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7. Steam Safety Valve Following PRV [FAIL] wrong metal type per 1810

(SVFPRV) (For Steam Boiler System only)

Item Make Capacity (lb/hr) Range SVFPRV Set Point DA Pres

SVFPRV Kunkle 17972 15 psi 8 psi Pressure Trerice 0-30 psi

Gage

• Setpoint must be 5 psig higher than DA safety set pressure and at least 5 psig below MA WP of DA tank.

Maximum lift pressure shall not exceed 2 psig above set pressure. Reseat pressure shall not exceed 4 psig below set pressure.

Item Make Type Size Pressure Pressure Wide Open

(in) Upstream Downstream Flow Capacity

PRV Spence Spring 2in 98 psi 9 psi Bypass Nibco Gate I in

• SVFPRV is required to relieve largest of wide open flow capacity, PRV (combined total if parallel PRV setup) or bypass valve. Manual valve downstream ofSVFPRV is required. SVFPRV is required to be directly vented outside. Vent line is required not to contact drip pan ell when hot. Any valves with a setpoint of 15 psig or hi_gher must be of steel construction .

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• Test the drains on the safety valve drip pan ells by pouring water into them and noting that water flows freely. Unstop drains before proceeding.

• Close the manual valve in steam line following the safety valve.

• Slowly open bypass valve to raise pressure until safety lifts. DO NOT RAISE PRESSURE MORE

THAN 2 PSIG ABOVE SETPOINT PRESSURE.

• Use manufacturer data to determine wide open capacity of PRV and bypass valve.

• Open larger of the bypass valve or PRV completely and perform accumulation test. The pressure should rise no more than 6% above the setpoint pressure. After lifting valve, close bypass valve, open manual

Full Steam Ahead !

VICTORY ENERGY OPERATIONS, LLC

10701 E. 126th ST. N, Collinsville, OK 74021 Phone: 918-274-0023 Fax: 918-274-0059

EQUIPMENT DESCRIPTION – Discovery Series Model DT-2-57

Victory Energy Operations, LLC provides three steam generating systems to be utilized by Department of Veteran Affairs, Jefferson Barracks facility in Saint Louis, Missouri. The boilers and economizers have been registered with the National Board for ASME Boiler and Pressure vessels.

The boiler is designed with the following characteristics:

Quantity: One (3) Boiler Capacity 35,000 lbs/hr Saturated Steam Design Pressure: 200 PSIG Operating Pressure: 100 PSIG Operating Temperature: Saturated at the NRV outlet Feedwater Temperature: 228° F to Inlet from DA Primary Fuel: Natural Gas (#2 Oil Secondary Fuel) Boiler Location: Indoors

The VEO boiler design offers the least amount of furnace refractory compared to other designs. The tube and membrane seal welded front and rear walls virtually eliminate all refractory in the furnace, other than localized seals. This design greatly reduces maintenance costs and offers increased unit availability. The furnace sidewalls are tube and membrane construction for the entire length of the furnace to eliminate the possibility of gas bypassing. The outer sidewalls are also tube and membrane design for gas tight construction. This design offers 100% water cooling.

The furnace wall tubes of any boiler encounter the highest heat flux. The VEO boiler design, has the shortest furnace wall tubes in the industry. This advantage removes heat from the furnace quickly and extends boiler life.

The VEO boiler design has a single lower drum which reduces maintenance compared to other designs that may have two lower drums or headers. The single large diameter drum makes it easier to perform inspections and to maintain lower tube connections. The steam drum includes steam separation equipment.

SCOPE OF SUPPLY

Supply

ITEM

Installation VEO Buyer VEO Buyer

X Boiler (Shop Assembled) including insulation, flat, painted lagging, corrugated galvanized lagging X

X Boiler Trim Package (Trim Piping Ships on Boiler) X X Water column, water column drain piping X X Water column relay box X X Steam pressure gauge X X Natural Gas Burner System: X X Burner X X Fuel Trains (incl. pilot line) X X Fuel PRV (Regulator) Shipped Loose X X Burner Management System (BMS) X X Combustion Control System (including instrumentation) X

X Forced Draft Fan (Ships on Burner) X X Forced Draft Fan Drive (Motor ships on FD fan) X X Economizer with Support Steel X X Ducting and Expansion Joints X X Boiler Outlet Transition Insulation and Lagging X X Flue Gas Recirculation Duct Insulation & Lagging X X Boiler Outlet mounted Single Wall Stack (Insulation by Customer) X

X Platforms and Walkways (rear of boiler & side of main steam drum) X

X Interconnecting Piping within Terminal Points X X Interconnecting Piping Insulation and Lagging X X Piping External of Terminal Points X

X Safety Valve Drip Pan Elbows X X Safety Valves X X Foundation, Anchor Bolts, Concrete, Grout X X Chemical Feed Storage and Feed Pump X

SCOPE OF SUPPLY (CONT’D)

Supply

ITEM

Installation

VEO Buyer VEO Buyer X Feedwater Treatment System (Water Soft/ Filter System) X X Blow Down Heat Recovery Tanks (Continuous and Intermittent) X X Deaerator & Feedwater Pump(s) w/ Drives X X Spare Parts (Optional – Available Direct from VEO – priced sep.) X N/A Special Tools

X Economizer By-Pass System X X Sample Cooler System X

X SootBlowers w/ Piping from Drum to SootBlower X N/A Steam Coil Air Heater X

X Loading Equipment at Shop X X Unloading Equipment at Jobsite X X Boil-Out Chemicals X X Site Disposal of Chemicals and Water X X Boiler Room/Site Modifications X X Site Storage Prior to Installation X X Environmental Permit X

X Erection and Start-Up Labor X X Field Balancing and Alignment of Rotating Equipment X X Electrical Power Supply and Lighting Protection X X Interconnecting Wiring or Cabling X X Erection Consultant X X Class Room Training X X Field Testing Labor, Equipment and Consumables X X Start-Up Consultant X

X Documentation X X O & M Manuals X

Heating Surfaces, Design Pressure and Size

Furnace Radiant Heating Surface 659 Sq. Ft.

Boiler Heating Surface 3,218 Sq. Ft.

Total Heating Surface 3,877 Sq. Ft.

Furnace Volume 990 Cu. Ft Overall Width 5’-11” Average Height 9’-0” Weld Line Length 18’-8” Design Pressure 200 PSIG

Drums Submerged arc automatic welded and stress relieved with radiographed welded seams

Drum material is SA-516 Gr. 70 Tubes are rolled and expanded into the drum Mud Drum is provided with a 12” x 16” hinged manway access in each drum head Steam Drum is provided with a 12” x 16” hinged manway access in each drum head

Upper (Steam) Drum

< Inside diameter is 36 inches < External connections consist of the following connections:

< main steam outlet, water column, auxiliary low water cut-off, steam gauge, vent, safety valve, feedwater, and continuous blowdown.

< The upper drum includes a feedwater distribution pipe and a blowdown collection pipe.

Lower (Mud) Drum < Inside diameter is 30 inches < External connections consist of chemical feed and intermittent blowdown < The intermittent blowdown connection is at the lowest point for draining of the unit

Tubes*

All tubes enter the drum radially with full parallel bearing through the drum plate All tubes are full diameter tubes with no swaging < Front Wall 2” O.D., 0.135” M.W., SA-178 A < Rear Wall 2” O.D., 0.135” M.W., SA-178 A < Furnace Floor, Sides & Roof 2” O.D., 0.135” M.W., SA-178 A < Convection: 2” O.D., 0.120” M.W., SA-178 A < Outer Side Wall: 2” O.D., 0.135” M.W., SA-178 A

BOILER (CONT’D)

Boiler Wall Construction The outer lagging of the boiler will have an average surface temperature of 140 Deg. F ambient with 2 MPH wind velocity. The boiler walls include the following:

The furnace sides, roof and floor consists of a tube and membrane design. The wall is constructed with 2” O.D. tubes with 1” wide by ¼” thick steel membranes welded to each tube.

The front wall consists of a tube and membrane design. The first layer is 2” O.D. tubes with 2” exposed width by ¼” thick carbon steel membranes welded to the tubes. The second layer is 3” of 1200 Deg. F.

board insulation. The outer surface is flat carbon steel lagging properly stiffened.

The rear wall consists of a tube and membrane design. The first layer is 2” O.D. tubes with 2” exposed width by ¼” thick carbon steel membranes welded to the tubes. The second layer is 3” of 1200 Deg. F.

board insulation. The outer surface is flat carbon steel lagging properly stiffened.

The outer boiler side wall is a tube and membrane design. The first layer is 2” O.D. tubes with 1” wide by ¼” thick carbon steel membrane welded to the tubes. The second layer is 3” of 1200 Deg. F. board insulation. The outer surface is flat carbon steel lagging properly stiffened.

The drum is insulated with 2” of 1200 Deg. F. blanket insulation. The outer lagging is 16 gauge carbon steel.

Boiler Access and Observation Ports The furnace is accessible through one (1) 15” x 18” rear wall access door. The rear wall also includes three (3) 1 1/2” diameter self closing, air purged observation ports.

Steam Purification The Voyager upper (steam) drum includes steam purifiers to provide 99.5% steam purity, when boiler water quality is in accordance with the ABMA recommendations as indicated in herein.

Structural Base The boiler includes a rigid structural steel base frame designed to distribute the loads onto a flat concrete foundation.

Painting Preparation and painting was done in accordance with the “Base” system shown on the following page. The top coat color is standard Victory Energy Blue.

Piping, Trim and Accessories

Water level piping to water column and auxiliary water cutout Drain piping for water column water gauge glass, auxiliary cutout, and pressure gauge drain Steam pressure piping to pressure gauge Cooling Air piping to the observation ports and flame scanners supplied and installed by others.

The trim included in our scope of supply is listed on page 1 and page 2 within this equipment description.

We have included feed water piping from the feedwater control valve by-pass assembly to the boiler inlet on the steam drum. This piping is shop fabricated to the maximum extent possible with minimal field fit-up joints. Support of this piping will be by others. The control valve by-pass assembly will be mounted at grade, on the feedwater inlet connection side, adjacent to the boiler.

BOILER (CONT’D)

Preparation and Painting Standards

Components Base Drum Openings:

Flanged Coat w/ Rust Inhibitor Screwed Capped Welded Weldable Rust Inhibitor Drum- No Paint Drum Heads Insulated with insulating covers, 16 Gauge C.S., c/w 3-5 Mils

D.F.T. High Temp. VEO Blue Base Frame Surface Preparation-SP3

Primer – 3-5 Mils D.F.T. VEO Blue Exposed Casing Surface Preparation-SP3

Primer – 3-5 Mils D.F.T. VEO Blue Flue Gas Outlet Surface Preparation-SP3

Finish – 3-5 Mils High Temperature Gray Windbox/ Burner Vendor Standard Trim Piping – (subassemblies)

2-3 Mils High Temp. Gray

Boiler Trim Package (Quantities listed for one (1) boiler)

BOILER QUANTITY SIZE MANUFACTURER

Water Column 1 1” VEO Titan Water Column Drain Valve 1 ¾” Vogt Water Column Gauge Drain Valve 2 ¾” Vogt Steam Gauge 1 8 ½” Ashcroft Steam Gauge Siphon 1 ½” VEO Steam Drum Vent Valve 1 1” Vogt Intermittent Blowoff Valve (1st valve) 1 1 1/2” Edwards Intermittent Blowoff Valve (2nd valve) 1 1 1/2” Edwards Continuous Blowdown Shutoff Valve 1 1” Vogt Main Steam Non-Return Valve 1 6” Crane Main Steam Gate Valve 1 8” Crane Continuous Blowdown Flow Control 1 1” Vogt Boiler Safety Valve #1 1 2 1/2” Kunkle Boiler. Safety Valve #2 1 2 1/2” Kunkle Feedwater Control Valve 1 2” Flowserve Feedwater By-pass Valve 1 3” Crane Feedwater Isolation Valve 2 3” Crane Manual Boiler Feedwater Check Valve 1 3” Crane Manual Boiler Feedwater Globe Valve 1 3” Crane

BOILER WATER CHEMISTRY RECOMMENDATIONS

ABMA RECOMMENDED BOILER WATER LIMITS

b Actual values within the range reflect the TDS in the feedwater. Higher values are for high solids; lower values are for low solids in the feedwater.

c Actual values within the range are directly proportional to the actual value of TDS of boiler water. Higher values are for high solids; lower values are for low solids in the boiler water.

d Dictated by boiler water treatment.

e These values are exclusive of silica.

Steam purity is often confused with steam quality. Steam quality is a measure of the amount of moisture in the steam. Steam quality is expressed as the weight of dry steam in a mixture of steam and water droplets. For example, steam with 99% quality contains 1% liquid water.

Steam purity refers to the amount of solid, liquid, or vaporous contamination in the steam. High-purity steam contains very little contamination. Normally, steam purity is reported as the solids content.

Boiler Type Drum pressure, psig

Total dissolved solidsb in boiler water, ppm (max.)

Total Alkalinityc in boiler water, ppm

Suspended solids in boiler water, ppm (max.)

Total dissolved solidsc,e in steam, ppm (max.

expected value)

Drum-type boiler 0-300 700-3500 140-700 15 0.2-1.0

Drum-type boiler 301-450 600-3000 120-600 10 0.2-1.0

Drum-type boiler 451-600 500-2500 100-500 8 0.2-1.0

Drum-type boiler 601-750 200-2000 40-400 3 0.1-0.5

Drum-type boiler 751-900 150-1500 30-300 2 0.1-0.5

Drum-type boiler 901-1000 125-1250 25-250 1 0.1-0.5

Drum-type boiler 1001-1800 100 variabled 1 0.1

Drum-type boiler 1801-2350 50 variabled N/A 0.1

Drum-type boiler 2351-2600 25 variabled N/A 0.05

Drum-type boiler 2601-2900 15 variabled N/A 0.05

Once-through boiler 1400 & above 0.05 N/A N/A 0.05

VICTORY ENERGY CUSTOMER SPEC SHEET

Customer: VA Jefferson Date: 02/14/2013 Reference: DT-2-57 SAT Quote Number: JVE 11756 NG Rev4

PREDICTED PERFORMANCE

LOAD DESIGN LOAD 1 LOAD 2 LOAD 3

Outlet Steam Flow, (lbs/hr) 35000 26250 17500 8750

Fuel/Firing Conditions - Fuel Fired Natural Natural Natural Natural Gas Gas Gas Gas Excess Air, (%) 10.00 10.00 10.00 10.00 Flue Gas Recirc., (%) 15.00 15.00 15.00 15.00

Steam/Water Conditions - Steam Temp @ NRV Outlet (deg F) 340.2 339.2 338.5 338.0 Steam Pres @ NRV Outlet (psig) 100.0 100.0 100.0 100.0 Boiler Saturation Temp. (deg F) 344.2 341.5 339.5 338.3 Boiler Operating Press. (psig) 110.0 105.6 102.5 100.6 Econ. Water Exit Temp, (deg F) 275.8 268.8 261.8 256.1 Feedwater Inlet Temp, (deg F) 228.0 228.0 228.0 228.0

Flow Quantities - Percent Blowdown, (%) 1.00 1.00 1.00 1.00 Blowdown Flow, (lbs/hr) 354 265 177 88 Feedwater Flow, (lbs/hr) 35,354 26,515 17,677 8,838 Fuel Flow, (lbs/hr) 1,924 1,437 958 485 Combustion Air Flow, (lbs/hr) 33,728 25,197 16,794 8,505 Flue Gas Flow LVG System,(lbs/hr) 35,652 26,634 17,752 8,990 Flue Gas Recirc. Flow, (lbs/hr) 5,348 3,995 2,663 1,349 Flue Gas Flow w/Recirc., (lbs/hr) 41,000 30,629 20,415 10,339

Air/Gas Temperatures - Ambient Air Temp., (deg F) 80.0 80.0 80.0 80.0 Comb. Air/FGR Mixture, (deg F) 115.3 111.9 108.9 106.5 Adiabatic Flame Temp, (deg F) 3,372.4 3,370.7 3,369.3 3,368.1 Flame Temp w/ Recirc., (deg F) 3,026.2 3,021.8 3,018.0 3,014.9 Effec. Furnace Gas Temp, (deg F) 2,006 1,876 1,698 1,416 Furnace Exit Gas Temp, (deg F) 1,888 1,745 1,551 1,242 Boiler Exit Gas Temp, (deg F) 473 429 386 351 Gas Temp. LVG Economizer, (deg F) 320 297 277 261 Flue Gas Recirc. Temp. (deg F) 320 297 277 261

System Efficiency - Dry Gas Losses, (%) 4.32 3.91 3.54 3.25 Water From Fuel Fired, (%) 10.70 10.60 10.51 10.44 Moisture in Air Losses, (%) 0.12 0.11 0.10 0.09 Radiation Loss, (%) 0.78 1.03 1.53 2.98 Manufactures Margin, (%) 1.00 1.00 1.00 1.00 Total Heat Losses, (%) 16.92 16.65 16.67 17.75 Boiler Efficiency, (%) 83.08 83.35 83.33 82.25 HHV Heat Input By Fuel,(mmbtu/hr) 41.963 31.348 20.895 10.582

System Draft Losses - Fan Inlet:

Silencer, (inwc) 1.50 0.88 0.41 0.11 Fan Inlet Ducts, (inwc) 0.50 0.29 0.14 0.04

Fan Outlet:

Fan Outlet Ducts, (inwc) 0.50 0.29 0.14 0.04 Burner, (inwc) 6.50 3.81 1.78 0.48 Convection Zone, (inwc) 1.46 0.80 0.35 0.09 Economizer, (inwc) 0.61 0.34 0.15 0.04 Outlet Gas Ducts, (inwc) 0.50 0.29 0.14 0.04 Total Draft Losses, (inwc) 11.58 6.70 3.09 0.82

Furnace Performance - Heat Available, (mmbtu/hr) 37.473 28.026 18.699 9.477 Heat Absorbed in Furn, (mmbtu/hr) 15.772 13.125 9.920 5.870 Liberation Rate, (btu/hr-ft^3) 42388 31666 21107 10689 *** Liberation Rate, (btu/hr-ft^3) 49266 36796 24530 12419 Furnace Release Rate,(btu/hr-ft2) 57308 42828 28557 14466 Residence Time, (sec) 1.486 2.100 3.410 7.745

Convection Zone Performance - Gas Mass Velocity (lb/hr-ft2) 3,047 2,277 1,517 768 Gas Velocity at Inlet, (ft/sec) 52.39 36.75 22.34 9.57 Heat Absorbed in Conv.,(mmbtu/hr) 17.73 12.17 7.06 2.67

Economizer Performance - Gas Mass Velocity (lb/hr-ft2) 5,511 4,117 2,744 1,390 Gas Velocity at Inlet (ft/sec) 37.65 26.79 17.00 8.25 Water Flow Through Econ, (lb/hr) 35,354 26,515 17,677 8,838 Water Mass Velocity, (lb/sec-ft2) 212.14 159.11 106.07 53.04 Feedwater Pressure Drop, (psi) 4.19 2.38 1.08 0.29 Heat Absorbed in Econ.,(mmbtu/hr) 1.71 1.10 0.61 0.25

PHYSICAL DESIGN

Furnace Design Data - Proj. Radiant HT, (ft2) 659 Effective Radiant HT, (ft2) 581

Convection Zone Design Data - Conv. Heating Surface (ft2) 3219

Economizer Design Data - Economizer Heating Surface (ft2) 1771

Fuel Analysis - Fuel Type Gaseous Fuel Name Natural Gas Mol. Weight (lb/mol) 17.37 Specific Gravity 0.5998 Density (lb/ft3) 0.0451

Fuel Constituents - By Volume By Weight

CH4 (%) 90.0000 83.1042

C2H6 (%) 5.0000 8.8339 N2 (%) 5.0000 8.0619

High Heating Value (btu/lb) 21,813.1 Low Heating Value (btu/lb) 19,667.0

Note:

*** Liberation rate based on effective furnace length before first plane of entry into convection tubes.

VICTORY ENERGY CUSTOMER SPEC SHEET

Customer: VA Jefferson Date: 02/14/2013 Reference: DT-2-57 SAT Quote Number: JVE 11756 #2 Oil Rev4

PREDICTED PERFORMANCE

LOAD DESIGN LOAD 1 LOAD 2 LOAD 3

Outlet Steam Flow, (lbs/hr) 35000 26250 17500 8750

Fuel/Firing Conditions - Fuel Fired No.2 No.2 No.2 No.2 Fuel Fuel Fuel Fuel Excess Air, (%) 10.00 10.00 10.00 10.00 Flue Gas Recirc., (%) 15.00 15.00 15.00 15.00

Steam/Water Conditions - Steam Temp @ NRV Outlet (deg F) 340.2 339.2 338.5 338.0 Steam Pres @ NRV Outlet (psig) 100.0 100.0 100.0 100.0 Boiler Saturation Temp. (deg F) 344.2 341.5 339.5 338.3 Boiler Operating Press. (psig) 110.0 105.6 102.5 100.6 Econ. Water Exit Temp, (deg F) 271.5 265.2 259.0 254.0 Feedwater Inlet Temp, (deg F) 228.0 228.0 228.0 228.0

Flow Quantities - Percent Blowdown, (%) 1.00 1.00 1.00 1.00 Blowdown Flow, (lbs/hr) 354 265 177 88 Feedwater Flow, (lbs/hr) 35,354 26,515 17,677 8,838 Fuel Flow, (lbs/hr) 1,955 1,462 975 494 Combustion Air Flow, (lbs/hr) 31,930 23,871 15,920 8,062 Flue Gas Flow LVG System,(lbs/hr) 33,885 25,333 16,895 8,556 Flue Gas Recirc. Flow, (lbs/hr) 5,083 3,800 2,534 1,283 Flue Gas Flow w/Recirc., (lbs/hr) 38,967 29,133 19,429 9,839

Air/Gas Temperatures - Ambient Air Temp., (deg F) 80.0 80.0 80.0 80.0 Comb. Air/FGR Mixture, (deg F) 113.5 110.4 107.7 105.5 Adiabatic Flame Temp, (deg F) 3,603.7 3,602.1 3,600.7 3,599.6 Flame Temp w/ Recirc., (deg F) 3,226.7 3,222.6 3,219.1 3,216.2 Effec. Furnace Gas Temp, (deg F) 2,027 1,889 1,704 1,413 Furnace Exit Gas Temp, (deg F) 1,889 1,739 1,536 1,217 Boiler Exit Gas Temp, (deg F) 466 423 382 349 Gas Temp. LVG Economizer, (deg F) 314 293 274 259 Flue Gas Recirc. Temp. (deg F) 314 293 274 259

System Efficiency - Dry Gas Losses, (%) 4.37 3.97 3.61 3.34 Water From Fuel Fired, (%) 6.82 6.76 6.71 6.66 Moisture in Air Losses, (%) 0.11 0.10 0.09 0.09 Radiation Loss, (%) 0.78 1.03 1.53 2.98 Manufactures Margin, (%) 1.00 1.00 1.00 1.00 Total Heat Losses, (%) 13.09 12.87 12.94 14.07 Boiler Efficiency, (%) 86.91 87.13 87.06 85.93 HHV Heat Input By Fuel,(mmbtu/hr) 40.111 29.988 20.000 10.128

System Draft Losses - Fan Inlet:

Silencer, (inwc) 1.50 0.88 0.41 0.11 Fan Inlet Ducts, (inwc) 0.50 0.29 0.14 0.04

Fan Outlet:

Fan Outlet Ducts, (inwc) 0.50 0.29 0.14 0.04 Burner, (inwc) 6.50 3.81 1.78 0.47 Convection Zone, (inwc) 1.28 0.70 0.30 0.07 Economizer, (inwc) 0.53 0.29 0.13 0.03 Outlet Gas Ducts, (inwc) 0.50 0.29 0.14 0.04 Total Draft Losses, (inwc) 11.31 6.56 3.03 0.80

Furnace Performance - Heat Available, (mmbtu/hr) 37.376 27.961 18.659 9.453 Heat Absorbed in Furn, (mmbtu/hr) 17.231 14.186 10.588 6.164 *** Liberation Rate, (btu/hr-ft^3) 47086 35212 23483 11898 Liberation Rate, (btu/hr-ft^3) 40518 30292 20202 10230 Furnace Release Rate,(btu/hr-ft2) 57116 42700 28478 14421 Residence Time, (sec) 1.612 2.282 3.715 8.474

Convection Zone Performance - Gas Mass Velocity (lb/hr-ft2) 2,896 2,165 1,444 731 Gas Velocity at Inlet, (ft/sec) 47.91 33.53 20.30 8.64 Heat Absorbed in Conv.,(mmbtu/hr) 16.42 11.20 6.44 2.39

Economizer Performance - Gas Mass Velocity (lb/hr-ft2) 5,238 3,916 2,611 1,322 Gas Velocity at Inlet (ft/sec) 34.14 24.35 15.49 7.54 Water Flow Through Econ, (lb/hr) 35,354 26,515 17,677 8,838 Water Mass Velocity, (lb/sec-ft2) 212.14 159.11 106.07 53.04 Feedwater Pressure Drop, (psi) 4.19 2.38 1.08 0.29 Heat Absorbed in Econ.,(mmbtu/hr) 1.56 1.00 0.55 0.23

PHYSICAL DESIGN

Furnace Design Data - Proj. Radiant HT, (ft2) 659 Effective Radiant HT, (ft2) 546

Convection Zone Design Data - Conv. Heating Surface (ft2) 3219

Economizer Design Data - Economizer Heating Surface (ft2) 1771

Fuel Analysis - Fuel Type Oil Fuel Name No.2 Fuel Oil

Fuel Constituents - By Weight By Volume H2 (%) 13.6000 48.3271 N2 (%) 0.0070 0.0018 S (%) 0.1000 0.0223 C (%) 86.6000 51.6487

ASH (%) 0.0100 0.0000

High Heating Value (btu/lb) 20,517.4 Low Heating Value (btu/lb) 19,229.5

Note:

*** Liberation rate based on effective furnace length before first plane of entry into convection tubes.

VEO PROJECT: VE-11756

PROTHERM - JEFFERSON BARRACKS

PACKAGE BOILER SYSTEM

PROJECT DATA AND EQUIPMENT LIST

VICTORY ENERGY OPERATIONS, LLC

JEFFERSON BARRACKS - PROTHERM

PACKAGE BOILER SYSTEM

PROTHERM P.O. # 412107301

ELEVATION: 700 FEET ABOVE SEA LEVEL

DATE: March 25, 2013

REVISION

(3) "D" STYLE WATERTUBE BOILERS

DISCOVERY SERIES DT-2-57

VICTORY ENERGY OPERATIONS SALES ORDER JVE-11756

UNITS 11756-1, -2, -3

PROJECT MANAGER - GREG McNUTT

JEFFERSON BARRACKS - PROTHERM

PACKAGE BOILER SYSTEM

PHYSICAL DATA: BOILER

CAPACITY (PPH): 35,000

DESIGN PRESSURE (PSIG): 200

DRY WEIGHT (LB): 57,800

FLOODED WEIGHT (LB): 82,500

OPERATING CAPACITY (GALS): 2,300

FLOODED CAPACITY (GALS): 3,000

SUPERHEATER HTG SURFACE (SQ.FT) N/A

CONVECTIVE HTG SURFACE (SQ. FT.) 3,218

RADIANT HTG SURFACE (SQ. FT.) 659

TOTAL HTG SURFACE (SQ. FT.) 3,877

FURNACE VOLUME (CU. FT) 990

NO. UNITS REQUIRED: 3

STEAM DRUM 36" ID 5/8" SA516-70

STEAM DRUM HEAD 36" ID 1/2" SA516-70

WATER DRUM 30" ID 5/8" SA516-70

WATER DRUM HEAD 30" ID 1/2" SA516-70

FURNACE MEMBRANE "D" TUBES 2" OD 0.135 MW SA-178-A

FURNACE/MEMBRANE TUBES 2" OD 0.135 MW SA-178-A

CONVECTION TUBES 2" OD .120 MW SA-178-A

DESIGN NOTES: MEMBRANE FRONT AND REAR WALLS

BOILER DESIGN NOTES: CONSTRUCTION PER ASME SECT I, 2010 EDITION 2011a ADDENDUM

ECONOMIZER PHYSICAL DATA:

ORIENTATION:

DESIGN PRESSURE (PSIG): 400

DESIGN TEMPERATURE (DEG. F.): 700

HEAT TRANSFERRED (mmBTU/HR): 1.7900

TOTAL HTG SURFACE (SQ. FT.) 1,764

DRY WEIGHT (LB): 3,700 OPERATING

ECONOMIZER HEADER 3" SCH 40 SA-312-TP316L

ECONOMIZER TUBES 1.9" OD .109 MW SA-312-TP316L

NO. UNITS REQUIRED: 3

AREA CLASSIFICATION: NON-HAZARDOUS

INSTALLATION: INDOORS

ECONOMIZER DESIGN NOTES: CONSTRUCTION PER ASME SECT VIII Div I, 2010 EDITION 2011a ADDENDA

VERTICLE - COUNTER

PACKAGE BOILER SYSTEM

BOILER DRUM CONNECTIONS: QTY. SIZE (NPS) TYPE

CONNECTION

DESCRIPTION

MAIN STEAM 1 10" FLG 300# RFLWN

SAFETY VALVE 1 2 1/2" FLG 300# RFLWN

SAFETY VALVE 1 2 1/2" FLG 300# RFLWN

FEEDWATER INLET 1 *2" FLG 300# RFWN

INTERMITTENT BLOW-OFF 1 1.5" FLG 300# RFWN

WATER COLUMN 2 1" FLG 300# RFWN

DRUM LEVEL 2 1" FLG 300# RFWN

VENT 1 1" FLG 300# RFWN

CONTINUOUS BLOWDOWN 1 1" FLG 300# RFWN

CHEMICAL FEED 1 *1" FLG 300# RFWN

AUX. LOW WATER CUT-OUT 2 1" FLG 300# RFWN

SOOT BLOWER STEAM SUPPLY 1 2" FLG 300# RFWN

DRUM HEATING COIL CONNECTION 1 1.5" FLG 300# RFWN

* CONNECTIONS BELOW WATER LEVEL PROVIDED WITH THERMALSLEEVES

AXIAL (LB)

TANGENT

(LB) MOMENT (FT-LB)

MAIN STEAM -1,210 -4,885 30,025 PER FIG. 6 ON MP702

SAFETY VALVE 395 180 605

SAFETY VALVE 395 180 605

FEEDWATER INLET 225 105 349

INTERMITTENT BLOW-OFF 110 50 176

WATER COLUMN 45 20 72

DRUM LEVEL 45 20 72

VENT 45 20 72

CONTINUOUS BLOWDOWN 45 20 72

CHEMICAL FEED 45 20 72

AUX. LOW WATER CUT-OUT 45 20 72

SOOT BLOWER STEAM SUPPLY 225 105 349

DRUM HEATING COIL CONNECTION 110 50 176

ALLOWABLE LOADS

PACKAGE BOILER SYSTEM

TAG # QTY EA SERVICE DESCRIPTION MODEL NUMBER SHIPPING

METHOD

SPECIFICATION

REFERENCE

LE-001 1 WATER COLUMN (3 PROBES) TITAN WATER COLUMN 21-11756-99 P 23 52 33 / 2.2.D

RP-001 1 WATER COLUMN RELAY PANEL TITAN WATER COLUMN RELAY PANEL CR# EC2384A L 23 52 33 / 2.2.D

ALE-001 1 AUXILARY LOW DRUM LEVEL SHUT-

DOWN

CLARK RELIANCE LOW LEVEL SHUTDOWN

FLOAT TYPE CR# EA100D P

23 52 33 / 2.2.E

LG-001 1 DRUM LEVEL SITE GAGE CLARK RELIANCE LEVEL GAUGE WITH 7.87"

VISABILITY CR# C5 L

23 52 33 / 2.2.D

GI-001 1 LEVEL GAUGE ILLUMINATOR CLARK RELIANCE PRISMATIC TILT VIEW LEVEL

GAUGE ILLUMINATOR GL53 L

23 52 33 / 2.2.D

GV-001 2 LEVEL GAUGE VALVES CLARK RELIANCE LEVEL GAUGE VALVES TG603RS I

23 52 33 / 2.2.D

HS-001 1 LOW WATER CUTOUT BY-PASS

PUSHBUTTON

VEO CONTROLS STANDARD DRUM LEVEL BY-

PASS SWITCH ASSEMBLY VEO 63-11756-03 I

23 52 33 / 2.2.F

PI-001 1 STEAM DRUM PRESSURE GAUGE ASHCROFT PRESSURE GAUGE - 8 1/2" FACE, 0 -

400PSIG W/ 2 VALVE MANIFOLD 85-1379 SS 04L L

23 52 33 / 2.2.C

PSA-001 1 STEAM DRUM PRESSURE HIGH

ALARM

STEAM PRESSURE SWITCH, ASHCROFT 0 - 400

PSIG RANGE

B420VXFS,X07,XFM

120 INCRS L

23 52 33 / 2.2.G

PSH-002 1 STEAM DRUM PRESSURE HIGH

SHUTDOWN

STEAM PRESSURE SWITCH, ASHCROFT 0 - 400

PSIG RANGE

B420VXFS,X07,XFM

125 INCRS L

23 52 33 / 2.2.G

HV-403 5 FEEDWATER BY-PASS ISOLATION

VALVES CRANE 3" GATE VALVE, CL300, RF 33 L

23 21 11 / 2.14

HV-405 1 FEEDWATER BYPASS GLOBE

VALVE CRANE 3" GLOBE VALVE, CL300, RF 151 P

23 21 11 / 2.14

CV-401 1 FEEDWATER CHECK VALVE CRANE 3" CHECK VALVE, CL300, RF 159 L 23 21 11 / 2.14

ST-400 1 FEEDWATER STRAINER MUELLER, Y STRAINER, 3" CL 300 RF 782 L 24 21 11 / 2.14

BOILER TRIM BILL OF MATERIALS

PACKAGE BOILER SYSTEM

TAG # QTY EA SERVICE DESCRIPTION MODEL NUMBER SHIPPING

METHOD

SPECIFICATION

REFERENCE

BOILER TRIM BILL OF MATERIALS

FCV-401 1 FEEDWATER CONTROL VALVE

FLOWSERVE VALTEK CONTROL VALVE - 2",

CLASS 300 CAST STEEL, GLOBE TYPE W/

LOGIX 3000 POSITIONER

VALTEK MARK 1 L

23 52 33 / 2.2.H

HV-401 4 FEEDWATER DRAIN VALVE VOGT 3/4" CL800 GATE VALVE, THREADED X

SW ENDS TSW12111 P

23 21 11 / 2.14

HV-402 1 FEEDWATER VENT VALVE VOGT 1" CL800 GATE VALVE, THREADED X SW

ENDS TSW12111 P

23 21 11 / 2.14

PSV-401 1 ECONOMIZER PRESSURE RELIEF

VALVE

KUNKLE SFETY RELIEF VALVE 3/4" MPT X 1"

FPT CONNECTIONS, SET AT 300 PSIG 927BEDM06ABE L

23 52 33 / 2.5.E

SB-002 1 ECONOMIZER SOOT BLOWER CLYDE BERGMAN, MODEL D5, MANUAL

ROTARY PRESSURIZED, SOOT BLOWER D5 L

23 52 39 / 2.3.E

HV-002 6 DRUM LEVEL DRAIN VALVES VOGT 3/4" CL800 GATE VALVE, SW ENDS SW12111 P 23 21 11 / 2.14

HV-003 2 DRUM LEVEL ISOLATION VALVES VOGT 1" CL800 GATE VALVE, SW ENDS SW12111 P 23 21 11 / 2.14

HV-004 1 DRUM PRESSURE TEST VALVE KF 1/2" FNPT X FNPT, SUT-OFF / TEST VALVE KF-N24-12 P 23 21 11 / 2.14

HV-005 1 STEAM DRUM VENT VALVE VOGT 1" CL800 GATE VALVE, THRADED X SW

ENDS TSW12111 P

23 21 11 / 2.14

PSV-001 1 BOILER SAFETY RELIEF VALVE KUNKLE SAFETY RELIEF VALVE 2 1/2"-250# RF

X 4" FPT CONNECTIONS SET AT 130 PSIG 6252FLJ-AS0130 L

23 52 33 / 2.2.B

PSV-002 1 BOILER SAFETY RELIEF VALVE KUNKLE SAFETY RELIEF VALVE 2 1/2"-250# RF

X 4" FPT CONNECTIONS SET AT 135 PSIG 6252FLJ-AS0135 L

23 52 33 / 2.2.B

DP-001 1 SAFETY VALVE DRIP PAN ELBOW KUNKLE DRIP PAN ELBOW, 4" FPT

CONNECTION 0299-M L

23 52 33 / 2.2.B

DP-002 1 SAFETY VALVE DRIP PAN ELBOW KUNKLE DRIP PAN ELBOW, 4" FPT

CONNECTION 0299-M L

23 52 33 / 2.2.B

PACKAGE BOILER SYSTEM

TAG # QTY EA SERVICE DESCRIPTION MODEL NUMBER SHIPPING

METHOD

SPECIFICATION

REFERENCE

BOILER TRIM BILL OF MATERIALS

HV-006 1 CONTINUOUS BLOW DOWN

ISOLATION VALVE VOGT 1" CL800 GATE VALVE, SW ENDS SW12111 P

23 21 11 / 2.14

HV-007 1 CONTINUOUS BLOW DOWN

METERING VALVE

VOGT 1" CL800 GLOBE METERING VALVE, SW

ENDS SW12443 P 23 21 11 / 2.14

HV-008 1 INTERMITTENT BLOW-OFF VALVE

(ANGLE)

EDWARD - 1443, 1 1/2" CL300 BLOW-OFF

VALVE, FLANGED 1443 L

23 21 11 / 2.14

HV-009 1 INTERMITTENT BLOW-OFF VALVE

(STRAIGHT)

EDWARD - 1441, 1 1/2" CL300 BLOW-OFF

VALVE, FLANGED 1441 L

23 21 11 / 2.14

HV-010 1 CHEMICAL FEED ISOLATION VALVE VOGT 3/4" CL800 GATE VALVE, SW ENDS SW12111 P 23 21 11 / 2.14

CV-010 1 CHEMICAL FEED CHECK VALVE VOGT 3/4" CL800 CHECK VALVE, SW ENDS SW701 P 23 21 11 / 2.14

HV-601 1 MAIN STEAM NON-RETURN VALVE CRANE 6", CL300, RF, ANGLED NON-RETURN

VALVE 30 L

23 21 11 / 2.14

HV-603 1 MAIN STEAM STOP VALVE CRANE 8" CL300, RF, MAIN STEAM STOP VALVE 33 L

23 21 11 / 2.14

HV-604 1 MAIN STEAM WARM UP GLOBE

VALVE VOGT, 1" CL 800 GLOBE VALVE, SW ENDS SW12141 P

23 21 11 / 2.14

HV-602 1 STEAM DRAIN VALVE VOGT, 3/4" CL800 GATE VALVES, THREADED X

SW ENDS TSW12111 P

23 21 11 / 2.14

N/A 3 OBSERVATION PORTS

WALLING CO. 1 1/2" OBSERVATION PORTS, AIR

COOLED w/QUARTZ GLASS (ONE CLEAR AND

ONE TINTED) WITH BLAST GATE

CIPBGQ1.5-1-1/2 I

23 52 33 / 2.3.E.5

HV-610 2 SOOT BLOWER VALVES VOGT, 2" CL800 GATE VALVE, SW ENDS SW12111 P

22 52 39 / 2.3.E

SB-001 1 ECONOMIZER SOOT BLOWER CLYDE BERGMAN, MODEL D5, MANUAL

ROTARY PRESSURIZED, SOOT BLOWER D5 L

23 52 39 / 2.3.E

PACKAGE BOILER SYSTEM

TAG # QTY EA SERVICE DESCRIPTION MODEL

NUMBER

SHIPPING

METHOD

SPECIFICATION

REFERENCE

BURNER 1 GAS / OIL BURNER

POWERFLAME LOW NOx, TYPE CMAX, HIGH CAPACITY, MODULATING GAS & OIL BURNER WREFRACTORY FRONT

PLATE

CM11A-G(0)-30 I 23 52 33 /2.3

SCANNER 1 FLAME SCANNER HONEYWELL I/R SELF CHECK FLAME SCANNER

MOUNTED ON BURNER C7061 I 23 09 11 / 2.2.A

MOTOR 1 ELECTRIC MOTOR 30 H.P., 3450 R.P.M. HIGH EFFICIENCY BLOWER MOTOR

FOR 460/3 PH/60 Hz VOLTAGE 30H.P.-460/3/60 I 23 52 33 / 2.3.E

BLOWER 1 BLOWER CHICAGO BLOWER CB XXX I 23 52 33 / 2.3.E

MAIN GAS 1 MAIN GAS FUEL TRAIN

3" MAIN GAS TRAIN W/ HONEYWELL MODULATING GAS

CONTROL VALVE, AARELL 5510 FEEDBACK ASSEMBLY,

MAXON SHUT-OFF VALVES, FISHER MAIN GAS

REGULATOR, 1 1/4" MAXON VENT VALVE, HIGH/LO

PRESSURE SWITCHES, GAS PRESSURE GAUGES, AND

GAS STRAINER WITH 10 MICRON MESH

POWERFLAME I 23 52 33 / 2.3.F

PILOT GAS 1 PILOT GAS FUEL TRAIN

GAS PILOT ASSEMBLY W/ IGNITION TRANSFORMER,

ASCO MAIN GAS & AUXILLARY SOLENOID VALVE, ASCO

VENT VALVE, REGULATOR, LOW GAS PRESSURE

SWITCH, PRESSURE GAUGE, STRAINER WITH 10 MICRON

MESH, AND THREE WAY PILOT COCK FOR N.G. OR L.P.

POWERFLAME I 23 52 33 / 2.3.I

#2 OIL 1 #2 OIL FUEL TRAIN

#2 FUEL TRAIN ASSEMBLY W/ SAFETY SHUT-OFF VALVES,

MANUAL SHUT-OFF VALVE, PRESSURE GAUGE,

HIGH/LOW PRESSURE SWITCHES, MODULATING

CONTROL VALVE, AARELL 5510 FEEDBACK

ASSEMBLY,PRESSURE REGULATOR, RELIEF VALVE,

FILTER WITH ROTATION HANDLE, AND CHECK VALVE

POWERFLAME I 23 52 33 / 2.3.G

ATOMIZING 1 ATOMIZING AIR/STEAM TRAIN

AUTOMATIC AND MANUAL SAFETY SHUT-OFF VALVES,

ATOMIZING AIR PRESSURE GAUGE, LOW ATOMIZING

PRESSURE SWITCH, ATOMIZING AIR CHECK VALVE,

STRAINER WITH 10 MICRON SCREEN, PRESSURE

REGULATOR, AND STEAM PURGE VALVE

POWERFLAME I 23 52 33 / 2.3.H

71-11756-01 1 ECONOMIZER SUPPORT

STRUCTURE ECONOMIZER SUPPORT STRUCTURE 71-11756-01 L 23 52 33 / 2.5

BURNER, COMBUSTION, AIR AND DUCTING BILL OF MATERIALS

PACKAGE BOILER SYSTEM

TAG # QTY EA SERVICE DESCRIPTION MODEL

NUMBER

SHIPPING

METHOD

SPECIFICATION

REFERENCE

BURNER, COMBUSTION, AIR AND DUCTING BILL OF MATERIALS

72-11756-01 1 BOILER OUTLET FLUE GAS DUCT

BOILER FLUE GAS OUTLET "L" DUCT W/ PROCESS TAP

CONNECTIONS (4"-150RF O2 ANALYZER, 3/4"

TEMPERATURE INDICATOR AND 1/2" PRESSURE)

72-11756-01 L 24 51 00 / 2.1

73-11756-01 1 ECONOMIZER OUTLET FLUE GAS

DUCT

ECONOMIZER OUTLET TRANSITION INCLUDES FGR DUCT

W/ PROCESS TAP CONNECTIONS (3/4" TEMPERATURE

INDICATOR AND 1/2" PRESSURE)

73-11756-01 L 25 51 00 / 2.1

74-11756-01 1 FLUE GAS RECIRCULATION DUCT FLUE GAS RECIRCULATION DUCT 74-11756-01 L 26 51 00 / 2.1

74-11756-02 1 FGR BUTTERFLY DAMPER FGR BUTTERFLY DAMPER, MANUAL W/LOCKING ARM 74-11756-02 L 26 51 00 / 2.1

75-11756-01 1 STACK

STACK 24" DIAMETER W/ CEMS CONNECTIONS (QTY 2, 4" -

150# RF), ROOF LINE RAIN SKIRT AND A DOUBLE CONE

RAIN CAP

75-11756-01 L 26 51 00 / 2.1

FGR - EJ 1 FGR EXPANSION JOINT FGR EXPANSION JOINT 9" FACE TO FACE AFS L 29 51 00 / 2.2

BOILER - EJ 1 BOILER OUTLET EXPANTION JOINT BOILER OUTLET EXPANSION JOINT 12" FACE TO FACE AFS L 30 51 00 / 2.2

REVISION DATE BY

1 12/3/2012 G. MCNUTT

2 3/25/2013 G. MCNUTT

SHIPPING METHOD L - LOOSE P - IN PIPING I - INSTALLED

REVISIONS

DESCRIPTION

CHANGED SFATEY VALVE SET PRESSURE

CHANGED STEAM OUTLET FLANGE TO 10" AND ADDED A TINTED OBSERVATION PORT GLASS

VA JEFFERSON BARRACKS

SAINT LOUIS, MO

DRAWING INDEX

J-VE-11756

VA JEFFERSON BARRACKS

TAB DRAWING NUMBER PROJECT DRAWINGS

00-11756-00 BOILER GENERAL ARRANGEMENT

00-11756-01 BOILER GENERAL ARRANGEMENT - FRONT VIEW

00-11756-02 BOILER GENERAL ARRANGEMENT - PLAN VIEW

14-STD-010 TYP. ACCESS DOOR BRICK INSTALLATION

21-11756-01 WATER TUBE BOILER P&ID

21-11756-98 DRUM LEVEL ARRANGEMENT UNIT 2

21-11756-99 DRUM LEVEL ARRANGEMENT UNITS 1 & 3

30-11756-00 ECONOMIZER GENERAL ARRANGEMENT

50-11756-01 PIPING GENERAL ARRANGEMENT

63-11756-01 TITAN WATER COLUMN JUNCTION BOX

63-11756-02 TITAN PUSH BUTTON BY-PASS STATION

63-11756-03 WATER COLUMN RELAY PANEL

63-11756-04 WATER COLUMN RELAY PANEL SCHEMATIC

71-11756-01 BOILER OUTLET TRANSITION

73-11756-01 FGR ASSEMBLY - UNITS 1 & 3

74-11756-01 FGR ASSEMBLY - UNIT 2

75-11756-01 BURNER STAND

80-11756-01 BOILER LADDER & PLATFORMS - PLAN VIEW

80-11756-02 BOILER LADDER & PLATFORMS - FRONT & REAR VIEWS

90-11756-00 FOUNDATION PLAN & ANCHOR BOLT LAYOUT

90-11756-10 BOILER SHIPPING ARRANGEMENT

90-11756-11 ECONOMIZER SHIPPING ARRANGEMENT

PACKAGE BOILER SYSTEM

TAG # QTY EA SERVICE DESCRIPTION MODEL NUMBER SHIPPING

METHOD

SPECIFICATION

REFERENCE

BOILER TRIM BILL OF MATERIALS

FCV-401 1 FEEDWATER CONTROL VALVE

FLOWSERVE VALTEK CONTROL VALVE - 2",

CLASS 300 CAST STEEL, GLOBE TYPE W/

LOGIX 3000 POSITIONER

VALTEK MARK 1 L

23 52 33 / 2.2.H

HV-401 4 FEEDWATER DRAIN VALVE VOGT 3/4" CL800 GATE VALVE, THREADED X

SW ENDS TSW12111 P

23 21 11 / 2.14

HV-402 1 FEEDWATER VENT VALVE VOGT 1" CL800 GATE VALVE, THREADED X SW

ENDS TSW12111 P

23 21 11 / 2.14

PSV-401 1 ECONOMIZER PRESSURE RELIEF

VALVE

KUNKLE SFETY RELIEF VALVE 3/4" MPT X 1"

FPT CONNECTIONS, SET AT 300 PSIG 927BEDM06ABE L

23 52 33 / 2.5.E

SB-002 1 ECONOMIZER SOOT BLOWER CLYDE BERGMAN, MODEL D5, MANUAL

ROTARY PRESSURIZED, SOOT BLOWER D5 L

23 52 39 / 2.3.E

HV-002 6 DRUM LEVEL DRAIN VALVES VOGT 3/4" CL800 GATE VALVE, SW ENDS SW12111 P 23 21 11 / 2.14

HV-003 2 DRUM LEVEL ISOLATION VALVES VOGT 1" CL800 GATE VALVE, SW ENDS SW12111 P 23 21 11 / 2.14

HV-004 1 DRUM PRESSURE TEST VALVE KF 1/2" FNPT X FNPT, SUT-OFF / TEST VALVE KF-N24-12 P 23 21 11 / 2.14

HV-005 1 STEAM DRUM VENT VALVE VOGT 1" CL800 GATE VALVE, THRADED X SW

ENDS TSW12111 P

23 21 11 / 2.14

PSV-001 1 BOILER SAFETY RELIEF VALVE KUNKLE SAFETY RELIEF VALVE 2 1/2"-250# RF

X 4" FPT CONNECTIONS SET AT 130 PSIG 6252FLJ-AS0130 L

23 52 33 / 2.2.B

PSV-002 1 BOILER SAFETY RELIEF VALVE KUNKLE SAFETY RELIEF VALVE 2 1/2"-250# RF

X 4" FPT CONNECTIONS SET AT 135 PSIG 6252FLJ-AS0135 L

23 52 33 / 2.2.B

DP-001 1 SAFETY VALVE DRIP PAN ELBOW KUNKLE DRIP PAN ELBOW, 4" FPT

CONNECTION 0299-M L

23 52 33 / 2.2.B

DP-002 1 SAFETY VALVE DRIP PAN ELBOW KUNKLE DRIP PAN ELBOW, 4" FPT

CONNECTION 0299-M L

23 52 33 / 2.2.B

6. Installing the pump

6.1 Pump location

The pump should be located in a dry, well-ventilated area which is not subject to freezing or extreme variation in temperature.

Care must be taken to ensure the pump is mounted at least 6 inches (150 mm) clear of any obstruction or hot surfaces.

The motor requires an adequate air supply to prevent overheating and adequate vertical space to remove the motor for repair.

For open systems requiring suction lift the pump should be located as close to the water source as possible to reduce piping losses.

6.2 Foundation

Concrete or similar foundation material should be used to provide a secure, stable mounting base for the pump.

See table of bolt hole center line dimensions for the various pump types.

Secure the pump to the foundation using all four bolts and shim pump base to assure the pump is vertical and all four pads on the base are properly supported (uneven surfaces can result in pump base breakage when mounting bolts are tightened).

Fig. 4 Pump position

The pump can be installed vertically or horizontally; see fig. 4.

Ensure that an adequate supply of cool air reaches the motor cooling fan. The motor must never fall below the horizontal plane.

Arrows on the pump base show the direction of flow of liquid through the pump.

To minimize possible noise from the pump, it is advisable to fit expansion joints on either side of the pump and anti-vibration mountings between the foundation and the pump.

Note: Care should be taken to ensure that the vent plug is located in the uppermost position.

Isolating valves should be fitted either side of the pump to avoid draining the system if the pump needs to be cleaned, repaired or replaced.

Warning Do not energize pump until properly installed.

TM

TM

Pump type L1 L2 B1 B2 ø in mm in mm in mm in mm in mm

CR 1s, 1, 3, 5 3 15/16 100 5 11/16 145 7 1/16 180 8 11/16 220 1/2 13

CRI, CRN 1s 1, 3, 5 3 15/16 100 5 7/8 150 7 1/16 180 8 11/16 220 1/2 13

CR 10, 15, 20 5 1/8 130 6 15/16 176 8 7/16 215 10 1/16 256 9/16 13.5

CRN 10, 15, 20 5 1/8 130 7 7/8 200 8 7/16 215 9 3/4 248 1/2 13

CR 32 6 11/16 170 8 3/4 223 9 7/16 240 11 3/4 298 9/16 14

CRN 32 6 11/16 170 8 7/8 226 9 7/16 240 11 3/4 298 9/16 14

CR 45,64 7 1/2 190 9 3/4 248 10 1/2 266 13 1/16 331 9/16 14

CRN 45,64 7 1/2 190 9 7/8 251 10 1/2 266 13 1/16 331 9/16 14

CR(N) 90 7 13/16 199 10 1/4 261 11 280 13 11/16 348 9/16 14

CR(N) 120, 150 10 13/16 275 13 9/16 344 14 15/16 380 18 9/16 472 11/16 18

L L

B

4 x ø

B

Grundfos.bk Page 10 Wednesday, March 18, 2009 10:38 AM

6.3 Pump mounting

6.3.1 Recommended installation torques

6.4 Suction pipe

The suction pipe should be adequately sized and run as straight and short as possible to keep friction losses to a minimum (minimum of four pipe diameters straight run prior to the suction flange). Avoid using unnecessary fittings, valves or accessory items. Butterfly or gate valves should only be used in the suction line when it is necessary to isolate a pump because of a flooded suction condition.

This would occur if the water source is above the pump; see fig. 5 and fig. 6. Flush piping prior to pump installation to remove loose debris.

Fig. 5 Flooded suction

Fig. 6 Suction lift*

*The suction pipe should have a fitting on it for priming.

CRN-SF pumps cannot be used for suction lift.

6.5 Minimum suction pipe sizes

The following recommended suction pipe sizes are the smallest sizes which should be used with any specific CR pump type.

The suction pipe size should be verified with each installation to ensure good pipe practices are being observed and excess friction losses are not encountered.

High temperatures may require larger diameter pipes to reduce friction and improve NPHSA.

6.6 Discharge piping

It is suggested that a check valve and isolation valve be installed in the discharge pipe.

Pipe, valves and fittings should be at least the same diameter as the discharge pipe or sized in accordance with good piping practices to reduce excessive fluid velocities and pipe friction losses.

Note: Pipe, valves and fittings must have a pressure rating equal to or greater than the maximum system pressure.

Before the pump is installed it is recommended that the discharge piping be pressure checked to at least the maximum pressure the pump is capable of generating or as required by codes or local regulations.

Whenever possible, avoid high pressure loss fittings, such as elbows or branch tees directly on either side of the pump. The piping should be adequately supported to reduce thermal and mechanical stresses on the pump.

Good installation practice recommends the system be thoroughly cleaned and flushed of all foreign materials and sediment prior to pump installation. Furthermore, the pump should never be installed at the lowest point of the system due to the natural accumulation of dirt and sediment. If there is excessive sediment or suspended particles present, it is advised a strainer or filter be used. Grundfos recommends that pressure gauges be installed on inlet and discharge flanges or in pipes to check pump and system performance.

Warning CR, CRI, CRN pumps are shipped with covered suction and discharge. The covers must be removed before the final pipe flange to pump connections are made.

Model Recommended foundation torque (ft - lbs)

Recommended flange torque

(ft - lbs)

CR, CRI, CRN

1s/1/3/5, and

CRT 2/4

30 37 - 44

CR, CRI,

CRN 10/15/20, and

CRT 8/16

37 44 - 52

CR, CRN

32/45/64/90/ 120/150

52 52 - 59

TM

TM

Reservoir

Butterfly

Valve

Butterfly

Valve

Strainer Check

Valve

Expansion Joint

Butterfly

Valve

Check

Valve

Eccentric

Reducer

Suction

Pipe

Reservior

Foot

Valve

Model Min. suction pipe size

CR(I)(N) 1s, 1, 3; CRT 2 1" Nominal diameter sch 40 pipe

CR(I)(N) 5;

CRT 4 1-1/4" Nominal diameter sch 40 pipe

CR(I)(N) 10, 15, 20;

CRT 8, 16 2" Nominal diameter sch 40 pipe

CR(N) 32 2-1/2" Nominal diameter sch 40 pipe

CR(N) 45 3" Nominal diameter sch 40 pipe

CR(N) 64, 90 4" Nominal diameter sch 40 pipe

CR(N) 120, 150 5" Nominal diameter sch 40 pipe

Warning To avoid problems with waterhammer, fast closing valves must not be used in CRN-SF applications.

Grundfos.bk Page 11 Wednesday, March 18, 2009 10:38 AM

6.7 Bypass orifice

A bypass should be installed in the discharge pipe if there is any possibility the pump may operate against a closed valve in the discharge line. Flow through the pump is required to ensure adequate cooling and lubrication of the pump is maintained. See

6.9 Minimum continuous duty flow rates for minimum flow rates.

Elbows should be a minimum of 12” from the orifice discharge to prevent erosion.

Fig. 7 Recommended bypass arrangement

Fig. 8 Optional bypass arrangement

Fig. 9 Optional bypass arrangement for CR(N) 32, 45, 64, and CR 90, 120, and 150 only

6.8 Nozzle loads

If not all loads reach the maximum permissible value stated in the forces and moments tables included here with fig. 10, one of these values may exceed the normal limit. Contact Grundfos for further information.

Fig. 10 Nozzle forces and moments

TM

TM

TM

By-pass line

Nipple

Orifice

Inlet Outlet

Inlet Outlet

By-Pass Line Nipple

Orifice

OutletInlet

Nipple

Orifice By-Pass Line

TM

Flange CR, CRI, CRN

Forces

Y-direction [lb]

Z-direction [lb]

X-direction [lb]

1-1/4" 1s to 5 171 263 175

2" 10, 15 and 20 303 371 337

2-1/2" 32 382 466 422 3" 45 461 562 506 4" 64 and 90 607 753 674

5" & 6" 120 and 150 607 753 674

Flange CR, CRI, CRN

Moments

Y-direction [ft-lb]

Z-direction [ft-lb]

X-direction [ft-lb]

1-1/4" 1s to 5 605 715 900

2" 10, 15 and 20 738 848 1,033

2-1/2" 32 793 904 1,106 3" 45 848 959 1,180 4" 64 and 90 922 1,069 1,291

5" & 6" 120 and 150 922 1,069 1,291

Y-direction: Direction of chamber stack Z-direction: 90 ° from inlet/outlet X-direction: Inlet/outlet

Grundfos.bk Page 12 Wednesday, March 18, 2009 10:38 AM

6.9 Minimum continuous duty flow rates

* Grundfos Cool-Top® is only available in the following pump types.

6.10 Check valves

A check valve may be required on the discharge side of the pump to prevent the pump’s inlet pressure from being exceeded.

For example, if a pump with no check valve is stopped because there is no demand on the system (all valves are closed), the high system pressure on the discharge side of the pump will “find” its way back to the inlet of the pump.

If the system pressure is greater than the pump’s maximum inlet pressure rating, the limits of the pump will be exceeded and a check valve needs to be fitted on the discharge side of the pump to prevent this condition. This is especially critical for CRN-SF applications because of the very high discharge pressures involved. As a result, most CRN-SF installations require a check valve on the discharge piping.

6.11 Temperature rise

It may sometimes be necessary to stop the flow through a pump during operation.

At shut-off, the power to the pump is transferred to the pumped liquid as head, causing a temperature rise in the liquid.

The result is risk of excess heating of and consequent damage to the pump. The risk depends on the temperature of the pumped liquid and for how long the pump is operating without flow; see the following temperature rise chart.

6.12 Conditions/Reservations

The listed times are subject to the following conditions/ reservations:

• No exchange of heat with the surrounding.

• The pumped liquid is water with a specific heat of 1.0 Btu/lb. °F

(4.18 kJ/kg °C).

• Pump parts (chambers, impellers and shaft) have the same thermal capacity as water.

• The water in the base and the pump head is not included.

These reservations should give sufficient safety margin against excessive temperature rise.

The maximum temperature must not exceed the pump maximum rating.

Pump Type min °F to 176 °F (min °C to 80 °C) at 210°F (at 99°C) at 248°F (at 120°C) at 356°F (at 180°C)

CR, CRI, CRN 1s 0.5 0.7 1.2 1.2*

CR, CRI, CRN 1 0.9 1.3 2.3 2.3*

CR, CRI, CRN 3 1.6 2.4 4.0 4.0*

CR, CRI, CRN 5 3.0 4.5 7.5 7.5*

CR, CRI, CRN 10 5.5 8.3 14 14*

CR, CRI, CRN 15 9.5 14 24 24*

CR, CRI, CRN 20 11 17 28 28*

CR, CRN 32 14 21 35 35*

CR, CRN 45 22 33 55 55*

CR, CRN 64 34 51 85 85*

CR, CRN 90 44 66 110 110*

CR, CRN 120 60 90 N/A N/A

CR, CRN 150 75 115 N/A N/A

CRT 2 1.3 2.0 3.3 N/A

CRT 4 3.0 4.5 7.5 N/A

CRT 8 4.0 6.0 10 N/A

CRT 16 8.0 0.7 20 N/A

Pump Type CR 1s CR 1 CR 3 CR 5 CR 10 CR 15 CR 20 CR 32 CR 45 CR 64 CR 90

Standard (CR) • • • • I Version (CRI) • • • • • • • N Version (CRN) • • • • • • • • • • •

Pump type Time for temperature rise of 18 °F (10 °C)

Seconds Minutes

CR 1s, 1, 3 210 3.5

CR 5 240 4.0

CR 10 210 3.5

CR 15 150 2.5

CR 20 120 2.0

CR 32, 45, 64, 90,

120, 150 60 1.0

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