on the side receiving the heat.
FURNACE VOLUME - The cubic contents of the furnace or combustion chamber.
HEATING VALUE - The quantity of heat released by a fuel through

complete 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.
HIGH OIL TEMPERATURE CONTROL - A control to stop the burner if

the oil temperature is too high.
GAS ANALYSIS - The determination of the constituents of a gaseous

mixture.
HYDROCARBON - A chemical compound of hydrogen and carbon.
J-5
09-09
Glossary
HYDROSTATIC TEST - A strength and tightness test of a closed pressure vessel by water pressure.
LOAD FACTOR - The ratio of the average load in a given period to the
maximum load carried during that period.
LOW GAS PRESSURE CONTROL - A control to stop the burner if gas

pressure is too low.
IGNITION - The initiation of combustion.
LOW OIL TEMPERATURE CONTROL - (Cold Oil Switch) A control to

prevent burner operation if the temperature of the oil is too low.
IGNITION TEMPERATURE - Lowest temperature of a fuel at which

combustion becomes self-sustaining.
LOW WATER CUTOFF - Safety device that shuts off the boiler/burner
in the event of low water, preventing pressure vessel failure.
ILLUMINANTS - Light oil or coal compounds that readily burn with a

luminous flame, such as ethylene, propylene and benzene.
LUG - Any projection, like an ear, used for supporting or grasping.
INCOMPLETE COMBUSTION - The partial oxidation of the combustible constituents of a fuel.
INDUCED DRAFT FAN- A fan exhausting hot gases from the heat
absorbing equipment.
MAKE-UP - The water added to boiler feed to compensate for that lost
through exhaust, blowdown, leakage, etc.
INERT GASEOUS CONSTITUENTS - Incombustible gases such as

nitrogen which may be present in a fuel.
MANHOLE - The opening in a pressure vessel of sufficient size to permit a man to enter.
INHIBITOR - A substance which selectively retards a chemical action.

An example in boiler work is the use of an inhibitor, when using acid
to remove scale, to prevent the acid from attacking the boiler metal.
MANIFOLD - A pipe or header for collection of a fluid from, or the distribution of a fluid to a number of pipes or tubes.
INJECTOR - A device utilizing a steam jet to entrain and deliver feed

water into a boiler.
MANUAL GAS SHUTOFF VALVE - A manually operated valve in a gas

line for the purpose of completely turning on or shutting off the gas
supply.
INSULATION - A material of low thermal conductivity used to reduce

heat losses.
MANUFACTURED GAS - Fuel gas manufactured from coal, oil, etc.,

as differentiated from natural gas.
INTEGRAL BLOWER - A blower built as an integral part of a device to

supply air thereto.
MAXIMUM ALLOWABLE WORKING PRESSURE - The maximum

gauge pressure permissible in a completed boiler. The MAWP of the
completed boiler shall be less than or equal to the lowest design pressure determined for any of its parts. This pressure is based upon either
proof tests or calculations for every pressure part of the boiler using
nominal thickness exclusive of allowances for corrosion and thickness
required for loadings other than pressure. It is the basis for the pressure setting of the pressure relieving devices protecting the boiler.
INTEGRAL-BLOWER BURNER - A burner of which the blower is an

integral part.
INTERLOCK - A device to prove the physical state of a required condition, and to furnish that proof to the primary safety control circuit.
INTERMITTENT BLOWDOWN - the blowing down of boiler water at
intervals.
MAXIMUM CONTINUOUS LOAD - The maximum load which can be

maintained for a specified period.
INTERNAL TREATMENT - The treatment of boiler water by introducing chemicals directly into the boiler.
MAXIMUM INSTANTANEOUS DEMAND - The sudden load demand

on a boiler beyond which an unbalanced condition may be established
in the boiler's internal flow pattern and/or surface release conditions.
ION - A charged atom or radical which may be positive or negative.

IRI - Industrial Risk Insurers.
MECHANICAL ATOMIZING OIL BURNER - A burner which uses the

pressure of the oil for atomization.
L
LAGGING - A light gauge steel covering used over a boiler, usually
combined with insulation, to provide a low temperature outer surface.
MECHANICAL DRAFT - The negative pressure created by mechanical

means.
MICRON - One millionth of a meter, or 0.000039 in. or 1/25400 in.
The diameter of dust particles is often expressed in microns.
LEAKAGE - The uncontrolled quantity of fluid which enters or leaves

through the enclosure of air or gas passages.
LIBERATION - See Heat Release.
MINIATURE BOILER - Fire pressure vessels which do not exceed the

following limits:
LIMIT CONTROL - A switching device that completes or breaks an

electrical circuit at predetermined pressures or temperatures. Also
known as an interlock. See interlock.
16 in. inside diameter of shell; 42 in., overall length to outside of

heads at center; 20 sq ft water heating surface; or 100 psi maximum
allowable working pressure.
LINING - The material used on the furnace side of a furnace wall. It is

usually of high grade refractory tile or brick or plastic refractory material.
MMBtu - Millions of Btus (British Thermal Units).
LOAD - The rate of output required; also the weight carried.
MOISTURE IN STEAM - Particles of water carried in steam, expressed

as the percentage by weight.
J-6
09-09
MOISTURE - Water in the liquid or vapor phase.
MOISTURE LOSS - The boiler flue gas loss representing the difference
in the heat content of the moisture in the exit gases and that at the
temperature of the ambient air.
PARTICLE SIZE - A measure of dust size, expressed in microns or per

cent passing through a standard mesh screen.
PASS - A confined passageway, containing heating surface, through
which a fluid flows in essentially one direction.
MULTIFUEL BURNER - A burner by means of which more than one

fuel can be burned.
PERFECT COMBUSTION - The complete oxidation of all the combustible constituents of a fuel, utilizing all the oxygen supplied.
MULTIPORT BURNER - A burner having a number of nozzles from

which fuel and air are discharged.
PETROLEUM - Naturally occurring mineral oil consisting predominately of hydrocarbons.
pH - The hydrogen ion concentration of a water to denote Acidity or

Alkalinity. A pH of 7 is neutral. A pH above 7 denotes alkalinity while
one below 7 denotes acidity. This pH number is the negative exponent
of 10 representing hydrogen ion concentration in grams per liter. For
instance a pH of 7 represent 10-7 grams per liter.
NATURAL CIRCULATION - The circulation of water in a boiler caused

by differences in density.
NATURAL GAS - Gaseous fuel occurring in nature.
NET POSITIVE SUCTION HEAT (NPSH) - The liquid pressure that
exists at the suction end of a pump. If the NPSH is insufficient, the
pump can cavitate.
PILOT - (See also Ignitor.) A flame which is utilized to ignite the fuel
at the main burner or burners.
PITOT TUBE - An instrument which will register total pressure and
static pressure in a gas stream, used to determine its velocity.
NOx - Abbreviation for all of the family of oxides of nitrogen.

NOZZLE - a short flanged or welded neck connection on a drum or
shell for the outlet or inlet of fluids; also a projecting spout through
which a fluid flows.
PITTING - A concentrated attack by oxygen or other corrosive chemicals in a boiler, producing a localized depression in the metal surface.
PORT - An opening through which fluid passes.
POST PURGE - A method of scavenging the furnace and boiler passes

to remove all combustible gases after flame failure controls have
sensed pilot and main burner shutdown and safety shut-off valves are
closed.
OIL BURNER - A burner for firing oil.

OIL HEATING AND PUMPING SET - A group of apparatus consisting
of a heater for raising the temperature of the oil to produce the
desired viscosity, and a pump for delivering the oil at the desired pressure.
ppm - Abbreviation for parts per million. Used in chemical determinations as one part per million parts by weight.
OPERATING CONTROL - A control to start and stop the burner - must

be in addition to the high limit control.
PRECIPITATE - To separate materials from a solution by the formation

of insoluble matter by chemical reaction. The material which is
removed.
OPERATING PRESSURE - The pressure at which a boiler is operated.
PRECIPITATION - The removal of solid or liquid particles from a fluid.
ORGANIC MATTER - Compounds containing carbon often derived

from living organisms.
PREHEATED AIR - Air at a temperature exceeding that of the ambient

air.
ORIFICE - (1) The opening from the whirling chamber of a mechanical atomizer or the mixing chamber of a steam atomizer through
which the liquid fuel is discharged. (2) A calibrated opening in a
plate, inserted in a gas stream for measure velocity of flow.
PRESSURE - Force per unit of area.

PRESSURE DROP - The difference in pressure between two points in
a system, caused by resistance to flow.
ORSAT - a gas-analysis apparatus in which certain gaseous constituents are measured by absorption in separate chemical solution.
PRESSURE VESSEL - A closed vessel or container designed to confine

a fluid at a pressure above atmospheric.
OVERPRESSURE - Minimum operating pressure of a hot water boiler

sufficient to prevent the water from steaming.
PRIMARY AIR - Air introduced with the fuel at the burner.
OXIDATION - chemical combination with oxygen.
PRIMING - The discharge of steam containing excessive quantities of

water in suspension from a boiler, due to violent ebullition.
OXIDIZING ATMOSPHERE - An atmosphere which tends to promote

the oxidation of immersed materials.
PROCESS STEAM - Steam used for industrial purposes other than for
producing power.
OXYGEN ATTACK - Corrosion or pitting in a boiler caused by oxygen.
PRODUCTS OF COMBUSTION - The gases, vapors, and solids resulting form the combustion of fuel.
PULSATION - Rapid fluctuations in pressure.
PACKAGED BOILER - A boiler supplied with all of its components burner, controls and auxiliary equipment, designed as a single engineered package, and ready for on-site installation.
PURGE - To introduce air into the furnace and the boiler flue passages
in such volume and manner as to completely replace the air or gas-air
mixture contained therein.
PACKAGED STEAM GENERATOR - See Packaged Boiler.
J-7
09-09
Glossary
R
SAFETY VALVE - A spring loaded valve that automatically opens when

pressure attains the valve setting. Used to prevent excessive pressure
from building up in a boiler.
RADIATION LOSS - A comprehensive term used in a boiler-unit heat

balance to account for the conduction, radiation, and convection heat
losses from the boiler to the ambient air.
SAFETY SHUT-OFF VALVE - A manually opened, electrically latched,

electrically operated safety shut-off valve designed to automatically
shut off fuel when de-energized.
RATED CAPACITY - The manufacturers stated capacity rating for

mechanical equipment; for instance, the maximum continuous
capacity in pounds of steam per hour for which a boiler is designed.
SAMPLING - The removal of a portion of a material for examination or

analysis.
RATE OF BLOWDOWN - A rate normally expressed as a percentage of

the water fed.
SATURATED AIR - Air which contains the maximum amount of water

vapor that it can hold at its temperature and pressure.
RATING - See Load.

RAW WATER - Water supplied to the plant before any treatment.
SATURATED STEAM - Steam at the temperature and pressure at

which evaporation occurs.
REACTION - A chemical transformation or change brought about by

the interaction of two substances.
SATURATED TEMPERATURE - The temperature at which evaporation

occurs at a particular pressure.
REASSOCIATION - The recombination of the products of dissociation.
SATURATED WATER - Water at its boiling point.
RECIRCULATION - The reintroduction of part of the flowing fluid to

repeat the cycle of circulation.
SCALE - A hard coating or layer of materials on surfaces of boiler pressure parts.
REDUCING ATMOSPHERE - An atmosphere which tends to 1) promote the removal of oxygen from a chemical compound; 2) promote
the reduction of immersed materials.
SECONDARY AIR - Air for combustion supplied to the furnace to supplement the primary air.
SECONDARY TREATMENT - Treatment of boiler feed water or internal
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 which settles out at bottom of a liquid; a small percentage is
present in residual fuel oils.
REFRACTORY - Brickwork or castable used in boilers to protect metal

surfaces and for boiler baffles.
RELATIVE HUMIDITY - The ratio of the mass of water vapor present
in a unit volume of gas to the maximum possible mass of water vapor
in unit volume of the same gas at the same temperature and pressure.
SEGREGATION - The tendency of refuse of varying compositions to

deposit selectively in difference parts of the unit.
SELF-SUPPORTING STEEL STACK - A steel stack of sufficient
strength to require no lateral support.
RELIEF VALVE (Safety Relief Valve) - An automatic pressure relieving

device actuated by the pressure upstream of the valve and characterized by opening pop action with further increase in lift with an
increase in pressure over popping pressure.
SERVICE WATER - General purpose water which may or may not have
been treated for a special purpose.
RESIDUAL FUELS - Products remaining from crude petroleum by

removal of some of the water and an appreciable percentage of the
more volatile hydrocarbons.
SHELL - The cylindrical portion of a pressure vessel.

SLUDGE - A soft water-formed sedimentary deposit which normally
can be removed by blowing down.
RESIN - A bead-like material used in chemical exchange for softeners

and dealkalizers.
SLUG - A large dose of chemical treatment applied internally to a

steam boiler intermittently. Also used sometimes instead of priming
to denote a discharge of water out through a boiler steam outlet in relatively large intermittent amounts.
RESISTANCE - Impediment to gas flow, such as pressure drop or

draft loss through a dust collector. Usually measured in inches water
column (wc).
SMOKE - Small gas borne particles of carbon or soot, less than 1

micron in size, resulting from incomplete combustion of carbonaceous
materials and of sufficient number to be observable.
RETURN FLOW OIL BURNER - A mechanical atomizing oil burner in

which part of the oil supplied to the atomizer is withdrawn and
returned to storage or to the oil line supplying the atomizer.
SOFTENING - The act of reducing scale forming calcium and magnesium impurities from water.
RINGELMANN CHART - A series of four rectangular grids of black

lines of varying widths printed on a white background, and used as a
criterion of blackness for determining smoke density in stack gas
streams.
SOFT WATER - Water which contains little or no calcium or magnesium salts, or water from which scale forming impurities have been
removed or reduced.
ROTARY OIL BURNER - A burner in which atomization is accomplished by feeding oil to the inside of a rapidly rotating cup.
SOLUTION - A liquid, such as boiler water, containing dissolved substances.
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.
J-8
09-09
SPALLING - The breaking off of the surface of refractory material as a

result of internal stresses.
SURFACE BLOWOFF - Removal of water, foam, etc. from the surface

at the water level in a boiler. The equipment for such removal.
SPECIFIC HEAT - The quantity of heat, expressed in Btu, required to

raise the temperature of 1 lb of a substance 1oF.
SURGE - The sudden displacement or movement of water in a closed

vessel or drum.
SPECIFIC HUMIDITY - The weight of water vapor in a gas watervapor mixture per unit weight of dry gas.
SUSPENDED SOLIDS - Undissolved solids in boiler water.

SWINGING LOAD - A load that changes at relatively short intervals.
SPRAY ANGLE - The angle included between the sides of the cone
formed by liquid fuel discharged from mechanical, rotary atomizers
and by some forms of steam or air atomizers.
T
TERTIARY AIR - Air for combustion supplied to the furnace to supplement the primary and secondary air.
SPRAY NOZZLE - A nozzle from which a liquid fuel is discharged in

the form of a spray.
THEORETICAL AIR - The quantity of air required for perfect combustion.
STACK - A vertical conduit, which due to the difference in density

between internal and external gases, creates a draft at its base.
STACK DRAFT - The magnitude of the draft measured at the inlet to
the stack.
THEORETICAL DRAFT - The draft which would be available at the

base of a stack if there were no friction or acceleration losses in the
stack.
STACK EFFECT - That portion of a pressure differential resulting from

difference in elevation of the points of measurement.
THEORETICAL FLAME TEMPERATURE - See Adiabatic Flame 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 the boiler shell.
STANDARD AIR - Dry air weighing 0.075 lb per cu ft at sea level

(29.92" Barometric Pressure) and 70 oF.
THERMAL SHOCK - A cycle of temperature swings that result in failure of metal due to expansion and contraction.
STANDARD FLUE GAS - Gas weighing 0.078 lb per cu ft at sea level

(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

standard brick.
STEAM - The vapor phase of water, unmixed with other gases.

STEAM ATOMIZING OIL BURNER - A burner for firing oil which is
atomized by steam. It may be of the inside or outside mixing type.
TOTAL AIR - The total quantity of air supplied to the fuel and products
of combustion. Percent total air is the ratio of total air to theoretical
air, expressed as percent.
STEAM BINDING - A restriction in circulation due to a steam pocket

or 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 suspended impurities in a unit weight of boiler water, usually expressed
in ppm.
STEAM GENERATING UNIT - A unit to which water, fuel, and air are
supplied and in which steam is generated. It consists of a boiler furnace, and fuel burning equipment, and may include as component
parts water walls, superheater, reheater, economizer, air heater, or
any combination thereof.
TRAP - A receptacle for the collection of undesirable material.

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

steam.
TUBE HOLE - A hole in a drum, heater, or tube sheet to accommodate

a tube.
STRAINER - A device, such as a filter, to retain solid particles allowing a liquid to pass.
TURBULENT BURNER - A burner in which fuel and air are mixed and
discharged into the furnace in such a manner as to produce turbulent
flow from the burner.
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 of saturation. The temperature in excess of its saturation temperature is referred to as superheat.
ULTIMATE ANALYSIS - See Analysis Ultimate.

UL LISTED - Product certification that indicates the product meets
J-9
09-09
Glossary
safety standards determined by Underwriters Laboratories. (ULC and
cUL indicate Canadian requirements.)
WATER VAPOR - A synonym for steam, usually used to denote steam

of low absolute pressure.
UNACCOUNTED-FOR LOSS - That portion of a boiler heat balance

which represents the difference between 100 per cent and the sum of
the heat absorbed by the unit and all the classified losses expressed
as per cent.
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.
UNBURNED COMBUSTIBLE - The combustible portion of the fuel

which is not completely oxidized.
WET-BULB TEMPERATURE - The lowest temperature which a water

wetted body will attain when exposed to an air current. This is the
temperature of adiabatic saturation, and can be used to measure
humidity.
UNFIRED PRESSURE VESSEL - A vessel designed to withstand internal pressure, neither subjected to heat from products of combustion
nor an integral part of a fired pressure vessel system.
WETNESS - A term used to designate the percentage of water in

steam. Also used to describe the presence of a water film on heating
surface interiors.
USE FACTOR - The ratio of hours in operation to the total hours in

that period.
WET STEAM - Steam containing moisture.
VAPOR - The gaseous product of evaporation.
WINDBOX - A chamber below the grate or surrounding a burner,

through which air under pressure is supplied for combustion of the
fuel.
VAPORIZATION - The change from liquid or solid phase to the vapor

phase.
WINDBOX PRESSURE - The static pressure in the windbox of a

burner or stoker.
VA - Volt amperes.
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.
J-10
09-09

Boiler Book 2010

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Boiler Book 2010

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The Boiler Book

Produced by the Employees of

Cleaver-Brooks 2008, 2010

Printed in the U.S.A.

The Boiler Book is intended for use by qualified engineering

Commercial Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B

Industrial Watertube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C

System Fundamentals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section I

FEATURES AND BENEFITS

Integral front head provides proper burner/boiler compatibility for maximum

Accurate, repeatable combustion control for responsiveness to load swings.

Guaranteed efficiency (Promethean) at 25, 50, 75 and 100% firing rate.

Low Excess Air:

Operates at 3% O2 with less than 200 ppm CO for maximum combustion

Reduced fuel and operating costs.

High efficiency and low maintenance requirements.

The Promethean Boiler Model CB-LE 125-800 HP is also a firetube

MODEL NUMBER, FUEL SERIES NUMBER, HORSEPOWER, AND DESIGN PRESSURE

Air Damper Type

UL & cUL Boiler/

Rotary & Louvers

Steam Trim Aux

60-80 hp1 Phase

Front Head with

LD, FV, LW, FF

Gas Burner Type

LD, FV, LW, FF

LD, FV, LW, FF

Front Head with

LD, FV, LW, FF

LD, FV, LW,

LD, FV, LW, FF

LD, FV, LW, FF

Control Circuit &

Control Circuit &

Control Circuit &

Control Circuit &

Control Circuit &

Main Oil Valves

No. 2 Oil 60200 hp Burner

Oil Burner Type

High & Low Gas

Main Gas Valve

Promethean Series Model CB-LE

Promethean Series Model CB-LE

Table A1-16. Predicted Fuel-to-Steam Efficiencies - No. 2 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-27

Promethean Series Model CB-LE

FEATURES AND BENEFITS

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.

True Boiler/Burner/Low NOx Package.

Assures highest fuel-to-steam efficiency.

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.

Model CB Firetube Boiler.

New integral front head with internal low NOx system.

Enhanced burner design.

For option details, contact your local Cleaver-Brooks authorized representative.

Full line of Model CB Firetube options.

Additional NOx reduction packages.