Packaged

Firetube Boilers
Installation Manual
STEAM

750-452 11/2021
 ! WARNING
DANGER
Do not operate the equipment until the unit is properly installed
and commissioned by an authorized service technician.

To the Installer
This manual presents information to assist in the installation of Cleaver-Brooks firetube boilers. Items cov-
ered include lifting and moving the boiler, placement of the boiler, boiler room requirements, and connec-
tions to the boiler, system operating requirements, and water treatment requirements. The information is
presented to enable the installer to quickly install the unit with the least risk of damage to the equipment.
Recommendations given in this manual are the minimum requirements pertaining to CB firetube boilers.
Insurance and local or state regulatory codes may contain additional or more stringent requirements than
those noted in this manual. Installation must conform to the requirements of the owner's insurance carrier,
state/provincial and local codes governing such equipment, and/or any other authority having jurisdiction.
Prior to installation, the proper authorities having jurisdiction are to be consulted, permits obtained, and
other preparatory actions taken as necessary.
This manual contains an installation checklist which should be completed before the initial start up of the
boiler. Refer to manual 750-454 for start-up procedures after the boiler has been properly installed.
Additional information may be obtained from your local Cleaver Brooks factory authorized representative.
Refer to the specific Dimension Diagram of the boiler for project specifics, tappings, and connection loca-
tions.
Throughout this manual, procedures or operations that require special attention are emphasized with a
cautionary note. The notes are identified by the symbols WARNING!, CAUTION! or NOTE, signifying the
following:

WARNING! Indicates a potentially hazardous situation which, if not avoided,

could result in serious personal injury or death.

CAUTION! Indicates a potentially hazardous situation which, if not avoided,

could result in damage to the equipment.

NOTE: Indicates information that is vital to the operation or maintenance of the equipment.
 FIRETUBE PRODUCT NOMENCLATURE

CB firetube boilers use the following naming convention:

CBEX-2W-200-500-150ST
Boiler horsepower ST = Steam
Number of passes HW = Hot water

Fuel Series Design pressure

Burner type and tube design 100 = light oil only
LE = smooth bore tubes, integral burner 200 = combination gas & light oil
EX = extended surface tubes, integral burner 700 = natural gas
JT = gun/jet burner

Turnaround design
W = Water back
D = Dry back

SCOPE OF THIS MANUAL

This manual covers the following products:

CBEX CBJT CBLE

2 and 3 pass waterback 2, 3, and 4 pass waterback 4-pass dry and waterback
2-pass dryback 2-pass dryback

natural gas, light oil, or combina- natural gas, light oil, or combina- natural gas, light oil, or combina-
tion tion tion

100-2200 horsepower 50-1800 horsepower 50-800 horsepower

50-250+ psig steam High and low pressure steam High and low pressure steam

iii
 ADDITIONAL RESOURCES

This manual is intended to be general in scope and appli-

cable to all Cleaver-Brooks firetube boilers. For dimen-
sions, boiler ratings, utility requirements, performance
criteria, and additional information on specific boiler mod-
els and sizes, refer to the applicable Cleaver-Brooks Boil-
er Book section. Boiler Book sections are accessible at
cleaverbrooks.com/products-and-solutions/boilers/fire-
tube on the respective product web pages.

For ultra low NOx applications and for CBEX 1300-2200

HP, also see the following manuals where applicable:

750-220 NTI burners

750-339 XL burners (vertical)
750-276 XL burners (horizontal)
750-291 NTXL burners
750-421 LNO burners
The Boiler Book
For CBJT boilers refer to the appropriate ProFire® burner manual:

PROFIRE® BURNERS, CBJT BOILERS

BURNER
MODEL BHP NOX RATING BURNER
MANUAL

STANDARD V
100-200 750-237
30 PPM LNV

STANDARD E
CBJT-2W 250-800 750-297
30 PPM LNE

STANDARD XL
900-1200 750-339
30 PPM LNXL

STANDARD K 750-282
100-300
30 PPM LND 750-204

CBJT-3W STANDARD D
350-800 750-204
CBJT-4W 30 PPM LND

STANDARD S1
900-1600 750-208
30 PPM LNS1

CBJT-2D 50-200 STANDARD V 750-237

iv
CONTENTS
LIFTING AND MOVING THE BOILER 1
Roller Rails 2
THE BOILER ROOM 3
Placement of the Boiler 3
Clearances 3
Combustion/Ventilation Air Supply 4
BOILER CONNECTIONS (GENERAL) 6
Bottom Blowdown 6
Safety Valve 6
Electrical Connections 8
Flue Vent Connections 8
STEAM BOILER CONNECTIONS 10
Steam Supply 10
Feedwater Makeup 11
Water Column Drain 12
Surface Blowoff 12
Other Options 12
FUEL SYSTEM 13
Main gas train 13
Pilot train 14
Burner drawer 14
Gas Supply Requirements 15
Oil Piping: 100 and 200 Fuel Series 18
WATER REQUIREMENTS 19
WATER TREATMENT 20
INSTALLATION CHECKLIST 21

v
NOTES

vi
LIFTING AND MOVING THE BOILER

1 - LIFTING AND MOVING THE BOILER

Cleaver Brooks firetube boilers are equipped with two lifting lugs located on the top centerline of the vessel.
These lugs should be used to the lift the boiler. Do not move the boiler by pushing, prying or pulling on the
boiler casing.

Consult the Cleaver-Brooks Boiler Book for specific models to find the lifting lug locations for each model by
size. The following recommendations are generic and apply to all boiler models.

60°
MAX

! Caution
In order to avoid damage to the unit, lifting or mov-
ing the boiler should only be done by experienced
personnel with suitable equipment for moving
heavy industrial equipment.

FIGURE 1. Lifting the boiler

Suitable equipment adequate to safely lift and support the boiler within the restrictions of the chain angles
should be on hand when the boiler arrives at the project site. Approximate shipping weights (dry weight) for
specific models can be found in the Cleaver-Brooks Boiler Book.

If rollers are used to transport the boiler, they should be positioned under the base in line with the lifting lugs
(see below). If pipes or other rollers are used to move the boiler, the boiler must be supported by at least
three evenly spaced rollers at all times.

If an overhead lifting device is not available, jack plates may be welded to the base rails to allow lifting by the
base for placement of rollers. Plates should be as close as possible to the boiler legs to avoid bending the
base rails.

750-452 1
Firetube Installation - Steam
 LIFTING AND MOVING THE BOILER

Roller Lifts
(fixed @ legs)

FIGURE 2. Roller placement

If the opening for the boiler is too narrow to permit the boiler to pass through, determine what controls may
be removed from the package to permit access. This should be discussed with the local Cleaver Brooks rep-
resentative before any items are removed.

1.1 - Roller Rails

For boilers with an optional roller rail assembly, remove this assembly before installing the boiler.

! Caution
Remove the (optional) roller rail assembly before
installing boiler. Failure to do so may result in
damage to the equipment.

FIGURE 3. Roller Rails (optional)

2 750-452
Firetube Installation - Steam
THE BOILER ROOM

2 - THE BOILER ROOM

2.1 - Placement of the Boiler

The boiler must be installed on a level non-combustible floor. If the floor is not level, piers or a raised pad will
make the boiler installation and leveling easier.

Six-inch high mounting piers are recommended for use beneath the boiler base frame. The use of these
piers provides increased inspection accessibility to the boiler and added height for washing down the area
beneath the boiler. See the Boiler Book for specific models for mounting pier length and width dimensions.

The floor, pad or piers must be of sufficient load bearing strength to safely support the operating weight of the
boiler and any additional equipment that may be installed with it. Approximate boiler operating weights can
be found in the Boiler Book section for the respective model.

After the boiler is placed, it must be leveled from side to side and front to back. If shims are required, the
weight of the boiler must be evenly distributed at all points of support.

! Caution
The pressure vessel support legs are welded to mounting skids in front and secured by bolts at the rear of the
pressure vessel. The bolts are tightened for shipment. When the boiler is installed, and prior to initial fir-
ing, the bolts securing the rear legs to the skid must be loosened to allow for expansion and contrac-
tion caused by differences in temperature between pressure vessel and skids.

2.2 - Clearances

The boiler must be installed so that all components are accessible for inspection, cleaning, or maintenance.
Field installed piping and electrical connections to the burner or boiler must be arranged in a manner that
permits swing out of the burner.

In addition to maintaining clearances to walls or other obstructions, boiler surfaces that become heated
during operation require minimum clearances to combustible materials.

Overall boiler room width must be sufficient to accommodate dimensions A (minimum distance between
boiler and wall) and B (distance between boilers) as shown below. These dimensions for specific models can
be found in the appropriate Boiler Book section.

750-452 3
Firetube Installation - Steam
 THE BOILER ROOM

A B
FEEDWATER
TANK

BOILER
FEEDWATER
PUMP

DRAIN

TRENCH

FIGURE 4. Typical boiler room layout

Boiler room length should allow for tube cleaning and replacement. Consult the Boiler Book for specific mod-
els for tube replacement clearances.

Local codes regarding boiler clearances should take precedence.

2.3 - Combustion/Ventilation Air Supply

A method of supplying combustion air, satisfactory for complete fuel combustion in the boiler and proper
ventilation of the boiler room, must be provided.

The volume of air required and the duct or air supply opening in square feet shall be determined relative to
the rating of the burner and the altitude of the project installation. Air inlets shall be sized in accordance with
applicable engineering guidelines and regulatory codes.

When determining boiler room air requirements for an unconfined space*, the size of the room, airflow, and
velocity of air must be reviewed as follows:

4 750-452
Firetube Installation - Steam
THE BOILER ROOM

1. Size (area) and location of combustion air supply for the boiler:
a. Two (2) permanent air supply openings in the outer walls of the boiler room are recommended. Locate one
(1) at each end of the boiler room, preferably below a height of 7 feet. This allows air to sweep the entire
length of the boiler.
b. Air supply openings can be louvered for weather protection, but they should not be covered with fine mesh
wire as this type of covering has poor air flow qualities and is subject to clogging with dust or dirt.
c. A vent fan in the boiler room is not recommended as it could create a slight vacuum under certain conditions
and cause variations in the quantity of combustion air. This would result in unsatisfactory or unsafe burner
performance.
d. Under no circumstance shall the total area of the air supply be less than one square foot.
e. Size the openings by using the formula:

Area [ft2] = cfm/fpm

Where cfm = cubic feet per minute of air
and fpm = feet per minute of air

2. Amount of air required (cfm) cubic feet per minute:

a. Combustion Air: Maximum Bhp x 8 cfm
b. Ventilation Air: Maximum Bhp x 2 cfm

= a total of 10 cfm per Bhp up to 1000 feet elevation. Add 3% more per each 1000 feet of added elevation.

3. Acceptable air velocity in the Boiler Room (fpm) feet per minute.
a. From floor to 7 feet in height - 250 fpm
b. Above 7 feet in height - 500 fpm
c. Duct from air supply to boiler - 1000 fpm

EXAMPLE: To determine the area of the boiler room air supply opening for a 60hp boiler at 700 ft elevation
with air opening 8 ft above the floor level:
ft2 = 10 cfm(60)/500 fpm from steps 2 and 3 above.

= 600/500 = 1.2 square feet of opening, minimum.

*Having at least 50 cubic feet of open area for every 1,000 Btu of input (NFPA).

750-452 5
Firetube Installation - Steam
 BOILER CONNECTIONS (GENERAL)

3 - BOILER CONNECTIONS (GENERAL)

NOTE: Connection sizes and locations and associated boiler trim components may vary. For installation
purposes consult the Dimension Diagram provided with the boiler.

3.1 - Bottom Blowdown

Connections for bottom blowdown are provided at the front and/or rear of the bottom drum.

A blowdown valve(s) must be piped from this connection to a safe point of discharge; piping is not supplied
with the boiler.

For high pressure boilers a quick open valve and a slow open valve are normally piped from the blowdown
connection; these valves must be rated at 150 psig or greater. If two blowdown connections are provided on
the boiler, two quick open valves piped in common to a single slow open valve may be utilized.

3.2 - Safety Valve

The safety valve is an essential device. Its purpose is to relieve pressure buildup within the vessel in excess
of the maximum design pressure. The size, rating, and quantity of valves on a boiler are determined in
accordance with the A.S.M.E. code or other code/specification requirements. Check the boiler dimension
diagram for the number and size of the boiler's safety relief devices. The location of the safety valve(s) is on
the top centerline of the vessel near the rear. Safety valves are shipped unmounted, normally in a separate
box or carton.

Each relief device must be mounted in a vertical position with no shutoff devices between it and the boiler
connection. Discharge piping must be properly piped to a safe point of discharge to the roof or to an area of
discharge that will not expose personnel to escaping steam or water. See figure below for suggested steam
pressure relief valve piping using a drip pan elbow. Discharge piping from the safety valve is not furnished by
Cleaver-Brooks.

6 750-452
Firetube Installation - Steam
BOILER CONNECTIONS (GENERAL)

NOTES
1. SUPPORT FROM BUILDING CONSTRUCTION
2. DISCHARGE OPENING MUST BE EQUAL TO OR LARGER THAN INLET
3. BACK PRESSURE OF STEAM EXHAUST SYSTEM MUST BE LESS THAN 6% OF SAFETY VALVE SETTING

FIGURE 5. Safety valve

Discharge piping must be arranged and properly supported so that the piping weight does not bear upon the
valve; piping should be as short and direct as possible.

Do not paint, oil, or otherwise cover any interior or working parts of the relief valve. A relief valve does not
require any lubrication or protective coating to work properly.

Ensure that the relieving capacity matches the output requirement of the boiler as stamped on the boiler and
on the relief valve.

NOTE: Discharge piping from relief valves, blowdown valves, and other drains must be arranged so that all
components remain accessible for inspections, cleaning, or maintenance. Relief valves and their discharge
piping are to be installed to conform to A.S.M.E. Code requirements.

750-452 7
Firetube Installation - Steam
 BOILER CONNECTIONS (GENERAL)

! Caution
Care must be exercised in the installation of a relief valve to ensure that the valve functions as designed.
Apply only a moderate amount of pipe compound to male threads. Avoid over-tightening, as this may dis-
tort valve seating surfaces. Use only flatted wrenches on the flats of the valve.

! Warning
Incorrect or improper installation of the relief valve may affect valve operation. Only certified personnel
such as the relief valve manufacturer's representative should adjust or repair the boiler relief valve.
Failure to observe this warning could result in serious injury or death.

3.3 - Electrical Connections

Electrical power supply to the boiler must be of proper voltage, phase, and hertz as inscribed on the burner
or electrical nameplate. All connections made to the boiler must comply with the National Electric Code and
local code requirements and must be arranged so that all components remain accessible for inspection,
cleaning, and maintenance. Refer to the wiring diagram (WD) prepared by Cleaver-Brooks for the specific
project when wiring to the boiler.

3.4 - Flue Vent Connections

The breeching between the boiler and the chimney/exhaust stack must be no smaller in diameter than the
connection provided on the boiler. The proper sizing of stacks and breeching is required in order to maintain
proper flue gas velocity with a static draft condition (0" w.c.) although the burner can work within a +/- 0.25"
variance. Therefore the pressure drop in the breeching and stack should not exceed these parameters.

The horizontal run to the stack should be held to a minimum and all horizontal runs pitched away from the
boiler at a minimum of 0.25" per 100 feet. A drain connection should be provided at all low spots. Round
breeching or stacks are recommended and are more efficient than square or rectangular shapes. In multiple
boiler applications, connections to the common breeching should be with sweeping elbows; avoid bull head
tees.

Material type of the breeching and stack will be governed by local codes and jurisdictions. For these pur-
poses most CB firetube boilers are considered a Class III appliance, defined as a non condensing positive
pressure venting product. Therefore, the stack/breeching must be of the positive pressure design, normally
double wall type (if single wall, stack/breeching should be insulated). Roof or wall penetrations should be in
accordance with UL and local code requirements.

The maximum load on the flue vent connection at the boiler is 2000 pounds. Boilers can be reinforced to
support up to 3000 pounds.

8 750-452
Firetube Installation - Steam
BOILER CONNECTIONS (GENERAL)

PITCH UP TO STACK
o
10 MAX

o
45

MAINTAIN ON
ONE PLANE

FIGURE 6. Breeching arrangement, multiple boilers

Breeching size for multiple boilers should take into account the volume of flue gas that will flow through suc-
cessive additions of boilers and breeching runs. Do not merely size the breeching for multiple boilers relative
to the exhaust connection of each boiler. Draft calculations should be performed and the common stack/
breeching designed accordingly.

NOTE for <9ppm, <7ppm, <5ppm NOx applications:

Every boiler requires its own independent exhaust stack
OR
If a single free standing or similar stack is used for multiple boilers, each boiler requires its own independent
breeching to the stack and the application requires C-B approval.

750-452 9
Firetube Installation - Steam
 STEAM BOILER CONNECTIONS

4 - STEAM BOILER CONNECTIONS

Exhaust Steam Outlet

Surface Blowoff Safety Valve(s)

Gauge Glass
Blowdown

Water Column Blowdown Bottom

Blowdown

Bottom Blowdown

Surface
Blowoff

Chemical
Feedwater Feed
Water Column
Blowdown

FIGURE 7. Steam boiler connections

4.1 - Steam Supply

Connection to the system header or system supply line is made at the fitting at the upper drum near the cen-
ter of the boiler.

10 750-452
Firetube Installation - Steam
STEAM BOILER CONNECTIONS

ASME code requires a stop valve in each steam outlet as near the boiler nozzle as possible. Valves of over
2" pipe size must be Outside Stem and Yoke (OS&Y), rising stem type.

If the boiler was not shipped with a stop valve, the installing contractor will have to supply the proper valve.

Check valves (non-return), where used, should be piped in the horizontal position to minimize the likelihood
of contaminant build up on the valve seat and disc.

Steam piping must be connected per the ASME Code and local jurisdictions and as defined in the project
specifications.

4.2 - Feedwater Makeup

The boiler feed piping requires a globe valve and a check valve (ASME Power Piping B31.1 Section
122.1.3). The connection size is noted on the boiler dimension diagram.

See the table below for the water quantity required based on the evaporation rate of the boiler; ensure the
pumps are rated greater than this capacity.

As an option, the boiler may have been provided with an electrically powered modulating feedwater valve or
an on/off feedwater valve. If so, this assembly will need to be piped to the boiler and may include a 3-valve
by-pass around the feedwater control valve. This assembly is generally factory pre-piped and shipped sepa-
rately from the boiler.

Table 1: Evaporation Rates

Approximate evaporation
Boiler HP Approximate gal/hr
rate (lb water/hr)
50 1,725 210
60 2,070 250
70 2,415 295
80 2,760 335
100 3,450 420
125 4,312 525
150 5,175 630
200 6,900 840
250 8,625 1,050
300 10,350 1,250
350 12,075 1,470
400 13,800 1,680
500 17,250 2,100
600 20,700 2,500
700 24,150 2,940
800 27,600 3,360
900 31,050 3,780
1000 34,500 4,200
1100 37,950 4,620
1200 41,400 5,000
1300 44,850 5,460
1400 48,300 5,880
1500 51,750 6,300
1600 55,200 6,720
1800 62,100 7,560
2000 69,000 8,400
2200 75,900 9,240

750-452 11
Firetube Installation - Steam
 STEAM BOILER CONNECTIONS

4.3 - Water Column Drain

The primary water column is equipped with a column drain valve. This must be piped to a safe point of dis-
charge.

The column drain may be connected to the boiler blowdown piping and also with the water column gauge
glass.

If a float or external probe type Auxiliary Low Water Cutoff control (ALWCO) has been provided, the drain
connection of this control must be piped to a safe point of discharge.

4.4 - Surface Blowoff

A surface blowoff tapping is standardly provided. As an option, a manually operated surface blowoff valve
may have been provided. If this has been provided, this valve should be piped to a safe discharge or blow-
down separator.

In lieu of an optional manual surface blowoff valve, an optional conductivity control valve assembly may
have been provided, shipped loose. If this has been provided, this assembly should be piped and wired to
the boiler.

4.5 - Other Options

There may be additional tappings provided in accordance with the project requirements and these are gen-
erally noted on the boiler dimensional diagram.

12 750-452
Firetube Installation - Steam
FUEL SYSTEM

5 - FUEL SYSTEM

NOTE: For technical details on the burner and fuel delivery systems for CBEX 1300-2200, CBJT, or ultra low
NOx applications, see the appropriate burner manual, provided separately.

A typical gas train is shown below. Local codes, project specifications, or insurance requirements may
require vent lines to be installed on some components.

5.1 - Main gas train

4 2
5
6 1
1

FIGURE 8. Main gas train

Depending upon the requirements of the insurance carrier or other governing agencies, the gas train may
consist of some or all of the following items.
1. Shutoff Cocks: For manually opening and closing the main fuel gas supply downstream of the main gas line pres-
sure regulator. A second shutoff cock, downstream of the main gas valve(s), is installed to provide a means of shut-
ting off the gas line whenever a test is made for leakage across the main gas valve.
2. Main Gas Valve: Double body safety shutoff valve. Electrically actuated valves open simultaneously to admit gas to
the burner. The downstream valve is equipped with a with a regulating actuator and a proof of closure switch that is
connected to the pre-ignition interlock circuit.
3. Main Gas Vent Valve (if required; not shown): A normally open solenoid valve installed between the two main gas
valves to vent gas to the atmosphere, should any be present in the main gas line when the gas valves are deener-
gized. The vent valve closes when the gas valves are energized.
4. Low Gas Pressure Switch: A pressure-actuated switch; closed whenever main gas line pressure is above a prese-
lected pressure. Should the pressure drop below the setting, the switch contacts open a circuit causing the main gas
valve(s) to close, or prevent the burner from starting. The switch is usually equipped with a device that must be man-
ually reset after being tripped.
5. High Gas Pressure Switch: A pressure actuated switch; closed whenever main gas line pressure is below a prese-
lected pressure. Should the pressure rise above the setting, the switch contacts will open a circuit causing the main
gas valve(s) to close, or prevent the burner from starting. The switch is usually equipped with a device that must be
manually reset after being tripped.
6. Test Cocks: The body of the gas valve has 1/4-inch NPT fittings for pressure test connection.
7. Butterfly Gas Valve (not shown): The pivoted disc in the valve is directly driven by a servo motor actuator to regulate
the rate of gas flow to the burner. In optional 700-800 HP single point systems, the valve is driven by the modulating
motor through connecting linkage.

750-452 13
Firetube Installation - Steam
 FUEL SYSTEM

5.2 - Pilot train

3 1
4
2

FIGURE 9. Pilot train

1. Gas Pilot Valve: A solenoid valve that opens during the ignition period to admit fuel to the pilot. It closes
after main flame is established. The sequence of energizing and de-energizing is controlled by the pro-
gramming relay. A second gas pilot valve may be required by insurance regulations.
2. Gas Pilot Shutoff Cock: For manually opening or closing the gas supply to gas pilot valve.
3. Gas Pressure Gauge: Indicates gas pressure to pilot.
4. Gas Pressure Regulator: Reduces incoming gas pressure to suit the pilot.

5.3 - Burner drawer

GAS HOUSING

BURNER SUPPORT

BURNER DRAWER

FIGURE 10. Burner drawer (typical integral burner)

14 750-452
Firetube Installation - Steam
FUEL SYSTEM

The burner is a nozzle-mixing orifice design with interrupted gas pilot. Burners equipped for oil use a low
pressure, air-atomized oil system.

Combination gas/oil burners use a fuel selector switch mounted in the control panel. Regardless of which
fuel is used, the burner operates with full modulation within its rated operating range. The burner returns to
minimum firing position for ignition.

5.4 - Gas Supply Requirements

The local gas utility should be consulted for specific requirements and authorization and inspection of the gas
supply piping. Installation of gas supply piping and venting must be accomplished in accordance with all
applicable engineering guidelines and regulatory codes. All connections made to the boiler's gas train con-
nection must be arranged so that all components remain accessible for inspection, cleaning, and mainte-
nance.

A manually operated shutoff valve is provided as standard. For some installations, local regulations may
require the installation of an approved gas filter between the gas shutoff valve and the boiler. Local require-
ments should be discussed with the local gas supply utility.

A drip leg should be installed in the supply piping before the connection to the boiler's gas train regulator sup-
plied by Cleaver Brooks. The drip leg should be at minimum as large as the inlet fitting supplied with the
boiler. Consideration must be given to both volume and pressure requirements when choosing gas supply
piping size. Connections to the boiler's gas train should be made with a union or flange so that the gas train
components or the burner may be easily disconnected for inspection or service.

If the upstream gas supply pressure is >5 psig, we recommend that an upstream pressure regulator be
installed to reduce the pressure to 5 psig or less relative to the inlet pressure requirement of the specific
boiler. This can be mounted at each individual boiler, or on the header pipe feeding each boiler.

All gas piping and components to the boiler gas train connection must comply with NFPA54, local codes, and
utility requirements as a minimum. Only gas approved fittings, valves, or pipe should be used. Standard
industry practice for gas piping is normally Schedule 40 black iron pipe and fittings.

For proper operation of a single unit or a multiple unit installation, we recommend that the gas pipe sizing be
sized to allow no more than 0.3" w.c. pressure drop from the source (gas header or utility meter) to the final
unit location. The gas supplier (utility) should be consulted to confirm that sufficient volume and normal pres-
sure are provided to the building at the discharge side of the gas meter or supply pipe.

For installation of a new boiler into an existing building, gas pressure should be measured with a manometer
to ensure sufficient pressure is available. A survey of all connected gas using devices should be made. If
appliances other than the boiler or boilers are connected to the gas supply line, then a determination must be
made of how much gas flow volume (cubic feet per hour) will be demanded at one time and the pressure
drop requirement when all appliances are firing.

The total length of gas piping and all fittings must be considered when sizing the gas piping. See the follow-
ing tables to determine required pipe size. Do not automatically size the supply piping the same size as
the boiler gas train connection. Pipe size will be relative to the pressure available, total length of pip-

750-452 15
Firetube Installation - Steam
 FUEL SYSTEM

ing and volume capacity of the selected pipe size. The following tables can be used as a minimum guide-
line.

Table 2 shows capacity of a natural gas line for a given initial pressure with a 5% pressure drop. For exam-
ple, consider a 500 hp boiler, which requires 20,925 ft3 / hr. A 5 psi initial pressure is available for 100 ft of
pipe. To find the correct pipe size, go to the line for initial gas pressure reading 5 pounds. Now move to the
right, until a number larger than 20,925 appears. In this case, the first greater number is 30,500. The number
at the top of that column shows the appropriate pipe size, in this case 4". Table 2 assumes gas at 60°F, 1000
Btu/ft3, and a specific gravity of 0.619.

To substitute a 300 ft pipe length in the above example, find the multiplier for 300 ft at the bottom of the table.
The pipe size will be the first column where the multiplier (.577) times the capacity shown is greater than
20,925 ft3 / hr. Since .577 x 55,400 = 31,965.8, 5” is the appropriate pipe size.

16 750-452
Firetube Installation - Steam
FUEL SYSTEM

Table 2: Gas Line Capacities

GAS LINE CAPACITIES (CU-FT/HR THROUGH 100 FT LENGTH)
TOTAL
INITIAL GAS
PRESS. DIAMETER OF PIPE IN INCHES
PRESSURE
DROP
1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 4 5 6 8
4” wc 0.2” 23 52 104 230 358 724 1180 2150 4510 8210 13400 27300
5” wc 0.25” 26 58 117 257 400 811 1320 2410 5050 9190 14900 30600
6” wc 0.30” 28 64 128 282 439 889 1450 2640 5540 10100 16400 33500
7” wc 0.35” 31 69 139 305 475 962 1570 2860 5990 10900 17700 36300
8” wc 0.40” 33 74 148 327 508 1030 1680 3060 6410 11700 19000 38800
9” wc 0.45” 35 79 158 347 540 1090 1780 3250 6810 12400 20200 41200
10” wc 0.50” 37 83 166 366 569 1150 1880 3430 7180 13100 21300 43500
11” wc 0.55” 38 87 175 385 598 1210 1980 3600 7550 13700 22300 45700
12” wc 0.6” 40 91 183 402 625 1280 2060 3760 7890 14300 23300 47700
1/2 psi .025 psi 43 98 197 433 673 1360 2220 4050 8590 15400 25100 51400
3/4 psi .038 psi 53 121 243 534 831 1680 2750 5000 10500 19100 31100 63500
1 psi .050 psi 62 141 282 622 967 1960 3190 5820 12200 22200 36100 73800
1-1/4 psi .062 psi 70 159 319 702 1090 2210 3600 6570 13800 25000 40800 83300
1-1/2 psi .075 psi 77 175 351 773 1200 2440 3970 7240 15200 27600 44900 91800
1-3/4 psi .088 psi 84 191 382 842 1310 2650 4320 7870 16500 30000 48900 99900
2 psi .100 psi 91 205 412 906 1410 2850 4660 8480 17800 32300 52600 108000
2-1/2 psi .125 psi 103 233 467 1030 1600 3240 5280 9620 20200 36700 59000 122000
3 psi .150 psi 114 259 519 1140 1780 3600 5870 10700 22400 40800 66300 136000
3-1/2 psi .175 psi 125 283 568 1250 1940 3940 6420 11700 24500 44600 72600 148000
4 psi .200 psi 135 307 615 1350 2110 4270 6960 12700 26600 48300 78700 161000
4-1/2 psi .225 psi 146 330 661 1460 2260 4580 7480 13600 28500 51900 84500 173000
5 psi .250 psi 155 352 706 1550 2420 4890 7980 14500 30500 55400 90200 184000
6 psi .300 psi 174 395 792 1740 2710 5490 8960 16300 34200 62200 101000 207000
8 psi .400 psi 211 477 957 2110 3280 6640 10800 19700 41300 75200 122000 250000
10 psi .500 psi 246 556 1120 2460 3820 7730 12600 23000 48200 87600 143000 292000
For total lengths other than 100 ft, multiply the capacity shown in the table by the factor corresponding to the desired length as follows:
Length of pipe in ft 10 15 25 50 100 150 200 250 300 350 400 500
Multiplier 3.16 2.58 2.00 1.41 1.00 .817 .707 .632 .577 .535 .500 .447
For pressures and diameters not shown, consult you local Cleaver-Brooks authorized representative.
This table shows gas flow capacities of pipes from 1/2” to 8” diameter, based upon a pressure drop of 5% of the initial gas pressure for 100-ft. length of pipe.
Turbulent flow is assumed, hence the non-linear ratio of length to capacity.

For specific boiler models and gas train sizes:

Refer to the Boiler Book for gas pressure requirements at the gas train inlet.

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 FUEL SYSTEM

5.5 - Oil Piping: 100 and 200 Fuel Series

Fuel oil is delivered into the system by a supply pump which delivers part of its discharge to the oil burner.
Excess oil is returned to the oil storage tank through the fuel oil relief valve and oil return line. Normally the
pump operates only while the burner is in operation, although a positioning switch is available for either con-
tinuous or automatic pump operation.
A fuel oil strainer keeps foreign material from entering the control valves and nozzle. The fuel oil controller
comprises a metering valve, a regulator, and a pressure gauge. The adjustable regulator controls the pres-
sure. To assist in the regulation, back pressure is created by an orifice nozzle located in the oil return line
immediately downstream of the fuel oil controller.
The solenoid oil valves energize/de-energize to permit or cut off oil flow to the burner. Two valves, operating
simultaneously, are used. The valves are closed when de-energized. They cannot be opened (energized)
unless the combustion air proving switch and the atomizing air proving switch are closed. The two switches
are satisfied, respectively, by sufficient combustion air pressure from the forced draft fan and pressurized air
from the air pump.

NOZZLE AIR
AIR STRAINER PRESSURE GAUGE
MANIFOLD OIL BURNER NOZZLE
BLOCK

SWING CHECK VALVE

ATOMIZING AIR
AIR PUMP
OIL SOLENOID
VALVES
ATOMIZING AIR PRESSURE
FEED BACK CONTROL TUBING
ATOMIZING AIR
PROVING SWITCH
FUEL OIL
CONTROLLER
LUBE OIL
STRAINER
OIL BURNER
PRESSURE GAUGE
AIR OIL OIL PRESSURE
RECEIVER TANK REGULATOR

LUBE OIL

OIL METERING
VALVE
OIL MODULATING
CAM

OIL RETURN
BACK PRESSURE ORIFICE

OIL RELIEF
VALVE

FUEL OIL
RETURN
FUEL OIL VACUUM
STRAINER CHECK GAUGE
VALVE
OIL SUPPLY FUEL OIL
PRESSURE SUPPLY PUMP
GAUGE SHUTOFF
PRIMING
TEE VALVE

FUEL
OIL
INLET
NOT SUPPLIED
FUEL OIL BY CLEAVER BROOKS
STRAINER

FIGURE 11. Light oil piping, typical

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Firetube Installation - Steam
WATER REQUIREMENTS

6 - WATER REQUIREMENTS
Feed Pump Operation
Before turning on the pump motor be certain that all valves in the water feed line are open to prevent possi-
ble damage to the feed pump mechanism. After opening the valves, momentarily energize the feed pump
motor to establish correct pump rotation. With the correct rotation established, close the boiler feed pump
entrance switch. The pump should shut down when the water level reaches the proper level.

Feedwater pumps must have adequate capacity to maintain required water level under all operating condi-
tions. Check the feedwater pumps periodically and maintain as necessary to prevent unexpected break-
downs.

NOTE: Prior to operating the pump, carefully check the alignment of the flexible coupling, if one is used. A prop-
erly aligned coupling will last a long time and provide trouble-free mechanical operation.

NOTE: In the event that water column isolation valves are provided, it must be established that the valves are
open and sealed or locked in the open position. If the valves are installed, it is illegal to operate the boiler with
closed or unsealed open valves.

! Warning
The isolation valves and the water column piping must be locked open during operation. Failure to do so may
result in a low water condition. Failure to follow these instructions could result in serious injury or death.

5 1
3
6 ITEM DESCRIPTION
2
1 Globe Valve
2 Check Valve
3 Gate Valve
4 Globe Valve
5 Feedwater Valve
6 Strainer
4 3

FIGURE 12. Feed piping, typical

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Firetube Installation - Steam
 WATER TREATMENT

7 - WATER TREATMENT
To protect the integrity of the boiler and ensure it continues to produce good steam quality, it is important to
properly treat the feedwater, or the water going into the boiler. Close attention to water quality will pay divi-
dends in the form of greater efficiency, improved performance, longer life, less downtime, and prevention of
costly repairs. The water used to fill the boiler or to make up for system losses should be free of dissolved
oxygen, corrosive gases, sediments, or other contaminants and should be at a minimum temperature of 70
degrees Fahrenheit.
Refer to the boiler startup and maintenance manuals for additional information regarding boil out, temporary
service, and water treatment.

The water treatment program should be developed in consultation with a qualified water treatment specialist.
An effective strategy will:
• prevent deposits on boiler surfaces that weaken metal and cause heat transfer losses,
• prevent oxygen corrosion, which causes pitting of boiler tubes and rust deposits,
• prevent low pH (below 9 causes corrosion), and
• prevent steam condensate contamination.

Recommended Guidelines

General guidelines to prevent corrosion and scaling for applications up to 300 psi are as follows:

Total Hardness 1 PPM Maximum

Total Alkalinity 700 PPM Maximum
Total Silica 150 PPM Maximum
Iron Content 0.1 PPM Maximum
pH 9.0 - 10.5
Total Dissolved Solids 3000 PPM (may be lower under certain operating conditions)
Oxygen Content 0 PPM
Carbon Dioxide 0 PPM

For higher pressures contact CB. In all cases, due to the variety of factors which may influence water treat-
ment decisions, it is essential to obtain the services of a water treatment specialist.

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INSTALLATION CHECKLIST

8 - INSTALLATION CHECKLIST

The following checklist is provided as a means to ensure that the boiler is ready for its initial start-up. The list
includes items that we feel, if not completed, cause delays in start-up. Prior to requesting a scheduled start-
up from your local Cleaver-Brooks authorized service representative, the installation must be completed and
all items checked off. A copy of this checklist could be copied and sent to the start-up representative for their
records and use in scheduling.

A. GENERAL

Yes No
_______ _______ 1. Are the boiler, burner, trim and controls in good operating condition? If not, note items that require
attention:
_______ _______ 2. Is the burner fuel and pilot supply properly installed?
_______ _______ 3. Is the boiler level?
_______ _______ 4. Where required, will qualified boiler operators be present for start-up?
_______ _______ 5. Will operating personnel be available for training during start-up?
_______ _______ 6. Will a person be available whenever needed to assist the service technician with miscellaneous
tasks in the boiler room?
_______ _______ 7. A full capacity load (sufficient for high fire fuel/air ratio adjustment) will be required for complete
burner adjustment. Can this load be absorbed by the system, and have provisions been made to
put a full load on the boiler during start-up?

B. BOILER

Yes No
_______ _______ 1. Are the boiler, burner, and auxiliary equipment installed in accordance with the manufacturer's and
insurer's requirements, and applicable insurance and regulatory codes?
_______ _______ 2. Has all system piping to and from the boiler been completed?
_______ _______ 3. Is the safety relief valve(s) properly installed?
_______ _______ 4. Is the safety relief valve discharge piping properly installed with no weight or strain on the
valve(s)?
_______ _______ 5. Are the boiler drain valve(s) or bottom blowoff valves installed properly?
_______ _______ 6. Are boiler drain or bottom blowoff valves and relief valves piped to a safe discharge, and are the
drain lines installed in accordance with all applicable regulatory codes?
_______ _______ 9. If supplied, has the stack thermometer been installed?
_______ _______ 10. Has the breeching/stack been properly installed?
_______ _______ 11. Has the source of combustion air been verified and properly sized?
_______ _______ 12. Have all shipped loose items been accounted for and installed?

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 INSTALLATION CHECKLIST

C. ELECTRICAL

Yes No
_______ _______ 1. Is the available power supply (voltage, phase, and hertz) correct per the burner data plate and wiring
diagram information?
_______ _______ 2. Have all electrical connections been made for the boiler, burner, and all auxiliary equipment?
_______ _______ 3. Have emergency and safety devices been installed in accordance with regulatory codes?
_______ _______ 4. Have all boiler field-wired connections been made according to the wiring diagram supplied by
Cleaver-Brooks for the particular installation?
_______ _______ 5. Is the equipment properly grounded to earth ground?

D. WATER

Yes No
_______ _______ 1. Have the make-up water system and pressure regulating valve been connected and are they opera-
ble?
_______ _______ 2. Have the boiler and system been filled with properly treated water at a minimum of 70 degrees Fahr-
enheit (21.1 Celsius)?
_______ _______ 3. Have the boiler and system been pressure tested to check for leaks?
_______ _______ 4. Has the system piping been flushed and cleaned or will this be accomplished during start-up?

E. GAS

Yes No
_______ _______ 1. Have all gas lines been pressure tested according to local codes, then purged of air?
_______ _______ 2. Is gas pressure and volume sufficient for the boiler(s) at maximum firing rate as stated on the burner
nameplate?
_______ _______ 3. Are gas pressure gauges installed and are they indicating proper gas pressure upstream of the boiler
mounted gas regulator?
_______ _______ 4. Are gas vents including vent valves, properly piped to a point of safe discharge?
_______ _______ 5. Has insurance inspection, if required, been completed?
_______ _______ 6. If upstream gas pressure exceeds 5 psig (34.5 kpa), have gas pressure relief valves been installed?

E. OIL

Yes No
_______ _______ 1. Has the oil supply line been pressure tested?
_______ _______ 2. Have proper min/max pressures to the CB oil pump been verified?
_______ _______ 3. Is the supply line sized for twice the maximum rated capacity of the burner?
_______ _______ 4. Have the fuel oil tank outlet valves been properly installed?
_______ _______ 5. Have the oil system shutoff valves, strainer, and vacuum gauge been properly installed?
_______ _______ 6. Is a return line piped back to the oil tank?

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