CLEAVER-BROOKS

PACKAGED
WATERTUBE BOILERS

MODELS D, DL, and DLD

© Aqua-Chem. Inc .• 1993

II
I
I
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Please direct purchase orders for replacement manuals
to your local Cleaver-Brooks representative

Manual Part No. 750-302

Printed in U.S.A
 WAKN/NG
DO NOT OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS YOU FULLY UNDERSTAND
ALL APPLICABLE SECTIONS OF THIS MANUAL.

DO NOT ALLOW OTHERS TO OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS THEY
FULLY UNDERSTAND ALL APPLICABLE SECTIONS OF THIS MANUAL.

FAILURE TO FOLLOW ALL APPLICABLE WARNINGS AND INSTRUCTIONS MAY RESULT IN SE-
VERE PERSONAL INJURY OR DEATH.

TO: Owners, Operators and/or Maintenance Personnel

This operating manual presents information that will help to properly operate and care for the equipment. Study its contents
carefully. The unit will provide good service and continued vperation if proper operating and maintenance instructions are
followed. No attempt should be made to operate the unit until the principles of operation and all of the components are
thoroughly understood. Failure to follow all applicable instructions and warning may result in severe personal injury or death.

It is the responsibility of the owner to train and advise not only his or her personnel, but the contractor's personnel who are
servicing, repairing or operating the equipment, in all safety aspects.

Cleaver-Brooks equipment is designed and engineered to give long life and excellent service on the job. The electrical and
mechanical devices supplied as part of the unit were chosen because of their know ability to perform; however, proper operating
techniques and maintenance procedures must be followed at all times. Although these componesnts afford a high degree of
protection and safety, operation of equipment is not to be considered free from all dangers and hazards inherent in handling and
firing of fuel.

Any "automatic" features included in the design do not relieve the attendant of any responsibility. Such features merely free
himlher of certain repetitive chores and give himlher more time tot devote to the proper upkeep of equipment.

It is solely the operator's responsibility to properly operate and maintain the equipment. No amount of written instructions can
replace intelligent thinking and reasoning and this manual is not intended to relieve the operating personnel of the responsibility
for pr0~ operation. On the other hand, a thorough understanding of this manual is required before attempting to operate,
maintain, service, or repair this equipment.

Because of state, local, or other applicable codes, there are a variety of electric controls and safety devices which vary consider-
ably from one boiler to another. This manual contains information designed to show how a basic boiler operates.

Operating controls will normally function for long periods of time and we have found that some operators become lax in their
daily or monthly tesing, assuming that normal operation will continue indefinitely. Malfunctions of controls lead to
uneconomical operation and damage and, in most cases, these conditions ca nbe traced directly to carelessness and deficiencies
in testing and maintenance.

It is recommended that a boiler room log or record be maintained. Recording of daily, weekly, nonthly and yearly maintenance
activities and recording of any unusual operation will serve as a valuable guide to any necessary investigation.

Most instances of major boiler damage are the result of operation with low water. We cannot emphasize too strongly the need
to
for the operator periodica:J!y checkhislher low water controls and to follow gOOdmaintenance and testIng practices. Cross-
connecting piping to low water devices must be internally inspected periodically to guard agamst any stoppages which could
obstruct the free flow of water to the low water devices. Float bowls of these controls must be inspected frequently to check for
the presence of foreign substances that would impede float ball movement

The waterside condition of the pressure vessel is of extreme importance. Waterside surfaces should be insp:o:cted frequently to
check for the presence of any mud, sludge, scale or corrosion.

The services of a qualified water treating company or a water consultant to recommend the proper boiler water treating practices
are essential.

The operation of this equipment by the owner and hislher operating personnel must comply with all requirements or regulations
ofhislher insurance company and/or other authority having jurisdiction. In the event of any conflict or inconsistency between
such requirements and the warnings or instructions contained herein, please contact Cleaver-Brooks before proceeding.
 CONTENTS
Page
CHAPTER 1 - GENERAL DESCRIPTION ....................................... 1-1
A. The Boiler ...................................................... 1-1
B. The Burner and Control System ................................. 1-1
C. Components and Accessories ..................................... 1-1
D. Installation ...................................................... 1-6
E. Hydrostatic Testing and Inspection ............................... 1-6
F. Boiling Out .................... , .................. , ............. 1-7
G. Feedwater System and Treatment ................................ 1-9

CHAPTER 2 - OPERATIONS AND PROCEDURES .............................. 2-1

A. Preparation to Initial Firing ..................................... 2-1
B. Filling the Boiler ................................................ 2-1
C. Initial Firing .................................................... 2-2
D. Routine Operation and Shutdown ................................ 2-2
E. Operating Procedures ............................................ 2-3
Feed Water Regulation and Control ............................ 2-3
Water Level Indicating System ................................. 2-3
Water Column ................................................. 2-4
Blowdown ..................................................... 2-5
Manual Blowdown ............................................. 2-5
Continuous Blowdown ......................................... 2-6
Soot Blowing .................................................. 2-6
Superhea ter ................................................... 2-7

CHAPTER 3 - MAINTENANCE ................................................. 3-1

A. General ......................................................... 3-1
Waterside Inspection ........................................... 3-1
Fireside Inspection ............................................. 3-2
B. Pressure Vessel Care and Repairs ................................ 3-3
C. Tube Cleaning ................................................... 3-3
Mechanical Tube Cleaning ..................................... 3-3
Chemical Cleaning ............................................. 3-5
D. Water Column ............................................... " .. 3-5
Probe Installation ............................................. 3-5
Gauge Glass or Prismatic Insert ............................... 3-5
E. Safety Valves .................................................... 3-5
F. Care and Protection of Idle Boilers .............................. 3-7

CHAPTER 4 - PARTS ORDERING INSTRUCTIONS AND PARTS LIST ........ .4-1

TO: Owners, Operators or Maintenance Personnel

This operating manual presents information that will help to properly operate and care for the equipment.
Study its contents carefu lIy, The unit will provide good service and continued operation if proper
operating and maintenance instructions are followed, No attempt should be made to operate the unit until
the principles of operation and all of the components are thoroughly understood, Only trained and
authorized personnel should be allowed to operate, adjust or repair this equipment.
Cleaver-Brooks products are designed and engineered to give long life and excellent service on the job,
The electrical and mechanical devices supplied as part of the unit were chosen because of their
known ability to perform: however, proper operating techniques and maintenance procedures must be
followed at all times, Although these components afford a high degree of protection and safety,
operation of equipment is not to be considered free from all dangers and hazards inherent in handling and
firing of fuel.
Any "automatic" features included in the deSign do not relieve the attendant of any responsibility,
Such features merely free him of certain repetitive chores and give him more time to devote to the proper
upkeep of equipment.

It is solely the operator's responsibility to properly operate and maintain the equipment. No amount of written
instructions can replace intelligent thinking and reasoning and this manual is not intended to relieve the
operating personnel of the responsibility for proper operation,

Because of state, local or other applicable codes there are a variety of electrical controls and safety
devices which vary considerably from one installation to another, This manual contains information
designed to show how a standardly equ ipped bu rner operates,
Operating controls will normally function for long periods of time and we have found that some
operators become lax in their daily or monthly testing assuming that normal operation will continue
indefinitely, Malfunctions of controls leads to uneconomical operation and damage and in most
cases these conditions can be traced directly to carelessness and deficiencies in testing and maintenance,
It is recommended that a boiler room log or record be maintained, Recording of daily, weekly, monthly
and yearly maintenance activities and recording of any unusual operation will serve as a valuable
gu ide to any necessary investigation,
Most instances of major boiler damage are the result of operation with low water, We cannot emphasize
too strongly the need for the operator to periodically check his low water controls and to follow' good
maintenance and testing practices, Cross connecting piping to low water devices must be internally
inspected periodically to guard against any stoppages which coUld obstruct the free flow of water to
the low water devices, Float bowls of these controls must be inspected frequently to check for the
presence of foreign substances that wou Id impede the float ball movement.
The waterside condition of the pressure vessel is of extreme importance, Waterside surfaces should be
inspected frequently to check for the presence of any mud, sludge, scale or corrosion,
It is customary to engage the services of a qualified water treating company or a water consultant to
recommend the proper boiler water treating practices,

The operation of this equipment by the owner and his operating personnel must comply with all requirements
or regulations of his insurance company and/or any other authority having jurisdiction, These legal
requirements take precedence over anything contained herein,

Cleaver-Brooks Service Engineers, or Cleaver-Brooks authorized service representatives, present

for start-up or service are present on Iy in an advisory capacity, The operation of the bu rner or boi ler is
under the scope of work to be performed by the owner's operating personnel at the owner's risk, and under the
owner's insurance protection, Recommendation for proper adjustments required to make the equipment
perform can 'be made by these Service Engineers,

III
 Chapt pr 1 - General Descript ion

CHAPTER

GENERAL DESCRIPTION
A. THE BOILER
B. THE BURNER AND CONTROL SYSTEM
C. COMPONENTS AND ACCESSORIES
D. INSTALLATION
E. HYDROSTATIC TESTING AND INSPECTION
F. BOILING OUT
G. FEEDWATER SYSTEM AND TREATMENT

A. THE BOILER provided for the -burner portion. The various

The Cleaver-Brooks Packaged Watertube Steam
Boiler is a two drum, bent-tube, "D" type Boiler.
The line consists of three Models; "D", "DL" and
"DLD" which vary only in size, dimensions, and
capacity. All models are covered by this manual.
The Boiler has a six-wall water cooled furnace.
The inside and outside furnace walls, as well as
the floor and roof, are constructed of tangent
tubes. The front and rear walls are refractory
faced and have water cooling tubes. Figure 1-1
shows typical construction.
The entire pressure vessel is covered with a
double seal-welded insulated casing. The
pressure vessel is mounted on a heavy structural
steel skid type frame.
The steam (upper) drum has factory installed in-
ternals and baffles to control water levels, reduce
surging, and to reduce the quantity of moisture
leaving the water level before it enters the final
dryer unit. Figure 1-2 shows a cross section of
typical drum internals.
The boiler is constructed in accordance with the
ASME Power Boiler Code, and all applicable
local laws, regulations and codes having juris-
diction.
B. THE BURNER AND CONTROL
SYSTEM
The boiler is standardly equipped with a Cleaver-
Brooks Burner. or in some instances, a burner
manufactured by others. An indIvidual manual is
safety and combustion controls are either covered
in the burner manual or by separate instructions.
All instructions and manuals applicable to the in-
stallation should be studied prior to firing the
boiler.
C. COMPONENTS AND
ACCESSO RIES
This section describes some of the various com·
ponents and accessories that comprise a boiler.
Some are integral to the pressure vessel while
others are devices that are necessary for nprmal
and safe operation. The accessory described may
be furnished with the boiler or it may be fur·
nished separately by others. Some installations
may not require a particular component or it may
vary somewhat from the following basic descrip·
tions. See Figure 1-4.
The operator must be familiar with the indio
vidual functioning of all controls and components
in order to understand the boiler's operation. The
following brief descriptions provide a basic un·
derstanding of the functions and relationships.
The descriptions are limited to those components
that affect the pressure vessel. The boiler 'and fuel
system controls, along with other special items
that might be provided. are covered elsewhere.
STEAM DRUM
The upper drum (steam drum) contains water
level control baffling to assure tha t all steam re-
leased from the generating tubes is released be·

1·1
Chapter I - General Description

FIGURE 1-1 TYPICAL TUBE ARRANGEMENT

1-2
 Chapter 1 - General Description

STEAM OUTLET STEAM OUTLET

c A F E o c
A. Dry Pan Carton D. Feedwater Pipe
B. Flow Control Baffles E. Chemical Feed Pipe
C. Dry Pan Drain F. Continuous Blowdown Pipe

FIGURE 1-2 DRUM INTERNALS AND SEPARATOR

STEAM OUTLET STEAM OUTLET

E o c
A. Purifier and Dryer Carton D. Chemical Feed Pipe
B. Flow Control Baffles E. Continuous Blowdown Pipe
C .. Feedwater Pipe F. Steam Chest

FIGURE 1-3 DRUM INTERNALS AND STEAM PURIFIERS

1-3
Chapter 1 - General Description
hind the baffles and not through the' water level.
Other drum internals include steam separators or
dryers to assure low moisture content steam.
The drum heads are fitted with 12" by 16" man-
ways on each end. The internal feed pipe, chemi-
cal feed pipe, and blowdown piping are attached
to the drum heads.
Figures 1-2 and 1-3 show typical drum internals.
LOWER WATER DRUM
The lower water drum has a blow off connection
on the underside near the rear head. Internally it
has a blow off guide baffle installed to insure ef-
fective blow off of the lower drum without distur-
bance to the water circulation of the boiler.
The drum incorporates two 12" x 16" manways
one at each end.
BLOW OFF VALVES
These are specially designed, manually operated,
valves connected to the lower drum for the pur-
pose of reducing the concentration of solids in the
boiler or for draining purposes. Two valves are
required .by the ASME Code. The valves' nor-
mally furnished are of. the slow opening type.
CONTINUOUS BLOWDOWN CONNECTION
The continuous blowdown connection is normally
located in the rear head of the upper drum with
the pipe located slightly below the normal water
level. Its purpose is to remove the concentrated
boiler water from the boiler and thereby reduce
the total solids concentration. A flow control
valve, or one with a variable orifice, is used to
closely control the percent of blowdown. A stop
valve is furnished, while the blowdown valve may
be either provided with the boiler or furnished by
others.
CHEMICAL FEED CONNECTION
This connection in the upper drum is provided for
the piping from a chemical feed pump and is the
means of introducing supplementary water treat-
ment chemicals. into. the boiler.
SOOT BLOWER
A boiler equipped with an oil fired burner has a
soot blower installed for cleaning accumulations
of soot from the convection bank tubes. Steam is
the most commonly used cleaning medium
although compressed air is als,o used.
The soot blower is normally located on the rear
wall of the boiler although front wall locations
are not uncommon. Larger sizes of boilers have
two soot blowers - front and rear. Stop and drain
valves are provided. A sight cap is provided.in the
side casing to allow visual checking of soot
blower nozzle alignment.
1-4
OBSERVATION PORT
These are located in the rear wall to provide a
good clear view of the flame.
STEAM GAUGE
Indicates the internal pressure of the boiler.
FEEDWATER REGULATING VALVE AND
GENERATOR
These items comprise a system that operates
automatically to maintain a predetermined water
level in the boiler. The generator is essentially a
closed hydraulic system, connected by tubing to a
bellows on the regulating valve, that is responsive
to the boiler water level. Hydraulic pressure
created within the generator forces the valve to
open to various positions thus regulating the flow
of water to maintain a constant level.
A single element system is standardly furnished
although other systems may be used depending
upon job requirements and specifications.
FEEDWATER BYPASS VALVE
A manually operated valve provided to initially
fill the boiler or to bypass the regulating valve.
SAFETY VALVE
This is an automatic pressure relieving device
and, as the name implies, is for the purpose of
safely relieving the boiler of any excessive steam
pressure. The size and number of valves - always
two and often three - and their pressure setting
are determined by job specifications and in ac-
cordance with ASME Code requirements.
The discharge piping from the valves must also
con'form to the ASME Code. See Figure 3-4. This
piping is not furnished with the boiler.
If the boiler is equipped with a super-heater, a
safety valve is also provided for the super-heater.
DRUM VENT VALVE
This manually operated valve is located on top of
the steam drum. Its sole purpose is to vent air
and entrained gases from the drum during start-
up. It should also be opened when the boiler is
being cooled down to prevent a vacuum from
forming within the boiler.
WATER COLUMN
The water column is connected at its top to the
steam space and at its bottom to the water space
of the upper drum. A water gage, trycocks, and
water level indicating devices are attached to or
are part of the column.
The gage glass attached to the side of the column
is used to visually indicate the boiler water level.
This glass is one of the most important guides

GAGE GLASS COCKS (TRY-COCKS)
GAGE GLASS WATER COLUMN
SHUT-OFF COCKS~\.
WATER LEVEL GAGE GLASS";;~?
~~.y•. . • . • ...••• :.. (J .•••••.•.•
STEAM GAUGE
FEEDWATER INLET
FEEDWATER
REGULATING VALVE
FIGURE 1-4 TYPICAL WATERTUBE BOILER
available to the boiler operator. It should be kept
clean and well· lighted for good visibility.
The gage glass is mounted between two valves
which can be operated from floor level by means
of an attached chain. The valve handles are
linked together so that they may be opened or
closed simultaneously. The valves can be quickly
closed in the event of glass breakage. Guard rods
are used to help protect the glass against ac-
cidimtai damage. A flat reflex type glass is often
used instead of a tubular glass.
Three trycocks are provided to check the accuracy
of the gage glass leveL
Chap! er I . General Descrip! ion
STEAM DRUM FEEDWATER REGULATOR
GENERATOR
BLOWER
MOTOR
PACKAGED
BURNER ASSEMBLY
The water column is fitted with probes, or elec-
trodes, extending through the top flange down-
wards into the steam and water spaces. These are
wi"red into an electric relay system that will shut
the burner down in the event of low water and
also activate signal lights that indicate normal,
low water or high water level conditions. The lat-
ter two are generally connected to an audibl~
alarm system to alert the operator of a condition
requiring immediate attention. -The operation of
the system is explained later in this manuaL
An auxiliary low water cut-off control is often i!1-
stalled to provide additional protection. This is
generally of the float operated type and is wired
1-5
 Chapt~er 1 - General Description
to interrupt the limit circuit and to shut off the
fuel flow in the event water drops below the
master low water cut-off point.
Drain valves are provided for the water column
and for the gage glass. Piping to a safe point of
discharge must be provided by others.
D. INSTALLATION
It is not within the scope of this manual to pro-
vide installation instructions. These should
follow the design specifications of the Architect,
Engineer or Contractor. Good engineering prac-
tices must prevail.
The boiler and related equipment must be in-
stalled to conform to applicable codes. Compli-
ance with codes will do much to insure a safe and
dependable installation as the codes have been
formulated to safeguard life and property. Fail-
ure to comply with established regulations can
necessitate costly modification or reconstruction.
The proper authorities should be consulted before
installation preparation of a permanent nature is
started, particularly in regard to boiler room
structure, boiler venting, electrical service, fuel
storage and piping and all other piping such as
steam, water supply, blow-off, and drain lines.
Application should be made immediately for all
permits required by law for boiler room con-
struction and boiler installation. Although it is
custom·ary for each Contractor involved to attend
to the permit required for his phase of the work, it
is advisable to make sure that no necessary per-
mit is 9verlooked.
The Cleaver-Brooks Boiler is constructed to con-
f~rm with the ASME Boiler Code and other codes
known to apply. A Manufacturer's Data Report
covering the boiler construction, test and in-
spection is provided.
When the boiler is received, it should be given a
thorough inspection by a competent person to de-
~_~ _ _~ Jermine iL~nyJiamagebas occurred in transiLAU __
boxes and cartons should be uncrated carefully
and checked against the packing slip. In case of
damage or shortage, immediately ~ notify the
carrier and file a claim.
The boiler should be inspected externally as well
as internally. The bracing or shoring that may be
used to protect the brick in the furnace area must
be removed. The refractory should be inspected
for evidence of loose or broken tile.
The following generalizations are intended for
assistance and do not supplant any codes or con-
struction criteria.
1-6
All piping and valves must be installed in accord-
ance with good engineering practices. Suitable
strength piping and valves are to be used. All
drains and discharge piping must be piped to a
safe point of discharge.
The discharge piping from the safety valves and
the method of connecting the piping is especially
important. The piping should be arranged so that
no "thrust from the weight or movement of the
.pipe cal! be· imparted to the valves. Refer to
Figure 3-4 for a typical recommended method of
piping.
Electrical wiring must conform to all electrical
codes and proper size wiring used. The necessary
switches, feed boxes, circuit breakers, etc. must be
installed and operable.
All auxiliary equipment should be installed in ac-
cordance with the recommendations of the
respective manufacturers. Fan wheels, bearings,
couplings, and shaft alignment should be checked
and aligned. If the bases of auxiliary equipment
are grouted, the alignment should be checked be-
fore grouting or doweling and rechecked af-
terwards.
Aisles, ladders, and stairs should be completed
and accessible for the convenience and safety of
the operating personnel. All obstructions such as
scaffolding, refuse, tools, etc. must be removed
from ducts, breechings, and platforms. Insulation
of piping and duct work should be done in accord-
ance with accepted practices.
The supply piping for a gas fired burner must not
be attached to or supported from the side casing
walls.
Occasionally a unit is repainted, especially in new
construction. When this is done, care must be
taken to see that paint is not applied to any
moveable linkage, to the generator portion of the
feedwater regulator, valve stems and any other
components where paint could interfere with nor-
~~..maLjlpeI"atiolL.. ___ n~~ __ ~
__ .. __ w ___ _
E. HYDROSTATIC TESTING
AND INSPECTIO N
The boiler was hydrostatically tested in our shop
and copies of the Manufacturers' Data Report,
signed by the inspector witnessing and evidencing
the test, have been forwarded to all jurisdictional
bodies as well as to the boiler owner. To be sure
that the pressure parts are still tight following
shipment and installation, a hydrostatic test
should be conducted as soon as possible after in-
stallation. This test will generally be under the

superVISIOn and witnessed by an authorized in-
spector who may represent either the state or
municipality having jurisdiction or the insurance
company covering the installation.
At the option of this inspector, this test may be at
1-1/2 times the design pressure of unit, or at a
pressure slightly less than the setting of the low-
est safety valve. The latter test will avoid the
necessity of blanking or gagging safety valves, re-
moving piping and plugging various pipe open-·
ings, removin~ controls and gage glass, etc.-
Before starting a test, make sure that all foreign
material, tools, personnel, etc., are removed from
the boiler. Rinse out the boiler by playing high
pressure water into the drums, tubes, nipples and
headers. Depending upon the test pressure, be
sure to blank off any part that is not designed to
withstand the pressure to be developed. This will
include water column, gage glass, feedwater regu-
lators, pressure controls, etc. Safety valves, in this
case, must be blanked or gagged.
All connections on the boiler should be closed
with the exception of the vent, pressure gauge,
and feed line through which pressure will be ap-
plied.
When the boiler is ready for the test, it should be
filled with water of a temperature not less than
ambient and in no case less than 70°F. Care
should be taken so that all air is vented while the
boiler is being filled.
Fill the boiler until water overflows the vent.
Close the vent.
Apply pressure slowly. The recommended rate of
pressure increase is less than 50 psi per minute.
Proper control must be maintained so that
pressure does not exceed the desired setting.
When this test pressure is reached, in!;lpection in
accordance with the test objective can begin.
Upon completion of the test, release pressure
slowly through a small drain valve. Then fully
open vents and drains. Particular care must be
given to make sure that parts not normally con-
taining water during operation, such as the super-
heater or circulating tubes above normal water
level are drained free of water.
If temporary handhole or manhole gaskets were
used for the test, they should be replaced with
regular service gaskets before readying the unit
for operation. Gaskets should never be reused.
Chapter 1 - General Description
Replace gage glass if necessary and make sure
that gage cocks ~re open.
Remove all blanks or gags from safety valves.
Additional inspection at lhis time by the
authorized inspector will determine whether the
installation including piping arrangements,
valves, gauges and controls and other equipment
on the boiler meet Code and/or other juris-
dictional requirements.
F. BOILING OUT
The internal surfaces of a new boiler will invar-
iably contain deposits of oil, grease and pro-
tective coatings inherent in manufacturing pro-
cedures. It is important that these deposit~ be re-
moved from the heating surfaces sinc~ this con-
tamination will lower the heat transfer rate ·and
possibly cause overheating of pressure vessel
metal. These deposits can generally be removed
by an alkaline boil out using readily available
chemicals.
Before boil out procedures can begin, the boiler
should be ready for firing and the operator must
be familiar with the operation of the burner and
follow instructions contained in the burner
manual.
There are several boiling out procedures that
may be followed and different materials are re-
commended by different authorities. There are
specially prepared trademarked chemicals avail-
able. Some firms that manufacture and provide
these are:
Betz Laboratories, Philadelphia, Pa.
Dearborn Chemical Company, Chicago, Illinois
Dow Chemical Company, Midland, Michigan
Hall Laboratories, Pittsburgh, Pa.
Nalco Chemical Company, Chicago, Illinois
The instructions and a"dvice provIded· by the
manufacturer of the chemical should be followed.
Any oils or coating that may have drained into
the drums should be wiped away with clean rags.
Also remove any debris that might be present.
One of the top manholes may be left open to aid
in filling the boiler.
If the water column if fitted with a prismatic type
gage glass, it is suggested that this be tempon~rily
replaced with a round glass of adequate design
pressure to avoid any aamage to the prismatic
glass.
In the event the boil out is not handi.ed by the
feed water consultant or water treatment com-
1-7
Chapter 1 - General Description
pany, the following procedure is effective for
cleaning a boiler.
The use of soda ash (sodium carbonate) and
caustic soda (sodium hydroxide) at the rate of 3
to 5 pounds each per 1,000 lbs. water is suggested.
A small amount of laundry detergent is often ad-
ded as a wetting agent.
The chemicals should be dissolved prior to plac-
ing them in the boiler. To make this solution,
. place warm water into a suitable container.
Slowly introduce the dry chemical into the water,
stirring at all times, untiI the chemical is com-
pletely dissolved. Add the chemical slowly and in
small amounts to prevent excessive heat and tur-
bulence.
Use of a suitable face mask, goggles, rubber
gloves and protective garments are strongly re-
commended when handling or mixing caustic
chemicals. Do not permit the dry material or the
concentrated solution to come in contact with
skin or clothing.
Fill the boiler with ambient temperature water to
a point just below the manhole opening in the up-
per drum. Add the chemicals in the solution
through either the upper drum manhole, the up-
per drum vent valve, or the chemical feed line.
Secure the manhole if it was used for filling.
Fill the boiler with water to about 8" above nor-
mal operating level. The normal level is at the
center of the water gage glass. Exercise caution to
prevent water spilling over into the superheater,
if the boiler is equipped with one.
Open the steam drum vent valve. If the boiler is
equipped with a superheater, open the super-
heater drain and vent valves. Recheck the burner,
feed water supply, gage glass, pressure gauge, and
the position of all valves.
Start the burner and allow the boiler to warm up
slowly. When steam vapor is noticed at the boiler
vent, close the vent valve. The superheater inlet
drain valve should also be closed, but the
superheater outlet drain valve should be left open
enough·· to permit continuous cooling of super-
heater tubes. Allow boiler pressure to increase at a
rate. not to exceed 100 psi per hour until pressure
has reached half of normal operating pressure but
not exceeding 150 psi. Keep the burner firing at a
low rate to maintain this pressure for approx-
imately 6 hours. During the pressure raising and
boiling out period, keep water above the bottom of
the gauge glass by adding water as required.
After completion of the boil out period, add water
slowly until the gauge glass shows full. Blow
down through the continuous blowdown line in
the steam drum until the water falls to the level
of the surface blowdown connection. From this
1-8
point, blow off with the bottom blowoff valves un-
til water level falls to within two inches of the
bottom of the gage glass. The water column and
gage glass should also be blown down.
After each blow, refill the boiler to the top of the
gage glass and allow the boiler to soak and boil for
about fifteen minutes before the next blow cycle.
Repeat this' cycle of blowdown operation for a
minimum of six times or until a cool sample of the
boiler water shows no oil.
If possible, maintain the cleaning concentration
during the blowdown by using a chemical feed
pump.
Pressure should be lowered somewhat during the
blowing and refilling cycle, however, the pressure
should not be allowed to fall below 50 psi.
At the completion of the boil out, shut off the bur-
ner and allow boiler to cool. Open all vents and
drain the boiler when the water temperature has
fallen to 120°F. or less.
Inspect the drums and wipe out any sludge or
scum that may be present. Then wash out boiler
thoroughly with a high pressure hose, using water
of approximately 70°F. temperature, or ambient.
Use a hose on each individual tube including
superheater and economizer tubes. If possible,
this washing should be done from the bottom of
the tube. The fireside of the boiler should be
checked for any unusual conditions.
Upon completion of the wash down, inspect the in-
ternal surfaces and if not clean, repeat the boil out.
Replace manhole covers and install new manhole
gaskets. Replace the gage glass if necessary. Re-
install the prismatic glass if boiler is so equipped.
Refill the boiler with clean, treated water. If not
immediately being placed into service, fire the
boiler until it is heated to at least 180°F. to drive
off any dissolved gases which might otherwise
corrode the metal.
1.) SYSTEM CONTAMINATION
Steam and water piping systems connected to the
boiler may contain oil, grease or foreign matter.
In new systems, the piping usually has an ac-
cumulation of oil, grease and dirt. Old systems
have an additional hazard in that the piping and
receivers may be heavily limed and full of scale
as the result of improper water treatment.
These impurities must be prevented from enter-
ing the boiler. On a steam system the condensate
should be wasted until tests show the elimination

of undesirable impurities. During the period that
,conjensate is wasted, attention must be given to
the treatment of the water used as make up so
that an accumulation of unwanted materials o~
corrosion of drums and tubes does not occur.
Follow the advice of your water treating com-
pany.
On a hot water system, chemical cleaning is
generally necessary and the entire system should
be drained after treatment. Consult water treat-
ment companies for recommendations, cleaning
compounds and application procedures.
If oil, di~t and scale accumulations are permitted
to get into the boiler, it may be necessary to re-
peat the boil out procedure. If this becomes
necessary, the same procedure as outlined under
boilout should be followed.
The waterside of the pressure vessel must be kept
clean from grease, sludge and foreign material.
Such deposits, if present, will not only shorten the
life of the pressure vessel and interfere with effici-
ent operation and functioning of control or safety
devices, but might quite possibly cause un-
necessary and expensive re-work, repairs and
down time.
The pressure vessel waterside should be inspected
on a periodic basis. This will reveal true internal
conditions and serve as a check against condi-
tions indicated by chemical analysis of the boiler
water. Inspection should be made three months
after initial starting and at regular 6, 9 or 12
month intervals thereafter. The frequency of fur-
ther periodic inspections will depend upon the in-
ternal conditions found.
If any unwanted conditions are observed your
water consultant or water treating company
should be contacted for recommendations.
Any sludge, mud or sediment found will have to
be flushed out. The effectiveness of the blowdown
practiced on steam boilers will be verified and
scheduling or frequency of blowdown may have to
be revised. The need for periodic draining or
washout will also be indicated.
G. FEEDWATER SYSTEM
AND TREATMENT
The subject of water supply and treatment is of
great importance and it cannot adequately be
covered in this manual. Maximum effectiveness
and long trouble-free life of the pressure vessel
are functions of properly treated water. The type
and extent of water treatment is determined by
the water supply. The services of a reliable boiler_
Chapter 1 . General Description
water treatment specialist or company should be
engaged to a-nalyze the water and prescribe treat-
ment. Their recommendations should be followed
rigidly to prevent the presence of unwanted solids
and corrosive gases. Failure to do so will result in
ever decreasing boiler efficiency as well as shor-
tened useful life.
Objectives of water treatment in general are:
a. Prevention of hard scale deposits or soft
sludge type deposits, which impair the rate
of heat transfer and can lead to overheated
metal and costly down time and repairs.
b. Elimination of corrosive gases, in supply or
boiler water.
c.. Prevention of intercrystalline cracking or
caustic embrittleihent of boiler metal.
d. Prevention of carryover and foaming.
The accomplishment of these objectives generally
require treatment before and after introduction of
water into the boiler.
The selection of pre-treatment processes depends
upon water source, chemical characteristics,
amount of make-up water needed, plant opera-
ting practices, etc. These treating methods in-
clude filtering, softening, demineralizing, de-
aerating and preheating.
After treatment involves the addition of chemi-
cals to the boiler water. This after treatment is
required to compensate for any variations in the
pre-treatment and pre-boiler system and to
assure the ultimate protection of the boiler. Be-
cause of the variables involved, no one "boiler
compound" can be considered a cure-all, nor is it
advisable to experiment with home-made treat-
ing methods. Sound recommendations and their
employment should be augmented by periodic
analysis of the raw water, boiler water and con-
densate.
The internal or waterside surfaces of the pressure
vessel should be inspected with sufficient fre-
quency to determine the presence of any contami-
nation, accumulations of foreign matter, corro-
sion, and/or pitting. If these conditions are de-
tected, the water consultant or feedwater treat-
ment company should be consulted for advice on
corrective action.
It is advisable to have a properly sized water
meter installed in the raw water make-up line to
accurately determine the amoun.t of raw water
admitted to the boiler. This will aid the water
treatment program in maintaining proper water-
side conditions.
1-9

CHAPTER 2
OPERA TIONS AND PROCEDURES
A. PREPARATION TO INITIAL FIRING
B. FILLING THE BOILER
C. INITIAL FIRING
D. ROUTINE OPERATION AND SHUTDOWN
E. OPERATING PROCEDURES
A. PREPARATION TO INITIAL
FIRING
The operator must be knowledgeable of the
boiler, the burner and all controls and compo-
nents and must be competent to operate this
equipment. The operating conditions of all auxili·
ary equipment and instrumentation that serves in
the firing and feeding of the boiler should be for-
mally checked out. Be sure that auxiliary equip-
ment not supplied by Cleaver-Brooks is of ade-
quate size and pressure to insure proper
operation.
Check for proper voltage, fuses and overloads.
Check rotation of all motors by momentarily clos-
ing the motor starter or relay. Check the reset of
all starters and controls having the manual reset
feature. To the extent possible, all operating me-
chanisms, valves, and the air damper and drive
should be checked for evidence of operation and
freedom from binding. Check the settings of all
controls.
Verify fuel supply. Make certain that fuel
pressure is sufficient and that gauges are indi-
cating correctly. Properly set any adjustable limit
on interlock controls. Pretest them for proper
function at set points if feasible.
Before operating a boiler feed pump or an oil sup-
ply pump, be sure that all valves in the line are
open or properly positioned. Be certain that
pump rotation is correct. If in doubt, remove
coupling and check motor rotation. Some pumps
can be severely damaged by even a momentarily
reversed rotation. Also recheck coupling align-
ment.
Check out the burner in accordance with pro-
cedures given in the burner instruction manuaL
Chapter 2 . Operations and Procedures
Safety valves should be inspected externally to
see that they are free to operate and that their
escape piping and drain piping are open to at-
mosphere and free to expand without imposing
strain upon the safety valve body. Make sure that
any gags used during testing are removed. Ascer-
tain that discharge piping from the safety valves
and also from all blowdown and drain valves is
piped to a SAFE point of discharge, so that
emission of hot water or steam can not possibly
cause injury to personnel or damage to property.
Prior to closing drum manholes, make certain
that all internal fittings are in place and that no
tools, gear or personnel remain inside. Make a
final check of the fireside area to make sure no
tools, construction gear, debris or personnel are
present.
For safety's sake, make a final and complete pre-
startup inspection especially checking fO.r any
loose or incompleted piping or wiring or any
other situation that might present a hazard.
B. FILLING THE BOILER
Check and close the manual blowoff valves, the
continuous blowdown valves, the gage cocks and
the water column and gage glass drain valves.
Open the upper drum vent valve, the water
column shutoff valves, if any, the gage glass
shutoff valves and the steam pressure gauge
valve. Open the superheater vent and drain
valves.
The boiler should be filled with properly treated
feedwater using the bypass feed line. The water
should be as close as possible to the metal tem-
perature to prevent excessive temperature
2·1
 Chapter 2 - Operations and Procedures
stresses that could cause tube leakage. 70°F.
minimum water temperature is recommended
unless ambient is considerably higher or lower.
Fill to a level about two inches above the bottom
of the .gage glass. Fill slowly and vent fully to
prevent any pressure buildup from the flashing of
warm water.
Blow down the water column and gage glass
making sure that the water level returns to the
proper level promptly. The gage cocks should also
be operated to verify water level.
C. INITIAL FIRING
Start the burner following the instructions in the
burner operating manual. Make sure that com-
bustion is stable. Check and adjust the burner
and its components as outlined in the burner
manual.
The firing rate should be manually controlled
and held in the low fire position until the boiler is
properly warmed. Generally, the control circuit
has a low fire control which will prevent the bur-
ner from firing in other than the low fire position,
until the boiler is sufficiently warm. This control
is usually adjusted to cut in at approximately 50
psi.
The boiler should be brought up to temperature
and pressure at a slow and carefully controlled
rate. Conditions can vary, however, an accepted
rate of water temperature rise for a steam boiler
is approximately 80 to lOO°F. per hour.
On a superheater equipped boiler, it is imperative
that the superheater vent valve be open while the
steam valve is closed. The flow of steam through
the superheater is essential for the protection of
the tubes. Refer to the superheater section in this
manual.
During this period of operation, carefully observe
that all components function properly. Be pre-
pared to shut the unit down should a lack of pro-
______p~:t'. ...Q.P~:t'atiQILh.eJ:.QJnJLeYjd ent. . _Yis.u.allyob.seLY~
combustion conditions for proof that gauges,
meters and other instrumentation are properly
reporting conditions.
Close the drum vent when steam pressure is 10 to
25 psi. Open any drain or bypass valve in the
steam piping, if provided. Refer to superheater
section for information on its vent and drain
valves.
Maintain the normal water level at all times.
This is usually 4 inches below the steam drum
center line. Maintain the water level by hand
feeding or by blowing down as necessary. Too
high a level will cause flooding and render the
2-2
separators ineffective, while too low a level will
allow possible overheating of pressure parts. If
the water level is not readily apparent, use the
gage cocks and close inspection to determine the
level. If the level is not visible, firing should be
stopped and the reason for low level determined.
The feed water regulator should be cut in when
operating pressure is obtained and the bypass
feed line valves closed.
The operation of the safety valves should be veri-
fied. This may involve raising the boiler pressure
beyond normal operating setting to actually
determine that valves open and close within the
proper limits or it may require the hand lifting of
the valve lever. The judgment and recommenda-
tion of the authorized inspector should determine
the method used.
When boiler pressure has increased to the desired
point, the boiler can be cut into service according
to good operating practice.
D. ROUTINE OPERATION AND
SHUTDOWN
Check water level and water supply. Check set-
ting of operating controls and burner equipment.
Start burner and slowly bring boiler up to
pressure. Observe functions of all controls during
normal operations.
Maintain normal water level at all times. This is
usually 4 inches below steam drum center line.
Gage glasses should be blown down on a regu-
larly scheduled basis. Illumination of the glass
should be provided and any leakage or breakage
of glass should be promptly repaired.
Blow down the boiler at regular intervals on a
schedule based upon analysis of the water. Make
any necessary adjustments to the con .. nuous
blowdown valve as indicated by a test analysis.
Refer to the blowdown section of this manual.
When operating with oil as the fuel, soot blowers
····-sheul4be..opel'ated-Fegulal'lyto.k~p-gaspa.gsages
free from soot and to maintain normal tempera-
tures and efficiency. Refer to the section on soot
blowing in this manual.
ROUTINE SHUTDOWN
Operate all soot blowers before taking the unit off
the line, if oil is the fuel being used.
Gradually reduce load and run burner to low fire
position.
With the burner in low fire position, blow down
boiler along with the water column gage glass
and the feed water regulator. Turn the burner off

in accordance with instructions in the burner
manual. Follow instructions in regard to burner
shutdown conditions. When shutting down a gas
fired burner, it is good practice to close the
manual gas shutoff cock.
When the boiler falls below line pressure, the
non-return valve should close automatically to
isolate the unit from those remaining in service.
On a single installation or if no other boilers are
in service, the stop valve should be closed when
the boiler setting has cooled enough to insure no
pressure build up. When the drum pressure falls
below 25 psi, open the top drum vent valve. This
will prevent a vacuum that can loosen well set
gaskets and cause future leaks.
The boiler should be filled with treated hot water
in preparation for the next start up. Additional
water care may be necessary and recommended
by the feed water consultant if the shutdown is
prolonged.
During an extended shutdown, the drain valves
under the furnace floor and the convection section
should be opened to permit any leaking water to
escape. Close valves during operation.
E. OPERATING PROCEDURES
1. FEED WATER REGULATION AND CONTROL
The boiler is standardly equipped with a thermo-
hydraulic, single element feed water regulator
which will automatically maintain the proper
water level when used with a suitable source of
water supply.
Refer to the manufacturer's literature, provided
separately, for specific instructions on the feed-
water regulator. The generator portion must be
properly filled with liquid - either water (pre-
ferably distilled) or with an anti-freeze solution,
if conditions require.
When placing the boiler into service, the drum
level must be maintained manually until the
boiler has reached operating pressure. Manual
control is accomplished through the manual
operation of the bypass valve orby locking the
regulator valve open with its hand jack lever and
throttling the adjacent hand valve to keep the
drum water level in the center of the gage glass.
To switch from manual to automatic operation,
release the regulator valve hand jack and open
wide the hand valve ahead of the regulator valve.
If the regulator fails to maintain proper water
level during normal operation, refer to the manu-
facturer's instructions for corrective adjustment.
The regulator and water column are factory
piped at the proper levels and generally need no
alteration. ' come erratic in operation or if its setting changes
Chapter 2 - Operations. and Procedures
2. WATER LEVEL INDICATING SYSTEM
The water level alarm system employs electrodes
or probes mounted in a water column. These are
electrically connected to relays in the limit and
alarm circuits. The action of the relay depends on
electrode immersions to complete each circuit.
See Figure 3-1 and also refer to the wiring dia-
gram provided for the boiler.
A minimum of 4 circuits is always provided al-
though individual installations may have addi-
tional. The four circuits are comprised of two low
water cut-off circuits, a low water alarm circuit,
and a high water alarm circuit.
Electrodes numbered 1 and 4 serve as low water
cut-offs. Each of these is connected to an indivi-
dual relay. A third electrode, identified as C, is a
common electrode wired to all relays.
As long as these three are immersed, the water
level is considered suitable for operation and the
relay contacts are closed to complete the limit cir-
cuit. Should the water level lower to the point
where these are no longer immersed, the limit cir-
cuit will be interrupted and the burner will shut
down or be prevented from operating.
To assure adequate water level above the cutoff
level, a shorter electrode identified as No. 2 is
wired to a low water alarm relay. This electrode
is normally immersed. Should this electrode be
exposed by lowering water level, the alarm horn
(AH) will sound and the low water light (LWL)
will glow to alert the operator to this condition.
This protection occurs while the burner is in
operation or when the burner switch is closed in
anticipation of operation.
Normally electrode No.3, which is connected to a
high water alarm relay, will not be immersed. If
the water level reaches the height of this elec-
trode, the relay will be energized to sound the
alarm horn and light the high water light (HWL).
An alarm test switch (A TS) is provided to simu-
late alarm conditions when depressed so that a
check may be made to determine that the alarm
signal devices are in working order without
disturbing burner operation.
The need to periodically check water level con-
trols and the waterside of the pressure vessel can-
not be overemphasized. Most instances of major
damage are the result of operating with low
water or the use of untreated (or incorrectly)
treated water.
Low water cut-off devices are generally set by the
original manufacturer and no attempt should be
made to adjust these controls to- alter the point of
low water cutoff. If a low water device should be-
2-3
Chapter 2 - Operations and Procedures
from previous established levels check for reasons
and correct: repair and replace device as
required.
Figure ~l is a replica of the low water cut-off
plate attached to a steam boiler. The instructions
should be followed on a definite planned
schedule. These controls normally function for
long periods of time which may lead to laxity in
testing on the assumption that normal operation
will continue indefinitely_
If the boiler is equipped with a float type water
column or an auxiliary low water cut-off, the
head mechanism should be removed from the
bowl at least once a month to check and clean the
float ball, the internal moving parts, and the
bowL
Periodically remove the pipe plugs from the tees
or crosses to make certain the cross connecting
piping is clean and free of obstructions_ Controls
must be mounted in a vertical position for proper
performance. Determine that piping is vertically
aligned after shipment and installation and
throughout life of equipment.
A scheduled blow down of the water controls
should be maintained.
WARNING
SAFE OPERATION OF YOUR BOILER DEMANDS PERIODIC
INSPECTION AND MAINTENANCE OF ALL lOW WATER
CUT -OFF DEVICES. INSPECT THEM AT LEAST ONCE A
MONTH. PROPER OPERATION SHOULD BE CHECKED PRE-
QUENTLY BY CLOSING FEED WATER VALVE WITH BOILER
IN OPERATION AND ALLOWING WATER LEVEL TO OROI'
AT A NORMAL RATE. IF CONTROLS UNDER TEST 00 NOT
CUT OFF BURNER AT PROPER SAFE WATER LEVEL OR
ARE SEEN TO BE IN POOR PHYSICAL CONDITION, REPAIR
OR REPLACE AT ONCE. MUD AND SEDIMENT ACCUMA-
LATIONS IN THE GAGE GLASS, WATER COLUMN, AND
AUXILIARY LOW WATER CONTROLS SHOULD BE ELIM-
,-INATED BY PROPER BLOWDOWN PROCEDURE.
FIGURE 2-1 LOW WATER CUT-OFF PLATE
3. THE WATER COLUMN
In addition to the probes described in the pre-
vious section, the water column also contains the
equipment to provide the operator with visual
knowledge of the water leveL
The gage glass attached to the side of the column
is used to visually check the boiler water leveL
The trycocks can be used to check the accuracy of
the gage glass levels. The gage cocks provide a
means of isolating the gage glass in the event of
the breakage or replacement.
2-4
This visual knowledge of the water level is one of
the most important operating guides available to
the operator. The importance of frequent ob-
servation of the water level cannot be over-
emphasized.
Keep the gage glass clean and properly lighted
for good visibility. Refer to the operating and
maintenance section of this manual for blowdown
test procedures and replacement.
Operate the gage cocks regularly to insure their
being satisfactory for emergency service.
The normal water level in a Cleaver-Brooks
Watertube Boiler is 4" below the center of the
steam drum. This level is indicated at the mid
point of the gage glass.
The low water alarm probe is usually positioned
to be energized should water fall approximately
5" below normaL The alarm signal will alert the
operator of this condition.
Should water level fall to approximately to 1/2"
visibility in the gage glass, the low water cut off
probe will be exposed and will act to shut down
the burner.
The ASME Boiler and Pressure Vessel Code
requires that the lowest visible point of the water
glass shall be at least 2" above the lowest per-
missible water level. This is the point at which
there will be no danger of overheating any part of
the boiler when operation is at that level.
CAUTION: In the event the burner is firing at
any time that water is not visible in the water
gage glass, immediately turn the burner off
manually. DO NOT TURN ON THE WATER
FEED LINE.
DO NOT OPEN THE SAFETY VALVE. Let the
~ boiler cool until a drum is at hand touch tem-
perature. Then add water to a height of 1" in the
gage glass. DO NOT PUT THE BOILER BACK
INTO SERVICE UNTIL THE CONDITION
RESPONSIBLE FOR THE LOW WATER HAS
BEEN IDENTIFIED AND CORRECTED. Do
not attempt to put the boiler back into operation
if there is evidence of overheated metal, or even
suspected damage, until a thorough inspection
and/or repairs have been made_
Check the water gage on a regular basis. A
weekly frequency is suggested. The check should
be made when there is steam pressure in the
boiler. Close the lower gage glass valve, then
open the drain cock on the bottom of the valve
and blow the glass clear. Close the drain valve
and open the lower gage glass valve. Water
should return to the gage glass immediately_ If

water return is sluggish, leave the lower gage
glass open and close the upper gage glass valve.
Then open the drain valve and allow water to
flow until it runs clear. Close the drain valve and
repeat the first test with the lower gage glass
valve closed.
If leaks appear around the water gage glass or fit-
tings, correct the leaks at once. Steam leaks may
result in a false water line and may also damage
fittings.
The handles on the gage glass cocks must be in-
stalled on the valve stems so that their position
indicates whether the valve is open or closed. The
operating chaifi on the right hand side of the
levers should be snug between levers so that both
valves will be closed tight when the chain is
pulled from below.
4. SLOWDOWN
Boiler water blowdown is the removal of some of
the concentrated water from the pressure vessel
while it is under pressure. The removed water
containing suspended solids and dissolved solids
is replaced with relatively' pure feedwater so that
a lowering of the concentration occurs.
Solids are brought in with the feedwater even
though this water is treated prior to use through
external processes designed to remove the un-
wanted substances which contribute to scale and
deposit formations. Regardless of their high ef-
ficiency, none of these processes in themselves are
capable of removing all substances and a small
amount of encrusting solids will be present in the
boiler water.
The solids become less soluble in the high tem-
perature of the boiler water and as the water
boils off as relatively pure steam, the remaining
water becomes thicker with either suspended
solids or dissolved solids.
Internal chemical treatment, based on water
analysis, is used primarily to precipitate many of
the solids and to maintain them as "sludge" in a
fluid form. This sludge along with suspended
solids that may be present must be removed by
the blow down process.
If the concentration of solids is not lowered
through blow down but rather accumulates, foam-
ing and priming will occur along with scale and
other harmful deposits.
The scale forming salts tend to concentrate and
crystalize on the heating surfaces. Scale has a low
heat transfer value. It acts as an insulation
barrier and retards the transfer. This not only re-
sults in low operating efficiency and consequently
higher fuel consumption, but also presents the
Chapter 2 - Operations and Procedures
possibility of overheating the boiler metal. The
result can be tube failures or other pressure
vessel metal damage causing costly repairs and
downtime. Deposits of sludge on heating surfaces
will have the same detrimental effect.
There are two principal types of blowdown; in-
termittent and continuous. Intermittent, or
sludge, is done manually and is necessary for the
operation of the boiler regardless of whether or
not continuous blowdown is employed. Continu-
ous blowdown is, as the name implies, a continu-
ous and automatic removal of concentrated
water.
Manual Slowdown
The manual blowdown valve and discharge lines
are located at the bottom or low point of a boiler
so that in addition to lowering the dissolved
solids in the boiler water, a portion of sludge
which might accumulate in the lower part of a
pressure vessel can also be removed. This opening
also provides a means of draining the boiler when
it is not under pressure.
When continuous blow down is utilized, manual
blowdown is primarily used to remove suspended
solids or sludge that may have accumulated in
the area. When continuous blowdown is not
utilized, manual blowdown is used to control the
concentration of dissolved or suspended solids in
addition to the sludge.
In practice, the valves of the bottom blowdown
are opened periodically in accordance with an
operating schedule and/or chemical control test.
The blowdown amount and schedule should be
recommended by a water treating company or a
water consultant. It is generally recommended
that a steam boiler be blown down at least once
in every eight hour period. In cases where the
feed water is exceptionally pure, blowdown may
be employed less frequently since less sludge ac-
cumulates in the pressure vessel.
From the standpoint of control, economy, and re-
sults, frequent short blows are preferred to infre-
quentlengthy blows. This is particularly true
when the suspended solids content of the water is
high. With the use of frequent short blows, a more
uniform concentration of the pressure vessel
water is maintained. Blowing down is most ef-
fective at a time when the generation of steam is
at the lowest rate since the feed water input then
is also low, providing a minimum dilution of the
boiler water with low concentration feedwater.
Make sure that blowoff piping, and tank if used,
are in proper operating condition, all discharge
vents clear of obstruction and that waste is piped
to point of safe discharge.
2-5
 Chapter 2 . Operations and Procedures
It is recommended that the blowdown valve near-
est the boiler be opened first and closed last, with
blowing down being accomplished by the valve
furthest from the boiler. The sequence of opera-
tion oncs established should provide that the
valve last opened should be the first closed so
that the other valve is saved from throttling ser-
vice to insure a tight closing.
Th~ downstream valve should be cracked slightly
to allow the discharge line to warm up, after
which this valve is opened slowly. Quickly close
the valve, and if necessary, repeat this opening
and closing.
Close the downstream valve tightly, then close
the valve next to the boiler. Slightly crack open
the downstream valve, then close it tightly. The
frequency and amount of each blow should be
determined by actual water analysis. It is advis-
able that blowdown does not exceed the necessary
amount since it involves heat losses and, if ex-
cessive, wastes treatment chemicals.
The water level should be observed during
periods of blowdown. If the glass cannot be
viewed by the party operating the valve, another
operator shou.ld watch the glass and direct the
valve operator. The blowoff valves should never
be left open and the operator should never leave
until the blowdown operation is completed and
the valves closed. Be sure the valves are shut
tight. Repair any leaking valves as soon as
possible.
Continuous Blowdown
The boiler is equipped with an internal continu-
ous blowdown pipe and an external stop valve.
Th.e collector pipe is located several inches below
the low water level at a point where the most con-
centrated water is found.
A controlled orifice valve is used in the discharge
pipe to allow continual, yet controlled, flow of
concentrated water. This removes sediment and
oil from the surface of the water along with the
prescribed amount of dissolved solids ..
·-~-tn-'a····boileri:hat-\)perates·-continuoustr-at· full··
...._ing...the~.elem.eD.t .._........
load, there is little chance for separation of
sludge in the lower drum because of the rapid
boiler water circulation. Thus, blowoff from the
lower part of the unit may not result in the proper
elimination of suspended solids. The use, how-
ever, of the continuous blowdown does not pre-
clude the regular use of the bottom or inter-
.niittent manual blowdown.
The amount of water lost through a continuous
surface blowdown is usually considerably less
than the water lost through bottom blowoff in or-
der to remove a given amount of suspended
2-6
solids, The amount of 'blowdown depends upon
the rate of evaporation and the amount of siudge
forming material in the feedwater.
Periodic. adjustments are made to the valve set-
ting to increase or decrease the amount of blow-
down in accordance with a test a·nalysis.
Internal inspection is the only true indication of
the effectiveness of water treatment and presence
of unwanted solids.
5. SOOT BLOWING
Systematic soot blowing should be included as a
regular feature in the operation of any oil burn-
ing watertube steam boiler. The frequency and
amount of cleaning will depend upon operating
conditions, grade of fuel and burner adjustment.
Experience will dictate the length of cleaning and
the interval between.
The following guidelines should be observed.
The soot blower must be operated only when the
burner is firing at a rate of 70% or higher, Place
the burner under manual operation, if necessary,
to 'hola the boiler at near maximum firing rate
despite load variations.
Operating at low loads should never be at-
tempted because of the possible hazards involved.
It is important to have all areas of the gas passes
thoroughly swept by utilizing maximum flue gas
flow to purge any combustible material from
pockets where it may collect. Cleaning operations
during a low firing rate may produce unfavorable
conditions that could interrupt combustion.
Prior to blowing, the drain valve in the steam line
to the soot.blower should be opened. Then open
the steam shut-off valve slowly and vent steam
for approximately five minutes to insure that no
water is present in the steam line and to warm
the piping. -Close the vent valve.and begin rotat-
Rotate with a steady pull on the chain wheel and
be sure to keep rotating whenever steam is issu-
ing from the nozzles.
The amount of cleaning, or number of times the
element is rotated, can be governed by observing
exit temperature or stack discharge.
A generally recommended pract.ice is to op~rate
all soot blowers prior to taking a boiler off line.
At the conclusion of blowing, close the steam
header valVE!. The factory installed drain valve
has a small·hole drilled in its gate to allow escape

of steam and condensate. If the drain valve wall
provided by others, open it to drain the line.
The blowing pressure is adjustable and should be
set in a range of 80 to 150 psi. Refer to the manu-
facturer's bulletin for instructions on pressure ad-
justment.
Maintenance:
Follow the manufacturer's recommendations for
lubrication of the gears and head. Keep the pack-
ing glands just tight enough to prevent leakage,
but do not overtighten. Also examine to the ex-
tent possible the external surfaces of the tubes
adjacent to the element nozzles for any signs of
abrasion possibly caused by movement of the ele-
ment due to distortion or shifting.
Air, taken from the blower discharge, is piped to
the head so that it and the element are suffici-
ently pressurized to prevent the backup of com-
bustion gases from the pressurized furnace.
Periodically check the condition of the airline to
make sure there are no obstructions or loose con-
nections. Also, inspect the air check valve on the
head for free operation.
6. SUPERHEATER
General
Correct operational procedures must be followed
during the starting up and shutting down of a
boiler equipped with a superheater to prevent
damage from occurring to the superheater tubes.
It is essential that definite procedures be
established and followed by all operators.
Start-up
A moderate firing rate (generally about 10% of
maximum) must be used during start-up and dur-
ing the warming up of a cold boiler and super-
heater. The addition of heat too rapidly may in-
crease the superheater metal temperature to a
point where it will oxidize or "burn". The control
. system~generarryiiiaudesa-rowfire~pressure con-
trol that limits the burner to low fire operation
until the boiler pressure reaches approximately
one-third operating pressure (or approx. 50 psi).
When starting the boiler, the superheater vent
valve must be opened until the non-return valve
is opened and steam flow through the system is
established. This keeps steam flowing through the
superheater tubes. It is imperative that a positive
flow of steam be maintained whenever the super-
heater is subjected to heat. The heat absorbed by
the superheater must be carried away at the same
rate that is transmitted to the tubes.
Chapter 2 - Operations ·and Procedures
When boiler pressure reaches 15 to 25 psi, close
the drain valve but leave the vent valve wide
open. A tendency may exist to throttle the vent
valve in order to save steam or to raise pressure
at a faster rate. While this is not without some
advantage, it is more desirable to protect the
superheater by leaving the vent valve open until
the boiler is on the line and with a definite (not
less than 10%) flow of steam into the system.
A steam temperature recorder or thermometer
should be installed on the upstream side of the
vent valve and as close to the outlet of the super-
heater as practical. Temperatures taken at a
more remote point may not provide true super-
heater temperature readings. Steam flow tem-
perature at this point can then be a fairly ac-
curate temperature indicator of the superheater
tube metal and the rate of firing can be con-
trolled within a safe range. The temperature
should increase gradually and should, in general,
be well below the maximum temperature for
which the superheater was designed. Tempera-
tures approaching this maximum will indicate
that the firing rate is too high. In this event, the
firing rate should be decreased or stopped alto-
gether.
An accepted rate of boiler water temperature rise
for a steam boiler is approximately 80°F. per
hour. The protection of the superheater is the pri-
mary factor controlling the time required for
placing the boiler into service.
Normal Operation
During normal operation, the superheater re-
quires no special safeguards other than the main-
tenance of the conditions for which it was
designed.
When firing on oil, use the soot blower on a regu-
larly scheduled basis to keep the superheater sur-
faces free of soot or other deposits. Periodically
check for effectiveness and also on the alignment
of the steam jets.
.. J'h~ !!!lperl1~A!~r..ha!l~a!!aJl:!ty. YaJYI:! th.1ij;i!l..!!~t to
open at a lower pressure than the boiler safety
valves. In the event of excessive steam pressure,
this valve will open first so that steam from the
boiler will continue to flow through the super-
heater tubes. If the boiler pressure is not dissi-
pated or the fire reduced, the boiler safety valves
will then open.
Shutting Down
During the shutting down operation, it is also
necessary to maintain steam flow through the
superheater. The vent valve should be opened as
the boiler is taken off the line. The drain valve
2-7
Chapter 2 . Operations and Procedures
should I:emain closed. An acceptable practice is to
open the vent valve fully when the boiler is first
taken off the line and then to close it in gradual
steps as furnace temperature decreases. The
amount 'Of valve opening can be based on the
temperature of the steam indicated by the
thermometer in the superheater outlet.
When the furnace is cool, the valve may be
closed. In some multiple unit installations, the
boiler may be kept on standby service with ·its
water kept hot through introd!lction of steam
from another unit and in this event, the vent
valve should rem'ain open.
2-8
If the boiler is removed from service, open all
drain valves to drain water caused by condensa-
tion. The superheater should be visually
examined during the annual inspection and, if
possible, during other down periods. Check the in-
ternal surfaces for scale, corrosion, also for
evidence of leaks or overheating. Replace the
gaskets in the header handholes. Make sure that
gasket seating surfaces are clean.
If the boiler is to be idle for any length of time,
follow the instructions in this manual pertaining
to the care and protection of idle boilers.
 Chapter 3 . Maintenance

CHAPTER 3

MAINTENANCE
A. GENERAL
WATERSIDE INSPECTION
FIRESIDE INSPECTION
B. PRESSURE VESSEL CARE AND REPAIRS
C. TUBE CLEANING
MECHANICAL TUBE CLEANING
CHEMICAL CLEANING
D. WATER COLUMN
PROBE INSTALLATION
GAUGE GLASS OR PRISMATIC INSERT
E. SAFETY V ALVES
F. CARE AND PROTECTION OF IDLE BOILERS

A. GENERAL tive action that may prevent excessive repairs or

A well planned maintenance program avoids un-
necessary down time or costly repairs, promotes
safety and aids boiler code and local inspectors.
An inspection schedule listing the procedures
should be established. It is recommended that a
boiler room log or record be maintained, re-
cording the daily, weekly, monthly and yearly
maintenance activities. This provides a valuable
guide and aids in obtaining economies and length
of service from the boiler.
Even though the boiler has electrical and me-
chanical devices that make it automatic or semi-
automatic in operation, these devices require
systematic and periodic maintenance. Any "auto-
matic" features do not relieve the operator from
responsibility, but rather free him from certain
repetitive· chores, providing him time to devote to
upkeep and maintenance.
Good housekeeping helps maintain a professional
appearing boiler room. Only trained and
authorized personnel should be permitted to
operate, adjust, or repair the boiler and its re-
lated equipment. The boiler room should be kept
free of all material and equipment not necessary
to the operation of the boiler or heating system.
Alertness in recognizing an unusual noise, im-
proper gauge readings, leaks, signs of over-heat-
ing, etc., can make the operator aware of a de-
veloping malfunction, permitting prompt correc-
unexpected down time. A steam, water, or fuel
leak should be repaired as soon as possible. They
are wasteful as well as hazardous.
Always be sure of the boiler water level. The
water column should be blown down at least once
each eight hour shift. Check samples of boiler
water and condensate in accordance with pro-
cedures recommended by your water consultant.
Daily maintenance should include a check of the
burner operation, including fuel pressure, atomiz-
ing air or steam pressure, visual appearance, etc.
Clean the observation ports during periods of low
fire or shutdown.
Maintain a daily schedule of soot blowing and in-
termittent blowdown. Refer to previous sections
for additional information.
WATERSIDE INSPECTION
Insurance regulations or local laws will require a
periodic inspection of the pressure vessel by an
authorized inspector. Sufficient notice is
generally given to permit removal of the boiler
from service and preparation for inspection.
Inspections of thi.s type are usually, though not
necessarily, scheduled for periods of normal
boiler down time 'such as an off season. This
major inspection can often be used to accomplish
maintenance, replacements or repairs that cannot

3-1
Chapter 3 - Maintenance
easily be done at other times. This also serves as
a good basis for establishing a schedule for an-
nual, monthly or other periodic maintenance
programs.
While this inspection pertains primarily to the
waterside and fireside surfaces of the pressure
vessel, it provides the operator an excellent op-
portunity for detailed inspection and check of all
components of the boiler including piping, valves,
pumps, gaskets, refractory, etc. Comprehensive
cleaning, spot painting or re-painting and the re-
placement ofexpendable items should be planned
for and taken care of during this time. Any major
repairs or replacements that may be required
should also if possible be coordinated with this
period of boiler shutdown.
Replacement spare parts, if not on hand, should
be ordered sufficiently prior to shutdown.
When shutting down, the load should be reduced
gradually and the pressure vessel cooled at a rate
that avoids damaging temperature differential
that can cause harmful stresses. Vessels should
not normally be drained until all pressure is re-
lieved and water temperature is less than 120°F. -
again to prevent uneven contraction and tem-
perature differentials that can cause expanded
tubes to leak. Draining the unit too quickly may
cause the baking of deposits that may be present
on the heating surfaces. Some heat, however, may
be desirable to dry out the interior of the boiler.
If the internal inspection is being made at the re-
quest of an authorized inspector, it is well to
learn from him whether he desires to observe the
conditions prior to cleaning or flushing of water-
side surfaces.
Be certain that a supply of manhole gaskets is
available along with any other gaskets or items
needed to place the unit back into operation after
inspection.
Have availabl€"'information on the boiler design,
dimensions, generating capacity, operating
pressure ox temperature; time in serviBe, defects
found previously and any repairs or modifi-
cations. Also have available for reference records
of pr.evious inspections.
Be prepaKed to perform any testing required by
the inspector including hydrostatic.
After proper cooling and draining of vessel, flush
out the waterside with a high pressure water
hose. Remove any scale or deposits from the
waterside surfaces and check for internal or ex-
ternal corrosion and leakage.
The fireside surfaces should also be thoroughly
cleaned so that metal surfaces, welds, joints, tube
3-2
ends, fittings' and any previous repairs can be
readily cMcked.
Be sure that steam valves, system valves, (hot
water) feedwater valves, blow-off valves, all fuel
valves, valves to expansion tanks, and electrical
switches are shut off'prior to opening the drums or
the combustion area. Adequately vent the presslJ,re
vessel prior to entry. Flashlights rather than ex-
tension cords are recommended as a safety factor.
Cleaners should preferably work in pairs. Always
have one man standing by outside when a man is
working inside a boiler.
Clean out the low water cut-off piping, the water
level controls and cross connecting piping. Re-
place water gage glass and clean out water cocks
and tri-cocks. Also check and clean drain and
blowdown valves and piping.
Check all water and steam piping and valves for
leaks, wear, corrosion and other damage. Replace
or repair as required.
If any deposits are noted during these inspections,
they should be flushed out with a high pressure
hose. If they are not thoroughly removed by flush-
ing, this may require immediate consultation
with your water treatment representative. In a
few cases, it may be necessary to resort to acid
cleaning. Professional advice is definitely re-
commended should acid cleaning be required.
The effectiveness of treatment, water conditions
and the amount of fresh water makeup required
are all factors to be considered in establishing
frequency of future pressure vessel inspections.
The feedwater consultant or water treatment
companies service should include periodic
pressure vessel inspection and water re-analysis.
FIRESIDE INSPECTION
An internal, or fireside, inspection should be
made at least semi-annually and oftener if pos-
sible. Wire brush or sweep away any deposits that
might be present in the furnace area. If excessive
soot or any signs or corrosion are evident,prompt
co:n:ective action must be taken. Combustion ad-
justments should be made to prevent further oc-
currences. Poor combustion contributes to a dirty
boiler, adds hazards and wastes fuel.
Check the condition of all the refractory. Parti-
cularly check the expansion joints in the fmnt
and rear walls, the seals at the corners and the
throat tile. Patch and repair as required.
Frequent wash coating of refractory surfaces is
recommended. Use high temperature bonding,
air-dry type mortar diluted with water, to the
consistency of light cream, for this purpose. This

will seal small cracks and prolong the life of the
refractory. Any large cracks should be cleaned
out and filled with mortar.
The breeching and stack should be inspected
periodically and cleaned if necessary. Also in-
spect the stack for -any signs of damage.
The fireside should be thoroughly cleaned prior
to any extended lay-up of the boiler.' Depending
upon circumstances a protective coating may be
required. See the section on storage.
B. PRESSURE VESSEL CARE
AND REPAIR
A well maintained and operated boiler with pro-
perly treated water will require a minimum of re-
pairs. Periodic inspection of the pressure vessel
will reveal its' condition, oftentimes permitting
corrective action designed to prevent failure of
some portion of the boiler.
Corrosion and erosion, or a combination of both,
are a chief cause of tube failure. Corrosion is a
chemical action occurring inside or outside the
tube wall. Internal corrosion appears as pitting
or a general failing of the tube walL Pitting oc-
curs when there is free oxygen in the water where-
as general thinning indicates an acid condition in
the boiler water. External corrosion is very likely
to occur when a full boiler covered with soot lies
idle. Most soot contains some percentage of sulfur
which in the presence of moisture from condensa-
tion forms a highly corrosive acid.
Erosion takes place when considerable quantities
of fine particles are driven at high velocity
against the outside surfaces of the tubes. Erosion
may also be caused by soot blowers if nozzles are
not kept in proper alignment.
Over-heating also contributes to damage. This
usually occurs when a tube is heated to a tem-
perature which reduces its tensile strength. The
weaker walls then rupture under normal opera-
ting pressure. The chief cause of over-heating is
scale on the water side of the tubes. Scale is a
poor conductor of heat and the cooling ability of
the boiler water is lessened: Low water is another
cause of over-heating since circulation of water is
impaired and the tube is starved of water. An oily
film also acts as an insulator permitting over-
heating. Any sign of oil in the boiler should be
considered serious and prompt action taken to
remove it.
Over-loading a boiler to produce more steam
than intende'd by its design.will also shorten the
boiler life, with the tubes being first to suffer.
Chapter 3 - Maintenance
If small leaks occur, locate their source and. re-
pair them as quickly as possible. Leaking man-
holes and handholes should be corrected promp-
tly. Gasket sealing surfaces should be cleaned
thoroughly to provide a tight seal.
In the event of a serious leak or a tube failure,
shut down the burner and the supply of feed-
water. When steam pressure has dropped to zero,
continue the cooling process in the normal man-
ner. Then conduct a thorough inspection to deter-
mine the extent of damage.
No repair of any type is to be made until pressure
is removed from the boiler. Observe all safety pre-
cautions before entering the boiler for inspection
or repairs. This includes securing the burner and
positive action in insuring all valves in lines to
and from the boiler are closed and remain closed.
Minor or leaking repairs may be handled by
authorized and experienced personnel. Any re-
pairs beyond this must have the approval of an
authorized inspector. His recommendations and
advice must be followed. If welding is required,
the welder must be certified to do the work.
Boiler tubes are secured in the boiler drums by
rolling or expanding to a tight fit. In the correction
of any leak, it is imperative that rerolliJ;lg of the
leaking tube be done only be experienced person-
nel. Inexperienced operators tend to overroll the
tube, thus thinning the joint and making it
difficult to tighten under any circumstances. When
seal welding is employed, a light rerolling should
be made after welding.
C. TUBE CLEANING
1. MECHANICAL TUBE CLEANING
The mechanical method of cleaning water tubes,
referred to as turbining or punching, is ac-
complished through the use of motor driven ro-
tary cutting tools and brushes. The necessity for
and frequency of this type of cleaning is deter-
mined by an internal inspection. The type of de-
posits will determine the ne-ed Jor using cutting or
scraping tools and a brush 01' a' brush only. Air
driven tools are most commonly used although
water driven tools are also employed. Steam
driven and electric driven tools are used infre-
quently. Cleaning tools furnished by or obtained
from Cleaver-Brooks are selected for the size of
the boiler tubes and for their ability to negotiate
the bends of 'the tubes.
The mecnanical cleaning of tubes and the use of
these tools should be 9,one by experienced opera-
tors or at least under their supervision. There are
companies who specialize in cleaning and their
3-3
Chapter 3 . Maint.enance
experience and equipment will quite often justify
their employment.
This work is generally done from within the up-
per drum, working the tool down through the
tubes so that debris falls into the lower drum
from. where it can be collected and removed. The
baffle plates in the upper drum will have to be reo
moved -for access to the tubes.
There are several general operating suggestions
that should be followed as good operating prac-
tices:
a) Start the cleaner rotating in the tube and
l1ass it slowly and uniformly through at ap-
proximately two to three feet per minute.
b) Do not allow cleaner to protrude from the
tube while under power. This can be danger-
ous to personnel and damaging to equip-
ment.
c) Care should be taken not to allow the
cleaner-.to stop in anyone position in the
tube.
d) Keep working tools in good condition.
e) If electrical driven tools are used, be sure
they are properly grounded.
The following specific operating instructions are
provided by Thomas C. Wilson, mc. - Manu-
•facturer of tube cleaning equipment.
OPERATING I~STRUCtIONS FOR AIR DRIVEN
CLEANER
RECOMMENDE·D OPERATING AIR PRESSURE
90 PSI. MAY BE OPERATED AT 60 TO 100 PSI.
HOW TO SET ~UP THE TUBE CLEANER:
L Blowout air line before attaching operating
hose in order to remove all dirt, rust, or other
foreigp- matter.
2. Attach automatic lubricator (if included in
your equipment) to air outlet. Connect hose.
3. Blowout the air-line and hose again.
4. Connect the tube-cleaner air v?lve (if included
in your equipment) to the hose.
5. Attach motor, making sure connections are
wrench-tight - buf not jammed - to prevent
air leakage.
6. Using wrench supplied with equipment, screw
universal joint or flexible holder to motor.
7. Attach the cleaning .or brushing tool.
HOW TO OPERATE -T~E TUBE CLEANER:
L Insert the cleaning tool into the tube, then
open the air valve and feed the motor into the
tube slowly enough to properly clean the tube.
3-4
2. Don't let the cleaning tool run out of the end
of the tube - you'll damage it. A good prac-
tice is to mark the operating hose with tape or
other visible marking to indicate exa-ct length
of tube.
3. Keep the motor running when pulling it back
through the tube.
4. Shut off the air and stop the motor before tak-
ing it out of the tube.
5. If cleaning tool jams in deposit, pull motor
back gently to release it. CO.ntiriue cleaning.
6. If motor functions improperly, it is probably
due to faulty lubrication or dirt in the air-line.
Take motor apart and clean all parts, includ-
ing the rotor blades, with kerosene.
LUBRICATION:
L To lubricate the motor, use one part Wilsolube
No. 9047 oil to two parts kerosene.
2. The needle valve on the automatic lubricator
controls the feed of oil to the motor. Feed 10 to
20 drops per minute depending on the size of
cleaner. This small amount of oil will not coat
the tubes. It will be absorbed and blown out
with the debris .
3. If you do not have an automatic lubricator use
an oil can to apply a few drops of oil into the
exhaust ports of the motor. Turn the motor by
hand to distribute the oil and then blowout
motor before inserting into the tube.
4. KEEP MOTOR LUBRICATED.
HOW TO PREVENT RUST AND CORROSION IN
STORAGE:
1. Before storing your tube cleaner, clean and oil
it thoroughly with machine oil to prevent
rusting.
2. The best method of storing straight tube
motors is to keep them in oil.
3. Curved tube motors, - suspend the motor in
011 keeping the hose piece above the level of
the oil as the hose piece will not stand pro-
longed immersion in oil.
OPERATING INSTRUCTIONS FOR
WATER DRIVEN CLEANER
The operation of the water driven cleaner is
essentially the same as the air driven type with
the following changes or instructions:
1. The water line from the pump to the hose con-
nection should be larger than the hqse fur-
nished with the water motor: If the water sup'"

ply is not free of sediment, be sure to use an
adequate strainer.
2. Motors should be operated at pressures of 125
to 175 lbs. psi. Consumption will vary from 20
to 30 gpm depending upon motor size and
operating pressure.
3. The water acts as a lubricant, therefore no
lubrication is necessary.
4. After using, it is a good policy to disassemble
motor, thoroughly clean and dry, oil and store
in a dry place.
2. CHEMICAL CLEANING
Should. a waterside inspection reveal a deposit
build-up that cannot be fully removed by flushing
or mechanical means, it may be necessary to
clean with chemicals (acid). Professional advice
is recommended. There are specialist companies
equipped to provide complete chemical cleaning
service. Your feedwater consultant should be con-
tacted and be aware of the situation.
D. WATER COLUMN
1. PROBE INSTALLATION INSTRUCTIONS
Thread electrode probe into holder finger tight.
Lock in place using a wrench on lower hex and
another on the lock nut. Do not use a wrench on
the upper hex while installing the probe.
See Figure 3-1. . The inner gasket and the glass should be placed
Clean the female threads in the water column
plate. If they require chasing, use a 3/8" SAE
DRY SEAL (PTF) tap. Do not use a standard
3/8" NPT tap. Teflon tape or a small amount of
pipe dope may be used on the male threads. Use a
13/16" deep socket wrench on upper hex to
tighten electrode holder. Take care not to crack
the insulator.
When attaching the wire lug use proper wrenches
on both lug nuts so that no torque is applied to
the electrode holder. Do not use a knurled nut or
10ck washer.
2. THE GAGE GLASS OR PRISMATIC
GAGE INSERT
When a tubular glass is used, it is imperative that
the gage cocks are mounted in exact alignment. If
they are not, the glass will be strained and may
fail prematurely.
A broken or discolored glass should be replaced
at once. Periodic replacement should be a part of
the maintenance program. Always use new
gaskets when replacing a glass. Use a proper size
Chapter 3. - Maintenance
rubber packing. Do not use "loose packmg
which could be forced below the glass and pos-
sibly plug the valve opening.
Close the valves when replacing the glass. Slip a
packing nut, a packing washer, and packing ring
onto each end of the glass. Insert one end of the
glass into the upper gage valve body far enough
to allow the lower end to be dropped into the
lower body. Slide the packing nuts onto each
valve and tighten. See Figure 3-2.
If the glass is replaced while the boiler is in ser-
vice, open the blowdown and slowly bring the
glass to operating temperature by cracking the
gage valves slightly. After glass is warmed up,
close the blow down valve and open the gage
valves completely.
If the water c.olumn is equipped with a prismatic
gage insert, it should be inspected for leakage af-
ter it has been placed in service. When thoroughly
heated, expansion of the metal parts causes the
bolting pressure to ease somewhat and if leakage
is apparent, it is advisable to go over to the bolts
and tighten them lightly and evenly to prevent
further leakage. See Figure 3-3.
To clean or replace the prismatic glass, remove
the insert from the gage valves. Thoroughly clean
the gasket seat surface after the old glass and
gaskets have been removed. The surface must be
smooth and free from scratches to prevent shat-
tering the replacement glass.
centrally on the insert body. Be careful that they
remain correctly located when the outer or
cushion gasket and cover plate are placed in posi-
tion. Put all the clamps, washers, and nuts
loosely on the studs. Finger tighten all of the nuts
first. Then starting from the center pair of nuts,
tighten in alternate pairs towards either end.
Tighten each nut about one sixth revolution at a
time. Go over the nuts enough times to draw them
all up to 35 to 40 foot pounds of torque.
After mounting the insert in the valves, open the
blowdown valve and slowly bring the glass up to
operating temperature by· cracking the stea.m
valve slightly to allow a small amount of steam
to heat the insert. When thoroughly heated, close
the blowdown valve and open both steam and
water valves. .
Figures and gauge replacement information cour-
tesy of the Clark Reliance Corporation.
E. SAFETY VALVES
The safety valve is a very important safety device
on the boiler and deserves attention accordingly.
3-5
 Chapter 3 - Maintenance

PLUGGED TAPPINGS FOR

OPTIONAL EQUIPMENT
LOW WATER HIGH WATER ALARM
FUEL CUTOFF *~~9--~~-
LOW WATER.
ALARM
~~~'-~__(..LLOW WATER
FUEL CUTOFF
873-96
ELECTRODE
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13/16" UPPER HEX-1~~~iit~~

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Distance
Elec Wire Top of Plote to
Function
No. Term. Tip of Electrode
1 A Low Water Fuel Cut-off' !18·3{8" i 67-243 20"
2 E Low Water Alarm i 15·5/8"; 67-242 17-1/4"
3 0 High Water Alarm 5·3{8" ! 67-241 7-1/4"
4 B Low Water Fuel Cut-off 118·3/8" ! 67-243 20"
C C Common .18·3/8" I 67-243 20"

FIGURE 3-1 STANDARD WATER COLUMN ASSEMBLY

MALLEABLE IRON
CLAMPS

PRISMATIC MACHINE
GLASS GLASS
PACKING BOLTS

(jASKETS

CROSS SECTION
BEFORE TIGHTENING
FIGURE 3-2 FIGURE 3-3
TUBULAR GAGE GLASS PRISMATIC GAGE INSERTS
3-6

The purpose of the valve(s) is to prevent pressure
build up over the design pressure of the pressure
vessel. The size, rating and number of valves on a
boiler is determined by the ASME Boiler Code.
The insta,llation of a valve is of primary import-
ance to its service life. A valve must be mounted
in a vertical position so that discharge piping and
Code required drains can be properly piped to
prevent build up of back pressure and accumu-
lation of foreign material around the valve seat
area. Apply only a moderate amount of pipe com-
pound to male threads and avoid overtightening
as this can distort the seats. Use only flat jawed
wrenches on the flats provided. When installing a
flange connected valve, use a new gasket and
draw the mounting bolts down evenly.
A drip pan elbow or a flexible connection be-
tween the valve and the escape pipe is re-
commended. See Figure 3-4. The discharge piping
must be properly arranged and supported so that
its weight does not bear upon the valve.
NOTES:
I. DIMENSION BETWEEN VALVE AND DRIP PAN ELBOW SHOULD BE
AS SHORT AS POSSIBLE.
2. DISCHARGE PIPING MUST BE fNDEPENDENTLY SUPPORTED SO
THAT NO S'rRAIN IS PLACE1> OK VALVE BODY.
3. ALL DRAIN LINES SHOULD BE INDEPENDENTLY SUPPORTED AND
PROPER EXPANSION PROVISIONS MADE TO ELIMINATE ALL
STRAIN ON VALVE BODY.
~. ALLOW SPACE TO COMPENSATE FOR UPWARD EX PANS ION OF
80 I LER WHEN HOT.
5. PROVIDE 3 OR ~ EQUALLY SPACED SPACERS TO CENTER
DISCHARGE PIPE. MUST BE FREE, TO ALLOW FOR EXPANSION.
FIGURE 3-4 STEAM SAFETY VALVE
Do not paint, oil, or otherwise cover any interior
or working parts of the safety valve. A valve does
not require any lubrication or protective coating
to work properly.
Chapter 3 - Ma.intenance
Follow the recommendations of your Boiler In-
spector pertaining to valve inspection and testing.
The frequency of testing, either by the use of the
lifting lever or by raising the steam pressure,
should be based on the recommendation of your
Boiler Inspector, and/or the valve manufacturer,
and in accordance with section VII of the ASME
Boiler and Pressure Vessel Code.
Avoid excessive operation of the safety valve as
even one opening can provide a means of leakage.
Safety valves should be operated only often
enough to assure that they are in good working
order. When a pop test is required, raise the oper-
ating pressure to the set pressure of the safety
valve, allowing it to open and reseat as it would
in normal service.
Do not hand operate the valve with less than
75% of the stamped set pressure exerted on the
underside of the disc. When hand operating, be
sure and hold the valve in an open position long
enough to purge accumulated foreign material
from the seat area and then allow the valve to
snap shut.
Frequent usage of the safety valve will cause the
seat and disc to become wire drawn or steam cut.
This will cause the valve to leak and necessitate
down time of the boiler for valve repair or re-
placement. Repair of a valve must be done only
by the manufacturer or his authorized repre-
sentative.
Avoid having the operating pressure too near the
safety valve set pressure. A 10% differential is re-
commended. An even greater differential is desir-
able and will assure better seat tightness and
valve longevity.
Steam is expensive to generate and, for the sake
of economy, wastage should be avoided whenever
possible.
F. CARE AND PROTECTION OF
IDLE BOILERS
Many boilers used for heating or seasonal loads,
or for standby service, may have extended periods
of non-use. Special attention must be given to
these, so that neither water side nor fire side sur-
faces are allowed to deteriorate from corrosion.
Corrosion can be more serious during this down
time than when the boiler is actually in service.
Too many conditions exist to lay down definite
rules. There are two methods of storage -- wet or
dry. Your water consultant or feed water treating
company can recommend the better m,ethod, de-
pending upon circumstances in a particular in-
stallation. Section VII of the ASME Code also
contains information relating to laying up a
boiler.
3-7
Chapter 3 - Maintenance
When shutting down, the pressure should be
reduced gradually, and the pressure vessel cooled
at a rate that avoids damaging temperature d5f-
ferential that can cause harmful stresses. A vessel
should not normally be drained until all pressure
is relieved -- again to prevent uneven contraction
and -temperature differentials. Draining the unit
too quickly may cause the baking of deposits that
may be present on the heating surfaces. Some
heat, however, may be desirable to dry out the in-
terior of the boiler.
After proper cooling and draining, fluslJ. out the
water side with a high pressure water hose. Re-
move any scale or deposits from the water side
surfaces and check for internal or external corro-
sion and leakage.
DRY STORAGE
Dry storage is generally employed when the boiler
will be out of service for some time or when freez-
ing temperatures may occur. In this method,- the
boiler must be thoroughly dried, since any
moisture will cause corrosion. Both water side and
fire side surfaces must be clean of all scale and
deposits, soot, etc. Steps must be taken to elimi-
nate moisture by placing moisture absorbing
material, such as quick-lime or silica-gel, on trays
inside the drums and furnace. These trays should
not be completely filled with the material, so that
the corrosive liquid gathered in them does not
overflow onto the boiler surfaces. Refractories
should be brushed clean and wash-coated. Fire
side surfaces may be sprayed or coated with an
anti-corrosive material. All openings to pressure
vessel must be shut tightly. Feedwater and steam
valves should be closed. Damper and vents should
be closed to prevent air from reaching fire side sur-
face. Periodic inspection must be made and the ab-
sorption m$iterials renewed.
Care must be taken to remove all of the moisture
absorbing material before any attempt is made to
refill the boiler. Serious damage can result other-
wise. As a precaution it is recoIIitnendedthat
warning signs be conspicuously posted. These
signs could be similar to the following;
3-8
IMPORT ANT -- MOISTURE ABSORP-
TION MATERIAL HAS· BEEN PLACED
IN THE WATERSIDE AND FURNACE
AREAS OF THIS BOILER. THIS MA-
TERIAL MUST BE REMOVED BEFORE
ANY WATER IS PLACED IN BOILER
AND BEFORE BURNER IS FIRED.
INSPECT PERIODICALLY AND RE-
PLACE WITH FRESH AND/OR REGENE-
RATED MATERIALS.
WET STORAGE
Wet storage is generally used for a boiler held in
standby condition or in a case where dry storage
is not practical. The possibility of freezing tem-
peratures must be considered. Care must be taken
to protect metal surfaces. Variables preclude defi-
nite recommendations, however, it is suggested
that after the vessel is drained and cleaned that it
be refilled to overflowing with treated water. If
deaerated water is not available, the boiler
should be fired to boil the water for a short
period of time. Additional chemicals may be
suggested by the water consultant to minimize
corrosion. Internal water pressure should be
maintained at greater than atmospheric pressure.
Nitrogen is often used for this purpose. Fire side
surfaces must be thoroughly cleaned and re-
fractories should be wash-coated. It is advis-
able, if feasible, to occasionally circulate the
water to prevent stratification and to insure that
fresh inhibitor is in contact with all the surfaces.
If additional chemicals are added for this idle
period, more frequent blowdowns may be re-
quired when the boiler is returned to service to
rapidly reduce the chemical composition to nor-
mal operating levels.
During storage, steps should be taken to protect
the exterior components from the possibility of
rust or corrosion. These parts should be coated
with a rust inhibitor and protected from moisture
and condensation. Operating controls, regulators,
valves, etc. should be drained and dried. Electri-
cal equipment should likewise be protected.
Keeping the control circuit energized may prevent
condensation from forming in the control cabinet
or on the flame safeguard control.
 CHAPTER 4

PARTS ORDERING INSTRUCTIONS AND PARTS LIST

FURNISH COMPLETE INFORMATION WHEN
ORDERING PARTS - When ordering parts for
your boiler, be sure to include on your order the
boiler serial number shown on the name plate at-
tached to the front head. Your order should state the
Cleaver-Brooks part number and the name and
description of the part required. State the quantity
desired, and specify method of shipment. Indicate
date material is required. If repair parts are required
for accessory equipment, such as an electric motor,
pump, etc., which may not be shown, be sure to give
the complete name plate data from the item for
which the parts are required.
WHERE TO ORDER PARTS - Repair or replace-
ment parts should be ordered from your Cleaver-
Brooks representative.
RETURNING PARTS FOR REPAIR - Parts to be
repaired should be directed to your Cleaver-Brooks
representative. A purchase order or a letter authoriz-
ing repairs and giving complete details should be
mailed to your representative. Prior to returning,
please remove fittings or accessories from the com-
poneqt, properly drain and clean part to comply with
shipping regulations and include jnside of the
package a packing slip identifying the part with your
company's name.
If you desire to return parts for reasons other than
repair or exchange, please contact your representa-
tive stating reasons for the return and await permis-
sion and directions prior to returning the material.
Many controls and other components can be factory-
rebuilt (FR) or have a trade-in value. These items
are available on an exchange basis. Consult your
Cleaver-Brooks representative.
Be sure to show the serial number of your unit on all
parts orders and correspondence.

®
~roOK5

WATERTUBE BOILER
MODEL PRESSURE PSI _

DATE
HEATING SURFACE
UNIT NO. BOILER SO. FT. _ WATERWALL SO. FT. _

CLEAVER-BROOKS DIVISION
AOUA·CHEM. INC.
MILWAUKEE. WISCONSIN U.S.A.

IT IS R,ECOMMENDED THAT YOUR LOCAL CLEAVER-BROOKS

REPRESENTATIVE BE CONTACTED FOR PROMPT SUPPLY OF
REPLACEMENT PARTS.
CLEAVER-BROOKS

4-1
Chapter 4-Parts List

PARTS LIST
Part No. Req. Description

853-798 4 Gasket, Manway, 12" x 16"

851-213 1 Gage Glass, 3/4" x 18-1/4"
853-711 2 Gasket, 3/4", Gage Glass
873-96 5 Fitting, Water Column Electrode
943-259 1 Wrench, Water Column Electrode
67-241 1 Electrode, Water Column, 1/4" x 5-5/8"
67-242 1 Electrode, Water Column, 1/4" x 15-5/8'"
67-243 3 Electrode, Water Column, 1/4" x 18-3/8" ,
67-201 1 Electrode, Water Column, 1/4" x 6-1/8"
67-247 1 Electrode, Water Column, 1/4" x 13-1/8"
825-142 1 Valve Set, Gage Glass
825-140 3 Trycock
880-100 2 Lens Kit, Blue - Observation Port
880-104 2 Lens Kit, Clear - Observation Port
880-106 2 Nut, Bakelite - Observation Port

NOTE: The above are standard replacement parts.

Refer to the Burner Manual for additional parts.

MODEL "A" BURNER Part No. 750-311

MODEL "BR" BURNER Part No. 750-305
MODEL "CN" BURNER Part No. 750-308

4-2