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Model 4WI 100 800 HP Boilers

BOILER ALL DIMENSIONS IN INCHES


HP A B C D E
100 79.5 21.375 84.75 10 3
125 79.5 21.375 108.75 10 3
150 87.125 21.375 96.75 10 3
200 87.125 21.375 130.75 10 3
250 99 28.75 104.25 10 3
300 99 28.75 128.25 10 3
350 107.625 33.25 126 10 3
400 107.625 33.25 144 10 3
500 125.375 34.5 145 10 3
600 125.375 34.5 180 10 3
700-800 134.5 34.5 164 10 3
NOTE: A, B, and C dimensions may vary by 1 inch.

Table A2-10. Lifting Lug Locations

Section A2-12 Rev. 09-09


Model 4WI 100 800 HP Boilers

PERFORMANCE DATA
The Low Emission Option provides NOx reduction at current published and predicted
fuel-to-steam efficiencies. Refer to Table A2-12 and Table A2-13.
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
The boiler manufacturer shall guarantee that, at the time of startup, the boiler will achieve
fuel-to-steam/water efficiency (as shown in Table A2-12 and Table A2-13) 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.
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
Hydrogen,% (wt) = 12.7
Sulfur,% (wt) = 0.2
Heating value, Btu/lb. = 19,420
No. 6 Oil
Carbon,% (wt) = 86.6
Hydrogen,% (wt) = 10.9
Sulfur,% (wt) = 2.09
Heating value, Btu/lb. = 18,830
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:

Section A2-13 Rev. 09-09


Model 4WI 100 800 HP 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 A2-12 a boiler operating
at 100% firing rate and an operating steam pressure of 125 psig, the efficiency is 82.1%.
Using Figure A2-3, 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 82.1 -.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 A2-11. Firing Rates 4WI Boilers with Integral Burner


Natural Gas, 1000 Btu/hr No. 2 Oil, GPH
BHP Low High Low High
100 1021 4082 7.3 29.2
125 1276 5103 9.1 36.4
150 1531 6124 10.9 43.7
200 2041 8165 14.6 58.3
250 1021 10206 9.1 72.9
300 1225 12247 10.9 87.5
350 1428 14280 12.8 102.1
400 1633 16329 14.6 116.6
500 2042 20415 18.2 145.8
600 2449 24494 21.9 175
700 2858 28576 25.5 204.1
750 3062 30617 27.3 218.7
800 3266 32659 29.2 233.3
Notes:
Fuel input rates are based on nominal 82% efficiency.
No. 2 Oil = 140,000 Btu/Gal

Section A2-14 Rev. 09-09


Model 4WI 100 800 HP Boilers

Table A2-12. Predicted Fuel-to-Steam Efficiencies - Natural Gas - Model 4WI


OPERATING PRESSURE = 10 psig OPERATING PRESSURE = 125 psig
BHP % OF LOAD % OF LOAD
25% 50% 75% 100% 25% 50% 75% 100%
100 84.4 84.6 84.1 83.6 81.6 82.0 81.7 81.3
125 84.6 85.0 84.7 84.3 81.8 82.3 82.2 82.0
150 84.5 84.8 84.4 83.9 81.6 82.0 81.7 81.3
200 84.7 85.2 85.1 84.8 81.8 82.4 82.3 82.2
250 84.7 85.1 84.9 84.5 81.8 82.4 82.3 82.1
300 84.8 85.3 85.2 85.0 81.9 82.6 82.6 82.5
350 84.7 85.2 85.1 84.8 81.8 82.4 82.3 82.1
400 85.4 85.6 85.5 85.2 82.6 82.9 82.8 82.6
500 85.4 85.6 85.5 85.3 82.6 83.0 82.9 82.8
600 85.5 85.8 85.7 85.6 82.7 83.2 83.2 83.1
700 85.5 85.7 85.7 85.6 82.7 83.1 83.1 83.0
800 85.5 85.8 85.7 85.6 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

Section A2-15 Rev. 09-09