Cleaver-Brooks CBH Series, CBH 25, CBH 30, CBH 50 A, CBH 50 Operation, Service And Parts Manual
...
$25.00
CLEAVER-BROOKS
PACKAGED
MODEL
BOILERS
Manual
Printed
U.S.A.
in
Part
No. 750-99
CLEAVER-BROOKS
MODEL
PACKAGED
Operation,
CBH
BOILERS
Service, and Parts Manual
Please direct purchase orders for replacement manuals
to
your
local Cleaver-Brooks representative
Manual
12/93 Printed
Part
No. 750-99
in
U.S.A
CONTENTS
CHAPTER
CHAPTER
CHAPTER
CHAPTER
CHAPTER
1 -
GENERAL
A.
The
B.
The
C.
Control
D.
Automatic
E.
Combustion
F.
Oil
G.
Gas
2 -
THE
A.
General
B.
Construction
C.
Water
1.
2.
Water
D.
E.
Cleaning
F.
Boil-out
G.
Washing
H.
Blowdown -Steam
I.
Periodic
J.
Preparation
3 -
SEQUENCE
A.
General
B.
Circuit
C.
Sequence
D.
Sequence
E.
Flame
4 -
STARTING
A.
General
Control
B.
C. Oil
D.
Gas
E.
Normal
5 -
ADJUSTMENT
A.
General
B.
Periodic
C.
Water
D.
Water
E.
Operating
Setting
Pressure
Temperature
Combustion
Low
High
Programming
Control
F.
Oil
Burner
Oil
Combustion
G.
Gas
Gas
Gas
Combustion
H.
Switch
I.
Air
J.
Safety
DESCRIPTION
Boiler
Burner
Fuel
Fuel
PRESSURE
Hot
Steam
Burner
Burner
Burner
Pump
Burner
Pilot
Pressure
Damper
......................................................
and
Control
and
Component
Ignition
Air
Flow
Flow
.........................................................
.....................................................
Requirements
Water
Boiler
Treatment
........................................................
of
a New
Out
Inspection
OF
..........................................................
and
Interlock
of
of
Loss
Sequence
AND
Preparation -Initial
Settings
Start-up
Operation
.........................................................
Inspection
Level
Gage
Controls
and
Controls -Steam
Gas
Pressure
Gas
Pressure
Operational
......................................................
Nozzles
.......................................................
Adjustment
and
Cam
Valves
...............................................
..................................................
...................................................
..................................................
VESSEL
.............................................
Boiler
....................................................
for
Operation -CB-20
Operation -CB-40
Start-up
Controls
Glass
Adjusting
Controls -Hot
Air
Control
Adjustment
.....................................................
and
Adjustment
Adjustment
....................................................
.............................................
.................................................
................................................
Unit
Boiler
..............................................
Extended
OPERATION
OPERATING
- All
..............................................
- All
AND
..............................................
...............................................
...............................................
Proving
Switch
Switch
Test
..................................................
Flow
Adjustment
AND
System
Function
.......................................
..........................................
........................................
Lay-up
.....................................
Controls
............................................
Fuels
.............................................
MAINTENANCE
............................................
............................................
............................................
..........................................
............................................
..........................................
..........................................
....................................
Start-up
......................................
Fuels
....................................
Boiler
Water
Switch
........................................
........................................
.........................................
.....................................
.........................................
PRINCIPLES
.................................
................................
.................................
- Oil
or
Gas
- Oil
or
Gas
INSTRUCTIONS
............................
...........................
.................................
Boiler
..................................
OF
......................
......................
.................
........................
OPERATION
..
1-1
1-1
1-1
1-2
1-9
1-9
1-9
1-12
2-1
2-1
2-1
2-1
2-1
2-3
2-4
2-5
2-6
2-7
2-7
2-9
2-9
3-1
3-1
3-1
3-2
3-4
3-6
4-1
4-1
4-1
4-2
4-3
4-4
5-1
5-1
5-2
5-2
5-3
5-3
5-4
5-4
5-5
5-6
5-6
5-7
5-7
5-7
5-8
5-8
5-9
5-10
5-11
5-11
5-12
5-14
5-15
5-18
5-18
CHAPTER
CHAPTER
K.
L.
M.
N.
0.
P.
Q.
6-
A.
B. No
C.
D.
E.
F.
7-
c
Motorized
Solenoid
Refractory
Door
Closing
Forced
Fireside
Lubrication
TROUBLE
Burner
Pilot
Burner
Shutdown
Damper
PARTS
Draft
Does
Ignition
Flame,
Stays
ORDERING
T
Gas
Valve
Valve
..................................................
.......................................................
and
Sealing
Fan
................................................
Cleaning
SHOOTING
Occurs
Motor
................................................
......................................................
not
Start
......................................................
But
No
in Low Fire .
During
..................................................
TS
............................................
........................................
...........................................
...........................................
Main
Firing
INSTRUCTIONS
(ConUm.med)
Flame
.......................................
................................
..................................
AND
PARTS
LIST
.........
5-19
5-19
5-19
5-21
5-22
5-22
5-22
6-1
6-1
6-1
6-2
6-2
6-2
6-2
7-1
ii
DO NOT OPERATE, SERVICE,
ALL
APPLICABLE SECTIONS
WARNING
OR
REPAIR THIS EQUIPMENT UNLESS YOU FULLY UNDERSTAND
OF
THIS MANUAL.
DO NOT
FULLY UNDERSTAND ALL APPLICABLE SECTIONS
FAILURE
VERE
TO:
This operating manual presents information that will help to properly operate and care for the equipment.
carefully. The unit will provide
followed.
thoroughly understood. Failure to follow all applicable instructions and warning may result in severe personal injury or death.
It
is the responsibility
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
techniques and maintenance procedures must be followed at all times. Although these componesnts afford a high degree
protection and safety, operation
firing
Any
him/her
It
is solely the operator's responsibility to properly operate and maintain the equipment.
replace intelligent thinking and reasoning and this manual is not intended to relieve the operating personnel
for proper operation.
maintain, service, or repair this equipment.
ALLOW
TO
PERSONAL INJURY
Owners,
No
attempt should be made
of
fuel.
"automatic"
of
certain repetitive chores and give him/her more time tot devote to the proper upkeep
OTHERS
FOLLOW
Operators
of
the owner to train and advise not only his or her personnel, but the contractor's personnel who are
features included in the design do not relieve the attendant
On
the other hand, a thorough understanding
TO
OPERATE, SERVICE,
ALL
APPLICABLE WARNINGS AND INSTRUCTIONS MAY RESULT IN SE-
OR
DEATH.
and/or
Maintenance
good service and continued operation
to
operate the unit until the principles
part
of
the unit were chosen because
of
equipment is not to be considered free from all dangers and hazards inherent in handling
Personnel
OR
REPAIR THIS EQUIPMENT UNLESS THEY
OF
THIS MANUAL.
if
proper operating and maintenance instructions are
of
operation and all
of
their know ability to perform; however, proper operating
of
any responsibility. Such features merely free
of
this manual is required before attempting to operate,
No
of
the components are
of
equipment.
amount
of
Study its contents
of
and
written instructions can
of
the responsibility
of
Because
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
daily or monthly tesing, assuming that normal operation will continue
uneconomical operation and damage and, in most cases, these conditions ca nbe traced directly to carelessness and
in testing and maintenance.
It is recommended that a boiler room log or record be maintained. Recording
activities and recording
Most instances
for the operator to periodically check his/her low water controls and to follow good maintenance and testing practices. CrossÂconnecting piping to low water devices must be internally inspected periodically to guard against any stoppages which could
obstruct the free flow
the presence
The waterside condition
check for the presence
The services
are essential.
The operation
of
his/her insurance company and/or other authority having jurisdiction. In the event
such requirements and the warnings or instructions contained herein, please contact Cleaver-Brooks before proceeding.
state, local, or other applicable codes, there are a variety
of
of
any unusual operation will serve as a valuable guide to any necessary investigation.
of
major boiler damage are the result
of
water to the low water devices. Float bowls
of
foreign substances that would impede float ball movement.
of
the pressure vessel is
of
any mud, sludge, scale or corrosion.
of
a qualified water treating company or a water consultant to recommend the proper boiler water treating practices
of
this equipment by the owner and his/her operating personnel must comply with all requirements or regulations
of
operation with low water. We cannot emphasize too strongly the need
of
extreme importance. Waterside surfaces should be inspected frequently to
of
time and
electric controls and safety devices which vary consider-
we
have found that some operators become lax
indefinitely. Malfunctions
of
daily, weekly, nonthly and yearly maintenance
of
these controls must be inspected frequently to check for
of
any conflict or inconsistency between
of
controls lead to
in
their
deficiencies
iii
FORCED
DRAFT
FAN
COMBUSTION
INLET
AIR
VENT
THE
FOUR PASS
Combustion
rotary
air
combustion
boiler
only
only
through
air
enters
damper
chamber,
through
pass
CONSTRUCTION
through
and
the
diffuser
constitutes
P.ass two;
three.
From
the
air
inlet.
into
the
pass
one. Baffling
here a baffle
the
rear
the
OF A
The
forced
combustion
allows
gases
are
iv
TYPICAL
draft
chamber.
allows
gases
to
forced
gases
through
MODEL
fan
to
pass
to
forces
The
pass
the
pass
CB
air
main
to
the
rear
four
BOILER
through
fire
tube
front
of
of
the
boiler
to
the
the
or
the
vent.
CHAPTER 1
AND
A.
THE BOILER
The
Cleaver-Brooks
packaged
vessel, oil
draft
ponents.
The
draft
accordance
Vessel Code.
the
boiler.
This
low
capacities
The
others,
the
stallation
codes governing
stallation,
tion
boilers
with
Association Div.
(F.I.A.),
underwriters
steel
or
fan,
air
boiler
pressure
boiler
National
are
is a four
boiler.
manual
rated
and
is
to
should
the
to
be
in
the
optional
Factory
gas
control
The
with
Chapter 2 deals
covers
steam
be in
Board
proper
consulted,
above
requirements.
B. THE BURNER AND
The
type
of
fuel used
series
classification.
Series
Series 200
Series
A
boiler
100
700
equipped
Model
boiler
burner,
damper,
pass
pressure
the
ASME
boilers
or
from 25
related
compliance
of
also
conform
such
authorities
series comply, when
equipment,
of
Mutual
SYSTEM
by
These
Light
Light
Gas
to
GENERAL
PRINCIPLES
A. THE BOILER
B. THE BURNER AND
C.
CONTROL
D. AUTOMATIC IGNITION
IE.
COMBUSTION
f.
OIL
fUEL
G.
GAS
fUEL
"CBH"
consisting
burner
and
horizontal
vessel is
Boiler
with
designed for
hot
water
thru
100
equipment
with
Fire
equipment.
permits
to
Factory
Industrial
(FM)
the
boiler
are:
oil (No. 2)
oil (No. 2)
only
burn
oil
Boiler
of a pressure
controls,
associated
firetube
constructed
and
Pressure
tfiis
portion
high
generation
horsepower.
installation,
the
standards
Underwriters.
to
state
and
Prior
having
obtained
Risk
or
other
jurisdic-
etc. All
equipped
Insurance
Insurers
insuring
CONTROl
determines
only
or
gas
and
gas
includes
DESCRIPTION
AND
COMPONENT
AIR
flOW
flOW
is a
forced
com-
up-
in
of
or
in
by
of
In-
local
to
in-
the
OF
CONTROL
equipment
uses
tor
The
attached
inspection
The
type
annular
pilot
light
combination
ignition
The
operates
fire. An
operates
ner
later
to
butterfly
OPERATION
only
switch is
Model
oil
burner
and
entry
which is
oil fuel
of
standard
on a modulating
and
in
this
Combustion
located
motor.
fuel
energize
properly
tion.
An
of
tor
the
shut
or
The
single
in
the
burner
This
through a linkage
the
electronic
operation
monitors
event
the
excessive
burner
phase
SYSTEM
fUNCTION
for
each
one
type
of
incorporated
CBH
boiler
to
the
front
and
maintenance.
is
of
the
gas
burner
type. A
spark
only
gas-oil
both
fuels.
burner,
at
two
burning
optionally
its
components
manual.
air
is
provided
the
front
is
under
same
motor
valve
proportioned
of
burner
or
oil
valves.
safety
and
in
the
flame
loss
down
steam
control
60
hertz
conjunction
of
pressure
distinct
fuel
at a time,
in
has
head,
the
high
is
gas
burner
ignited. A
is
normally
unit
whether
rates
equipped
firing
are
head.
Combustion
the
regulates
system
by
actuating
Fuel
for
control
to
shut
flame.
under
circuit
(or 50
fuel. Since
a gas/oil selec-
the
combination
the
burner
readily
pressure
of
the
is ignited by a
burner
spark
uses a
firing on oil
- high fire
gas-fired
principle.
described
by a
centrifugal
control
the
connected
input
and
most
efficient
programs
with a flame
the
burner
Other
or
operates
hertz
low
water
safety
water
when
the
burner
units.
assembly
accessible for
atomizing
high
radiant
gas
that
uses
ignited.
gas
pilot
or
gas,
and
low
boiler
The
bur-
in
detail
blower
air
delivery
of
the
damper
flow
of
gas
to
the
gas
switches
air
the
temperatures.
on
that
are
thus
combus-
sequence
detec•
down
controls
conditions
115
volt,
equipped)
A
for
in
1-1
Chapter
1-General
Description
and
Principles
of
Operation
alternating
generally
able
The
wired
the
techniques.
The
standard
control,
ture
valve(s
The
through
control
and
timer
at
the
The
gas
valves
spark
firmed.
the
a
safety
The
proving
ance
the
In
plied,
specific
local
with
in
the
tion
chapter
Chapter
C.
The
valves
to
electrical
programming
familiar
trols
stand
outlined
Identify
out.
The
will
equipped
boiler.
Boilers
operated
main
operating
into
burner
major
control
limit
controls,
),
and
sequence
shutdown
in
interlock
that
proper
same
pilot
operation
to
open.
ignited
The
event
of a flame
interlock.
safety
equipment
company
presence
addition
other
requirements
code.
the
burner
burner
of
individual
and
3.
CONTROL
term
and
with
whether
the
in
and
actual
depend
and
having
energizes
control
"control"
controls
current.
power
the
and
electrical
low
conjunction
control
interlocks
of
to
Refer
the
The
on 3 phase
supply
limit
circuitry
protect
system
and
operating
water
motor
devices.
devices
and
starter.
of
burner
is
governed
or
time.
monitors
prior
The
ignition
oil
burner
will
loss
and -depending
requirements-
adequate
the
standard
to
the
to
determine
limit
components
electrical
FUNCTION
components,
controls
control.
the
individual
or
not
outlined
boiler's
the
locate
upon
whether
operation,
manual.
each
furnished
the
optionally
forced
service
voltage.
and
other
provide
against
components
consist
cut-off,
with
This
de-energizes
or
include
may
of
wiring
control
AND
covers
including
or
The
item
type
it
incorrect
pressure
damper
operation
by
the
programmer
the
to
allowing
of
low fire
must
shut
the
as a result
combustion
controls
fuel
pressure.
basic
be
an
insurance
diagram
the
is
sequence
COMPONENT
the
those
operator
functioning
before
using
with
of
fuel for
is a
hot
ordered
draft
fan
motor
at
the
avail-
interlock
safe
included
of a programming
from
the
operating,
other
flame
likewise
burner
required
specific
circuits.
outlined
more
but
monitored
he
and
the
any
water
features
devices
operation
operating
in
the
or
tempera-
motor,
programming
to
flame
of
upon
that
controls
is
covered
not
must
can
procedures
figure
given
which
fuel
start-up
limit
contains
controls
confirm
main
fuel
on
be
con-
down
action
carrier
furnished
The
important
of
or
by
and
air
insur-
prove
sup-
to
meet
controls
func-
in
this
limited
by
the
become
all
con-
under-
call-
boiler
it
steam
may
is
of
a
in
or
in
is
have
control
PROGRAMMING
CONTROL
Automatically
and
shutdown
operating,
cludes,
operation
valve(s)
cludes
shutdown.
The
both
the
a
The
operation,
must
down
internal
which
causes
period.
The
components
sequence
air
flame
oil
event
control
be
caused
causes a safety
control
Master
and
operating
to
start
forced
Flame
tector
gized by a
through
Lockout
failure
or
on
control,
inter-locks
during
short
reset.
should
tempting
Timer:
ching
quence
through
the
burner.
Timer
the
timer
operating
Flame
pilot
lay
in
monitor
of
pilot
components
AND
(Figure
limit,
in a timed
of
the
and
the
purges
detector
and
gas
of
loss
recycles
or
manually
by loss
checking
the
flame
contains
that
text.
relay
program
draft
relay
senses a suitable
the
Switch
to
ignite
loss
of
lock-out
the
cooling
CAUTION.
be
investigated
to
Actuates
contacts
to
all
Position
and
cycle.
Detector:
and
energizes
response
main
proving
1-1)
programs
period
and
blower
damper
prior
portion
flames
of a flame
automatically
following a
reset
of
circuit
lockout
relay
the
are
referred
(1K):
Energized
controls
sequencing
fan
motor
(2K):
Energized
flame
or a flame
loss
lockout
(LS
the
flame.
will
programmer's
period
The
re-start.
cams
in a non-adjustable
program
the
functions
Dial:
the
(Figure
(figure 1-1):
the
to a flame
flame
period. A standardly
not
listed
FLAME
each
starting,
in
conjunction
interlock
and
proper
motor,
to
switch.
):
pilot
is
(oil
ignition
motor.
ignition
of
this
and
provides
signal.
power
following a
flame.
Additionally,
occur
Indicates
stage
Incorporated
effective
in
the
to
hold
following
to
and
switches
and
starter.
when
flame.
it
routes
Trips
or
main
upon
simulating
checking
required
reason
and
corrected
to
open
the
burner's
necessary
reached
1-1)
Monitors
programmer's
signal.
or
gas)
here.
SAFEGUARD
operating,
devices.
sequence,
system, fuel
The
sequence
and
upon
control
protection
during
interruption.
safety
on
every
event
in
during
major
in
the
operating
when
all
are
to
energize
the
flame
When
control
in
the
burner
on a CB-40
the
opening
condition
period.
before
for
any
before
and
close
timed
operation
to
the
position
in
gas
flame
It
continues
after
expiration
equipped
with
This
in-
the
in-
burner
monitors
in
normal
It
shutÂis
an
start
anything
this
integral
the
limit
closed
the
de-
de-ener-
circuit
event
it
of
flame,
of
can
be
lockout
at-
swit-
se-
operate
of
burner
or
oil
re-
to
A
1-2
Chapter
1-General
Description
and
Principles
of
Operation
boiler
detector.
BURNER
manually
A
rectly
starting
FORCED
Directly
bustion
an
oil
fired
motor
by
has a lead
SWITCH
operated
and
stopping
DRAFT
FAN
drives a forced
air.
Also
referred
unit
the
a V
-belt.
BLOWER MOTOR
BLOWER
MOTOR
sulfide
(Figure
start-stop
MOTOR
draft
to
oil
pump
STARTER
(infrared
1-1)
switch
burner
fan
to
as
blower
is
driven
sensitive)
used
operation.
(Figure
provide
motor.
from
for di-
1-1)
com-
On
this
FORCED
(Figure
Energizes
DAMPER
two
A
DRAFT
1-1)
forced
MOTOR
position
motor
through a linkage
fuel
ratio
under
The
spring
The
motor
motor
is
powered
returned
to
actuates
-------mrTIMER
-
---------!!!!-GAS-OIL
FAN
draft
(Figure
that
system,
low fire
the
one
MOTOR
fan
(blower)
positions
to
and
to
the
closed.
or
more
STARTER
1-1)
the
provide
high
fire
open
auxiliary
PROGRAMMING
AND FLAME
SAFEGUARD
CONTR.OL
DIAL
SWITCH
motor.
air
damper
proper
conditions.
position
switches.
air-
and
COMBUSTION
AIR PROVING
SWITCH
DAMPER
MOTOR
AUXILIARY
SWITCH
DAMPER
LINKAGE
BUTTERFLY
GAS
VALVE
----OIL
OIL PRESSURE
PUMP
GAUGE
FIGURE
1-l.
TYPICAL
OIL
AND
GAS
FIRED
MODEL
CBH
BOILER
1-3
Chapter
It
also
1-General
operates,
through
valve.
A
modulating
equipment
tion
G for
DAMPER
motor
on a gas
details.
POSITIONING
(Manual-Automatic)
A
three-position
high
fire
through
the
or
switch
low fire
high-low fire
operation.
AUXILIARY
Actuated
SWITCH(S)
by
damper
Description
linkage,
can
be
fired
unit.
(Figure
for
manually
rate
or
motor
and
Principles
the
supplied
(Figure
butterfly
1-2)
as
optional
See
of
Sec-
SWITCH
1-1)
setting
either
establishing a circuit
control
(Figure
shaft
for
automatic
1-1)
rotation.
HIGH-LOW
Each
OPERATING PRESSURE,
HIGH
Operation
gas
PRESSURE.
FIRE
boiler
to
prove
before
has
additional
valves
ped
boiler
per
opening
GAS/OIL
Toggle
either
IGNITION
Provides
of
gas
AND
CONTROLS
MODULATING
(OPTIONAL
GAS FIRING)
has a switch
that
the
ignition
can
switches
for
high
fire
has
an
during
SWITCH
switch
gas
or
used
oil
TRANSFORMER
high
voltage
pilot
or
light
CONTROL
FOR
that
serves
damper
take
place.
that
operation.
additional
the
pre-purge.
(Figure
to
manually
firing.
spark
oil
burner
is
in
An
switch
1-1)
for
control
as a low
a closed
An
oil fired
optionally
to
select
(Figure
ignition
ignition.
fire
switch
position
boiler
oil
solenoid
equip-
prove
circuitry
1-1)
electrode
dam-
for
M lNG
DAMPER
MOTOR
(OPTIONAL
GAS FIRING)
FOR
FIGURE
1-2
TYPICAL
STEAM
CHECK
VALVE
BOILER
AND
GAGE
GLASS
CONTROLS
1-4
Chapter
!-General
Description
and
Principles
of
Operation
OPERATING
Steam
Boiler
OPERATING
TROL -Hot
Water
Breaks a circuit
of
boiler
pressure
setting.
a
HIGH
Steam
HIGH
Hot
It
is
pre-selected
LIMIT
Boiler
LIMIT
Water
Boiler
adjusted
Breaks a circuit
selected
ting
manually
HIGH-LOW
A
placed
damper
circuit
pressure
limit
pressure
into
positioning
to
control
reset
FIRE
or
the
the
damper
LIMIT
(Figure
LIMIT
to
pressure
PRESSURE
1-2)
TEMPERATURE
Boiler
stop
burner
or
temperature
to
start
or
(Figure
temperature
PRESSURE
(Figure
1-2)
TEMPERATURE
(Figure
to
stop
or
temperature
setting.
to
restore
1-3)
burner
This
the
CONTROL
temperature
circuit
by
switch,
motor
proper
makes
causing
CONTROL
1-3)
operation
above a selected
or
stop
the
CONTROL
CONTROL
operation
above
control
circuit.
(Figures
control
which,
setting
or
the
CON-
on a rise
burner
setting.
at a pre-
the
opera-
must
1-2 & 1-3)
when
of
breaks
burner
at
be
the
the
to
operate
ance
at
with
either
load
MODULATING
Senses
and
damper
only
When
moved
is fired
LOW
(Steam
This
level
changing
transmits
motor
as
optional
installed
from
the
on
oil.
WATER
Boiler)
float-operated
in
the
boiler.
tions:
(a)
Stops
firing
below
the
safe
in
the
control
bell
(optional
ments
for
some
of
low
water
high
or
requirements.
CONTROL
boiler
this
to
pressures,
information
change
equipment
on
a 200
operating
CUT-OFF
(Figure
control
It
performs
of
the
burner
operating
panel;
also
equipment)
models
cutoff.
require a manual
This
low
(Figure
the
firing
for a
Series
circuitry
AND
1-2)
responds
if
point
causes
to
type
fire
or
to
the
gas
boiler,
while
PUMP
two
water
and
low
ring.
requires
rate
rate.
low
Code
in
accord-
1-2)
temperatures,
modulating
Provided
fired
boiler.
it
is re-
the
boiler
CONTROL
to
the
water
distinct
level
water
water
func-
lowers
light
alarm
require-
reset
type
manual
OPERATING
HIGH
LIMIT
AND
HIGH-LOW
CONTROLS
TEMPERATURE,
TEMPERATURE
FIRE
FIGURE
1-3.
TYPICAL
HOT
WATER
BOILER
AND
CONTROLS
1-5
Chapter
1-General
Description
and
Principles
of
Operation
resetting
to
down.
(b)
Starts
to
maintain
NOTE;
and
Determine
shipment
operating
AUXILIARY
(Not
shown)
This
float-operated
stop
burner
drops
Manual
manual
a
LOW
(Hot
A
stop
drops
WATER
This
pump
gage
glass
water
WATER
The
the
regularly
piping
below
reset
resetting
low
water
WATER
Water
float
operated
burner
below a safe
COLUMN
assembly
control
glass
provides a means
level.
COLUMN
water
water
column
to
and
start
the
stops
water
LOW
(Optional
operation
the
type
condition.
CUT-OFF
Boiler)
operation
houses
and
shutoff
column
assist
float
bowl
burner
the
at
the
that
and
installation
life.
WATER
control
master
(optional
in
order
(Figure
control
if
operating
(Figure
includes
cocks,
DRAIN
drain
and
in
maintaining
clean
after
feedwater
proper
control
CUTOFF
equipment)
breaks
in
the
event
low
water
equipment)
to
start
1-3)
that
breaks a circuit
water
level
point.
1-2)
the
low
the
and
trycocks.
for
visually
VALVE
valve
is
its
piping
and
free
a low
water
shut-
pump
(if
used)
operating
is
plumb
and
the
boiler
cutoff
level.
throughout
circuit
water
point.
requires
the
burner
in
the
boiler
water
water
cutoff
gage
glass,
The
determining
(Figure
provided
can
be
so
flushed
cross-connecting
of
sediment.
after
to
after
to
and
gage
1-2)
that
A
similar
water
drain
cutoff
valve
is
(optional
furnished
equipment)
pose.
WATER
(Figure
This
TEST
This
filling,
PRESSURE
(Stearn
Indicates
GAGE
1-2)
valve
VALVE
valve
and
Boiler)
boiler's
GLASS
is
provided
(Figure
allows
the
facilitates
GAUGE
(Figures
internal
DRAIN
to
1-2)
boiler
routine
1-1 & 1-2)
TEMPERATURE/PRESSURE
(Hot
Water
compound
A
water
STACK
Indicates
Boiler)
gauge
temperature
THERMOMETER
temperature
(Figure
that
and
of
indicates
water
tional)
SAFETY
safety
A
lieve
signed
purchaser. A relief
boiler
Safety
piping
Code
WARNING:
OR
RELIEF
valve(s)
the
boiler
pressure
for
and
are
the
relief
to
be
of
or
same
installed
requirements.
Only
is
used
pressures
the
valve(s)
purpose.
valves
(Figure
the
VALVE
on a steam
pressure
and
to
valve
with
flush
the
to
be
boiler
pressure.
GAUGE
1-3)
pressure.
(Figure
vented
(Figures
higher
designated
is
used
their
escape
conform
1-7)
manufacturer
auxiliary
for
same
VALVE
gage
vented
inspection.
boiler's
1-2)
flue
gases.
boiler
than
on a hot
to
the
low
pur-
glass.
during
internal
(Op-
1-2 & 1-3)
to
re-
the
de-
by
the
water
and
drain
ASME
or
his
LOW GAS
PRESSURE SWITCH
1-6
GAS PILOT
PRESSURE REGULATOR
FIGURE
1-4.
GAS
PRESSURE SWITCH
MAIN GAS VALVE
WITH INTEGRAL
PROOF OF CLOSURE
SWITCH
TRAIN
WITH
HIGH
TWO
GAS
VALVES
GAS PILOT
SOLENOID
VALVE
representative
repair
COMBUSTION
(Figure
A
sure,
sure
OIL
Draws
pressure
an
rotary
nected
OIL
Indicates
1-1)
pressure
whose
of
combustion
PUMP
oil
to
integral
filter.
to
BURNER
sensitive
contacts
(Figure
from
the
adjustable
The
the
the
fuel
zle.
FUEL
Electrically
quence
ner
OIL
to
nozzles.
VALVES
operated
allow
The
these
AIR
PROVING
switch,
close
air
1-1)
supply
burner
nozzles.
pump
blower
motor.
PRESSURE
pump
(Figures
to
oil flow
function
valves.
actuated
to
prove
from
the
tank
and
pressure
is
driven
GAUGE
discharge
open
from
the
of
the
should
adjust
SWITCH
by
air
sufficient
forced
delivers
The
pump
draft
it
contains
regulator
by
a V
-belt
(Figure
pressure
to
1-1 & 1-6)
in a controlled
pump
to
the
valves
is
described
or
presÂpres-
fan.
under
and
con-
1-1)
noz-
se-
bur-
Chapter
!-General
in
the
FUEL
For
manually
LOW
OIL
(Figure
Switch
below
limit
circuit
for
correct
AIR
DAMPER
Controls
the
burner
ficient
NOTE:
the
cies,
may
items.
that
shown
Description and Principles of Operation
oil
fuel flow
OIL
SHUT-OFF
PRESSURE
section
shutting
later
COCK
off
oil
SWITCH
in
(Figure
supply
(Optional)
1-3)
contacts
selected
pressure.
upon
open
loss
when
Switch
of
sufficient
fuel
oil
pressure
will
fuel oil
combustion.
(Figure
the
amount
in
proper
combustion
Depending
insurance
the
gas
consist
Refer
are
applicable. A typical
in
figure 1-4.
flow
of
to
1-5)
of
combustion
proportion
at
high
upon
carrier
control
some,
your
boiler
or
or
to
or
low
the
other
system,
all,
to
air
fuel
firing
requirements
governing
of
determine
this
chapter.
1-1)
to
burner.
interrupt
pressure
admitted
input
rates.
or
gas
the
following
gas
train
drops
the
to
for ef-
of
agen-
train,
those
is
INTERMEDIATE
FRONT
HEAD
HEAD
GASKET
NOTE:
tration
must
head.
Burner
shown
purposes
be removed
AIR BAFFLE
in
only.
Burner
prior
PLATE
place
to
for
illus-
drawer
opening
FIGURE
1-5.
BOILER
WITH
FRONT
HEAD
OPEN,
CBH
50-100A
OIL
AND
GAS
FIRED
1-7
Chapter
1-General
Description
and
Principles
of
Operation
GAS
PILOT
solenoid
A
period
main
ing
ming
GAS
For
gas
GAS
to
flame
and
de-energizing
relay.
PILOT
manually
pilot
valve.
PRESSURE
Indicates
GAS
PRESSURE
(Figure
Reduces
1-4)
incoming
requirement
VALVE
valve
admit
is
established.
SHUT-OFF
opening
gas
pressure
of
between
(Figure
that
opens
fuel
to
the
The
is
controlled
COCK
or
closing
GAUGE
to
(not
pilot.
REGULATING
gas
pressure
5"
1-4)
during
pilot.
sequence
by
(not
the
shown)
(Optional)
to
to
10"
the
It
closes
of
the
shown)
gas
VALVE
suit
the
W.C.
ignition
after
energiz-
program-
supply
pilot's
to
BUTTERFLY
The
pivoted
necting
the
MAIN
An
it
valve.
closure"
lock
is
GAS
linkage
rate
of
GAS
electrically
admits
The
main
valve
switch
circuit. A second
often
used.
VENT
(Optional)
A
normally
the
two
main
mosphere
should
GAS
disc
in
from
gas
flow
VALVE
actuated
flame
may
connected
VALVE:
open
solenoid
gas
any
VALVE
this
the
to
(Figure
shutoff
gas
be
motorized
(Figure
valves
be
(Figure
valve
damper
the
burner.
is
1-l)
actuated
motor
to
1-4)
valve.
When
through
equipped
the
butterfly
with a "proof
into a pre-ignition
shutoff
1-4)
valve
installed
to
vent
gas
present
in
the
by
regulate
gas
between
to
the
main
con-
open,
gas
of
interÂvalve
at-
gas
1-8
FIGURE
1-6.
FUEL
OIL
CONTROL
VALVES
line
when
the
vent
valve
closes
energized.
MAIN
For
gas
pressure
stream
to
GAS
COCK
manually
supply
downstream
regulator. A second
of
the
main
provide a means
whenever a test
mam
gas
valve.
LOW
GAS
PRESSURE
A
pressure
main
pressure.
ting,
the
main
ner
from
gas
the
actuated
line
Should
switch
gas
valve(s)
starting.
with a device
being
tripped.
HIGH
A
main
sure.
switch
main
from
a
GAS
pressure
gas
Should
contacts
gas
starting.
device
PRESSURE
actuated
line
pressure
the
valve(s)
The
that
must
tripped.
LEAKAGE
The
body
that
is
CONNECTION
of
the
used
whenever
conduct a test
closed
valve.
gas
valves
when
(Figure
opening
gas
is
made
switch
pressure
the
contacts
This
that
must
switch
pressure
will
to
switch
be
gas
for
possible
are
de-energized.
the
gas
1-4)
and
closing
of
the
main
shut-off
valve(s),
of
shutting
for
may
off
leakage
SWITCH
that
is
closed
is
above a preselected
pressure
to
switch
drop
will
open a circuit
close,
or
is
be
manually
prevent
usually
SWITCH
that
is
closed
is
below a preselected
rise
above
open a circuit
close,
or
prevent
is
usually
manually
valve
it
is
necessary
reset
has a plugged
leakage
valves
the
main
gas
cock,
be
installed
the
gas
across
(Figure
whenever
below
this
the
equipped
reset
(Figure
whenever
the
setting,
causing
the
equipped
after
opening
or
desirous
across
The
are
fuel
line
down-
line
the
1-4)
set-
causing
bur-
after
1-4)
pres-
the
the
burner
with
being
to
the
Chapter
1-General
On a Model
fire oil
two
electrodes
from
the
the
ignition
and
ignition
gized.
The
ter
low
Air
for
ondary"
(Figure
ation,
and
forced
mixture
The
supply
matically
regulating
amount
ficient
Description
100
boiler
nozzle
is
ignited
supplied
ignition
transformer.
cycle,
transformer
ignition
fire is
the
1-3)
air
established
E.
COMBUSTION
combustion
air)
is
furnished
mounted
pressure
through a diffuser
with
the
fuel
of
combustion
throttling
the
air
of
air
for
correct
combustion
the
transformer
is
damper
at
rates.
F.
Oil
An
oil
fired
boiler
fuel
pump
(Figures
oil
from a storage
capacity
oil
to
The
can
SUPPORT FROM BUILDING
than
not
delivered
the
storage
pump
has
be
adjusted
CONSTRUCTION
the
maximum
to
tank.
an
integral
to
is
1-1 & 1-5)
tank.
the
provide
and
Principles
with
spark
by a spark
with
low
fire
are
and
of
fuel,
by
in
the
built
up
for
proper
air
the
output
to
ratio
both
FUEl
equipped
The
burner
pressure
the
TO STEAM
of
Operation
ignition,
high
At
oil
arcing
voltage
the
between
beginning
solenoid
simultaneously
is
de-energized
proven.
AIR
(also
called
the
front
in
plate
forced
the
head.
entire
for a
draft
In
thorough
combustion.
is
governed
furnish
of
air
low
of
and
to
by
the
the
fuel
high
FlOW
with a belt
that
withdraws
pump
burning
has a greater
rate
nozzles
regulator
necessary
VENT
is
returned
atomizing
the
low
current
valve
ener-
af-
"sec-
fan
oper-
head
auto-
fan
by
proper
for ef-
firing
driven
fuel
and
all
that
of
D.
A
gas
burner
unit),
is
ignited
Some
insurance
burner
though
The
electric
the
Flow
regulator
have
pilot
At
solenoid
simultaneously
former
igniting
trode
itself.
de-energized
(Model
standardly
gas
pilot
spark.
utility
rate
combustion
gas
the
beginning
supplies
spark
within
The
mains
(flame
(Figure
stream
valve
gas
AUTOMATIC IGNITION
(and
an
oil
by
regulations
100)
flame
Fuel
or
size)
air
to
of
and
energized.
which
the
pilot
pilot
after
burner
an
interrupted
be
ignited
this
model
is
ignited
for
the
from a tank
is
regulated
1-4
).
The
flow
provide a suitable
the
ignition
ignition
high
voltage
arcs
tube
solenoid
main
flame
on a combination
require
with a gas
has
automatically
pilot
is
(bottle)
burner
into
and
cycle,
transformer
The
ignition
current
between
and
the
wall
and
transformer
is
ignited.
the
type
that a light
spark
supplied
by a pressure
is
designed
mix
the
single
of
gas
pilot.
pilot
ignition.
by
from
supply.
with
flame.
pilot
trans-
for
the
oil
al-
an
to
the
gas
are
the
elecÂtube
are
Discharge
MUST
inlet
NOTE:
SAFETY
opening
be
larger than
WATER LEVEL
Back-pressure
be less than 10%
FIGURE
VALVE
of
1-7.
INSTALLATION
steam
of
exhaust
safety
valve
system
setting-!--
RECOMMENDED
PROCEDURE
MUST
1-9
Chapter
1-General
HIGH FIRE ORIFICE
VALVE BLOCK
OIL
(HFOV)
Description
and
Principles
OIL SHUTOFF SOLENOID
of
OIL PRESSURE
VALVE
(LFOV-1)
Operation
GAUGE
t
CHECK
VALVE
OIL
TERMINAL
BLOCK
-sUPPLY
__.OIL
OIL
RETURN
FIGURE
MANIFOLD BLOCK
INTERMEDIATE
HIGH FIRE I
OIL VALVE :
(HFOV-1)
HIGH FIRE
VALVE !
OIL
(HFOV-2) )J
HIGH FIRE
OIL NOZZLE
~-
1-8.
SCHEMATIC
---
\----1---L_j------j__J.-----\
OIL FLOW DIAGRAM, MODEL
MANUAL
SHUTOFF
-·
LOW FIRE
OIL NOZZLE
OIL
VALVE
ORIFICE
FITTING
CBH
25-40 AND 50A
t
OIL
STRAINER
OIL
SUPPLY
OIL
RETURN
1-10
FIGURE
1-9
SCHEMATIC
OIL FLOW DIAGRAM,
MODEL
CBH 50-100
Chapter
1-General
Description
and
Principles
of
Operation
pressure
read
Oil flow
noid
quence,
(LFOV-1)
energized
ing
fire nozzle.
When
position,
motor,
to
on
the
to
valves.
the
of
these
the
energizes a high
the
oil
the
At
primary,
and
by
the
valves
damper
an
auxiliary
burner
pressure
burner
the
nozzles
proper
the
low
programming
allows
motor
nozzles.
gauge.
time
or
safety,
fire
valve
the
moves
switch
fire
valve.
This
is
controlled
in
the
control.
oil
to
flow
to
actuated
pressure
by
operating
shut-off
(LFOV-2)
The
to
the
the
high
by
is
sole-
se-
valve
are
open-
low
fire
the
Figure
40
and
the
valves
the
high
The
oil
100
size flows
The
intermediate
high
fire
change
ing
the
the
damper
fold
is
I
1-8
shows
50A size
fire
discharge
valve.
from
oil
orificed
the
boilers.
prevents a sudden
valve
from
into a manifold
valve
The
low
to
input
with
opens.
The
to
maintain a constant
valves
The
opens.
the
is
purpose
high
fire
the
increasing
return
used
on
orifice
pressure
pump
on
block
energized
for
this
smoother
line
the
block
the
(Figure
prior
is
flow
from
25
through
between
drop
50
through
to
make
by
balanc-
of
the
pressure.
when
1-9).
to
air
mani-
the
the
as
PILOT GAS
MAIN GAS
MAIN
SHUTOFF
FIGURE
GAS
VALVE
1-10.
SCHEMATIC
MAIN
VALVE(S)
GAS
GAS
FLOW
DIAGRAM
1-11
Chapter
!-General
Description
and
Principles
of
Operation
G.
GAS
The
gas
flow
system
flow
indicated
Metered
gas
piping
through a pressure
reduced
quirements;
gas
burner.
from
Gas
cock
ating
trols
(opened)
is
ignited
the
time
At
solenoid
programmer
pilot
energizes
allowing
burner.
upon
This
motor
damper,
bustion
to
valve
Gas
this
for
the
into a pressure
pressure
the
mixed
by a controlled
pilot
required
the
beginning
valve
flame
The
the
is
mechanically
and
thus
air.
by
gas from
through a main
the
pressure
through
and
through a butterfly
required
line
prior
pilot
operation
is
established. A solenoid
flow
of
allows
position
with
flame.
for
is
control
is
the
electrically
flow
through
rate
varied
properly
the
combustion
The
energized
proven,
fUEl
is
shown
arrows.
the
utility
regulator
suitable
an
electrically
for
to
the
regulator
the
gas
to
electric
pilot
main
of
the
and
the
the
of
flow
of
the
vane
controlled
in
the
proportioning
flOW
with
(Figure
flows
gas
where
pilot
main
flows
where
gas
and
flow
to
air.
burns
flame
ignition
through
the
pilot
programming
operated
butterfly
to
the
in
the
same
the
direction
1-10)
into
the
burner's
shut-off
the
to
the
operated
gas
valve
operation
gas
shut-off
through a shut-off
the
when
the
pilot
This
spark
only
ignition.
cycle,
circuitry
ignited.
main
valve
burner
butterfly
by
the
maimer
gas
pressure
burner's
to
is
taken
pilot
valve
energized
where
mixture
to
establish
during
the
in
When
control
gas
valve
to
depends
valve.
damper
as
the
and
cock;
main
the
cock.
oper-
con-
the
pilot
the
the
air
com-
of
re-
is
it
is
High-Low
The
firing;
steam
water
damper
either
ance
Modulating
An
modulating
reversible
at
any
Through a linkage
damper
constant
Gas
the
combustion
with
The
unless
to
indicate a sufficient
Some
valves.
mally
for
venting
line
vent
Burner
standard
either
boiler,
boiler,
motor
the
high
with
load
Burner
optionally
damper
and
position
and
air-fuel
flows
through
combustion
main
gas
the
combustion
insurance
Additional
open
vent
gas
when
main
valve
closes
burner
low
or a temperature
makes
causing
fire
requirements.
equipped
will
within
the
zone
valve
requirements
should
gas
Operation
is
equipped
or
high. A
or
breaks
the
or
the
Operation
motor.
move
its
arrangement
butterfly
ratio
throughout
the
burner
where
air
to
produce
cannot
air
supply
requirements
valve
to
any
valves
when
the
pressure
burner
low fire
gas
This
in
either
range.
gas
it
be
proving
specify
be
placed
be
are
main
for
two
control
control
the
circuit
to
rate
fired
boiler
type
of
direction
it
controls
valve
to
maintain
the
firing
orifice
is
present
ring
intimately
main
energized
switch
of
combustion
two
call
for a
between
in
de-energized.
gas
valves
position
on a hot
to
operate
in
accord-
has
motor
or
the
range.
to
enter
mixed
flame.
(opened)
is
closed
main
them
main
open.
on
the
stop
air
air.
gas
nor-
gas
The
a
at
a
is
a
1-12
CHAPTER 2
This
chapter
care
of
the
Water
boilers
vice.
dends
and
placing
vital.
remodeled
oil, grease
boiling
lations
The
adequately
less
your
the
Feedwater
for use. See
pumps,
with
A boiler,
proper
operated
or
the
The
chapter
operation.
requirements
are
essential
Constant
in
the
prevention
the
The
waterside
steam
out
is
described
subject
it
is
of
boiler
amount
equipment
and
prevailing
as a part
circulation
as
severe, possibly
pressure
operator
before
A.
is
devoted
pressure
attention
form
of
pressure
or
or
other
the
vessel
of
water
be
covered
prime
performs
of
waterside
that
receivers
codes
intended
vessel.
should
attempting
TH
A.
GENERAl
B. CONSTRUCTION
C. WATER RECWIREMENTS
1.
2.
D. WATER TREATMENT
E.
ClEANING
F.
BOilmOUT
G.
WASHING
H.
BlOWDOWN-STEAM
t PERIODIC INSPECTION
J.
PREPARATION FOR EXTENDED
GENERAl
primarily
vessel.
for
both
to
boiler
to
this
of
longer life, less
costly
hot
importance.
aU valves, piping,
of a hot
damaging,
repairs.
vessel
of
new
water
foreign
to
remove
later
in
supply
in
this
has
an
care
should
are
installed
and
and
the
by
its
designer
familiarize
to
steam
life
and
area
Care
into
initial
boilers
systems
matter. A method
these
this
chapter.
and
treatment
manual.
The
important
it
witl
be checked
practices.
water
system,
system
stresses
himself
to
place
p
HOT
STEAM
the
waterside
and
hot
length
will
pay
down
taken
service is
and
may
accumu-
Neverthe-
type
of
bearing
require.
and
boiler
in
accordance
must
to
avoid
occurring
with
the
unit
ESSU
WATER
water
of ser-
new
contain
cannot
service
ready
requires
shock
BOlliER
BOlliER
OF
A NEW UNIT
OUT
divi-
time,
in
or
of
in
feed
be
to
this
into
E
VESSEL
BOlliER
lAYaUP
B. CONSTRUCTION
All
pressure
with
the
Steam
ceeding 15 psig,
valve
practices,
Pressure
boilers
exceeding 240°F.
but
because
psig
design
Pressure
peratures
pressure
be
as
IV
of
Those
ceeding 15 psig
section I
water
built
to
ASME
boilers
Heating
for
operation
Heating
between
is 60 psig,
high
as
Low
Pressure
steam
Power
boilers
this
vessels
Boiler
for
but
are
of
static
and
constructed
160 psig
boilers
are
Boilers,
for
operation
Code.
Boilers,
may
C. WATER REQUIREMENTS
1.
HOT
WATER
Air Removal
The
hot
water
tends 2 to 3 inches
reduces
trapped
the
Any oxygen
will collect
shell.
the
at
system.
BOilER
outlet
possibility
the
top
or
air
or
be
trapped
are
constructed
and
Pressure
operation
within
constructed
with
be
head
Boiler
240-250°F,
but
because
Heating
designed
constructed
includes a dip
into
of
the
which
the
of
this
water
built
may
to
Code.
and
constructed
of
the
over 250°F
the
boiler.
of
any
shell
is
released
at
the
at
in
accordance
Vessel Code.
pressure
limits
of
good
to
section
Code.
temperature
as
30 psig design,
be
built
section
For
water
minimum
of
static
Boiler
Code.
for
operation
in
accordance
ASME
tube
This
air
which
from
entering
in
top
of
are
not
IV, Low
Hot
up
IV
of
head
to
section
Code.
likewise
which
dip
may
the
the
ex-
safety
water
not
to
160
Low
tem-
design
may
ex-
with
Hot
ex-
tube
be
into
boiler
boiler
2-1
Chapter 2-The
The
air
vent
boiler
pression
of
through
the
should
tank.
boiler
this
Minimum
mum
recommended
170
degrees
than
170
are
reduced
water
vapor
corrosion
This
condensation
unit
which
greatly
matter
since
heat
oversized
which
an
from
problem
water
temperatures
Pressure
tapping
be
piped
Any
will
tapping.
Boiler
F.
Water
When
degrees F are
in
temperature
condenses.
occurs
in
operates
for
can
be
efficient
the
can
boiler
combustion
be
minimized
Rapid Replacement
system
prevent
of
or
cannot
that
cannot
water
mal
operation"
This
having
burner
the
When
it
though
The
continuous
help
with
layout
the
cold
water
thermal
stresses. A formula,
be
given,
200
degrees
be
in
a few
stress.
problem
the
so
that
circulating
individual
is
recommended
the
relief
device
circulation
prevent
"cold"
and
controls
possibility
into a hot
but
or
completely
minutes'
This
applies
as
well
can
be
circulating
the
pump
zone
that
heat
users
or
rapid
zone
water.
Contiru.1ous Flow
system
arranged
through
The
trols
boiler
through
stratification
even
A
power
tinuous
operating
Before
operation
should
will
water
rule
of
can
initial
should
that
the
boiler
of
be.
not
the
boiler
within
temperatures
thumb
be
used
flow
rate
conditions.
firing
be
there
under
three
checked
be
by-passed.
of
to
Vessel
on
the
into
the
air
which
find
its
way
Temperature-
boiler
water
used,
The
the
boiler
problem
intermittently
the
actual
controlled
extracts
by
above
of
170
Boiler
should
of
pumping
boiler,
it
should
240
degrees
replaced
time
to
as
during
avoided
pump
burner
is
running.
cannot
circulating
they
be
do
not
by-pass
through
replacement
Through
piped
will
and
be
all
way
valves
to
eliminates
the
unit
to
1/2
to 1 gpm
determine
through
or
refiring
top
center
expansion
is
trapped
out
of
water
temperature
temperatures
the
combustion
to a point
net
result
and
breeching.
is
more
and
load.
by
boiler
all
gases.
However,
maintaining
degrees
Water
be
large
thus
causing
or
"magic
be
borne
water
with
without
causing
periods
initial
in
some
interlocked
operate
pumps
kept
running -even
require
valve
will
the
boiler
of
boiler
the
Boiler -The
the
water
operating
and
make
sure
Constant
the
possibility
and
results m more
the
system.
per
boiler
the
minimum
the
boiler
after
line
of
or
at
the
the
boiler
The
mini-
lower
where
is
severe
which
This
is
design,
the
possible
boiler
F.
-
arranged
quantities
shock,
number"
in
mind
in a boiler
80
degrees
of
"normal-
start-up.
systems
with
unless
are
used,
hot
water.
thus
allow
and
water
controls.
circulation
conditions.
system
that
circulation
horse-
under
boiler
the
com-
top
is
gases
the
that
on
a
is
not
a
this
The
to
ther-
by
the
can
so
con-
the
of
con-
an
has
been
drained,
flow
of
water
Water
The
circulation
boiler
Multiple
boilers
be
through
by
line
plates
psi)
accomplish
If
tional
wide
In
fire''
be
mon
would
portant
Circulation
chart
output
of
taken
use
of
from
are
must
care
is
flow
variations
extreme
position,
loafing.
header
not
in
rate
Boiler
equal
to
insure
the
boilers.
balancing
each
used, a significant
be
this
not
through
cases,
The
be
consideration
stallations.
Pressure Drop
pressure
2.31 ft.
drop
hd.)
Cleaver-Brooks
which
has
more
drop.
Pump
system
outlet
discharge
and
pump.
decreases
impose
It
circulating
pumps
in
Pump
and
desirable
that
culating
location
circulating
connection
to
the
the
expansion
This
air
the
system
is
common
pump,
are
usually
the
boiler
Operation -Pumps
stopped
to
interlock
the
burner
pump
Pressure
The
design
requirements
ted
upon
the
with
air
or
with
Caution
proper
exists
ternal
must
relationship
within
the
surfaces
the
operator
exists
Fig. 2-1
of
boiler
and
system
Installations
or
unequal
adequate
This
cocks
boiler.
taken
across
purpose.
taken
to
the
in
firing
one
and
the
net
result
water
up
to
the
Through
of
less
through
boilers
than a 10
-
pumps
on
system
tank
location
entry
into
head
practice
and
located
room.
by
manual
cannot
is
running.
of
the
will
often
boiler.
Some
an
be
exercised
boiler
are
fully
should
through
shows
the
the
water
temperature
-
size
are
or
can
best
and
gauges
If
balancing
pressure
the
balancing
insure
adequate
boilers,
rates
between
boiler
other
may
boiler
would
temperature
desired
in
point.
multiple
Boiler -There
than
three
all
standardly
operating
degree
It
is
recommended
take
the
boiler
load.
This
on
the
is
preferred
the
system
on
the
to
install a standby
these
adjacent
are
switches.
the
pump
operate
system
dictate
systems
inert
gas,
to
make
of
pressure
so
that
all
wetted
determine
boiler.
maximum
in
relation
drop.
When
used,
care
proportional
be
accomplished
in
the
cocks
drop
or
this
can
the
be
in
the
or
boilers
be
that
to
the
This
boiler
feet
head
equipped
in
any
F.
temperature
suction
suction
and
puts
from
that
the
side
because
and
boiler.
main
circulating
to
the
normally
It
with
the
burner
unless
and
the
the
pressure
are
pressurized
such
as
sure
to
temperature
of
the
boilers'
at
all
times.
that
G.P.M.
to
full
multiple
must
flow
supply
or
orifice
(e.g. 3-5
device
to
propor-
result
in
boilers.
"high
may
the
com-
system
is
an
im-
in-
will
be
( 1 psi-
system
that
the
the
they
boiler
of
the
does
not
system
boilers
started
is
also
so
the
cir-
usage
exer-
nitrogen.
that
the
in-
It
a
a
it
is
2-2
Chapter 2-The
Pressure
Vessel
15
20
30
40
50
60
70
80
Boiler
Output
( 1
()()())
Btu/Hr
500 100 50 33
670
1,005
1,340
1,675
2,010
2,345
2,680
Boiler
Size
(BHP)
100 3,350 670
125 4,185
150 5,025 1,005
200
250
300
350
400
500
600
700
800
6,695 1,340
8,370 1,675
10,045 2,010 1,005
11,720 2,350 1,175 784 587 470 392 336 294
13,400
2,680 1,340
16,740 3,350 1,675 1,120
20,080 4,020 2,010
23,430 4,690 2,345 1,565
26,780 5,360 2,680 1,785 1,340 1,075
System
10
200
134
20
67
100
30
Maximum
45
67
268 134 89
335
402
470
536
168
201
235
268
112 84
134
157 118
179 134
335 223 168
836
418
503
670
279
335
447
838 558
670
895
1,340 1,005
Temperature
40 50
Circulating
25
33
50
67
40
54
67
101
107
134 112
209 168 140
251
201
335 268
419
335
503 402
670 535
838
670 558
805 670
1 '175
940
Drop
- Degrees f'
60
Rate -
20
17
27
22
33
45
56
67
80
94
78
90
168
224 192 168
280 240 210
335
447
785
895 765
70
80
90 100
GPM
14 12
11
19 17 15
25 22
29
38 33
48
58
67
77
96
120 105
144
126
30
42 37
45
50
59
52
67 60
84
75
93
112
149 134
186
251
287
223
261
383 335 298
479
575 502
670
419
585
372
448 402
520
670 595 535
10
13
20
27
33
40
47
54
67
84
100
167
201
235
268
335
470
for
this
reason
indicated
held
to
the
When
when
system,
initially
cutting
the
operation
system
It
the
and/or
is
advisable
return
perature.
ply
water
perature
knowledge
easily
detect
appropriate
Special
any
might
boiler
ticularly
caution
condition,
lead
or
hot
true
operated
water
for
that
on
the
water
level
shown
firing a newly
an
existing
boiler
MUST
be
other
to
have a thermometer
line
to
With
this
temperature
differential
of
the
pumping
any
excessive
corrective
must
or
combination
to
the
transfer
water
in
the
for
purposes
the
normal
the
internal
pressure
in Fig. 2-2.
boiler
or
boilers
pressurized
boilers
indicate
determined
to
system
will
be
rate,
load
action.
be
taken
of
to
a cold boiler.
case
of
other
system
FIGURE
boiler
gauge,
installed
into
to
prior
to
return
and
known,
established.
the
condition
(See
to
guard
of
conditions
cold
water
boilers
than
supplying
load
(as
pressure,
must
boiler
an
operating
be
cut
equal
cutting
installed
water
with
the
the
operator
and
Figure
to a hot
This
which
an
example,
2-1.
CIRCULATION
as
be
or
into
to
the
in.
in
tem-
sup-
tem-
With
can
take
2-1
).
against
which
is
par-
are
hot
CHART
boilers
It
equipped
cannot
be
over
temperature
do,
cause
damage.
2.
STEAM BOILER
Feed Pump
Make
certain
are
open
BEFORE
prevent
After
pump
With
trance
level
Feedwater
maintain
conditions.
and
possible
opening
motor
correct
switch.
reaches
pumps
required
Check
maintain
breakdowns.
NOTE:
Prior
alignment
used. A
with
coils for
emphasized
within
Operation
that
the
all
turning
damage
valves,
to
establish
rotation,
Pump
should
proper
must
water
feedwater
as
necessary
to
operating
of
properly
domestic
that
boiler
can,
valves
to
in
on
feed
the
the
momentarily
correct
close
boiler
shut
level
shown
have
adequate
level
under
pumps
to
prevent
pump,
flexible
coupling
aligned
rapid
and
water
pump
pump
mechanism.
energize
pump
feed
down
in
Figure
all
periodically
carefully
coupling
hot
water).
changes
sometimes
feed
line
motor
feed
rotation.
pump
when
en-
water
2-3.
capacity
operating
unexpected
check
if
one
will
last
in
to
to
is
2-3
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