This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
T iny T otsfor you
WAR NING !
R ick Marino is hazardous to your health
B ut, he has managed to hireexceptional employees .
Unfortunately, they continueto write crazy unnecessary
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 guar-anteed emission performance levels.
A1-303-08
Promethean Series Model CB-LE Firetube Boilers
A1-4
03-08
FEATURES AND BENEFITSThe 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 boilerhorsepower, and maximum boiler efficiency. In addition to the features of the ModelCB 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.
NOTES: All connections are threaded unless indicated:A. ANSI 150 psig flange.
BOILER HP DIM 400 500 600 700 750 800
Table A1-8. Model CB-LE Hot Water Boiler Dimensions, 96” (30 and 125 psig Design Pressure) - Sheet 2 of 2
A1-17
03-08
Promethean Series Model CB-LE Firetube Boilers
Table A1-9. Model CB-LE Combustion Air Fan Motor Horsepower Requirements - Operating Pressures 150
psig and Less, and All Hot Water Boilers
A1-18
BOILER HP
MOTOR HP
60 PPM
30 PPM
25 PPM
20 PPM
125 5 10 5 10
150 7.5 10 10 10
200 15 15 20 NA
250 7.5 10 15 15
300 10 15 20 25
350 15 25 40 40
400 10 15 20 20
500 15 20 25 30
600 25 30 50 60
700 30 50 75 75
750 50 60 75 NA
800 50 75 NA NA
NOTES: For elevations above 700’ - contact your local Cleaver-Brooks authorized representative.
06-11-07
Table A1-10. Model CB-LE Combustion Air Fan Motor Horsepower Requirements - Operating
Pressures Greater than 150 psig (Steam Boilers)
03-08
BOILER HP
MOTOR HP
60 PPM
30 PPM
25 PPM
20 PPM
125 5 10 10 10
150 10 10 10 15
200 15 20 20 NA
250 7.5 10 15 20
300 10 20 30 40
350 20 30 40 50
400 10 15 20 25
500 20 25 30 40
600 25 40 60 60
700 40 60 75B 75C
750 50 75 NA NA
800 60 75A NA NA
NOTES: For elevation above 700’ - contact your local Cleaver-Brooks authorized representative.A. Downrate to 770 hp.B. Downrate to 675 hp.C. Downrate to 660 hp.
Firetube Boilers Promethean Series Model CB-LE
Table A1-11. Model CB-LE Boiler Weights
A1-19
03-08
BOILER HP FUELSERIES
HOT WATER STEAM
30 PSIG 125 PSIG 15 PSIG 150 PSIG 200 PSIG
125
100 11200 11600 11300 12000 12600
200 11400 11800 11500 12400 13000
700 11300 11700 11400 12300 12900
150
100 12300 12700 12400 13200 13900
200 12500 12900 12600 13500 14200
700 12300 12700 12400 13300 14000
200
100 14400 14800 14500 15500 16300
200 14500 14900 14600 15600 16400
700 14500 14900 14600 15600 16400
250
100 20700 21500 20800 22000 23800
200 21400 22200 21500 22800 24600
700 20900 21700 21000 22500 24300
300
100 23100 23900 23200 24800 26800
200 23500 24300 23600 25200 27200
700 23400 24200 23500 25000 27000
350
100 26200 27000 26300 27600 29100
200 26700 27500 26800 27800 29300
700 26400 27200 26500 27700 29200
400
100 33000 36970 33200 36270 39380
200 33300 37270 33500 36570 39680
700 33200 37170 33400 36470 39580
500
100 36600 40470 36810 39670 43480
200 36900 40780 37110 39970 43580
700 36800 40680 37010 39870 43280
600
100 41850 45905 42000 44725 49100
200 42150 46005 42300 45025 49400
700 42050 45915 42200 44925 49300
700800
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 weightwill be determined at time of shipment. Shipment will then be made on shippers weight and count. All weights are in US pounds.
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
03-08
Promethean Series Model CB-LE Firetube Boilers
A
BOILER HP A B C D E F G
400 6 14 134 50 78 6-1/2 58-7/8
500 6 14 155 50 78 6-1/2 58-7/8
600 6 14 187 50 78 6-1/2 58-7/8
700-750-800 6 14 220 50 78 6-1/2 58-7/8
NOTE: 1. All numbers in table are in inches.2. 6-inch high mounting piers recommended for use beneath the boiler base frame. The use of these piers provides in-
creased inspection accessibility to the piping beneath the boiler and added height for washing down the area beneaththe boiler.
Figure A1-9. Model CB-LE Boiler Mounting Piers (96”)
1-22
03-08
Firetube Boilers Promethean Series Model CB-LE
NEAR
SIDE
VIEW B
FAR
SIDE
FRONT
FLANGE
VIEW A
E DIA. HOLE
A
CL
B
DD
C
BOILER HP
VIEW
ALL DIMENSIONS IN INCHES
A B C D E
125 All B 80-1/4 29-3/4 70-1/2 10 3
150 All B 80-1/4 29-3/4 83-1/2 10 3
200 All B 80-1/4 29-3/4 114-1/2 10 3
250Steam B 99 36 72 10 3
Hot Water B 99 36 81 10 3
300Steam B 99 36 99 10 3
Hot Water B 99 36 108 10 3
350Steam B 99 36 129 10 3
Hot Water B 99 36 138 10 3
400Steam B 119 35-3/4 78 11 3
Hot Water B 119 35-3/4 78 11 3
500Steam B 119 35-3/4 99 11 3
Hot Water B 119 35-3/4 99 11 3
600Steam B 119 35-3/4 131 11 3
Hot Water B 119 35-3/4 131 11 3
700, 750 & 800
Steam B 119 35-3/4 164 11 3
Hot Water B 119 35-3/4 164 11 3
NOTE: A, B and C dimensions may vary by 1/2 inch.
Figure A1-10. Lifting Lug Location, Model CB-LE Boilers
A1-23
03-08
Promethean Series Model CB-LE Firetube Boilers
PERFORMANCE DATAThe Low Emission Option provides NOx reduction at current published andpredicted fuel-to-steam efficiencies.
Specifying Boiler Efficiency
Cleaver-Brooks offers an industry leading fuel-to-steam boiler efficiency guaranteefor Model CB-LE Firetube Boilers. The guarantee is based on the fuel-to-steamefficiencies shown in the efficiency tables and the following conditions. Theefficiency percent number is only meaningful if the specific conditions of theefficiency calculations are clearly stated in the specification (see Cleaver-Brookspublication CB-7768 for a detailed description of efficiency calculations).
When specifying the efficiencies in the tables, be sure to include the specificguarantee conditions to maximize the effectiveness of your efficiency specification. Ifyou have any questions regarding the efficiency specifications, please contact yourlocal Cleaver-Brooks authorized representative.
Efficiency Specification
The boiler manufacturer shall guarantee that, at the time of startup, the boiler willachieve fuel-to-steam efficiency (as shown in Table A1-14 and Table A1-15) at100% firing rate (add efficiency guarantees at 25%, 50%, and 75% of rating, ifrequired). If the boiler(s) fail to achieve the corresponding guaranteed efficiency aspublished, the boiler manufacturer will rebate, to the ultimate boiler owner, fivethousand dollars ($5,000) for every full efficiency point (1.0%) that the actualefficiency is below the guaranteed level.
The specified boiler efficiency is based on the following conditions.
1. Fuel specification used to determine boiler efficiency:
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 manufacturer’s 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, followthese procedures:
A1-24
03-08
Firetube Boilers Promethean Series Model CB-LE
When the operating steam pressure is between 10 psig and 125 psig, interpolatethe values from the efficiency tables.
When the operating steam pressure is above 125 psig, estimated efficiency can becalculated as follows:
Example:
Boiler: 350 hp.
Fuel: natural gas.
Operating steam pressure: 200 psig.
Find the fuel-to-steam efficiency at 100% firing rate. FromTable A1-14 for a 350 hpboiler 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 higheroperating pressure. To estimate boiler efficiency, use this rule of thumb: For every40 °F increase in stack temperature, efficiency decreases by 1%. Since the stacktemperature rise is 36 °F, the decrease in the boiler efficiency at 200 psig operatingpressure is calculated as follows: 36/40 =.9%. Therefore, the boiler efficiency at200 psig operating pressure is 82.5 -.9 = 81.6%
Emissions The emission data included in this section consists of typical emission levels forModel CB boilers equipped with 60, 30, 25, and 20 ppm LE Options when firingnatural gas and No. 2 oil.
NoticeThe data in Table A1-16 and Table A1-17 represent typical emission levels only.Guaranteed emission levels are available from your local Cleaver-Brooks authorizedrepresentative.
A1-25
03-08
Promethean Series Model CB-LE Firetube Boilers
Table A1-14. Predicted Fuel-to-Steam Efficiencies - Natural Gas
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.
60 ppm LE Option 30, 25, 20 ppm LE Option 15 ppm 9 ppm
CO ppmA
lb/MMBtu50
0.03950
0.03950
0.03950
0.039
NOx ppmA
lb/MMBtu140
0.18690
0.12085
0.11370
0.093
SOx ppmA
lb/MMBtu2780.52
2780.52
2780.52
2780.52
HC/VOCs ppmA
lb/MMBtu4
0.0024
0.0024
0.0024
0.002
PM ppmA
lb/MMBtu-
0.025-
0.025-
0.025-
0.025
A. ppm levels are given on a dry volume basis and corrected to 3% oxygen (15% excess air).BASED ON THE FOLLOWING CONSTITUENT LEVELS:
Fuel-bound Nitrogen content = 0.015% by weight.Sulfur content = 0.5% by weight.Ash content = 0.01% by weight.
A1-27
03-08BBA1_02-08
Promethean Series Model CB-LE Firetube Boilers
ENGINEERING DATA Sound Level Table A1-18 gives a summary of predicted sound pressure levels for Model CB
boilers with 30 ppm LE Options. Contact your local Cleaver-Brooks authorizedrepresentative for sound levels or other LE Options.
Units
The units for the sound level tables are dbA (decibels, measured on the A-weightedscale) in reference to 0.0002 microbars (20 micro-Newtons per square meter).Their reference are standardly used in specifying and reporting sound pressure levelson industrial equipment.
Test Method
The sound pressure levels in the above tables were obtained from tests inaccordance with the “ABMA Test Code for the Measurement of Sound fromPackaged Boilers.” In accordance with this code the sound pressure levels reportedwere measured on the boiler centerline 4-1/2 feet vertically above the bottom of thebase rails and 3 feet horizontally in front of the end of the blower motor or frontsurface of the electrical cabinet.
Sound Level Meter
The sound level meter used complies with ANSI S1.4, Type 1 (Precision). Thereadings are taken with the meter set for slow response and corrected forbackground levels.
Sound Pressure
The large size boilers, the need for auxiliary equipment, and the necessaryinterconnecting piping make it impractical (and sometimes impossible) to provide aboiler testing environment which is suitable for taking the data needed to developSound 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 thesame boiler. And finally, no two boilers can be expected to give precisely the samesound levels. For these reasons, we can only predict, but not guarantee, soundlevels (dbA).
NOTES1. Sound pressure levels measured on boilers operating in various locations and ex-pressed in dbA are as shown:2. Based on standard altitude fans and fan motors, 60 Hz.3. Contact your local Cleaver-Brooks authorized representative for sound levels of 60, 25,or 20 ppm LE Options.
ABBREVIATIONS: HF = High Fire LF = Low Fire O = Oil G = Gas
Firetube Boilers Promethean Series Model CB-LE
Gas-Fired Burners Table A1-19 shows gas pressure with standard, over- and undersized gas trains.
Table A1-20 shows recommended NTI gas train sizes and pressure ranges.
Table A1-21 shows minimum required gas pressure altitude conversion.
Figure A1-12 shows standard gas train sizes and locations for Model CB FiretubeBoilers.
Figure A1-13 shows typical gas train piping layouts for multiple boiler applications.
Figure A1-14 shows standard gas train components.
A1-29
03-08
Promethean Series Model CB-LE Firetube Boilers
A1-30
03-08
Table A1-19. Standard, Undersize, and Oversize Gas Trains
CBLE 20 PPM CBLE 30 PPM CBLE 60 PPM
Boiler HPGas Train Pressure Gas Train Pressure Gas Train Pressure Size, in PSI Size, in PSI Size, in PSI
NA NA 3 4.6 - 6.9 3 4.6 - 6.94 3.2 - 4.6 4 3.2 - 4.6
8002.5-3 7.2 - 10.0 2.5-3 7.1 - 10.0
NA NA 3 5.0 - 7.2 3 4.9 - 7.14 3.7 - 5.0 4 3.6 - 4.9
Note: Some units list two diameters because the gas train increases in size after the regulating valve. The first number is the customer connection size.
UNDERSIZESTANDARDOVERSIZE
Table is based on Siemens gas train, which includes aregulating actuator.
Firetube Boilers Promethean Series Model CB-LE
Naf
Ta
Table A1-20. Recommended NTI Gas Train Sizes and Pressure Ranges
A1-31
03-08
LE 15 PPM LE 9 PPM
Boiler HPGas Train Pressure Range Gas Train Pressure RangeSize, in PSI Size, in PSI
ote: Some units list two diameters because the gas train increases in size ter the regulating valve. The first number is the customer connection size.
UNDERSIZE
STANDARDOVERSIZE
ble is based on Siemens gas train, which includes a regulating actuator.
Promethean Series Model CB-LE Firetube Boilers
Table A1-21. Minimum Required Regulated Gas Pressure Altitude Conversion
A1-32
0
BOILER
FRONT
ALTITUDE (FT)
CORRECTION FACTOR
ALTITUDE (FT)
CORRECTION FACTOR
1000 1.04 6000 1.25
2000 1.07 7000 1.30
3000 1.11 8000 1.35
4000 1.16 9000 1.40
5000 1.21 - -
To obtain minimum required gas pressure at altitudes above 700 feet, multiply the pressure by the listed factors: Inches WC x 0.577 = oz/sq-in. Oz/sq-in x 1.732 = Inches WCInches 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.
BOILERHP
MODEL CB
CONNECTION SIZE
(IN. NPT)
LOCATION DIMENSION
“A” (IN.)
125-200 1-1/2 52
250-350 2 56
400 2 58
500 2-1/2 60
600 2-1/2 - 3 71
700-800 3 65
Table A1-22. Maximum Gas Consumption (CFH) for Natural Gas and Propane Vapor
A
PLAN VIEW
BOILER HP
TYPE OF GAS AND HEAT CONTENT
NATURAL GAS1000 (Btu/cu-ft)
PROPANE GAS2550 (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
Figure A1-12. Standard Gas Train Connection Size and Location
3-08
Firetube Boilers Promethean Series Model CB-LE
Oil-Fired Burners Fuel oil consumption information is shown on the boiler rating sheets in theDimensions and Rating Section.
Figure A1-15 shows the oil connection sizes and locations for Model CB Boilersfiring 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 pumpand the boiler oil pump.
General Boiler Information
Table A1-23 shows blowdown tank sizing information.
Table A1-24 provides heating surface information.
Table A1-25 provides steam volume and disengaging area information
All standard Cleaver-Brooks Firetube Boilers with an LE option can support up to2,000 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 boilerflue 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. Theallowable 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 providedby a reputable stack supplier who will design the stack and breeching system basedon the above criteria. Your local Cleaver-Brooks authorized representative is capableof 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, andvelocity 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, preferablybelow 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 shouldnot be covered with fine mesh wire, as this type of covering has poor air flowqualities 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 slightvacuum under certain conditions and cause variations in the quantity ofcombustion air. This can result in unsatisfactory burner performance.
A1-33
03-08
Promethean Series Model CB-LE Firetube Boilers
D. Under no condition should the total area of the air supply openings be lessthan (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/bhpC. 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 hpboiler 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).
NoticeConsult local codes, which may supersede these requirements.
A1-34
03-08
Firetube Boilers Promethean Series Model CB-LE
MODELCB-LE
BOILERSPLUGCOCK
A
B
C
DCONTRACTORCONNECTION
POINT
GAS TRAINON BOILER
STREET GAS MAIN
MODELCB-LE
BOILERS
This figure illustrates the basic gas valve arrangement on Cleaver-Brooks Model CB boiler and shows the contractor's connection point. The valves and controls between the contractor connection point and the gas main in the street are representative of a typical installation. Actual requirements may vary depending on local codes or local gas company requirements which should be investigated prior to preparation of specifications and prior to con-struction.
A. Utilities service valve.B. Utilities service regulator.C. Gas meter.D. Piping from meter to boiler.
The size of the gas line from the meter to the gas pressure regulator at the boiler can be very important if gas pressures are marginal. The gas line sizing is dependent on:
1. Gas pressure at outlet of gas meter (C)2. Rate of gas flow required, CFH3. Length of pipe run (D)4. Pressure required at contractor connection point.
The local gas utility will advise the pressure that is available at the outlet of their meter.
Figure A1-13. Typical Gas Piping Layout
A1-35
03-08
Promethean Series Model CB-LE Firetube Boilers
5
6
S
1
3
42
PILOT GAS LINE
S
S
MAIN GAS LINE
M M
ToBurner
GasSupply
11
10
97
12138
14 15
FLOW
FLOW
CSD-1 NFPA-85125 hp - 300 hp
350 hp - 800 hp
125 hp - 300 hp
350 hp - 800 hp
125 hp - 300 hp
350 hp - 800 hp
1 Pilot Shut Off Cock X X X X X X2 Pilot Pressure Regulator X X X X X X3 Pilot Pressure Gauge X X X X X X4 Gas Pilot Valve X X X X X X5 Pilot Vent Valve X6 Gas Pilot Valve X7 Manual Shut Off Valve X X X X X X8 Low Gas Pressure Switch X X X X X X9 Main Gas Valve w/o POC X X X X
10 Main Gas Valve w/ POC X X11 Vent Valve or Valve Proving Switch X X X12 Regulating Gas Valve w/ POC X X X X X X13 High Gas Pressure Switch X X X X X X14 Manual Shut Off Valve X X X X X X15 Butterfly Valve X X X X X X
UL FMITEM DESCRIPTION
Figure A1-14. Model CB-LE Gas Train Components
A1
BOILER BASE FRAME
RIGHT HAND SIDE VIEW
BOILERFRONT
A
CONTRACTORCONNECTIONS
BOILERHP
MODEL CB
SUPPLYAND RE-
TURN CONN SIZES
(IN.) (NPT)
A(IN.)
RECOMMENDED OIL LINEA
SIZES (STANDARD PIPE)
(IN. - IPS)
STOR-AGE
TANK TO BOILER
OR PUMP CONNECT
PUMP TO
BOILER
RE-TURN
LINE TO TANK
125 150 200
3/4 12-1/2 1 1 1
250 300350
3/4 34 1 1 1
400 500600
3/4 11-3/4 1 1 1
700750800
1 11-3/4 1 1 1
NOTE: See No. 2 Oil Line Sizing Instruction for systems with otherconditions.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
Altitude: 700 ft and less - Design Pressure: 150 psi and less
* 800 HP - to be de-rated to 720 HP for 9 ppm and to 750 HP for
mpp9mpp51NominalBoiler Size Blower Motor HP Blower Motor HP
Boiler HP
ERATING ESSURE PSIG
125 150 200 250 300 350 400 500 600 700 750 800
15 8 8 10 10 12 12 12 12 12 12 12 12
30 6 6 8 8 8 10 10 10 12 12 12 12
40 6 6 6 8 8 8 10 10 10 12 12 12
50 6 6 6 6 8 8 8 10 10 10 12 12
75 4 4 6 6 6 8 8 8 8 10 10 10
100 4 4 6 6 6 6 6 8 8 8 8 10
125 4 4 4 6 6 6 6 8 8 8 8 8
150 3 3 4 4 6 6 6 6 6 8 8 8
200 2.5 3 4 4 4 4 6 6 6 6 6 6
250 2.5 3 3 4 4 4 4 6 6 6 6 6
ES: eam nozzle sizes given in inches.ecommended steam nozzle sizes based on 4000 to 5000 fpm steam velocity. l standard steam nozzle sizes for 150 psig design pressure or greater are the sam25 psig operating pressure on the above table. To increase or decrease the standar, request the change with your local Cleaver-Brooks authorized representative.haded area denotes special surge load baffles must be installed to avoid possibr carry-over.r incremental operating pressures, see Table I3-1 Steam Systems Fundamentals
Table A1-27. Recommended Non-Return Valve Size
100 3450 2-1/2 2-1/2 NA NA NA NA NA NA
125 4313 3 2-1/2 2-1/2 2-1/2 NA NA NA NA
150 5175 3 3 2-1/2 2-1/2 2-1/2 2-1/2 NA NA
200 6900 3* 3 3 3 3 2-1/2 2-1/2 2-1/2
250 8625 4 3* 3 3 3 3 3 3
300 10350 4 4 4 3* 3 3 3 3
350 12025 4 4 4 4 4 3* 3 3
400 13800 5 4 4 4 4 4 4 3*
500 17210 6 5 5 4 4 4 4 4
600 20700 6 6 5 5 5 4 4 4
700 24150 6 6 6 5 5 5 5 4
800 27600 6 6 6 6 6 5 5 5
NOTE: Valve sizes (300 # Flanges) given in inches.Standard Non-Return valve selections limited to a maximum 2 to 1 turndown(50% of full load); selections based on typical non-return valve sizing recommen-dations. For final valve selection contact your C-B authorized representative. Forhigh 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
ed
le
.
6 psig pressure drop.
Table A1-28. Blower Motor Selection CB-LE NTI Boilers
03-08
15 ppm.
Firetube Boilers Promethean Series Model CB-LE
FRONT
FEEDWATERTANK
BOILERFEEDWATER
PUMP
DRAIN
TRENCH
1. Shortest boiler room length (Dwg A) is obtained by allowing for possible future tube replacement (from front or rearof 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 workingspace.2. Next shortest boiler room length (Dwg B) is obtained by allowing for possible future tube replacement from thefront 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 workingspace.3. A slightly longer boiler room (Dwg C) is obtained by allowing for possible future tube replacement from the rear ofthe boiler. Allowance for door swing at the front provides sufficient aisle and working space at the front.
d Minimum Distance Between Boiler and Wall. Dimen-” allows for a “clear” 42" aisle between the water col-
n the boiler and the wall. If space permits, this aisle be widened.ed Minimum Distance Between Boilers.sion “B” between boilers allows for a “clear” aisle of:25 -200 hp50-350 hp00-800 hpe permits, this aisle should be widened.
Figure A1-22. Boiler Room Width (Typical Layout)
A1-41
03-08
Promethean Series Model CB-LE Firetube Boilers
A1-42
STACK
DRAINCONNECTION
CLEAN-OUT
MANUALDAMPER
LOCK (OPEN)
TIGHT SEALCLEANOUT
STACK
DRAINCONNECTION
CLEAN-OUT
MANUALDAMPER
LOCK (OPEN)
TIGHT SEALCLEANOUT
STACK
DRAINCONNECTION
CLEAN-OUT
MANUALDAMPER
LOCK (OPEN)
TIGHT SEALCLEANOUT
MAXIMUM 10°CONE ANGLE
MAXIMUM 10° CONE ANGLEEVEN WITH LIMITED SPACE
DETAIL OF TRANSITION PIECES
NOTE: These stack breeching arrangements for multiple boilers are generic and not intended for your specific design requirements. For additional information, review Section F, Stacks.
Stack and breeching sizes should always be provided by a reputable stack supplier who will design the stack and breeching system based on your specific criteria. Your local Cleaver-Brooks authorized representative is capa-ble of assisting in your evaluation of stack and breeching design.
Model CB-LE Steam Boiler Specifications Section A1
Model CB-LE Steam Boiler Specifications
(125-800 hp, Steam 15-300 psig)
PART 1 GENERALThe 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 DesignA. 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
NoticeThe 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.
A1-445-08
Section A1 Model CB-LE Steam Boiler Specifications
F. Front and rear tube sheets and all flues must be fully accessible for inspection and cleaning when the doors are swung open. The boiler shall be furnished with adequate handholes to facilitate boiler inspection and cleaning.
G. For boilers 125 horsepower and over, a manhole shall be provided.H. The exhaust gas vent shall be located near the front of the boiler on the top center
line and shall be capable of supporting:1. 15-100 hp. 1000 lbs and shall contain a stack thermometer2. 125-800 hp. 2000 lbs and shall contain a stack thermometer
I. The boiler shell shall contain a chemical feed connection.J. Observation ports for the inspection of flame conditions shall be provided at each end
of the boiler.K. The boiler insulation shall consist of a 2 inch blanket under a sectional preformed
sheet metal lagging. This insulation must be readily removable and capable of being reinstalled, if required.
L. The entire boiler base frame and other components shall be factory painted before shipment using a hard finish enamel coating.
2.2 Steam Boiler TrimA. Water Column
A water column shall be located on the right hand side of the boiler complete with gauge glass set and water column blowdown valves.1. Feedwater Pump Control
The boiler feedwater pump control shall be included as an integral part of the water column to automatically actuate a motor driven feed water pump maintaining the boiler water level within normal limits.
2. WATER COLUMN/LOW WATER CUTOFF AND WATER LEVEL CONTROL SYSTEM(150-250 psig design): Shall be a CB LEVEL MASTER Water level control system and shall be comprised of a microprocessor-based electronic controller, a non-contact, non-wearing, continuously reading absolute level sensor and pressure chamber. The control system shall be designed as follows: The electronic controller shall be mounted in the common control panel (see 2.4 below) and operate in ambient temperatures from 32 degrees F to 125 degrees F. The pressure chamber shall be boiler mounted and operate to pressures of 250 PSIG and the level sensor shall operate to pressures of 250 PSIG and temperatures to 400 degrees F. The pressure-containing components shall be constructed in accordance with ASME Code. A shielded, four conductor cable with ground shall be run in metal conduit between the level sensor and the controller. Supply power shall be 115VAC-1 phase- 60 Hz. All wiring shall be in compliance with the National Electrical Code.
The pressure chamber shall have a sight glass mounted on the side. The level sensor shall have an accuracy of .01" or greater. The electronic controller shall have level and error indicating lights, alphanumeric display for messaging, reset/menu switch and the following features:
a. Continuous Level Indicationb. Low Water Cutoff & Alarmc. High Water Alarmd. Low & High Water Warning
A1-455-08
Model CB-LE Steam Boiler Specifications Section A1
e. Full Modulating Control of Modulating Feedwater Control Valvef. Continuous Monitoring of Float Operationg. Column Blowdown Detection and Reminderh. Auto or Manual Reseti. Real Time Clockj. Alarm Annunciationk. Alarm History Files with Time Stampl. Water Column Blowdown Recordm. Auxiliary Low Water Cutoff Checkn. RS 232 Interfaceo. Maximum Contacts Rating 15 amps Resistive Load
3. Low Water Cutoff (15 psig design)The low water cutoff shall be included as an integral part of the boiler feedwater control wired into the burner control circuit to prevent burner operation if the boiler water level falls below a safe level.
B. Auxiliary Low Water CutoffAuxiliary low water cutoff manual reset shall be included, piped to the vessel, and wired to the burner control circuit. A manual reset device shall be used on this control.
C. Steam Pressure GaugeThe steam pressure gauge shall be located at the front of the boiler and include cock and test connection.
D. Safety ValvesSafety valves of a type and size to comply with ASME Code requirements shall be shipped loose.
E. Steam Pressure ControlsThe steam pressure controls to regulate burner operation shall be mounted near the water column. Controls shall be a high limit (manual reset), operating limit (auto reset), and firing rate control (30-800 hp).
2.3 Burner and ControlsA. Mode of Operation
Burner operation shall be full modulation principle. The burner shall always return to low fire position for ignition.
B. Blower1. 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).
A1-465-08
Section A1 Model CB-LE Steam Boiler Specifications
D. Fuel Specification and PipingSelect one of the following fuel types:
Fuel series 700 - Gas fired (4.4.1).Fuel series 100 - Light oil (No. 2) fired (4.4.2).Fuel series 200 - Light oil or gas fired (4.4.3).
1. Fuel Series 700 - Gas Fired a. Burner Type - The burner shall be integral with the front head of the boiler
and of high radiant multi-port type for gas. The burner shall be approved for operation on natural gas fuel and equipped with an LE option.
b. Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot flame has been established. The pilot train shall include two manual shut-off valves, solenoid valve, pressure regulator and pressure gauge.
c. Gas Burner Piping - Gas burner piping on all units shall include pressure regulating gas shutoff valve, motor operated with proof of closure switch and plugged leakage test connection. The main gas valve(s) shall be wired to close automatically in the event of power failure, flame failure, low water or any safety shutdown condition. A lubricating plug cock or butterfly shutoff valve shall be provided as a means for a tightness check of the primary shut off valve. An additional plug cock on butterfly valve shall be furnished at entrance to gas train. Select one of the following:1) 125-300 hp. High and low gas pressure switches shall be provided.
A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided.
2) 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.
d. Burner Turndown - Select one of the following:1) 125-200 hp. Turndown range of burner shall be 4:1 when firing
natural gas.2) 250-800 hp. Turndown range of the burner shall be 10:1 when firing
natural gas with a 60 or 30 ppm LE option. (Consult with Cleaver-Brooks Representative regarding high turndown capability based on available gas pressure and 25 and 20 ppm LE options.)
2. Fuel Series 100 - Light Oil Fireda. 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 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.
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.
A1-475-08
Model CB-LE Steam Boiler Specifications Section A1
d. Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid shutoff valves, pressure gauges and fuel strainer, all integrally mounted on the unit. A fuel oil controller shall be provided to combine all of the fuel oil controls into a single casting which is mounted on the front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. A low oil pressure switch shall be included in the oil piping.
e. Low Pressure Air AtomizingSeparate air compressor module mounted on boiler base rail with low atomizing air pressure switch.
f. Burner Turndown.Select one of the following:1) A. 125 hp through 200 hp. Turndown range shall be 4:1 when firing
No. 2 oil.2) B. 250 hp through 800 hp Turndown range shall be 8:1 when firing
No. 2 oil. (Consult your local Cleaver-Brooks authorized representative regarding No. 2 oil turndown capabilities when utilizing LE Options to achieve NOx levels of 25 or 20 ppm when firing natural gas.)
3. Fuel Series 200 - Light Oil or Gas Fireda. 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.
b. 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.
c. Oil Burner1) 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.
A1-485-08
Section A1 Model CB-LE Steam Boiler Specifications
d. Gas BurnerGas Burner Piping - gas burner piping on all units shall include pressure regulatinggas 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: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.
2) 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:1) 125-200 hp. Turndown range of the burner shall be 4:1.2) 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.)
2.4 Boiler Controls and Control PanelA. Control/Entrance Panel
A common enclosure shall house the control panel and the entrance panel. Enclosure shall be NEMA 4 rated and shall be mounted at the side of the boiler in a location convenient to the operator. Enclosure shall consist of upper and lower sections divided by a partition with a separate hinged door for each section. Upper section (low voltage) will house boiler controls including flame safeguard, water level system controller, and Hawk ICS if so equipped. Lower panel section (high voltage) will house entrance panel.
B. CB780E Flame Safeguard 1. Boilers with CB780E Control - Each boiler shall be factory equipped with flame
safeguard controller providing technology and functions equal to the Cleaver-Brooks Model CB780E.Controller shall be computerized solid state having sequence and flame-on lights and digital “first out” fault code indications of flame safeguard trip functions. It shall include dynamic self-check logic. The controller shall have a fixed operating sequence incapable of being manually altered. The sequence shall include start, pre-purge, pilot and main fuel ignition run and post-purge cycles.
Controller shall be the non-recycle type for maximum safety that shall shutdown the burner and indicate as a minimum the following trip functions: pilot and main flame failure, high and low fire proving switch faults, running interlocks open, false flame signal and fuel valve open (when proof of closure switch is furnished).
The controller shall have a run/test switch. It shall allow interruptions to
A1-495-08
Model CB-LE Steam Boiler Specifications 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.
3. Control SwitchesBurner On-Off.Manual-Automatic.Manual Firing Rate Control.
4. Oil, heat and moisture resistant wire shall be used and identified with circuit numbers corresponding to the electrical wiring diagram.
5. All electrical equipment and wiring shall be in conformance with Underwriters Laboratories requirements.
6. Boiler to be supplied with a control circuit transformer and fuse protection for the control circuit.
C. CB-HAWK ICS Integrated Boiler Control and Management System: Boiler Control System combining a Digital Burner Management System for flame safety and a Programmable Logic Controller for boiler modulation and operator interface functions.
The factory pre-configured Boiler Control System shall integrate the Burner Management functions and the PLC based modulation and operator interface functions. The logic of the Burner Management System and the modulating controls will not be run in the same processor or powered by the same DC supply. The PLC and Operator Interface Hardware shall be as manufactured by Allen Bradley.
Major system components shall include:
•Programmable Logic Controller•Touch Screen HMI•One Burner Management Controller with Wiring Sub-Base•One Flame Scanner and amplifier•Various Temperature and Pressure Sensors
Major functions provided by the Boiler Control System shall be:
•Automatic sequencing of the boiler through standby, pre-purge, pilot flame establishing period, main flame establishing period, run, flame proving and lockout and post-purge
•Full modulating control of fuel and air •Utilize solid state controls and sensors to provide various control functions, such as:
Modulating control (algorithm shall be Proportional-lntegral-Derivative (PID) type)Thermal shock protectionHigh and Low limit alarms and shutdowns
•Touch Screen graphical operator interface and monitoringManual control of the boiler firing rate using control screens on the HMI to increment or decrement the firing rate
A1-505-08
Section A1 Model CB-LE Steam Boiler Specifications
On screen indication of burner management controller status and diagnosticsOn screen display of system alarms and faultsOn screen history of alarms and faultsOn screen recommendations for troubleshooting of fault conditionsOn 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 GuaranteeA. 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.
The specified boiler efficiency is based on the following conditions.
B. Fuel specification used to determine boiler efficiency:Natural Gas
C. Efficiencies are based on ambient air temperature of 80 °F, relative humidity of 30%, and 15% excess air in the exhaust flue gas.
D. Efficiencies are based on manufacturer’s published radiation and convection losses. (For Cleaver-Brooks radiation and convection losses, see Boiler Efficiency Facts Guide, publication number CB-7767).
E. Any efficiency verification testing will be based on the stack loss method.
2.6 WarrantyAll 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 CriteriaManufacturer: CLEAVER-BROOKSModel: Promethean LineHorsepower: ________HPOutput: ________#/hr (from and at 212°F)Gas Input: ________MBHOil Input: ________GPHDesign Pressure: ________PSIGOperating Pressure ________PSIGSteam Disengaging Area (minimum) ________Sq. InchesSteam storage area (minimum) ________Cu. Ft.Heating Surface (minimum): ________Sq. Ft. FiresideHeating Release (maximum): ________BTU/Cu. Ft.Burner Turndown Ratio Natural Gas:Overall Efficiency (Fuel to Steam)Natural Gas (%):No. 2 Oil (%):
________% at High Fire________% at High Fire
NOX Emission (maximum)Gas (Natural):Oil (No. 2):
________PPM (corrected to 3%O2)________PPM (corrected to 3%O2)
CO Emissions (maximum)Gas (Natural):Oil (No. 2):
________PPM (corrected to 3%O2)________PPM (corrected to 3%O2)
A1-525-08
Section A1 Model CB-LE Steam Boiler Specifications
PART 3 EXECUTION
3.1 Shop TestsA. 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 ServiceA. After boiler installation is completed, the manufacturer shall provide the services of a
field representative for starting the unit and training the operator at no additional costs.1. A factory approved and authorized start-up report shall be submitted to the
customer/user at the time of start-up.
Electrical:Fan Motor: Air Compressor Motor: Oil Pump Motor: Noise Level (3' from burner):
____ V / ____ H / ____ P____HP____HP____HP____dBA
Available Gas Supply Pressure: ____PSIGWeightDry: Flooded:
________
Seismic Zone: ____Altitude: ____ ASLCode Requirements: ASME / NATIONAL BOARD
1.1 Boiler Characteristics (Hot Water)A. The Hot Water Boiler shall be Cleaver-Brooks Model CB, Fuel Series ______ (100,
200, 700), _____ hp designed for _____ psig (30, 125 psig, or other hot water). The maximum water temperature shall be _____ degree F, and the maximum system temperature drop shall be _____ degrees F.
B. The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower when fired with CS 12-48 _____ oil and/or natural gas, _____ Btu/cu-ft. Electrical power available shall be _____Volt _____ Phase _____ Cycle.
PART 2 PRODUCTS
2.1 General Boiler DesignA. The boiler shall be a four pass horizontal firetube updraft boiler with five (5) square
feet (except 750 or 800 hp) of heating surface per rated boiler horsepower. It shall be mounted on a heavy steel frame with integral forced draft burner and burner controls. The complete package boiler shall be approved as a unit by Underwriters Laboratories and shall bear the UL/ULC label.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, Industrial Risk Insurance, ASME CSD-1).
B. Boiler Shell (Hot Water)1. The boiler shell must be constructed in accordance with ASME Boiler Code and
must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser.
2. The hot water return and outlet connections shall be located on the top center line of the boiler. The boiler shall be designated to rapidly mix the return water with the boiler water. Forced internal circulation shall be used.
3. A dip tube shall be included as an integral part of the water outlet.4. Two lifting eyes shall be located on top of the boiler.5. Front and rear doors on the boiler shall be hinged or davited. Doors are to be
sealed with fiberglass tadpole gaskets and fastened tightly using heavy capscrews that thread into replaceable brass nuts.
6. Rear refractory and insulation shall be contained in the formed door, which must swing open for inspection of brick work.
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.
A1-565-08
Section A1
C. Observation ports for the inspection of flame conditions shall be provided at each end of the boiler.
D. The boiler insulation shall consist of a 2 inch blanket under a sectional preformed sheet metal lagging. This insulation must be readily removable and capable of being reinstalled, if required.
E. The entire boiler based frame and other components shall be factory painted before shipment using a hand finish enamel coating.
F. Emission Controls1. 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 TrimA. 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 GaugesPressure and temperature gauges shall be mounted on the boiler with temperature sensing element located adjacent to the hot water outlet.
C. Relief ValvesWater relief valves of a type and size to comply with ASME Code requirements shall be shipped loose.
D. Temperature ControlsTemperature 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 ControlsA. Mode of Operation
Burner operation shall be full modulation principle. The burner shall always return to low fire position for ignition.
B. Blower1. 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).
A1-575-08
Section A1
3. The impeller shall be cast aluminum, radial blade, carefully balanced, and directly connected to the blower motor shaft.
C. Combustion Air ControlCombustion 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).
D. Fuel Specification and PipingSelect one of the following fuel types:
•Fuel series 700 - Gas fired.
•Fuel series 100 - Light oil (No. 2) fired.
•Fuel series 200 - Light oil or gas fired.
1. Fuel Series 700 - Gas Fired a. Burner Type - The burner shall be integral with the front head of the boiler
and of high radiant multi-port type for gas. The burner shall be approved for operation on natural gas fuel and equipped with an LE option.
b. Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot flame has been established. The pilot train shall include two manual shut-off valves, solenoid valve, pressure regulator and pressure gauge.
c. Gas Burner Piping - Gas burner piping on all units shall include pressure regulating gas shutoff valve, motor operated with proof of closure switch and plugged leakage test connection. The main gas valve(s) shall be wired to close automatically in the event of power failure, flame failure, low water or any safety shutdown condition. A lubricating plug cock or butterfly shutoff valve shall be provided as a means for a tightness check of the primary shut off valve. An additional plug cock on butterfly valve shall be furnished at entrance to gas train. Select one of the following:1) 125-300 hp. High and low gas pressure switches shall be provided.
A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided.
2) 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.
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 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.)
2. Fuel Series 100 - Light Oil Fireda. 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
A1-585-08
Section A1
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
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.
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.
d. Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid shutoff valves, pressure gauges and fuel strainer, all integrally mounted on the unit. A fuel oil controller shall be provided to combine all of the fuel oil controls into a single casting which is mounted on the front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. A low oil pressure switch shall be included in the oil piping.
e. Low Pressure Air Atomizing - Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch.
f. Burner Turndown - Select one of the following:1) 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.)
3. Fuel Series 200 - Light Oil or Gas Fireda. 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.
b. 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.
c. Oil Burner1) 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.
A1-595-08
Section A1
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.
d. Gas Burner1) 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 Panel1. 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).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
A1-605-08
Section A1
adjustments to firing rate motor, damper linkages and pilot flame for minimum turndown tests.
b. Control Panel - The control panel shall be mounted on the front door of the boiler in a location convenient to the operator. The hinged metal cabinet shall have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key type lock.The panel shall contain the boiler flame safeguard controller, blower motor starter, indicating lights and selector switches.The panel shall have a removable sub-base for mounting the flame safeguard controller, blower motor starter, and terminal blocks. For combination gas-oil fired boilers the panel shall contain the fuel selector switch.
The panel shall contain the following lights and switches:
c. Lights•White - load demanded.
•White - fuel valve open.
•Red - low water.
•Red - flame failure.
d. Control Switches•Burner On-Off.
•Manual-Automatic.
•Manual Firing Rate Control.
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.
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
A1-615-08
Section A1
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 protectionHigh and Low limit alarms and shutdowns
•Touch Screen graphical operator interface and monitoringManual control of the boiler firing rate using control screens on the HMI to increment or decrement the firing rateOn screen indication of burner management controller status and diagnosticsOn screen display of system alarms and faultsOn screen history of alarms and faultsOn screen recommendations for troubleshooting of fault conditionsOn 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 via Ethernet as a standard. OPC compliant Internet communications shall be supported, with the Boiler Control System supplied with its own IP address.Efficiency Guarantee
F. The boiler manufacturer shall guarantee that, at the time of startup, the boiler will 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.
The specified boiler efficiency is based on the following conditions.
G. Fuel specification used to determine boiler efficiency:• Natural Gas
H. Efficiencies are based on ambient air temperature of 80 °F, relative humidity of 30%, and 15% excess air in the exhaust flue gas.
I. Efficiencies are based on manufacturer’s published radiation and convection losses. (For Cleaver-Brooks radiation and convection losses, see Boiler Efficiency Facts Guide, publication number CB-7767).
J. Any efficiency verification testing will be based on the stack loss method.
2.4 Performance Criteria
Performance Criteria
Manufacturer: CLEAVER-BROOKSModel: Promethean LineHorsepower: ________HPOutput: ________#/hr (from and at 212°F)Gas Input: ________MBHOil Input: ________GPHDesign Pressure: ________PSIGOperating Pressure ________PSIGOperating Temperature ________degrees FHeating Surface (minimum): ________Sq. Ft. FiresideBurner Turndown Ratio Natural Gas:Overall Efficiency (Fuel to Steam)Natural Gas (%):No. 2 Oil (%):
________% at High Fire________% at High Fire
NOX Emission (maximum)Gas (Natural):Oil (No. 2):
________PPM (corrected to 3%O2)
A1-635-08
Section A1
PART 3 EXECUTION
3.1 WarrantyAll 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 TestsA. The packaged boiler must receive factory tests to check the construction, controls,
and operation of the unit. All tests may be witnessed by the purchaser, if desired.B. Start-up Service
1. After boiler installation is completed, the manufacturer shall provide the services of a field representative for starting the unit and training the operator at no additional costs.a. A factory approved and authorized start-up report shall be submitted to the
customer/user at the time of start-up.
CO Emissions (maximum)Gas (Natural):Oil (No. 2):
________PPM (corrected to 3%O2)________PPM (corrected to 3%O2)
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: ____PSIGWeightDry: Flooded:
________
Seismic Zone: ____Altitude: ____ ASLCode Requirements: ASME / NATIONAL BOARD