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Model 4
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-7
Insurance/Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-7
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-8
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-15
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-15
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16
Feedwater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16
Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-17
Boiler Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-17
Oil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-20
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-20
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-27
MODEL 4 BOILER
1,500 - 6,000 MBTU &
Watertube Boiler
CONTENTS
Section B2-1
1,500 - 6,000 MBTU
Rev. 03-08
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Summary of Contents for CleaverBrooks Model 4
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Page 1: Table Of Contents
Model 4 1,500 – 6,000 MBTU MODEL 4 BOILER 1,500 - 6,000 MBTU & Watertube Boiler CONTENTS FEATURES AND BENEFITS ..........B2-3 PRODUCT OFFERING . - Page 2 Figure B2-2. Model 4 Standard Pilot and Main Gas Trains ......B2-2...
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Page 3: Features And Benefits
Model 4 1,500 – 6,000 MBTU FEATURES AND BENEFITS The following features and benefits apply to the Model 4 Boiler product line. 33" Cased Width: • Boiler fits through most standard doorways. • Reduced installation costs. Direct Driven, Vibration-Free Centrifugal Impeller: •... -
Page 4: Product Offering
1500 - 6000 MBTU/hr PRODUCT OFFERING The Model 4 (M4) Boiler is a compact carbon steel, extended fin, watertube boiler. Heat transfer design is configured in a "3-pass" gas travel across the watertube surfaces. The pressure vessel is constructed to conform to the A.S.M.E. Code, either Section IV for low pressure steam @ 15 PSIG MAWP (maximum allowable working pressure) or Section I for MAWP greater than 15 PSIG. -
Page 5: Table B2-1. Model 4 Boiler Sizes
Model 4 1500 - 6000 MBTU/hr Table B2-1. Model 4 Boiler Sizes MODEL INPUT HEAT EQUIV STEAM SHIPPING OUTPUT OUTPUT WEIGHT LB/HR 1500 1500 1200 1237 3100 2000 2000 1600 1649 3100 2500 2500 2000 2062 3700 3000 3000 2400... - Page 6 Model 4 1500 - 6000 MBTU/hr Gas Train consists of the following: • Primary gas shutoff valve with integral proof of closure switch. • A manual shutoff valve located ahead of the primary gas valve. • A plugged leakage test connection and a second manual shutoff valve for tightness checking of the primary shutoff valve.
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Page 7: Optional Equipment
UL or CSA and are below these inputs are exempt from these recommendations. The Model 4 boiler is UL listed and labeled. In addition to the standard UL requirements the following are needed to comply with FM when required. -
Page 8: Dimensions And Ratings
Non-fused disconnect to remove boiler from all sources of power. DIMENSIONS AND RATINGS For layout purposes, the nominal dimensions and connections for the Model 4 Standard Package Boiler are shown in Figure B2-1 and Table B2-2. Ratings of each boiler size are noted in Table B2-3. Additional information is shown in the following figures, tables, and illustrations. -
Page 9: Figure B2-1. Model 4 Dimension Drawing
Model 4 1500 - 6000 MBTU/hr Figure B2-1. Model 4 Dimension Drawing Rev. 03-08 Section B2-9... -
Page 10: Table B2-2. Model 4 Dimensions
Model 4 1500 - 6000 MBTU/hr Table B2-2. Model 4 Dimensions Boiler Size Note 1 1500 2000 2500 3000 3500 4000 4500 5000 6000 All D imensions are in inches Lengths Overall 84.25 84.25 100.25 100.25 117.375 117.375 136.75 136.75 152.375... -
Page 11: Table B2-3. Model 4 Steam Ratings
Model 4 1500 - 6000 MBTU/hr Table B2-3. Model 4 Steam Ratings 1500 2000 2500 3000 3500 4000 4500 5000 6000 Boiler SIZE Ratings [Note A] Rated Capaci ty - Steam (lbs . s team/hr 1,237 1,649 2,062 2,474 2,887... -
Page 12: Figure B2-2. Model 4 Standard Pilot And Main Gas Trains
Model 4 1500 - 6000 MBTU/hr Figure B2-2. Model 4 Standard Pilot and Main Gas Trains SIZES ITEM PART DESCRIPTION INCHES Pilot Sizes 1500 TO 2500 Butterfly Valve 1-1/2 Main Pilot Shutoff Cock Pilot Gas Regulator Pilot Solenoid Valve Manual Shutoff Valve... - Page 13 Model 4 1500 - 6000 MBTU/hr Table B2-5. Minimum required NATURAL GAS pressure at entrance to STANDARD UL, FM, & XL GAP gas trains (upstream of gas pressure regulator) INLET PIPE HONEYWELL PRESSUR E REQ UIRED BOILER REQ UIRED FUEL...
- Page 14 Model 4 1500 - 6000 MBTU/hr Table B2-7. Minimum required PROPANE GAS pressure at entrance to STANDARD UL, FM, & XL GAP gas trains (upstream of gas pressure regulator) PRESSUR E REQ UIRED INLET PIPE HONEYW ELL BOILER REQ UIRED FUEL...
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Page 15: Performance Data
Model 4 1500 - 6000 MBTU/hr Table B2-9. Safety valve outlet size SAFETY VALVE SETTIN G 15 PSIG STEAM 150 PSIG STEAM VALVES OUTLET SIZE VALVE VALVES OU TLET SIZE VALVE Boiler Size REQ'D (IN.)** C APACITY REQ 'D (IN .)**... -
Page 16: Emissions
Fuel bound nitrogen = 0.05% (max) by weight. Sulfur = 0.5% (max) by weight. Ash = 0.01% (max) by weight. ENGINEERING DATA The following engineering information is provided for the Model 4 steam boiler. Additional information may be obtained from your local Cleaver-Brooks authorized representative. Feedwater Steam boilers require make-up water for steam production. -
Page 17: Blowdown
Local codes will dictate the manner of treating the blowdown affluent. Boiler Stacks General - The Model 4 boiler operates with a positive vent pressure and a vent gas temperature that is non-condensing. Therefore, the stack must be a positive pressure design. - Page 18 Model 4 1500 - 6000 MBTU/hr room is neutral or slightly positive pressure), or with a direct vent to outside the boiler room where air is drawn directly from the exterior of the building. Regardless of the method, all installations must comply with NFPA 54 (National Fuel Gas Code - NFGC) for U.S.
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Page 19: Figure B2-3. Boiler Room Air Supply - "Engineered Design
Model 4 1500 - 6000 MBTU/hr Table B2-15. Model 4 fuel, combustion air, and flue gas flow rates Boiler Size 1500 2000 2500 3000 3500 4000 4500 5000 6000 1500 1500 2500 3000 3500 4000 4500 5000 6000 Fuel Consumpi on Oi l 10.72... -
Page 20: Oil Piping
1500 - 6000 MBTU/hr Oil Piping General - Oil operation of the Model 4 boiler requires proper oil to the standard burner mounted oil pump. As the combustion of oil utilizes mechanical pressure atomization, line sizing to the pump must be sufficient to provide 125 gph of oil to the suction side of the pump. - Page 21 Model 4 1500 - 6000 MBTU/hr Gas Supply Pipe Sizing - For proper operation of a single unit or multiple units, we recommend that the gas pipe 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...
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Page 22: Table B2-16. Gas Line Capacity - Schedule 40 Metallic Pipe
Model 4 1500 - 6000 MBTU/hr Table B2-16. Gas line capacity - Schedule 40 metallic pipe Pipe Size Nominal 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4" 1.049 1.380" 1.610" 2.067" 2.469" 3.068" 4.026" Actual I.D. Length in feet **Maximum Capacity in Cubic Feet of Gas per Hour (cfh) -
Page 23: Table B2-18. Gas Line Capacity - Schedule 40 Metallic Pipe
Model 4 1500 - 6000 MBTU/hr Table B2-18. Gas line capacity - Schedule 40 metallic pipe Pipe Size Nominal 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4" Actual I.D. 0.622 0.824 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026" Length in... -
Page 24: Table B2-19. Gas Line Capacity - Schedule 40 Metallic Pipe
Model 4 1500 - 6000 MBTU/hr Table B2-19. Gas line capacity - Schedule 40 metallic pipe Pipe Size Nominal 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4" Actual I.D. 0.622 0.824 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026" Length in... -
Page 25: Table B2-20. Gas Line Capacity - Schedule 40 Metallic Pipe
Model 4 1500 - 6000 MBTU/hr Table B2-20. Gas line capacity - Schedule 40 metallic pipe Pipe Size Nominal 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4" Actual 0.622 0.824 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026" I.D. Length... -
Page 26: Figure B2-4. Typical Gas Header Piping
Model 4 1500 - 6000 MBTU/hr Figure B2-4. Typical gas header piping Rev. 03-08 Section B2-26... -
Page 27: Specifications
Model 4 1500 - 6000 MBTU/hr Model 4 Boiler Steam Specifications Submittals ..............B2-28 Codes . -
Page 28: Submittals
The boiler shall have an integral forced draft burner and burner controls. The boiler shall be a Cleaver Brooks Model 4, series (100 = No. 2 oil, 200 = No. 2 oil and gas, 700 = gas) steam boiler. -
Page 29: Product Design
Model 4 1500 - 6000 MBTU/hr The maximum sound level shall not exceed 80 dBA measured 3 feet in front of the boiler. PRODUCT DESIGN Pressure Vessel The upper drum shall have a 20" OD, manufactured from SA– 53 Gr. B seamless pipe, with a minimum wall thickness of 0.375". - Page 30 Model 4 1500 - 6000 MBTU/hr Observation ports shall be provided at each end of the boiler for visual inspection of the pilot and main flame conditions. Two lifting eyes shall be located on top of the boiler. The exhaust gases shall vent at the rear of the boiler, on the top centerline.
- Page 31 Model 4 1500 - 6000 MBTU/hr Burner Design – General The burner shall be integral to the windbox. All air for combustion shall be supplied by a forced draft blower mounted in the windbox, above the burner, to minimize noise and vibration level.
- Page 32 Model 4 1500 - 6000 MBTU/hr [Optional] Automatic electric ignition of the premix gas pilot shall be furnished. An electric scanner, of the UV principle, shall confirm the pilot prior to the delivery of the low fire oil supply. The single combustion air damper motor shall operate the low and high fire oil valves.
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Page 33: Burner Management System
Model 4 1500 - 6000 MBTU/hr Natural Gas Pilot Train A pilot gas pressure regulator shall be factory mounted and piped for pressure regulation of the pilot gas to the burner. The pilot gas train shall include a safety shutoff valve. It shall be controlled by the programming relay to start the burner. -
Page 34: Shop Tests
Model 4 1500 - 6000 MBTU/hr The combustion safeguard control shall be microprocessor based, with self–diagnostics, non–volatile memory, and a message center with a vocabulary of 42 different messages. Messages shall scroll across an alpha–numeric display and provide sequence status and flame failure mode information. -
Page 35: Operation And Maintenance Manuals
Model 4 1500 - 6000 MBTU/hr The boiler start–up shall include boiler operator training and shall cover boiler operation, water treatment, and maintenance of the unit. OPERATION AND MAINTENANCE MANUALS Manufacturer shall supply copies of the Operating & Maintenance Manual.
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