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Glanbia Ingredients
Ireland Wexford New
Boilers
Air Quality Assessment
March 2016
Glanbia Ingredients
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Glanbia Ingredients Ireland
Wexford New Boilers
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Air
Quality Assessment
Glanbia Ingredients Wexford Boiler Project
March 2016
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Glanbia Ingredients
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Air Quality Assessment
Mott MacDonald, Victory House, Trafalgar Place, Brighton BN1 4FY, United Kingdom
+44 (0)1273 365 000 F +44(0) 1273 365 100 W www.mottmac.com
T
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Glanbia Ingredients Wexford Boiler Project
Air Quality Assessment
Issue and revision record
Revision
Rev A
Date
10 December 2015
Originator
S. Arora
Checker
M. O’Brien
Approver
R. Hallissey
Description
1st issue
Rev B
17 December 2015
S. Arora
M. O’Brien
R. Hallissey
P. Kelly
2nd issue
Rev C
07 January 2016
S. Arora
Rev D
4 March 2016
S. Arora
3rd issue
4th issue, updated to account for
higher NOx emission rate.
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C. Mills
Information class:
Standard
This document is issued for the party which commissioned it and
for specific purposes connected with the above-captioned
project only. It should not be relied upon by any other party or
used for any other purpose.
We accept no responsibility for the consequences of this
document being relied upon by any other party, or being
used for any other purpose, or containing any error or
omission which is due to an error or omission in data
supplied to us by other parties.
This document contains confidential information and
proprietary intellectual property. It should not be shown to
other parties without consent from us and from the party
which commissioned it.
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Glanbia Ingredients Wexford Boiler Project
Air Quality Assessment
Contents
Title
Page
1
Introduction
1
1.1
1.2
1.3
1.4
Background _______________________________________________________________________
Project Description __________________________________________________________________
Air Quality Standards ________________________________________________________________
Baseline conditions__________________________________________________________________
1
1
3
4
2
Methodology
9
2.1
2.2
2.3
2.4
Overview _________________________________________________________________________ 9
Model selection ____________________________________________________________________ 9
Model inputs _______________________________________________________________________ 9
Assessing significance ______________________________________________________________ 18
3
Results
3.1
3.2
3.3
Discrete receptor results_____________________________________________________________ 19
Gridded receptor results _____________________________________________________________ 20
Conclusion _______________________________________________________________________ 24
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Chapter
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Appendices
19
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Appendix A. Bosch Technical Data Sheet _________________________________________________________ 26
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1
Introduction
1.1
Background
Mott MacDonald was commissioned by Glanbia Ingredients to undertake an air quality assessment of the
potential impacts from the installation of three new gas-fired boilers at Glanbia Ingredients Wexford,
Rocklands, Wexford. Glanbia Ingredients own Glanbia Ingredients Wexford. Currently Glanbia Ingredients
Wexford obtains all of its steam requirements from the adjacent “Danone” facility which principally uses
heavy fuel oil (HFO) to fuel the boilers on site.
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Project Description
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The Glanbia Ingredients Wexford site operates under an Integrated Pollution Prevention Control (IPPC)
Licence (PO794-2). In order to evaluate the significance of emissions to atmosphere arising from the new
boilers an air dispersion modelling assessment has been undertaken.
The project site is presented overleaf in Figure 1.1. The area immediately surrounding the site is
comprised of other industrial uses, agricultural land and residential areas. The site is bordered on the east
by a railway line and the River Slaney estuary. The location is approximately 150m from the Slaney River
Valley Special Area of Conservation (SAC) and the Wexford Harbour Slobs Special Protection Area (SPA).
SACs and SPAs are Natura 2000 sites, protected under European Union Directive 92/43/EEC (the
Habitats Directive) and Directive 2009/147/EC (the Birds Directive) for their environmental value.
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Based on the fuel to be used (natural gas), modelling for the operational phase included consideration of
emissions of nitrogen oxides (NOX) only as potentially significant emissions of other pollutants would not
occur from the combustion of natural gas, due to its chemical composition1.
1
1
Natural gas consists of a high percentage of methane and varying amounts of other hydrocarbons, nitrogen, carbon dioxide and
trace amounts of other gases. During combustion, such as in a boiler, the nitrogen (N2) in the natural gas reacts with oxygen (O2) to
produce NOx. Other pollutant gases in the fuel (such as sulphur) are typically only present in trace amounts and emissions
associated with these are not significant.
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Project Location
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Figure 1.1:
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1.3
Air Quality Standards
The air quality standards currently applicable in Ireland are sourced from the Ambient Air Quality Directive
(2008/50/EC), as implemented by the Air Quality Standards Regulations 2011 (S.I. No. 180 of 2011). As
described above, only NOx emissions are considered in the assessment as only NOx has the potential to
be emitted in significant quantities from natural gas fired boilers.
Statutory ambient air quality limit values and objectives for NOx and NO2
Nitrogen dioxide (NO2) (human health)
Nitrogen oxides (NOX) (vegetation and
ecosystems)
Limit value
Concentration
Allowance
1 hour
200µg/m3
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en
Pollutant
Averaging
period
18 per calendar year, also known as the
99.79th percentile of values
Annual
40µg/m3
-
Annual
30µg/m3
-
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Table 1.1:
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NOx emissions comprise nitrogen monoxide (NO) and nitrogen dioxide (NO2); both NO and NO2 can have
detrimental impacts on ecological sites either directly through uptake by vegetation or through nitrogen
deposition and acidification of ecosystems. NO is not considered harmful to human health at typical
ambient concentrations, however NO2 is known to have cardiopulmonary (heart and lung) effects on the
human body and can trigger increased hospital admissions and contribute to premature mortality. The air
quality standards (AQS) applicable to this assessment are therefore the NOx standards for the protection of
vegetation and the NO2 standards for the protection of human health; these AQS are presented in Table
1.1.
Source: Directive 2008/50/EC
The air quality limits for the protection of human health only apply at locations of relevant exposure. Table
1.2 provides details of where the respective limits should and should not apply and therefore the types of
receptors that are relevant to the assessment.
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Locations where the air quality objectives for the protection of human health apply
Averaging
period
Building façades of residential properties,
schools, hospitals, care homes etc.
Building façades of offices or other places of work where
members of the public do not have regular access.
Hotels, unless people live there as their permanent
residence.
All locations where the annual mean objective
would apply, together with hotels. Gardens of
residential properties.
Kerbside sites (as opposed to locations at the building
façade), or any other location where public exposure is
expected to be short-term.
All locations where the annual mean and 24
and 8-hour mean objectives apply.
Kerbside sites where the public would not be expected
to have regular access.
.
Gardens of residential properties.
Kerbside sites (as opposed to locations at the building
façade), or any other location where public exposure is
expected to be short-term.
se
1 Hour
All locations where members of the public
might be regularly exposed.
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24 Hour
Objectives should not apply at:
he
Annual
Objectives should apply at:
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Table 1.2:
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Kerbside sites (for example, pavements of
busy shopping streets).
Those parts of car parks, bus stations and
railway stations etc. which are not fully
enclosed, where members of the public might
reasonably be expected to spend one hour or
more.
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Any outdoor locations where members of the
public might reasonably expected to spend
one hour or longer.
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Note: Adapted from UK Government guidance and applied to this assessment in the absence of specific Republic of Ireland
guidance.
Source: Department for Environment Food and Rural Affairs (February 2009). Local Air Quality Management Technical Guidance
LAQM TG09.)
In addition, Environment Protection Agency (EPA) ‘Air Dispersion Modelling from Industrial Installations
Guidance Note (AG4)’ (2010)2 recommends that the maximum allowable process contributions (PC)
should be no more than two-thirds (66.7%) of the ambient air quality standard (AQS).
1.4
Baseline conditions
1.4.1
Overview
Information on existing air quality in Ireland can be obtained from the EPA, who undertake monitoring at a
number of locations across the country. For the purposes of air quality management, Ireland is divided into
four zones:
Zone A: Dublin conurbation
Zone B: Cork conurbation
Zone C: 23 large towns with population >15,000
2
4
Available at:
http://www.epa.ie/pubs/advice/air/emissions/airdispersionmodellingfromindustrialinstallationsguidancenoteag4.html#.VmGDMWcn
waU
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Zone D: Remainder (i.e. rural Ireland)
The Project site lies within Zone C. The assessment of baseline conditions is focussed on NOx and NO2 as
these are the key pollutants of concern with respect to the Project.
1.4.2
Data selection
In selecting monitoring sites to inform the baseline conditions at the Project area, Environment Protection
Agency (EPA) ‘Air Dispersion Modelling from Industrial Installations Guidance Note (AG4)’ (2010) was
followed:
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“It is reasonable to assume that if monitoring data is available in a Zone C urban
background location that this information would also be broadly representative of other
urban background locations in Zone C locations although each scenario should be
assessed on an individual basis to ensure that this approach is appropriate.In order to
allow for local factors, meteorological variability and anomalies when sourcing
background data from stations outside of the modelling domain, an average of at least
two and preferably more representative stations should be used. Similarly, the data
should be averaged over the most recent 2-3 years available.”
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There are no active monitoring sites within the Wexford Zone C area and therefore it was necessary to use
monitoring data from other Zone C monitoring sites to determine the baseline conditions. In accordance
with EPA AG4, three sites were selected:
Kilkenny Seville Lodge
Portlaoise
Mullingar
Following a review of the available data it appears that the EPA relocated two mobile monitoring sites
during the year of 2014 and therefore monitoring of NO2 at Mullingar ceased on 17 June 2014, replaced by
monitoring at Portlaoise that began on 29 July 2014. No other Zone C sites monitored NOx or NO2
concentrations in 2014.
1.4.3
Baseline data
Where available, data for these three sites has been obtained from the EPA data archive and is
summarised in Table 1.3 to Table 1.5.
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Table 1.3:
Annual mean NO2 concentration
Location (UTM 29N)
Site name
X
Annual mean NO2 concentration (µg/m3)
Site type
Y
2012
2013
2014
Average
4
4
5
4
Kilkenny Seville Lodge
617,905
5,832,822
Suburban background
Portlaoise
614,730
5,878,118
Suburban
-
-
16**
16
Mullingar
609,372
5,930,903
Suburban
7*
6
4***
6
Source: EPA Annual Reports (2012-2014): ‘Air Quality in Ireland’
* Data only collected between 7 October 2012 and 31 December 2012
** Data only collected between 29 July 2014 and 31 December 2014
*** Data only collected between 1 January 2014 and 17 June 2014
Site name
Kilkenny Seville Lodge
2012
2013
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Hourly maximum NO2 concentration (µg/m3)
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Hourly maximum NO2 concentration
2014
Average
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Table 1.4:
62
90
57
70
Portlaoise
-
-
74**
74
Mullingar
62*
68
53***
61
ns
en
Source: EPA Annual Reports (2012-2014): ‘Air Quality in Ireland’
* Data only collected between 7 October 2012 and 31 December 2012
** Data only collected between 29 July 2014 and 31 December 2014
*** Data only collected between 1 January 2014 and 17 June 2014
Annual mean NOx concentration
Co
Table 1.5:
Site name
Kilkenny Seville Lodge
Annual mean NOx concentration (µg/m3)
2012
2013
2014
Average
7
6
8
7
Portlaoise
-
-
27**
27
Mullingar
11*
12
6***
10
Source: EPA Annual Reports (2012-2014): ‘Air Quality in Ireland’
* Data only collected between 7 October 2012 and 31 December 2012
** Data only collected between 29 July 2014 and 31 December 2014
*** Data only collected between 1 January 2014 and 17 June 2014
1.4.4
Other emission sources
It is understood that the adjacent Danone facility operate an HFO boiler on site. Emissions to air from this
source may contribute to ambient concentrations at the Glanbia Ingredients Wexford site. However the
Danone facility does not have an IPPC licence and it has therefore been assumed that emissions to air
from this site are not significant and thus do not require inclusion in the baseline concentrations applied to
the assessment. There are no other licenced facilities in the vicinity of the Project.
It is also important to note that existing steam use at Glanbia Ingredients Wexford is sourced directly from
the Danone site; introduction of the proposed new boilers at the Glanbia Ingredients Wexford facility will
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displace atmospheric emissions from the Danone facility and therefore there would be no cumulative
impacts from the two adjacent facilities.
1.4.5
Summary
Baseline concentrations (BC) used in the assessment have been determined for the entire modelled
domain based on consideration of the data presented above. Taking account of the issues with data
capture due to incomplete calendar years’ of data at Portlaoise and Mullingar, it is considered appropriate
to apply the averaged 2012-2014 concentrations from Kilkenny Seville Lodge to the entire modelled
domain.
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Hourly maximum concentrations can be substantially higher than the 99.79th percentile of annual hourly
means (for comparison with the standard) and it is therefore not recommended to use these values in the
assessment. UK Environment Agency guidance3 suggests that short term background concentrations can
be estimated by doubling the annual mean background concentrations. This approach has been adopted
for this assessment.
Baseline concentrations (BC) are summarised in Table 1.6.
BCs used in the assessment
Annual mean NO2
Hourly NO2
Annual mean NOx
3
7
Baseline concentration (µg/m3)
4
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Parameter
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Table 1.6:
8
7
Environment Agency (UK), Horizontal Guidance Note H1 [https://www.gov.uk/government/publications/h1-environmental-riskassessment-for-permits-overview]
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Air quality monitoring sites and zones relevant to this assessment
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Figure 1.2:
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2
Methodology
2.1
Overview
This section outlines the assessment approach, data inputs and any assumptions made. The air quality
assessment has been undertaken in accordance with EPA AG4 (2010). The approach involves predicting
the process contribution (PC) from the project using a dispersion model. PCs are then added to the
baseline concentrations (BC) to determine the total predicted environmental concentration (PEC).
2.2
Model selection
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The dispersion model selected for this assessment is Atmospheric Dispersion Modelling System (ADMS);
the latest version (5.1.2.0) has been used. ADMS is a PC-based model of dispersion in the atmosphere of
pollutants released from single or multiple sources which may be point, area or line sources, produced and
validated by Cambridge Environmental Research Consultants (CERC). It is designed to allow for
consideration of dispersion problems ranging from simple single isolated point sources to modelling the
impact of existing and proposed industrial installations.
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ADMS is a ‘new generation’ dispersion model and applies up-to-date physics of the boundary layer
structure based on the Monin-Obukhov length and the boundary layer height. The use of the MoninObukhov length in ADMS allows the differing states of the boundary layer to be represented on a
continuous scale rather than being segregated into the discrete Pasquill-Gifford classes. ADMS more
accurately represents vertical variation in boundary layer parameters, such as wind speed. It includes
parameters such as variable meteorological and complex terrain conditions, the effect of plume rise, the
effect of buildings and the surface roughness of the surrounding terrain.
2.3
Model inputs
2.3.1
Stack emission parameters
As noted above only NOx emissions have been modelled as NOx is the only pollutant emitted in significant
quantities from natural gas fired boilers. Information on the boilers was obtained from the Bosch Technical
Data sheet for the Project (see Appendix A) and supplemented by information provided by Mott
MacDonald technical specialists. The NOx emission rate has been calculated based on parameters
including the boiler fuel flow rate, assuming a maximum NOx emission rate of 200mg/Nm3 NOx (3% O2,
dry). The guaranteed performance standard of the boilers as stated in the Bosch Technical Data sheet is
100mg/Nm3 NOx. The assessment is therefore conservative and accounts for situations such as equipment
malfunction in which NOx emissions may temporarily increase above the guarantee of 100mg/Nm3.
It is understood that three boilers are to be installed; each boiler will have a gross thermal output of
approximately 6.1MW. The operating scenarios for the three boilers are as follows:
Boiler 1: permanent standby
Boiler 2: half operational load for half day, full operational load for half day
Boiler 3: half operational load for half day
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Following consultation with the Mott MacDonald technical specialists it was confirmed that the worst case
operating scenario is two boilers operating at full load. For the purposes of the modelling it has therefore
been assumed that Boiler 2 and Boiler 3 are permanently operating at full load.
Table 2.1 summarises the stack emission parameters assumed for both operational boilers.
Table 2.1:
Stack emission parameters per boiler
Parameter
Unit
Input value
-
Natural gas
Fuel
Boiler 2 stack location
673804, 5800365
UTM 29N X,Y
Boiler 3 stack location
m
13.1
Stack diameter
mm
495
Exit velocity
m/s
15.1
ru
he
Am /s
o
Exit temperature
2.9
C
134
mg/Nm3 (3% O2, dry)
200
g/s
0.29
NOx emission rate
Source:
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3
Volumetric flow rate (actual)
NOx emission guarantee
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Stack height
673805, 5800353
Bosch Technical Data Sheet and Mott MacDonald
Buildings
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2.3.2
The movement of air over and around buildings generates areas of flow circulation, which can lead to
increased ground level concentrations in the building wakes. Where building heights are greater than
about 30 - 40% of the stack height, downwash effects can be significant. ADMS includes a building effects
module (as described above) used to calculate the dispersion of pollution from sources near large
structures. The buildings likely to have a dominant effect (i.e. with the greatest dimensions likely to
promote turbulence) are listed in Table 2.2 and have been included within the model as shown in Figu re
2.1.
Table 2.2:
Building dimensions used within the assessment
UTM N29 Grid Reference
X
Y
Height
(m)
Length
(m)
Width
(m)
Angle
(o)
Rectangular
673838
5800378
21.1
15.2
23.7
354
Proposed penthouse
Rectangular
673796
5800363
10.1
12.0
5.0
354
Office area
Rectangular
673815
5800312
6.3
75.0
21.2
354
4
Services area
Rectangular
673816
5800354
6.4
9.7
43.6
354
5
Existing penthouse
Rectangular
673802
5800371
8.1
3.8
5.2
354
6
Plant room
Rectangular
673800
5800375
5.0
12.2
9.1
354
7
Boiler house
Rectangular
673802
5800364
6.4
12.0
7.7
354
ID
Building
Shape
1
Evaporator building
2
3
Source: Mott MacDonald - Proposed New Gas Boilers, Boiler House Layout, Preliminary Plan, Option One.
Drawing No. 355022BA01-005-01
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Air Quality Assessment
Figu re 2.1: Buildings included in the model
Stacks
6
5
1
3
4
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2
Source: Mott MacDonald
Note: Representative view from south-west of the site.
Building 1 in red is the ‘main’ building in the model.
Red dots indicate the location of the two modelled stack emission points (i.e. the top of each stack).
2.3.3
Meteorological data
The most important meteorological parameters governing the atmospheric dispersion of pollutants are
wind direction, wind speed and atmospheric stability as described below:
Wind direction determines the sector of the compass into which the plume is dispersed.
Wind speed affects the distance the plume travels over time and can affect plume dispersion by
increasing the initial dilution of pollutants and inhibiting plume rise.
Atmospheric stability is a measure of the turbulence of the air, and particularly of its vertical motion. It
therefore affects the spread of the plume as it travels away from the source. ADMS uses a parameter
known as the Monin-Obukhov length that, together with the wind speed, describes the stability of the
atmosphere.
For meteorological data to be suitable for dispersion modelling purposes, a number of meteorological
parameters need to be measured on an hourly basis. These parameters include wind speed, wind
direction, cloud cover and temperature. There are only a limited number of sites where the required
meteorological measurements are made.
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The year of meteorological data that is used for a modelling assessment can have a significant effect on
source contribution concentrations; dispersion model simulations were performed for emissions from the
site using three years of data. Meteorological data was obtained from Met Éireann, for their monitoring site
at Johnstown Castle (approximately 5km from the project site), as this was the most representative. As no
cloud cover data was available for Johnstown Castle, cloud cover data was taken from the Cork Airport
monitoring site instead as this was considered the closest and most representative site with the required
data, according to EPA guidance on the selection of suitable meteorological sites (EPA AG4). Data from
the last three years was used, comprising the years 2012 to 2014.
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Wind roses have been constructed for each of the three years of meteorological data used in this
assessment. The wind roses presented in Figure 2.2 illustrate that in all three meteorological years there
is a dominance of strong winds from the south west.
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Figure 2.2:
Windroses for Johnstown Castle (2012 – 2014)
2013
2012
340°
350°
0°
10°
800
330°
340°
20°
600
300°
20°
30°
40°
600
310°
50°
300°
60°
400
290°
50°
60°
400
290°
70°
200
70°
200
80°
280°
270°
90°
270°
90°
260°
100°
260°
100°
ru
240°
230°
130°
220°
150°
200°
190°
180°
170°
160°
2014
340°
350°
0°
10°
800
330°
20°
30°
320°
130°
220°
140°
210°
120°
ot
120°
230°
to
f c Fo
op r i
yr ns
ig pe
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fo y.
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240°
110°
.
250°
110°
he
250°
80°
se
280°
140°
210°
150°
200°
190°
180°
170°
160°
40°
600
300°
50°
ns
en
310°
60°
Co
400
290°
0
3
180°
6
10
16
80°
270°
90°
260°
100°
250°
(knots)
Wind speed
70°
200
280°
0
1.5
3.1
5.1
8.2
(m/s)
110°
240°
120°
230°
130°
220°
140°
210°
150°
200°
13
10°
320°
40°
310°
0°
800
330°
30°
320°
350°
190°
180°
170°
160°
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2.3.4
Terrain
The presence of elevated terrain can significantly affect (usually increase) ground level concentrations of
pollutants emitted from elevated sources such as stacks by reducing the distance between the plume
centre line and ground level. Terrain can also increase turbulence and, hence, plume mixing which can
also reduce ground level concentrations.
Terrain data has been included in the dispersion model to take account of changes in elevation
surrounding Glanbia Ingredients Wexford. Figure 2.3 presents the terrain data for the project.
Figure 2.3: Terrain data included in the dispersion model
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Terrain file
0
17
35
53
71
89
107
125
143
161
Point sources
Source:
NASA Shuttle Radar Topography Mission (SRTM) data, accessed via the United States Geological Survey website:
http://gdex.cr.usgs.gov/gdex/
Note: Terrain file data in elevation (metres)
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2.3.5
Surface roughness data
Roughness of terrain over which a plume passes can have a significant effect on dispersion by altering the
velocity profile with height, and the degree of atmospheric turbulence. Surface parameters surrounding
Glanbia Ingredients Wexford have been split into a 100 metre by 100 metre grid and each grid square has
been assigned a surface roughness as shown in Figure 2.4.
Figure 2.4:
Surface roughness values assigned in the dispersion model
Surface roughness
0.0001
0.0
Point sources
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0.1
0.3
Source: Mott MacDonald
Note: Surface roughness of 0.3 is the value assigned to agricultural areas. A value of 0.0001 is assigned to the sea.
2.3.6
Receptors
The modelling has been used to predict ground level pollutant concentrations at sensitive human health
and ecological receptors closest to the site; these locations are known as ‘discrete receptors’ and have
been selected to represent the closest residential properties to the site and the closest boundaries of
ecologically designated sites. Concentrations have also been predicted at regular intervals across a 10km2
grid (with 100m resolution) and a 2km2 grid (50m resolution) centred on the site. Predicted concentrations
have been compared against the relevant AQS.
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Two Natura 2000 sites are in close proximity to the proposed development location and have therefore
been included in the assessment:
Slaney River Valley SAC
Wexford harbour and Slobs SPA
The SAC and SPA boundaries adjacent to the project are approximately overlain and therefore ecological
discrete receptors have been selected that represent both the SAC and SPA.
Discrete receptors included in the model are presented in Table 2.3; receptor locations are shown
alongside the modelled grid extents in Figure 2.5.
Discrete receptors included in the model
Y
Z
E1
673862
5800239
0
E2
673984
5800477
0
E3
673970
5800242
0
E4
673957
5800613
0
E5
673946
5800684
0
E6
673721
5800969
0
H1
673655
5800399
1.5
H2
673673
5800498
1.5
H3
673666
5800526
1.5
H4
673693
5800557
1.5
H5
673758
5800600
1.5
H6
673781
5800595
1.5
H7
673808
5800463
1.5
H8
673840
5800646
1.5
H9
673707
5800234
1.5
H10
673847
5800096
1.5
H11
673695
5800039
1.5
H12
673793
5800487
1.5
se
ru
X
Co
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ID*
.
Receptor height (m)
he
Grid reference (UTM Zone 29N)
ot
Table 2.3:
Note: *E = ecological receptor; H = human health receptor
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Modelled receptors and grid extents
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Figure 2.5:
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2.3.7
NOx to NO2 relationship
The NOX emissions associated with combustion activities at the site will typically comprise approximately
90-95% nitrogen monoxide (NO) and 5-10% nitrogen dioxide (NO2) at source. The NO oxidises in the
atmosphere in the presence of sunlight, ozone and volatile organic compounds to form NO2, which is the
principal concern in terms of environmental health effects.
ot
Assessing significance
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2.4
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There are various techniques available for estimating the portion of the NOX that is converted to NO2,
which will increase with distance from the source. The EPA’s ‘Air Dispersion Modelling from Industrial
Installations Guidance Note (AG4)’ (2010) identifies that a 100% conversion of NOX to NO2 can be used for
calculation of annual average concentrations and a 50% conversion of NOX to NO2 is applicable for
calculation of short term concentrations. For the purposes of this assessment, the EPA’s recommended
conversion rates have been used.
A number of approaches can be used to determine whether the potential air quality effects of a
development are significant. However, there remains no universally recognised definition of what
constitutes ‘significance’.
Co
ns
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Guidance is available from a range of regulatory authorities and advisory bodies on how best to determine
and present the significance of effects within an air quality assessment. It is generally considered good
practice that, where possible, an assessment should communicate effects both numerically and
descriptively. EPA AG4 does not define specific significance criteria for assessments of industrial
emissions. Discussion of the significance of impacts in this assessment has therefore been made
considering existing pollutant concentrations, the relative contribution of the Project to the AQS and the
extent of modelled impacts.
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3
Results
3.1
Discrete receptor results
3.1.1
Human health
Table 3.1 and Table 3.2 present predicted NO2 concentrations at the closest residential receptors to the
site for the annual mean and hourly averaging periods respectively, for comparison against the NO2
standards for the protection of human health.
Annual mean NO2 results at human health receptors
PC as %
of AQS
BC
(µg/m3)
PEC
(µg/m3)
PEC as %
of AQS
1.5
1.1
2.8
4
5.1
12.8
5800498
1.5
0.8
1.9
4
4.8
11.9
5800526
1.5
0.6
1.6
4
4.6
11.6
673693
5800557
1.5
0.6
1.4
4
4.6
11.4
H5
673758
5800600
1.5
0.8
H6
673781
5800595
1.5
H7
673808
5800463
1.5
H8
673840
5800646
1.5
H9
673707
5800234
1.5
H10
673847
5800096
1.5
H11
673695
5800039
1.5
H12
673793
5800487
1.5
673655
5800399
H2
673673
H3
673666
H4
se
H1
AQS
(µg/m3)
he
Z
ot
Y
2.0
4
4.8
12.0
1.0
2.5
4
5.0
12.5
3.7
9.2
4
7.7
19.2
1.2
2.9
4
5.2
12.9
1.1
2.8
4
5.1
12.8
0.9
2.3
4
4.9
12.3
0.3
0.7
4
4.3
10.7
2.5
6.4
4
6.5
16.4
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Receptor
.
PC
(µg/m3)
ru
Table 3.1:
Co
Notes: PC: Process contribution; BC: Baseline concentration; PEC: Predicted environmental concentration
Annual mean NO2 PC is less than 10% of the AQS at all discrete human health receptors. Baseline
concentrations are low and the predicted environmental concentrations (PEC) are well below the AQS.
Table 3.2:
Hourly 99.79 %ile NO2 results at human health receptors
PC
(µg/m3)
PC as %
of AQS
BC
(µg/m3)
PEC
(µg/m3)
PEC as %
of AQS
1.5
20.9
10.5
8
28.9
14.5
5800498
1.5
15.3
7.7
8
23.3
11.7
5800526
1.5
10.9
5.5
8
18.9
9.5
673693
5800557
1.5
10.3
5.1
8
18.3
9.1
H5
673758
5800600
1.5
11.4
5.7
8
19.4
9.7
H6
673781
5800595
1.5
12.5
6.3
8
20.5
10.3
H7
673808
5800463
1.5
30.1
15.0
8
38.1
19.0
H8
673840
5800646
1.5
9.8
4.9
8
17.8
8.9
H9
673707
5800234
1.5
29.4
14.7
8
37.4
18.7
H10
673847
5800096
1.5
10.6
5.3
8
18.6
9.3
H11
673695
5800039
1.5
7.3
3.6
8
15.3
7.6
H12
673793
5800487
1.5
27.4
13.7
8
35.4
17.7
Receptor
X
Y
Z
H1
673655
5800399
H2
673673
H3
673666
H4
AQS
(µg/m3)
200
Notes: PC: Process contribution; BC: Baseline concentration; PEC: Predicted environmental concentration
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The 99.79th percentile of hourly NO2 PCs is equal to or less than 15% of the AQS at all discrete human
health receptors. Baseline concentrations are low and the predicted environmental concentrations (PEC)
are well below the AQS.
3.1.2
Ecological
Table 3.3 presents predicted annual mean NOx concentrations at the closest ecological receptors to the
site, for comparison against the NOx standard for the protection of sensitive vegetation and ecosystems.
Annual mean NOx results at ecological receptors
5800239
0
673984
5800477
0
E3
673970
5800242
0
E4
673957
5800613
0
E5
673946
5800684
0
E6
673721
5800969
0
30
PC as %
of AQS
BC
(µg/m3)
PEC
(µg/m3)
PEC as %
of AQS
2.6
8.8
4.7
15.5
7
9.6
32.1
7
11.7
38.9
1.7
5.6
8.7
28.9
.
673862
E2
PC
(µg/m3)
se
E1
AQS
(µg/m3)
ru
Z
7
6.0
7
8.8
29.4
1.3
4.2
7
8.3
27.6
0.3
0.9
7
7.3
24.2
1.8
he
Y
ot
X
Receptor
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Table 3.3:
Notes: PC: Process contribution; BC: Baseline concentration; PEC: Predicted environmental concentration
Co
ns
en
Annual mean NOx PCs are less than 10% of the AQS at all but one modelled ecological discrete receptor.
The maximum PC is predicted at receptor E2; the PC here is 15.5% of the AQS, which is still relatively low
and well below the maximum allowable PC according to EPA guidance. The PEC at this receptor is 38.9%
of the AQS. E2 is located on the border of the Project site and the SAC / SPA and represents the worst
case location with respect to air quality impacts on the ecological designated sites. Overall the results
indicate that increases in NOx concentrations as a result of the Project are small and would not result in
any exceedances of the AQS for the protection of vegetation. No impacts on the SAC and SPA as a result
of increased atmospheric NOx concentrations or subsequent nitrogen deposition or acidification are
predicted to occur.
3.2
Gridded receptor results
PCs were predicted across the entire 10km2 modelled domain and are presented in the contour plots in
Figure 3.1 to Figure 3.3. The plots show that concentrations beyond the site boundary are low and well
below the long term and short term AQS for human health and the annual mean AQS for the protection of
vegetation.
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Annual mean NO2 contour plot
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Figure 3.1:
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Hourly 99.79%ile NO2 contour plot
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Figure 3.2:
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Annual mean NOx contour plot
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Figure 3.3:
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Maximum PCs from the modelled grid are presented for information in Table 3.4. However it should be
noted that the AQS do not apply at the points of maximum concentrations as there are no relevant
receptors present at these locations (both the long term and short term maximum impacts are predicted at
the boundary of the Glanbia Ingredients Wexford site).
Table 3.4:
Maximum process contributions (PC) and predicted environmental concentrations (PECs) (µg/m³) across
the modelled domain
Max PC
Max PC as %
of AQS
BC
Max PEC
Max PEC as %
of AQS
4
14.9
37.1
8
66.7
33.3
7
17.9
59.5
10.9
27.1
99.79 %ile of hourly
averages
200
58.7
29.3
NOx
Annual mean
30
10.9
36.2
se
40
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
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ot
Annual mean
NO2
.
AQS
ru
Averaging period
he
Pollutant
Note maximum PCs do not occur at locations where the standards apply (i.e. there is no relevant exposure) – the values in this table
are presented for reference only
PC: Process contribution; BC: Baseline concentration; PEC: Predicted environmental concentration
3.3
Conclusion
Co
ns
en
The results of the dispersion modelling show that increases in ground level pollutant concentrations as a
result of emissions from the stack are small across the entire study area. Overall, the results show that
process contributions from the project are small; baseline concentrations are also low and overall the
predicted environmental concentrations are well below the AQS. Impacts are therefore not significant.
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Appendices
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Appendix A. Bosch Technical Data Sheet __________________________________________________________ 26
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Appendix A. Bosch Technical Data Sheet
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Load securing device
UNIVERSAL steam boiler UL-S
in three-pass flame-tube smoke-tube technology with integrated flue gas heat exchanger
DA368
Project number: 170862/1.50
Offer No.: 1168994115-50
to
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Printing date: 14.04.2015
Explanation of symbols
Lifting equipment to be fastened here, only
Lashing equipment
ns
en
centre of gravity
Trailing load
Co
UNIVERSAL steam boiler UL-S
Nominal output
Mean working gauge pressure
Transportation weight
A1
A2
[kg/h]
[bar]
[kg]
[kg]
[kg]
7500
10
16935
7918
9017
Dimension(s)
L1
L3
L6
L8
L9
B1
H1 1)
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
7625
3415
835
105
73
2500
2958
Base frame



1)
centre of gravity
Lashing point requirements
L2
L7
B2
wide flange beam
L4
B3
H2
L5
B4
[mm]
[mm]
[mm]
[IPB - HEB - DIN1025]
[mm]
[mm]
[mm]
[mm]
[mm]
4000
500
1890
180
2153
909
1358
 1000
 1890
The scope of delivery is defined in the order confirmation.
Transport the boiler on anti-slip mats (positioned below the boiler feet) with a coefficient of sliding friction of µ >= 0.6.
The entire surface of the base frame must rest on the loading platform.
Height to top edge Flue gas connection
Subject to change
Page 1 of 1
EPA Export 11-01-2017:02:34:51
Main dimensions
UNIVERSAL steam boiler UL-S
in three-pass flame-tube smoke-tube technology with integrated flue gas heat exchanger
DA009
Project number: 170862/1.50
Offer No.: 1168994115-50
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
Printing date: 14.04.2015
terminal box
A01.000
Burner
D03.000
Flue gas connection socket
D03.002
Flue gas chamber
D04.007
Reversing chamber door
D05.000
Inspection opening steam-side
D05.001
Inspection opening water side
D05.002
Inspection opening flue gas side
D05.004
Inspection opening flue gas side
D15.003
Level transducer
D05.005
Sight hole
D15.006
Level limiter
D06.000
Base frame
D16.002
Desalting shut-off valve
D06.002
Lifting lug
D16.005
Desalting control valve
D07.000
Operating platform option
D16.006
Conductivity transducer option
D08.000
Pressure safeguard valve 1
D19.001
vent shut-off valve option
D08.100
Pressure safeguard valve 2 option
W32.000
flue gas heat exchanger
D09.000
Steam shut-off valve
W32.026
Connecting pipe
D12.001
Drain shut-off valve
Co
ns
en
51.004
Explanation of symbols
Warning: dangerous
voltage
electrical
D12.002
Quick shut-off blow down valve
D12.503
Connection for drainage flue gas condensate
D14.001
Pressure indicator (with test unit)
D14.002
Pressure limiter
D14.005
Shut-off valve
D14.013
Pressure transducer
D15.001
Level indicator 1
Level indicator 2
Lifting equipment to be fastened
here, only
Warning: hot surface, e. g. uninsulated fitting
Subject to change
Page 1 of 2
EPA Export 11-01-2017:02:34:51
Main dimensions
UNIVERSAL steam boiler UL-S
in three-pass flame-tube smoke-tube technology with integrated flue gas heat exchanger
DA009
Project number: 170862/1.50
Offer No.: 1168994115-50
Printing date: 14.04.2015
UNIVERSAL steam boiler UL-S
Nominal
output
Mean working gauge pressure
Transportation
weight
Operating
weight
Maximum weight
[kg/h]
[bar]
[kg]
[kg]
[kg]
[kW]
7500
10
16935
25928
29088
28,1
3)
Flue gas connection
L1
L 2 1)
L3
L6
B1
B 2 1)
H1
H 2 1) 4)
L 11
B4
H3
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
7625
6210
5100
780
2774
2500
3312
2958
373
153
2958
L4
L5
L7
L8
L9
L 10 2)
B3
wide flange beam
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
se
Dimension(s)
Connected load (electrical)
[mm]
[IPB - HEB - DIN1025]
4000
3650
675
500
175
225
1890
180




References and defaults to Requirements for the boiler installation room see technical information TI024.
Dimensions with ± 1 % tolerance; transport weight indication with ± 4 % tolerance and operating weight indication with ± 2 % tolerance
The scope of delivery is defined in the order confirmation.
The indicated transport weight already includes the surcharges for normal sheet metal thickness tolerances, hence difference
downwards is possible.
Dimensioning insertion opening:

Positioning height: addition of at least 100 mm to dimension H1 resp. dimension H2
(mounted / not mounted fittings)

Positioning width: addition of at least 200 mm to dimension B1 resp. dimension B2
(mounted / not mounted fittings)
Smallest transport dimensions once fittings, burner and terminal box have been removed (without cable ducting; with cable ducting
+ 75 mm on right).
The boiler operating weight must be absorbed by the foundation in the area of the front and rear supports.
Maximum weight incl. 100 % filled with water
Height to top edge Flue gas connection
Co
ns
en

to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
.
Base frame
1)
2)
3)
4)
Subject to change
Page 2 of 2
EPA Export 11-01-2017:02:34:52
Individual dimensions
UNIVERSAL steam boiler UL-S
in three-pass flame-tube smoke-tube technology with integrated flue gas heat exchanger
DA010
Project number: 170862/1.50
Offer No.: 1168994115-50
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
Printing date: 14.04.2015
Flue gas connection socket
D12.503
Connection for drainage flue gas condensate
D05.000
Inspection opening steam-side
D05.001
Inspection opening water side
D14.500
Connection for manostat pipe
D15.501
Connection for Level indicator 1
D05.002
Inspection opening flue gas side
D05.004
cleaning opening flue gas side
D16.501
Connection for Desalting shut-off valve
D08.500
Connection for Pressure safeguard valve 1
D19.501
Connection for vent shut-off valve option
D08.600
Connection for Pressure safeguard valve 2 option
W32.509 Connection for Water inlet flue gas heat exchanger
D09.500
Connection for Steam shut-off valve
W32.510 Connection for Water outlet flue gas heat exchanger
D12.500
Connection for drain
Co
ns
en
D03.000
Connection for Level indicator 2
Subject to change
Page 1 of 2
EPA Export 11-01-2017:02:34:52
Individual dimensions
UNIVERSAL steam boiler UL-S
in three-pass flame-tube smoke-tube technology with integrated flue gas heat exchanger
DA010
Project number: 170862/1.50
Offer No.: 1168994115-50
Printing date: 14.04.2015
UNIVERSAL steam boiler UL-S
Dimension(s)
Nominal output
L1
B1
H 1 4)
[kg/h]
[mm]
[mm]
[mm]
7500
6210
2500
2958
Nozzle position
L3
L4
L5
L6
L7
L8
L9
L 10
L 12
L13
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
2750
2650
1650
1150
1050
750
420
Nozzle position
B3
B5
H3
H4
H5
H6
H8
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
63
950
348
2725
1960
1350
1920
340
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
L 15
Flue gas connection
Base frame
L14
B4
H2
L2
L 11
B2
H7
wide flange beam
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[IPB - HEB - DIN1025]
373
153
2958
4000
500
1890
150
180
D03.000 1)
[mm]
500
PN
[bar/120°C]
0,1
D09.500 2)
D12.500 2)
D12.503 3)
50
125
40
3/4“
40
40
40
0,1
D19.501 2)
W32.509 2)
W32.510 2)
Co
DN
D08.500 / D08.600 2)
ns
en
Connection
Connection




1)
2)
3)
4)
D14.500 2)
D15.501 2)
D16.501 2)
DN
[mm]
20
25
25
40
40
PN
[bar/120°C]
40
40
40
40
40
References and defaults to Requirements for the boiler installation room see technical information TI024.
Missing dimensions are not contained in scope of delivery.
The scope of delivery is defined in the order confirmation.
Dimensions with ± 1 % tolerance
Nominal diameter for pipe connection according to DIN 24154 part 4
Nominal diameter for flanges in accordance with DIN 2633 / 2634 / 2635 or EN 1092-1/-2 / DN65PN16 with 4 holes
Pipe thread according to DIN 2999
Height to top edge Flue gas connection
Subject to change
Page 2 of 2
EPA Export 11-01-2017:02:34:52
Piping diagram
UNIVERSAL steam boiler UL-S
DA021
Project number: 170862/1.50
Offer No.: 1168994115-50
Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
Printing date: 14.04.2015
Position
Designation
Position
Designation
D08.000
Pressure safeguard valve
D15.003
Level controller
D08.100
Pressure safeguard valve option
D15.006
Level limiter
D09.000
Steam extraction shut-off valve
D15.007
Level limiter
D12.001
Drain shut-off valve
D15.008
level switch
D12.002
Quick shut-off blow down valve
D15.009
Shut-off valve
D12.005
three-way regulator valve (magnetic)
D15.101
Level indicator
D12.006
Filter valve
D15.109
Shut-off valve
D12.007
Shut-off valve
D16.002
Desalting shut-off valve
D13.001
Feed water shut-off valve
D16.003
conductivity controller 1)
D13.002
Feed water non-return valve
D16.004
flow rate indicator
D14.001
Pressure indicator (with test unit)
D16.005
Desalting control valve (motorized)
D14.002
Pressure limiter
D16.007
Shut-off valve
D14.004
pressure regulator
D16.010
Non-return valve
D14.005
Shut-off valve
D23.001
Flue gas temperature indicator
D15.001
Level indicator
Subject to change
Page 1 of 2
EPA Export 11-01-2017:02:34:52
Piping diagram
UNIVERSAL steam boiler UL-S
DA021
Project number: 170862/1.50
Offer No.: 1168994115-50
Printing date: 14.04.2015
Position Piping
Position
Piping
08.001
Pressure safeguard blowoff line
12.004
Discharge line flue gas condensate
08.002
Pressure safeguard drainage line
15.001
water level blowoff pipe
08.101
Pressure safeguard blowoff line
16.001
boiler water desalting line
09.001
Steam pipe
16.002
Water sample extraction pipe
12.001
Drain pipe
23.001
Flue gas line
12.002
control line control medium
40.002
Feed water pressure line
.
se
ru
he
ot
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ns
en
1)
Depicted equipment is on the basis of EN12953 Part 6
References and defaults to Requirements for the boiler installation room see technical information TI024.
The scope of delivery is defined in the order confirmation.
The conductivity measuring transducer with shut-off at the limit value is a minimum requirement of EN12953 Part 6.
Co



Subject to change
Page 2 of 2
EPA Export 11-01-2017:02:34:52
Piping diagram
flue gas heat exchanger, integrated, ECO 1
closable, uncontrolled
DA057
Project number: 170862/1.50
Offer No.: 1168994115-50
Designation
Position
Designation
D13.001
Feed water shut-off valve
W32.011
Shut-off valve
W32.017
vent shut-off valve
W32.018
Drain shut-off valve
W32.012
W32.013
Shut-off valve
W32.020
temperature indicator
Non-return valve
W32.023
Pressure safeguard valve
W32.015
Shut-off valve
W32.024
Pressure indicator
Co
Position
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
Printing date: 14.04.2015
Position Piping
Position
Piping
23.001
Flue gas line
32.007
drainage line
32.001
Drainage- and vent pipe economizer
32.008
individual station
32.013
connection line boiler - Heat exchanger
40.002
Feed water pressure line
32.002
Pressure safeguard drainage line
32.003
Pressure safeguard blowoff line

The scope of delivery is defined in the order confirmation.
Subject to change
Page 1 of 1
EPA Export 11-01-2017:02:34:52
Main and individual dimensions
connection line boiler - flue gas heat exchanger
DA083
Project number: 170862/1.50
Offer No.: 1168994115-50
W32.016
Pressure safeguard valve
D03.002
Flue gas chamber
D13.001
Feed water shut-off valve
W32.017
vent shut-off valve
W32.020
temperature indicator 3)
W32.000
flue gas heat exchanger
W32.011
Shut-off valve
W32.021
Pressure indicator
W32.022
temperature indicator option
W32.012
W32.013
Shut-off valve
W32.023
Pressure safeguard valve option
Non-return valve
W32.024
Pressure indicator option
W32.015
Shut-off valve
ns
en
boiler
Co
D01.002
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
Printing date: 14.04.2015
Subject to change
Page 1 of 2
EPA Export 11-01-2017:02:34:52
Main and individual dimensions
connection line boiler - flue gas heat exchanger
DA083
Project number: 170862/1.50
Offer No.: 1168994115-50
Printing date: 14.04.2015
connection line
Mean working gauge pressure
Maximum weight 1)
Transportation weight
Type
[bar]
[kg]
[kg]
7500
10
41,5
46,3
Dimension(s)
L1
L2
L3
L4
L5
L6
B1
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
1166
980
671
378
278
178
348
Dimension(s)
H2
H3
H4
H5
H6
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
2825
2293
1877
1328
1329
1325
Connection for
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
H1
D13.001 2)
W32.011 2)
W32.012 2)
W32.013 2)
DN
[mm]
40
40
40
40
PN
[bar/120°C]
40
40
40
40
W32.015 2)
W32.016 2)
W32.017 2)
W32.023 2)
40
20
20
40
40
40
Connection for
[mm]
PN
[bar/120°C]



1)
2)
3)
Co
ns
en
DN
References and defaults to Requirements for the boiler installation room see technical information TI024.
Dimensions with ± 1 % tolerance; transport weight indication with ± 4 % tolerance and operating weight indication with ± 2 %
tolerance
The scope of delivery is defined in the order confirmation.
Maximum weight incl. 100 % filled with water
Nominal diameter for flanges in accordance with DIN 2633 / 2634 / 2635 or EN 1092-1/-2 / DN65PN16 with 4 holes
The temperature indicator is installed towards the operating side.
Subject to change
Page 2 of 2
EPA Export 11-01-2017:02:34:52
Main dimensions
Flue Gas Flange
Dimensions in accordance with Part 4 of the DIN 24154 Standard
DA078
Project number: 170862/1.50
Offer No.: 1168994115-50
Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
Printing date: 14.04.2015
nominal diameter




Dimension(s)
Quantity
wall thickness
weight
[-]
[mm]
[kg]
12
8
4,3
[DN] 1)
D1
D2
D3
D4


Bores
[mm]
[mm]
[mm]
[mm]
[mm]
[°]
[°]
500
587
551
495
11,5
15
30
The scope of delivery is defined in the order confirmation.
The bores are evenly distributed along the periphery.
Dimensions with ± 1 % tolerance; transport weight indication with ± 4 % tolerance and operating weight indication with ± 2 %
tolerance
The exhaust pipe is not pushed through and welded, as in DIN 24154 R4, but rather butted onto the flange and welded!
Subject to change
Page 1 of 1
EPA Export 11-01-2017:02:34:52
Main and individual dimensions
Pump module PM
DA004
Project number: 170862/1.50
Offer No.: 1168994115-50
A37.009
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
A37.001 Shut-off valve (throttle cone)
A37.002 Non-return valve
A37.003 Pressure indicator
A37.004 Shut-off valve
A37.005 Filter valve
A37.008 Pump
discharge
pressure
Min. required positive suction
head
ns
en
Pump module
Pump engine
A37.011
bracket
A37.019
pressure monitor (minimum pressure)
A37.501
Connection for suction side
A37.502
Connection for pressure side
Transportation
weight
Operating
weight
Connected load
(electrical)
Co
Discharge
flow
ot
he
ru
se
.
Printing date: 14.04.2015
[kg/h]
[bar]
[mm]
[kg]
[kg]
[kW]
8107
13,73
991
252
269
7,5
Dimension(s)
L1
L2
L3
B1
B3
B4
H1
H2
H3
H4
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
1175
767
692
295
159
260
1439
600,5
260
180
Bearing area






1)
Connection for
A37.501 1)
A37.502 1)
L4
B2
Surface area
[mm]
[mm]
[cm²]
DN
PN
DN
PN
620
80
992
100
16
40
40
References and defaults to Requirements for the boiler installation room see technical information TI024.
During assembly, please note the specified flow direction
The scope of delivery is defined in the order confirmation.
Install the consoles onto anti-vibration supports
Missing dimensions are not contained in scope of delivery.
Dimensions with ± 1 % tolerance; transport weight indication with ± 4 % tolerance and operating weight indication with ± 2 %
tolerance
Nominal diameter for flanges in accordance with DIN 2633 / 2634 / 2635 or EN 1092-1/-2 / DN65PN16 with 4 holes
Subject to change
Page 1 of 2
EPA Export 11-01-2017:02:34:52
Main and individual dimensions
Pump module PM
DA004
Project number: 170862/1.50
Offer No.: 1168994115-50
Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
Printing date: 14.04.2015
Subject to change
Page 2 of 2
EPA Export 11-01-2017:02:34:52
Piping diagram
Feed water supply steam boiler
Boiler level control via constant regulation with a feed water control
valve
DA390
Project number: 170862/1.50
Offer No.: 1168994115-50
Printing date: 14.04.2015
Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
Depiction of the feed water supply from the tank to the boiler
depiction with 2 feed pumps per boiler
Subject to change
Page 1 of 2
EPA Export 11-01-2017:02:34:52
Piping diagram
Feed water supply steam boiler
Boiler level control via constant regulation with a feed water control
valve
DA390
Project number: 170862/1.50
Offer No.: 1168994115-50
Printing date: 14.04.2015
Position
Designation
Position
Designation
A37.001
Shut-off valve (throttle cone)
A37.008
Feed pump
A37.002
Non-return valve
A37.019
pressure monitor option
A37.003
Pressure indicator
A40.001
feed water control valve (motorized)
A37.004
Shut-off valve
B30.000
Feed water tank
A37.005
Filter valve
D01
steam boiler
Position
Piping
Position
Piping
30.001
Feed water suction piping
40.001
feed pump bypass line
30.010
Feed water suction piping
40.002
Feed water pressure line
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
The scope of delivery is defined in the order confirmation.
Co

Subject to change
Page 2 of 2
EPA Export 11-01-2017:02:34:52
technical specification
Pump curve
DA398
Project number: 170862/1.50
Offer No.: 1168994115-50
Printing date: 14.04.2015
Pump module 1 und 2 of boiler 1, serial number 100000
Type Booster pump
CR 10-18 XK
-
Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
Type pump
Subject to change
Page 1 of 2
EPA Export 11-01-2017:02:34:52
technical specification
Pump curve
DA398
Project number: 170862/1.50
Offer No.: 1168994115-50
Q
H
NPSH
Curve A
Curve B
Curve D
Printing date: 14.04.2015
Discharge capacity in m³/h
Discharge head in m
NPSH value in m
Curve of the pump
System characteristic based on mean working gauge pressure (throttled)
NPSH curve of the pump
Discharge flow
[kg/h]
8107
Pump operating point following throttling of the pump (point O)
Mean working gauge pressure
water volume 1)
discharge head 2)
[bar]
[m³/h]
[m]
13,73
8,48
162,43
discharge pressure 3)
[bar-Ü]
15,23
ru
The scope of delivery is defined in the order confirmation.
The necessary water volume for the boiler is calculated on the nominal output of the boiler plus the volume lost through blowdown.
The necessary discharge pressure / discharge head of the boiler is calculated on the mean working gauge pressure of the
boiler (basis of calculation: 83 % of the response pressure of the pressure safeguard valve) plus the back-pressure between
pump and boiler.
The pump must be throttled to the specified delivery pressure indicated at the pump pressure indicator by means of the shutoff valve with throttle cone.
Important! If the boiler is running with reduced working gauge pressure (deviating from the working gauge
pressure indicated in the order confirmation), the pump must be throttled so that at the lowest possible
pressure (burner cut-in point) the pump continues to follow the characteristic and the necessary NPSH value
is achieved.
ns
en
3)
Co
2)
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
1)
he

se
.
Important! In order to avoid cavitation in the pump at every operating point (between switch-on and switch-off
points of the burner), the pump must be throttled. The correct procedure for throttling the pump is described in
the operating instructions for the E001.
Subject to change
Page 2 of 2
EPA Export 11-01-2017:02:34:52
Main dimensions
Feed pump
DA399
Project number: 170862/1.50
Offer No.: 1168994115-50
Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
Printing date: 14.04.2015
1
pump
5
Motor terminal box
2
Pump engine
6
venting screw
3
Connection for suction side
7
Drain plug
4
Connection for pressure side
Feed pump
Discharge
flow
discharge
pressure
Min. required positive suction
head
Type
CR 10-18
XK
Transportation
weight
Connected load
(electrical)
[kg/h]
[bar]
8107
13,73
[mm]
[kg]
[kW]
991
111
7,5
Dimension(s)

1)
Connection for
3 1)
4 1)
L
L1
L2
L3
B
B1
H
H1
H2
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
DN
PN
DN
PN
280
130
159
260
256
215
1259
880
379
40
16
40
40
The scope of delivery is defined in the order confirmation.
Nominal diameter for flanges in accordance with DIN 2633 / 2634 / 2635 or EN 1092-1/-2 / DN65PN16 with 4 holes
Subject to change
Page 1 of 1
EPA Export 11-01-2017:02:34:52
Main and individual dimensions
feed water regulation module - RM
supply flow control
DA073
Project number: 170862/1.50
Offer No.: 1168994115-50
feed water regulation
module
Type
RM 40
Nominal
output
[kg/h]
7500
A40.006
A40.007
A40.501
A40.502
A40.503
ns
en
feed water control valve (motorized)
Shut-off valve
Shut-off valve
Filter valve
Shut-off valve (throttle cone)
Mean working gauge
pressure
Co
A40.001
A40.002
A40.003
A40.004
A40.005
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
Printing date: 14.04.2015
[bar]
10
Shut-off valve
Non-return valve
Connection for Water inlet
Connection for Water outlet
Connection for Pump idling
Transportation
weight
[kg]
83
Connected load
(electrical)
Connection for
A40.501 /
A40.502 1)
DN
40
[kW]
0,05
A40.503
1)
DN
25
Dimension(s)
L1
[mm]
1440
L2
[mm]
1326
L3
[mm]
669
B4
[mm]
210
B5
[mm]
278
H1
[mm]
1122
B1
[mm]
878
B2
[mm]
500
B3
[mm]
110
H2
[mm]
375
H3
[mm]
673
H4
[mm]
444
Dimension(s)




1)
The scope of delivery is defined in the order confirmation.
References and defaults to Requirements for the boiler installation room see technical information TI024.
During assembly, please note the specified flow direction
Dimensions with ± 1 % tolerance; transport weight indication with ± 4 % tolerance and operating weight indication with ± 2 %
tolerance
Nominal diameter for flanges in accordance with DIN 2633 / 2634 / 2635 or EN 1092-1/-2 / DN65PN16 with 4 holes
Subject to change
Page 1 of 1
EPA Export 11-01-2017:02:34:52
Individual dimensions
UNIVERSAL steam boiler UL-S
in three-pass flame-tube smoke-tube technology with integrated flue gas heat exchanger
DA010
Project number: 170862/1.50
Offer No.: 1168994115-50
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
Printing date: 14.04.2015
Flue gas connection socket
D12.503
Connection for drainage flue gas condensate
D05.000
Inspection opening steam-side
D05.001
Inspection opening water side
D14.500
Connection for manostat pipe
D15.501
Connection for Level indicator 1
D05.002
Inspection opening flue gas side
D05.004
cleaning opening flue gas side
D16.501
Connection for Desalting shut-off valve
D08.500
Connection for Pressure safeguard valve 1
D19.501
Connection for vent shut-off valve option
D08.600
Connection for Pressure safeguard valve 2 option
W32.509 Connection for Water inlet flue gas heat exchanger
D09.500
Connection for Steam shut-off valve
W32.510 Connection for Water outlet flue gas heat exchanger
D12.500
Connection for drain
Co
ns
en
D03.000
Connection for Level indicator 2
Subject to change
Page 1 of 2
EPA Export 11-01-2017:02:34:52
Individual dimensions
UNIVERSAL steam boiler UL-S
in three-pass flame-tube smoke-tube technology with integrated flue gas heat exchanger
DA010
Project number: 170862/1.50
Offer No.: 1168994115-50
Printing date: 14.04.2015
UNIVERSAL steam boiler UL-S
Dimension(s)
Nominal output
L1
B1
H 1 4)
[kg/h]
[mm]
[mm]
[mm]
7500
6210
2500
2958
Nozzle position
L3
L4
L5
L6
L7
L8
L9
L 10
L 12
L13
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
2750
2650
1650
1150
1050
750
420
Nozzle position
B3
B5
H3
H4
H5
H6
H8
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
63
950
348
2725
1960
1350
1920
340
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
L 15
Flue gas connection
Base frame
L14
B4
H2
L2
L 11
B2
H7
wide flange beam
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[IPB - HEB - DIN1025]
373
153
2958
4000
500
1890
150
180
D03.000 1)
[mm]
500
PN
[bar/120°C]
0,1
D09.500 2)
D12.500 2)
D12.503 3)
50
125
40
3/4“
40
40
40
0,1
D19.501 2)
W32.509 2)
W32.510 2)
Co
DN
D08.500 / D08.600 2)
ns
en
Connection
Connection




1)
2)
3)
4)
D14.500 2)
D15.501 2)
D16.501 2)
DN
[mm]
20
25
25
40
40
PN
[bar/120°C]
40
40
40
40
40
References and defaults to Requirements for the boiler installation room see technical information TI024.
Missing dimensions are not contained in scope of delivery.
The scope of delivery is defined in the order confirmation.
Dimensions with ± 1 % tolerance
Nominal diameter for pipe connection according to DIN 24154 part 4
Nominal diameter for flanges in accordance with DIN 2633 / 2634 / 2635 or EN 1092-1/-2 / DN65PN16 with 4 holes
Pipe thread according to DIN 2999
Height to top edge Flue gas connection
Subject to change
Page 2 of 2
EPA Export 11-01-2017:02:34:52
Main and individual dimensions
connection line boiler - flue gas heat exchanger
DA083
Project number: 170862/1.50
Offer No.: 1168994115-50
W32.016
Pressure safeguard valve
D03.002
Flue gas chamber
D13.001
Feed water shut-off valve
W32.017
vent shut-off valve
W32.020
temperature indicator 3)
W32.000
flue gas heat exchanger
W32.011
Shut-off valve
W32.021
Pressure indicator
W32.022
temperature indicator option
W32.012
W32.013
Shut-off valve
W32.023
Pressure safeguard valve option
Non-return valve
W32.024
Pressure indicator option
W32.015
Shut-off valve
ns
en
boiler
Co
D01.002
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
Printing date: 14.04.2015
Subject to change
Page 1 of 2
EPA Export 11-01-2017:02:34:52
Main and individual dimensions
connection line boiler - flue gas heat exchanger
DA083
Project number: 170862/1.50
Offer No.: 1168994115-50
Printing date: 14.04.2015
connection line
Mean working gauge pressure
Maximum weight 1)
Transportation weight
Type
[bar]
[kg]
[kg]
7500
10
41,5
46,3
Dimension(s)
L1
L2
L3
L4
L5
L6
B1
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
1166
980
671
378
278
178
348
Dimension(s)
H2
H3
H4
H5
H6
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
2825
2293
1877
1328
1329
1325
Connection for
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
H1
D13.001 2)
W32.011 2)
W32.012 2)
W32.013 2)
DN
[mm]
40
40
40
40
PN
[bar/120°C]
40
40
40
40
W32.015 2)
W32.016 2)
W32.017 2)
W32.023 2)
40
20
20
40
40
40
Connection for
[mm]
PN
[bar/120°C]



1)
2)
3)
Co
ns
en
DN
References and defaults to Requirements for the boiler installation room see technical information TI024.
Dimensions with ± 1 % tolerance; transport weight indication with ± 4 % tolerance and operating weight indication with ± 2 %
tolerance
The scope of delivery is defined in the order confirmation.
Maximum weight incl. 100 % filled with water
Nominal diameter for flanges in accordance with DIN 2633 / 2634 / 2635 or EN 1092-1/-2 / DN65PN16 with 4 holes
The temperature indicator is installed towards the operating side.
Subject to change
Page 2 of 2
EPA Export 11-01-2017:02:34:52
technical specification
Pump curve
DA398
Project number: 170862/1.50
Offer No.: 1168994115-50
Printing date: 14.04.2015
Pump module 1 und 2 of boiler 2, serial number 100000
Type Booster pump
CR 10-18 XK
-
Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
Type pump
Subject to change
Page 1 of 2
EPA Export 11-01-2017:02:34:52
technical specification
Pump curve
DA398
Project number: 170862/1.50
Offer No.: 1168994115-50
Q
H
NPSH
Curve A
Curve B
Curve D
Printing date: 14.04.2015
Discharge capacity in m³/h
Discharge head in m
NPSH value in m
Curve of the pump
System characteristic based on mean working gauge pressure (throttled)
NPSH curve of the pump
Discharge flow
[kg/h]
8107
Pump operating point following throttling of the pump (point O)
Mean working gauge pressure
water volume 1)
discharge head 2)
[bar]
[m³/h]
[m]
13,73
8,48
162,43
discharge pressure 3)
[bar-Ü]
15,23
ru
The scope of delivery is defined in the order confirmation.
The necessary water volume for the boiler is calculated on the nominal output of the boiler plus the volume lost through blowdown.
The necessary discharge pressure / discharge head of the boiler is calculated on the mean working gauge pressure of the
boiler (basis of calculation: 83 % of the response pressure of the pressure safeguard valve) plus the back-pressure between
pump and boiler.
The pump must be throttled to the specified delivery pressure indicated at the pump pressure indicator by means of the shutoff valve with throttle cone.
Important! If the boiler is running with reduced working gauge pressure (deviating from the working gauge
pressure indicated in the order confirmation), the pump must be throttled so that at the lowest possible
pressure (burner cut-in point) the pump continues to follow the characteristic and the necessary NPSH value
is achieved.
ns
en
3)
Co
2)
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
1)
he

se
.
Important! In order to avoid cavitation in the pump at every operating point (between switch-on and switch-off
points of the burner), the pump must be throttled. The correct procedure for throttling the pump is described in
the operating instructions for the E001.
Subject to change
Page 2 of 2
EPA Export 11-01-2017:02:34:52
Individual dimensions
Feed water tank FT
Full deaeration - trickle deaeration device
DA019
Project number: 170862/1.50
Offer No.: 1168994115-50
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
Printing date: 14.04.2015
Explanation of symbols
Lifting equipment to be fastened here, only
Co
ns
en
Warning: hot surface, e. g. uninsulated fitting
B30.100
Feed water tank
B30.521
Connection for Draining
B30.501
Connection for extraction
B30.522
Connection for Level indicator
B30.504
Connection for Heating-up steam
B30.523
Connection for Negative pressure safeguard valve
B30.506
Connection for oxygen-free, directly returning
condensate
B30.525
Connection for Pressure safeguard valve 4)
B30.507
Connection for Expansion steam return device
option
B30.527
Connection for Pressure safeguard valve 4) option
B30.508
Connection for Chemical dosing O2
B30.528
Connection for temperature indicator
B30.509
Connection for Chemical dosing pH
B30.529
Connection for Temperature measuring transducer
B30.510
Connection for Pump idling
B30.531
Connection for Overflow valve option
B30.512
Connection for deaeration device
D05.001
Inspection opening (water side)
B30.519
Connection for sample extraction
D06.002
Lifting lug
B30.520
Connection for level control
Subject to change
Page 1 of 2
EPA Export 11-01-2017:02:34:52
Individual dimensions
Feed water tank FT
Full deaeration - trickle deaeration device
DA019
Project number: 170862/1.50
Offer No.: 1168994115-50
Printing date: 14.04.2015
Feed water tank FT
Transportation weight
Type
6)
FT 10
Maximum weight 1)
Operating weight
[kg]
[kg]
[kg]
2066
8987
11987
Dimension(s)
L 1 5)
L2
L3
L4
L5
L6
L7
L8
L9
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
5570
3158
3098
3060
2860
2660
2660
2185
L 10
L 11
L 12
L 13
L 14
L 15
L 16
L 17
L 18
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
1135
1085
1455
1090
935
1185
785
690
Dimension(s)
[mm]
[mm]
[mm]
[mm]
200
1930
1235
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
690
se
B2
[mm]
ru
B 1 5)
he
L 21
ot
L 20
.
Dimension(s)
L 19
B3
B4
B5
[mm]
[mm]
[mm]
900
949
905
Dimension(s)
B6
B7
B8
[mm]
[mm]
[mm]
893
646
200
H3
H4
D
[mm]
[mm]
[mm]
[mm]
2625
1300
225
50
1800
B30.504 2)
B30.506 2)
50
65
[mm]
100
PN
[bar/120°C]
16
B30.520
40
3)
B30.521
DN
[mm]
1/2“
1 1/2“
PN
[bar/120°C]
16
16
B30.507 2)
B30.508 3)
B30.509 3)
B30.510 2)
B30.512 2)
B30.519 3)
1/2“
1/2“
25
550
3/8“
16
3)
ns
en
DN
Connection for
H2
[mm]
B30.501 2)
Co
Connection for
H 1 5)
B30.522
16
2)
B30.523
2)7)
B30.525
16
2)
B30.527
40
2)
B30.528
16
3)
B30.529
25
100
125
1/2“
1/2“
40
16
16
16
16
16
3)
B30.531 2)



The scope of delivery is defined in the order confirmation.
References and defaults to Requirements for the boiler installation room see technical information TI024.
Dimensions with ± 1 % tolerance; transport weight indication with ± 4 % tolerance and operating weight indication with ± 2 %
tolerance
 The indicated transport weight already includes the surcharges for normal sheet metal thickness tolerances, hence difference
downwards is possible.
 Dimensioning insertion opening:

Positioning height: addition of at least 100 mm to dimension H1 resp. dimension H2
(mounted / not mounted fittings)

Positioning width: addition of at least 200 mm to dimension B1 resp. dimension B2
(mounted / not mounted fittings)
1)
Maximum weight incl. 100 % filled with water
2)
Nominal diameter for flanges in accordance with DIN 2633 / 2634 / 2635 or EN 1092-1/-2 / DN65PN16 with 4 holes
3)
Pipe thread according to DIN 2999
4)
If 3 pressure safeguard valves are necessary, the 3rd fitting will be symmetrically arranged between 1 and 2.
5)
Smallest transport dimensions once fittings have been removed
6)
With tank type FT-C 50, 3 saddle feet must be taken into account. Arrangement dimension L2/2.
7)
If several negative pressure safeguard valves are required, then these are arranged at the tank apex.
Note! The container may be fitted with extra feed connections. The connections are not shown on this data sheet. For the number of
feed connections, see description of scope of delivery in the order confirmation!
Subject to change
Page 2 of 2
EPA Export 11-01-2017:02:34:52
Individual dimensions
Trickling dearator module DM
Design: trickle deaeration device
DA015
Project number: 170862/1.50
Offer No.: 1168994115-50
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
Printing date: 14.04.2015
Explanation of symbols
Lifting equipment to be fastened here, only
Non-return valve
B30.059
B30.064
B30.130
Type
DM 20
H1
[mm]
1900




1)
2)
3)
ns
en
Non-return valve
B30.035
B30.131
Shut-off valve (throttle cone)
B30.503
Connection for vapours
insulation Feed water tank
B30.512
Connection for deaeration device
Lifting lug
B30.562
Connection for oxygenic, unpressurized condensate
Control valve (magnetic)
B30.563
Connection for make-up water
Co
B30.034
Warning: hot surface, e. g. uninsulated fitting
Transportation weight
[kg]
330
Dimension(s)
H2
H3
D
[mm]
[mm]
[mm]
385
240
1000
Trickling dearator module DM
Operating weight
[kg]
325
Connection for
d
[mm]
550
DN
PN
[mm]
[bar/120°C]
Maximum weight 1)
[kg]
1142
B30.503 2)
B30.562 2)
B30.563 3)
32
10
40
40
25
16
The scope of delivery is defined in the order confirmation.
References and defaults to Requirements for the boiler installation room see technical information TI024.
Dimensions with ± 1 % tolerance; transport weight indication with ± 4 % tolerance and operating weight indication with ± 2 %
tolerance
The indicated transport weight already includes the surcharges for normal sheet metal thickness tolerances, hence difference
downwards is possible.
Maximum weight incl. 100 % filled with water
Nominal diameter for flanges in accordance with DIN 2633 / 2634 / 2635 or EN 1092-1/-2 / DN65PN16 with 4 holes
Pipe thread according to DIN 2999
Subject to change
Page 1 of 1
EPA Export 11-01-2017:02:34:52
Piping diagram
Complete deaeration of feed water
Designed as a trickle deaeration device
DA395
Project number: 170862/1.50
Offer No.: 1168994115-50
Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.
Printing date: 14.04.2015
Position
B30.000
B30.020
B30.021
B30.023
B30.024
B30.025
B30.026
B30.027
B30.029
B30.030
B30.031
B30.032
B30.033
B30.034
Designation
Feed water tank
Level controller
pressure regulator
Negative pressure safeguard valve
Drain shut-off valve (magnetic)
Pressure safeguard valve
Heating-up adjustment valve (motorized)
Filter valve option
vapours drain-off fitting
Control valve
Shut-off valve (throttle cone)
Shut-off valve option
Shut-off valve (throttle cone) option
Non-return valve
Position
B30.035
B30.036
B30.037
B30.038
B30.041
B30.043
B30.044
B30.053
B30.054
B30.058
B30.060
B30.068
B30.069
B30.125
Designation
Non-return valve option
Non-return valve
Chemicals non-return valve option
Chemicals non-return valve option
Drain shut-off valve
temperature indicator option
Level indicator option
Pressure indicator option
temperature indicator option
Overflow valve option
trickle deaeration device
Filter valve option
Shut-off valve option
Pressure safeguard valve option
Subject to change
Page 1 of 2
EPA Export 11-01-2017:02:34:52
Piping diagram
Complete deaeration of feed water
Designed as a trickle deaeration device
DA395
Project number: 170862/1.50
Offer No.: 1168994115-50
Printing date: 14.04.2015
Position
Piping
Position
Piping
30.002
Pressure safeguard drainage line
30.011
Overflow steam pipe
30.003
Pressure safeguard blowoff line
30.020
Water sample extraction pipe
30.004
Drain pipe
30.102
Pressure safeguard drainage line
30.005
Vapour line
30.103
Pressure safeguard blowoff line
30.006
line oxygenic, unpressurized condensate
40.001
feed pump bypass line
30.007
line oxygen-free, directly returning condensate
41.001
Make-up water pipe
41.003
Chemicals dosing line
30.008
Heating-up steam line
41.004
Chemicals dosing line
30.010
Feed water suction piping
ns
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f c Fo
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References and defaults to Requirements for the boiler installation room see technical information TI024.
The scope of delivery is defined in the order confirmation.
Two-stage level regulator is also possible.
Co



Subject to change
Page 2 of 2
EPA Export 11-01-2017:02:34:52
Main dimensions
Water service module WSM-V
Design: trickle deaeration device
DA008
Project number: 170862/1.50
Offer No.: 1168994115-50
Explanation of symbols
Warning: dangerous
voltage
electrical
to
f c Fo
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Printing date: 14.04.2015
Lifting equipment to be fastened
here, only
Pressure safeguard blowoff line
Pressure safeguard drainage line
Control panel
Chemicals dosing plant option
Feed water tank
support structure
Level controller
Negative pressure safeguard valve
Pressure safeguard valve
Heating-up adjustment valve (motorized)
Control valve for make-up water (magnetic)
B30.510
B30.527
B30.528
B30.562
B30.563
B34.000
B34.006
B34.007
B34.012
B34.100
B34.101
B30.031
B30.060
Shut-off valve for make-up water (throttle cone)
trickle deaeration device
B34.102
B34.103
B30.501
B30.503
B30.504
B30.506
Connection for extraction
Connection for vapours
Connection for Heating-up steam
Connection
for
oxygen-free,
condensate
Connection
for
oxygen-free,
condensate
Connection for Chemical dosing
B30.507
B30.508
e.
g.
directly
B34.104
B34.105
D05.001
returning D06.002
Connection for Pump idling
Connection for Pressure safeguard blowoff line
Connection for Overflow valve option
Connection for oxygenic, unpressurized condensate
Connection for make-up water
Blow-down, expansion and cooling tank option
Shut-off valve for Cooling water (throttle cone) option
Control valve for Cooling water (magnetic) option
Inspection opening water side option
Connection for venting option
Connection for Blow-down water over ambient
pressure at saturation temperature option
Connection for Drain to canal option
Connection for Blow-down water below ambient
pressure at saturation temperature option
Connection for Draining
Connection for Cooling water option
Inspection openings steam and water side
Lifting lug
directly
returning W69.000
Water sample cooling device
Co
ns
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08.001
08.002
51.000
A49.000
B30.000
B30.013
B30.020
B30.023
B30.025
B30.026
B30.030
Warning: hot surface,
uninsulated fitting
W69.501
Connection for Boiler water sample
Subject to change
Page 1 of 2
EPA Export 11-01-2017:02:34:52
Main dimensions
Water service module WSM-V
Design: trickle deaeration device
DA008
Project number: 170862/1.50
Offer No.: 1168994115-50
Printing date: 14.04.2015
Water service module Transportation weight Operating weight Maximum weight 1) Connected load (electrical)
Dimension(s)
L1
B1
H1
Type
[kg]
[kg]
[kg]
[kW]
[mm] [mm] [mm]
WSM-V 18.0
3158
10634
14451
0,75
2088 4598
Dimension(s)
L4
B8
B9
H2
H3
[mm]
[mm]
[mm]
[mm]
[mm]
1066
238
3720
2624
Bearing area
L2
L3
B2
B3
B4
B5
Surface area
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[cm²]
4717
1325
7547
1)
ns
en

The scope of delivery is defined in the order confirmation.
References and defaults to Requirements for the boiler installation room see technical information TI024.
Missing dimensions are not contained in scope of delivery.
Dimensions with ± 1 % tolerance; transport weight indication with ± 4 % tolerance and operating weight indication with ± 2 %
tolerance
The indicated transport weight already includes the surcharges for normal sheet metal thickness tolerances, hence difference
downwards is possible.
Maximum weight incl. 100 % filled with water
Co
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80
Subject to change
Page 2 of 2
EPA Export 11-01-2017:02:34:52
EPA Export 11-01-2017:02:34:52
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Thermotechnology
Page 4 of Offer number 1168994115-50 to Bosch Thermotechnology Ltd., Worcester
14.04.2015
Technical data
Description
Attribute
General Data
Unit
Value
Country of destination
Location
Assembly and operating conditions
ot
he
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.
m
°C
°C
V
%
Hz
%
kW
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Erection altitude max. about sea level
Ambient temperature min.
Ambient temperature max.
Voltage
Voltage fluctuations max. +/Neutral conductor
Earth connection
Frequency
Max. frequency fluctuations (+/-)
Direct switching up to
Ireland
indoors
free of frost, dust as well as
dripping water
100
20
40
400
5
yes
yes
50
1
5,5
Co
Position
EPA Export 11-01-2017:02:34:52
Thermotechnology
Page 5 of Offer number 1168994115-50 to Bosch Thermotechnology Ltd., Worcester
Position
14.04.2015
Description
Attribute
01
Unit
Value
Steam boiler plant
Medium
Direct, electrical conductivity in the feed water
Water quality
01.01.01
Boiler type
Steam capacity (nominal load)
Max. design pressure
Trip pressure safety valve
Mean working gauge pressure
Trip pressure safety pressure limiter
Cold water test pressure
Nominal heating area
Feed water temperature
Operation side
Category (DGRL)
Boiler and equipment
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01.01
Fuel
Fuel standard
Net calorific value (rated to 0 °C / 1013 mbar) (gas)
kWh/Nm³
Gas flow pressure on gas regulation module inlet
mbar
All details ref. to the O2-contents in the dry smoke gas %
of
UNIVERSAL UL-S
Saturated steam
containing salt > 30 µS/cm
acc. to Operating Manual
"Directive water condition"
B002
Gas / Natural Gas H
DVGW G260
10,35
100
2,1
kg/h
bar
bar
bar
bar
bar
m²
°C
Nominal diameter flue gas connection (DIN24151,
DIN24154)
Water content up to low-water
Steam capacity from and at 212 °F
Gross thermal capacity (nominal load)
Efficiency gas
calculation of efficiency (gas)
DN
Total burner capacity (gas)
Norm volume flow fuel (gas)
Radiation loss gas (TI 005/01)
Norm volume flow moist smoke gas (gas)
Mass flow moist smoke gas (gas)
kW
m³/h
%
m³/h
kg/h
l
kg/h
kW
%
7000
7500
13,0
13,0
10,0
12,4
24,7
150,0
103
right-hand side
IV
500
9140
7797
4890
94,9
acc. to EN 12953 part 11 indirect method
5154
498
0,36
5926
7358
EPA Export 11-01-2017:02:34:52
Thermotechnology
Page 6 of Offer number 1168994115-50 to Bosch Thermotechnology Ltd., Worcester
Description
Attribute
Unit
Flue gas loss approx. (acc. to prEN 12953 Part 11)
(gas)
Flue gas temperature approx. (gas)
Furnace volume load (gas)
Heating surface on burner side
Total resistance on heating gas side of boiler in
operation with gas (based on altitude)
Total resistance on heating gas side includes
Maximum permissible local flue gas pressure at the
limit of supply
Minimum permissible local flue gas pressure at the
limit of supply
Total sound pressure level caused by flue gas noises
from the boiler at the chimney top (see TI032)
Transportation weight boiler body approx.
Total weight boiler body (full) approx. +/- 2%
Material of insulation cladding
Insulation thickness min.
Thickness of insulation cladding
Mounting place terminal box
%
°C
MW/m³
m²
mbar
Value
4,8
134
1,5
146,2
12,4
mbar
-1,0
.
mbar
Boiler with Eco
0,0
se
db(A)
87,0
to
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Position
14.04.2015
kg
kg
mm
mm
Flue gas heat exchanger ECO 1
bar
01.01.03
Cold water test pressure
Outlet direction of flue gas connection
Thermal capacity of economizer in operation with gas
Flue gas temperature approx. (gas)
Heating surface ECO
Water throughput (gas)
Water outlet temperature (gas)
Resistance on water side
Insulation thickness min.
Boiler control panel
Extra space in the boiler control panel
Protection type
Width control panel
Height control panel
Depth control panel
Surface
Control panel design
%
Co
ns
en
01.01.02
kW
°C
m²
kg/h
°C
mbar
mm
mm
mm
mm
16935
29088
ALU Stucco
100
0,6
Boiler front - top left (10
o'clock position)
56,0
to top
273
134
108
7500
134
83
100
20
IP54
800
1800
400
grey
Standing control panel
EPA Export 11-01-2017:02:34:52
Thermotechnology
Page 7 of Offer number 1168994115-50 to Bosch Thermotechnology Ltd., Worcester
Position
Description
Attribute
Unit
Base height
Installed load
Display size Touch Panel
Cable harness feeder at the boiler (o´clock)
Cable harness length
Total weight control panel
Firing equipment
mm
kW
Guaranteed NOx-Emission (gas)
Emission evaluation according to
emissions
mg/Nm³
m
kg
mbar
m³/h
DN
mbar
right-hand side
100
497
100
600
m³/h
m³/h
QA 400/100
32,0
650,0
se
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01.01.06
Assembly side of gas fitting
Gas flow pressure at inlet of gas regulation module
Max. possible standard volume flow
Nominal diameter gas shut-off valve
Max. permissible gas flow pressure of the gas
regulation module (safeguarding pressure of gas
transfer station)
Gas meter module GMM
Co
01.01.05
Turn down ratio burner (gas)
Rated capacity engine(s) (electrical)
Weight burner
Sound pressure level burner without sound insulation
Separate medium for ignition
Sound pressure level burner (with sound insulation)
Gas regulation module GRM
Type gas consumption meter
Measurement range Q min. (operating m³/h)
Measurement range Q max. (operating m³/h)
100
28,05
9"
12
10,0
200,0
db(A)
°C
ns
en
Temperature of aspirated air
Burner brand
Type of control (gas)
Assembly side of gas fitting
Type of burner
Type designation burner
Value
100
EN 267/676
Basis for NOx: NO2 based
on 3% O2 in dry flue gas;
measurement tolerance
and reference conditions in
acc. with EN 676
25,0
Dreizler
Continuous modulating
right-hand side
monobloc
M 5001.4 VM18,5
HIGHTECH ARZ
8,0
18,5
650
90
not required
75
.
01.01.04
14.04.2015
kW
kg
db(A)
EPA Export 11-01-2017:02:34:52
Thermotechnology
Page 8 of Offer number 1168994115-50 to Bosch Thermotechnology Ltd., Worcester
Position
01.01.07
14.04.2015
Description
Attribute
Unit
Operating/transport weight gas meter module +/- 4%
Pump module PM
kg
Min. required positive suction head
Type of control feed pump
mm
01.01.07.01
Pump module
01.01.08
Pump manufacturer
Type designation feed pump
Rated capacity engine(s) (electrical)
Dispatch weight pump module +/- 4%
Operating weight pump module +/- 2%
Feed water regulation module RM
01.02
Type of regulation valve
Total length regulation module
mm
Dispatch weight feed water regulation module +/- 4% kg
Operating weight feed water regulation module +/- 2% kg
UNIVERSAL UL-S
01.02.01
refer to item 01.01
Boiler and equipment
01.02.02
refer to item 01.01.01
Flue gas heat exchanger ECO 1
01.02.03
refer to item 01.01.02
Boiler control panel
01.02.04
refer to item 01.01.03
Firing equipment
01.02.05
refer to item 01.01.04
Gas regulation module GRM
01.02.06
refer to item 01.01.05
Gas meter module GMM
01.02.07
refer to item 01.01.06
Pump module PM
01.02.07.01
refer to item 01.01.07
Pump module
01.02.08
refer to item 01.01.07.01
Feed water regulation module RM
01.03
refer to item 01.01.08
Water service module WSM-V
36,53
991
Continuous with regulation
module
Grundfos
CR 10-18 XK
7,5
252
269
RMZ
1.440,0
83
87
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kW
kg
kg
Value
EPA Export 11-01-2017:02:34:52
Thermotechnology
Page 9 of Offer number 1168994115-50 to Bosch Thermotechnology Ltd., Worcester
Description
Attribute
Unit
Supply steam pressure
Steam supply line safeguarded at
Design temperature (deaeration)
Safety valve trigger pressure feed water tank
Deaeration capacity
Max. O2-content
Tank material
Material of insulation cladding
Mean working gauge pressure
Cold water test pressure
Water content (in operation)
Insulation thickness
Type designation deaeration
Connected power - control panel of feed water
treatment
Protection type
Width control panel
Height control panel
Depth control panel
Surface
Mass flow of oxygen-free condensate (average flow)
Mass flow of oxygen-free condensate (minimum flow)
Temperature of oxygen-free condensate
Pressure of oxygen-free condensate
Mass flow of oxygenic condensate (average flow)
Mass flow of oxygenic condensate (minimum flow)
Temperature of oxygenic condensate
Pressure of oxygenic condensate
Mass flow heating-up steam
Mass flow vapour steam
Mass flow make-up water
Make-up water temperature min.
Min. required make-up water pressure
Maximum supply pressure for make-up water
Type WSM
Type of deaerator
Tank size (total volume)
Content feed water tank
bar
bar
°C
bar
kg/h
mg/l
ru
se
.
bar
bar
l
mm
he
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en
Co
Position
14.04.2015
kW
mm
mm
mm
kg/h
kg/h
°C
bar
kg/h
kg/h
°C
bar
kg/h
kg/h
kg/h
°C
bar
bar
l
l
Value
10,0
13,0
103
0,5
14127
0,02
steel (St.37)
ALU Stucco
0,2
2,0
7000
100,0
DM 20
0,8
IP54
500
500
210
grey
900
0
174
9,5
7500
0
90
1,0
1256
70,0
6627
10
1,0
10,0
WSM-V 18.0
Cascade deaerator
10000
10.000,0
EPA Export 11-01-2017:02:34:52
Thermotechnology
Page 10 of Offer number 1168994115-50 to Bosch Thermotechnology Ltd., Worcester
Position
14.04.2015
Description
Attribute
Steuerschranktyp (LWC)
Dispatch weight WSM
Operating weight WSM +/- 2%
Maximum weight WSM +/- 2%
Connection of control to control system at site
kg
kg
kg
AE 1050
3158
10634
14451
Modbus RTU
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Type of data transfer
Value
Co
01.04
Unit
EPA Export 11-01-2017:02:34:52
Thermotechnology
Page 11 of Offer number 1168994115-50 to Bosch Thermotechnology Ltd., Worcester
14.04.2015
Delivery scope description
Steam boiler plant
01.01
UNIVERSAL UL-S
for the generation of saturated steam.
Suitable for the combustion of fuels acc. to data sheet.
For technical data, please refer to the attached technical data sheets, for further
information to the current leaflets and specification sheets.
01.01.01
Boiler pressure vessel, consisting of the cylindrical boiler shell, the front and rear boiler
end, the asymmetrical flame tube located on the right-hand side which connects the boiler
ends, the internal water-cooled reversing chamber, the smoke tubes of the 2nd and 3rd
pass, the steam drying device and the connection sockets for steam extraction, pressure
safeguard, feeding, pressure measurement, water level gauge and drain, protective tube
for feed water pump control and limiter probes, inspection openings for the furnace on the
rear wall, revision openings on water and steam side, two transportation lugs and one
boiler rating plate.
Testing during manufacture:
The welding quality is monitored by means of X-ray- and ultrasonic testing. All pressurized
parts are welded and undergo an increased hydrostatic pressure test after manufacture.
The inspection facilities guarantee an optimum, cost-effective revision of the boiler. Due to
the good revision possibilities as well as the monitored production process, it is possible in coordination with local and/or national legal requirements - to achieve maximum
intervals between repeated inspection.
Mountings:
Front reversing chamber, easily accessible, for cleaning and inspection purposes on flue
gas side.
Door swivels open to the left-hand side, inner surface lined with high-quality thermal
insulation.
Flue Gas Chamber with flue gas condensate socket and inspection opening on flue gas
side, prepared for installation of the economizer.
Boiler Base Frame, sturdy profile steel construction, for even distribution of load and easy
transportation, suitable for the placement of sound absorbing pads. The boiler body is
positioned on the base frame by supports, if required with front sliding bearing.
1 Drilled Burner Plate(s), suitable for the burner
1 Refractory Lining(s), suitable for the burner
Corrosion protection paint of those Built-on accessories which are not covered by the
insulation. 2 coats of paint with one component lead- and chromate-free paint based on
modified polymer dispersions. The portion of organic solvents is below 5 weight percent.
Hoisting jacks (4 pieces), welded to the boiler supports, suitable for applying lifting
equipment (e.g. lifting cylinder, jacks). The boiler can be conveniently lifted by means of
the hoisting jacks during bringing in, placement and leveling of the boiler, e.g. in order to
Co
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01
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Thermotechnology
Page 12 of Offer number 1168994115-50 to Bosch Thermotechnology Ltd., Worcester
14.04.2015
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slide transport devices below the boiler supports or to remove the same.
1 Flame sight hole(s) for viewing of the flame, with sight glass clear Ø 32 mm, protective
cover, connection for cooling air and measurement.
Acceptance of the pressure vessel:
Acceptance at the workshop acc. to the European Pressure Equipment Directive PED
(97/23EC).
CE-Marking of the Pressure Vessel:
acc. to the European Pressure Equipment Directive PED (97/23EC).
Equipment boiler:
Pressure gauge manostat pipe with 3 connections G 1/2 inch A, acc. to ISO 228/1.
1 Set of Operation and Instruction Labels
Insulation of boiler shell and boiler ends with mineral wool mats and protective cladding of
structured aluminium.
Platform (with grating) for maintenance of the fittings arranged on top of the boiler.
Max. admissible surface load for accessible surfaces: 300 kg/m²
Width of Platform: 600 mm
Safety railing for platform
Equipment Boiler
Steam extraction valve, consisting of:
- shut-off valve, maintenance-free with bellow seal DN125 PN25
Mounting form: globe valve
1 x Pressure safeguard, each consisting of:
- full-stroke corner safety valve, type-accepted, DN 50 PN 40
- 3.1.B certificate for safety valve
Feed water shut-off valve consisting of:
- shut-off valve, maintenance-free with bellow seal DN40 PN40
Mounting form: globe valve
Feed water non-return valve, consisting of:
- disc non-return valve DN40 PN40
Drain shut-off valve consisting of:
- shut-off valve, maintenance-free with bellow seal DN40 PN40
Mounting form: globe valve
1 x Direct Water Level Indicator, each consisting of
- reflexion water level gauge, lockable
- Water level-blow-off tap
1 x Direct Water Level Indicator, each consisting of
- reflexion water level gauge, lockable
- Water level-blow-off tap
Pressure gauge-manostat pipe shut-off valve , consisting of:
- shut-off valve, maintenance-free with bellow seal DN20 PN25
Mounting form: globe valve
Pressure gauge device, consisting of:
EPA Export 11-01-2017:02:34:52
Thermotechnology
Page 13 of Offer number 1168994115-50 to Bosch Thermotechnology Ltd., Worcester
14.04.2015
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.
- Pressure gauge
- Pressure gauge shut-off valve
1 xSafety pressure limiting device max., consisting of:
- safety pressure limiter, CE examined
for merging into the safety chain
Combined feed water level control and limiter probe for steam boilers
equipped and certified acc. to EN 12953 Part 6, suitable for operation without permanent
supervision (BosB) for max. 72 h, consisting of:
Level control incl. electronic max. water level safeguard, consisting of:
- level transmitter (signal output 4-20mA)
- electric switching unit for feed pump control. Incorporation of the electronic switching
device into the control panel if control panel is delivered by us.
The electronic device is designed for installation into a control panel with protection class
IP54.
Low water level limiter, self-monitoring, CE-/TÜV-tested, electronic, for the limitation of
min. water level consisting of:
- limiter probe with permanent isolation supervision
- electronic switching unit to switch off burner and alarm notification. Installed in control
panel if control panel is in our scope of delivery. The electronic system is designed for
installation in a control panel with protection level IP54.
- limiter probe with permanent isolation supervision
- electronic switching unit to switch off burner and alarm notification. Installed in control
panel if control panel is in our scope of delivery. The electronic system is designed for
installation in a control panel with protection level IP54.
Separate Highest Water Level Safeguard electronic, as overfill protection for boiler water
conductivity at 25 °C = 10 µS/cm
- level transmitter
Amplifier unit for the highest water level safeguard for switching-off the boiler feed pump
and alarm signal. The electronic is designed for installation into a control panel with
protection class IP 54. Assembly into boiler control panel, if control panel is not delivered
by us.
Function
This control and limiter combination controls the water level in the boiler by means of
switching the feed pump on and off resp. by control of the feed water supply flow. Once
the highest water level is being exceeded, the feed pump is switched off. Once the lowest
permissible water level has been reached, the burner will be switched off and locked
reliably.
Workshop Assembly of the electronic switching devices into the control panel if control
panel is delivered by the contractor.
Automatic Desalting Device, consisting of:
Conductivity Measuring Device for boiler water, consisting of:
- conductivity measuring transducer with temperature compensation
(signal output 4-20 mA)
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Conductivity Control Device for boiler water, consisting of:
1 Desalting shut-off device, designed as:
- shut-off valve, maintenance-free with bellow seal DN25 PN25
Mounting form: corner valve
- desalting control valve with electric servo-drive, DN25 PN40
- Conductivity tester (manual device) for control of the water conductivity,
battery-operated, with digital display.
Application
The desalting device serves for avoiding boiler breakdowns caused by high coagulation of
the boiler water as well as for avoiding boiler damages due to excess salt concentration in
the boiler. The demand-driven drain of a portion of the boiler water minimizes the purging
rate, thus saving considerable amounts of feed water, energy and chemicals. Depending
on the fresh water consumption, the blow-down periods can be reduced and the
blow-down breaks extended.
Function
In the BCO, the boiler water conductivity which fluctuates due to thickening of the boiler
water is controlled automatically. If the conductivity exceeds a preset value, the desalting
valve opens and drains saline boiler water. A further increase of the conductivity is
recorded in the operating log . If a max. admissible limit value is reached, a fault shutdown
of the burner will take place and is recorded. In case of falling short of a minimum value
resp. in case of a burner fault shut-down, the desalting valve will close.
Automatic Blow Down Device for time dependant control of the blow down valve
control medium: compressed air/water
Pressure control medium: 4,5 - 8 bar (resp. depending on the boiler design gauge
pressure)
consisting of:
- self-closing quick shut-off blow-down valve DN40 PN40
- diaphragm drive for the blow-down valve
- BCO-software-module with digital time display and outputs for the control of the blow
down valve
- Three-way pilot valve for compressed air/water
Application
If large quantities of fresh water are fed in, there is increased precipitation of suspended
matter in the boiler because of the addition of chemicals. The suspended matter builds up
at the base of the boiler and must be blown down at regular intervals.
Function
The BCO software module with adjustable pulse and pause times controls the pilot valve
which, using compressed air, activates the membrane drive of the quick shut-off
blow-down valve.
Terminal Box
Protection class IP54, of steel sheet, powder-coating grey/structure, galvanized assembly
plate, cable entry from below. Control design in accordance with DIN-/EN-standards.
Connection of the control devices and the control panel via terminal strips in the terminal
box. Terminal box is function-tested, 1 set of wiring diagrams inside the terminal box.
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Advantages
Reading of the instruments and operating of the plant is facilitated by individual mounting
or installation of the boiler control panel. Easy and mix-up proof connection to the terminal
box by means of individually customized, coded and marked cable bundles with plug
connections on both sides.
Workshop assembly of manometer manostat pipe, terminal box and sensor technology at
the boiler (as far as inclueded in scope of delivery).
Documentation, consisting of:
Operating manual
Operating manual acc. to European regulations for the scope of delivery.
Quantity: 1
Language: English
Design: print-out
Deadline: with delivery
Additional set of documents:
Quantity: 1
Language: English
Design: CD-ROM
Deadline: with delivery
Operation log
Operation log acc. to European regulations for the scope of delivery.
Quantity: 1
Language: English
Deadline: with delivery
Additional set of documents:
Quantity:
1
Language:
English
Deadline:
with delivery
Acceptance documentation
Acceptance documentation in accordance with European directives as far as required for
the supply of the boiler plant, respectively for the part concerning the delivery scope,
however without assembly drawing and PI-diagram.
Quantity: 1
Language: English
Deadline: 2 weeks after delivery date
Additional set of documents:
Quantity:
1
Language:
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English
Deadline:
2 weeks after delivery date
Shrink-Wrapping for Transportation
All weather-sensitive parts shrink-wrapped or packed in plastic wrapping. Loose parts - if
necessary - to be packed in cases, cartons or other suitable type of packing. Disposal of
packing material at site.
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Flue gas heat exchanger ECO 1 - integrated
for saving energy and reducing CO2 by reduction of the flue gas temperature by means of
feed water.
Design acc. to European Pressure Equipment Directive PED (97/23 EC), suitable for
high-pressure steam boilers.
Heat Exchanger , welded design, for installation onto the rear flue gas chamber, with
connection for water inlet, water outlet and drainage incl. inspection opening on flue gas
side.
Highly efficient heat transfer based on the counterflow principle.
Heat exchanger tubes with fully welded fins for optimizing the heat transfer.
The heat exchanger casing consists of a sturdy welded construction of steel sheet. It is
stiffened against flue gas vibrations and pressure-tight.
Function
In the flue gas heat exchanger, heat is retrieved from the (warmer) boiler flue gas, in
which (cooler) feed water flows through the heat exchanger tubes and the temperature of
the flue gas is reduced. The energy gained in this way gives a higher boiler efficiency and
therefore lower fuel consumption and lower emissions of air pollutants such as carbon
dioxide or nitrogen oxide.
Equipment Heat Exchanger
Venting valve, designed as:
- shut-off valve, maintenance-free with bellow seal DN20 PN40
Mounting form: globe valve
Drain valve, designed as:
- shut-off valve, maintenance-free with bellow seal DN20 PN40
Mounting form: globe valve
Temperature indicator for water outlet, designed as:
- Thermometer, display area 0,0°C to 250,0°C.
Shut-off device on water side, consisting of:
- shut-off valve, maintenance-free with bellow seal DN40 PN40
Mounting form: globe valve
Shut-off device on water side, consisting of:
- shut-off valve, maintenance-free with bellow seal DN40 PN40
Mounting form: globe valve
Pressure safeguard, before ECO designed as:
- full-stroke corner safety valve, type-accepted, DN 20 PN 40
Co
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- 3.1.B certificate for safety valve
Pressure gauge device, on inlet consisting of:
- Pressure gauge
- Pressure gauge shut-off valve
Bypass on water side with fittings, consisting of:
- shut-off valve, maintenance-free with bellow seal DN40 PN40
Mounting form: globe valve
Flue gas temperature display device
for display of the flue gas temperature upstream of the Flue gas heat exchanger in the
display and operating unit of the boiler control BCO, consisting of:
- Temperature transducer for proportional provision of signal 0/4-20 mA
Insulation of the flue gas heat exchanger, the flue gas chamber and the flue gas
exchanger housing with mineral wool mats - 100 mm thick - and protective cladding of
structured aluminium.
Insulation of the connection line on water side between the heat exchanger and the boiler
without fittings and flanges.
Connection line for connecting the feed water nozzle on the boiler to the connection for
the water outlet on the heat exchanger.
Piping for a closable heat exchanger design.
The acceptance procedure for the lines is carried out at the factory in accordance with
European Pressure Equipment Directive 97/23/EC (PED).
Flue gas connection socket DN 500 with counterflange, packing, nuts and bolts, welded
into the flue gas collection chamber.
Assembly of all afore-mentioned components at the factory. Dismantling of those parts
which have to be delivered separately for transport reasons.
Boiler Control Panel for Boiler control BCO
Enclosure type IP 54, made of steel sheet, powdercoated grey structure, galvanized
mounting plate, cable ducting from below. The switching and control devices are
assembled on a mounting plate and inside the control panel door. Wiring in the control
panel is executed by means of flexible cables in sufficiently dimensioned cable ducts. The
control devices are designed in accordance with DIN-/EN- standards. The control devices
are connected on terminal strips inside the control panel. The control panel is
function-tested, 1 set of wiring diagrams is provided inside the panel.
The marking of the electrical operating equipment in the wiring diagrams is made in
accordance with DIN EN 81346- 2.
Assemblies:
- Main switch with locking device
Additional connections (potentially coupled) provided for:
- emergency cut-out
- external alarm buzzer
- contact of the feed water pump contactor for the control of a dosing pump (combination
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product or oxygen scavenger)
- Automation device BCO with touch-sensitive touchscreen colour display
Industrially proven hardware from the range of stored-program controls are applied in the
Boiler Control BCO. The complete control software is stored on a memory card provided
with the device. A graphic TFT-display with touch-sensitive interface serves as display and
operating unit. Operating signals and process value archive are stored on a multi-media
card included in the delivery scope.
Basic functions:
- Load control
- Niveauregelung
- Low load control
- Boiler operation hours meter
- Burner operation hours meter
- Registration of number of burner starts
- Clear text display of operation and fault signals, signal history on 500 signals with time
recording (Coming, Going, Acknowledging) and all relevant operation data at the time
- Intuitive, menu-driven operation by means of the touch-sensitive graphic display
- Display of all operation-relevant measured values and conditions
MODBUS RTU Connection, consisting of
1 communication processor with link-up possibility to a superior plant control (not in scope
of supply) via a 9-pin SUB-D-connector, configurated as MODBUS-RTU-Slave, with
RS485 and RS232 interface.
Condition Monitoring basic
CMbasic is an analysis and evaluation system integrated in the BCO boiler control. It
gathers, analyses and evaluates system operating statistics and parameters, consumption
values, and measurements, and uses a traffic light-style display to clearly show the
results. It detects, evaluates and notifies the user, in good time, of increased wear or
uneconomical operation of the boiler system.
Scope of delivery:
Temperature-recording device at boiler outlet on flue gas side
Software module integrated in boiler control
Scope of functions
-Displays operating hours; frequency of starts; cold starts as a function of time
-Detects unfavourable start-up conditions
-Detects contamination on water and flue gas side
-Detects unwanted condensation
-Generates service notifications
-Displays boiler load profiles as a function of time
-In steam boilers where the fittings are controlled electrically, highlights energy losses
from blow-down and desalting
-Displays measurements as actual values at time of delivery and as a function of time
-Displays volume measurements (if available in BCO) at time of delivery, with additional
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reset function
Intended use
CMbasic gives customers the option of monitoring the efficiency and correct
operation of their system. In this way CMbasic makes a positive contribution to
system availability and to ensuring consistently high system efficiency.
Heating device HD via burner - pressure-controlled - acc. to Fig. 2 of TI 019, consisting of:
1 software program module with timer incorporated in the control panel BCO
Application
To achieve faster availability of the boiler and to avoid corrosion when inactive and from
cold starts, this is kept at a lowered pressure level.
Function
This device can be used to set an additional lower switching pressure for the burner.
Normal operation or heat maintenance operation can be manually selected using a
selection menu in the BCO control panel. The timer can be programmed with switching
times to allow automatic switching between heat maintenance and normal operation. In
heat maintenance operation, the burner's output is limited to low load and the burner
switching frequency is reduced. If there is a controlled steam extraction valve, it is closed
during heat maintenance operation.
Automatic Feed Pump Switch-Over Device
for two feed pumps. In case of release of the motor protecting switch of the operating
pump, the device will automatically switch-over to the auxiliary pump. The required electric
control is part of the delivery scope and completely wired in the control panel.
Wiring diagrams for the scope of delivery.
Quantity: 1
Language: English
Design: print-out
Deadline: with delivery
Additional set of documents:
Quantity:
1
Language:
English
Design:
eMail
Deadline:
with delivery
Additional set of documents:
Quantity:
1
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Gas Burner Fully Automatic, equipped acc. to EN 676 for positive furnace pressure,
consisting of:
1 Burner(s) complete with
- ignition device
- fuel-air-ratio device
- double fuel safety shut-off fittings
Load Control, consisting of:
- transmitter (signal output 4 - 20 mA)
Combustion air fan, mounted on burner, with motor.
Automatic burner control acc. to the valid European standards.
Automatic gas tightness diagnosis device for checking the tightness of the gas safety
shut-off fittings.
Electronic Compound for control of the fuel-air-ratio. The signal from the power control is
used via an electronic switching amplifier for control of the servo drives for air, fuel and where required- for the mixing device in accordance with a preset compound curve.
Burner Management System
Microprocessor-assisted burner control for gas-, oil- or dual fuel burners, incl. flame
supervision for continuous operation acc. to EN 12953
- plain text display of operational and fault messages
- diagnostic memory for 10 fault signals incl. time specification
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Language:
English
Design:
eMail
Deadline:
with delivery
Cable Harness
for quick and error-free cabling between terminal box and boiler-/ plant components with
mix-up proof connection plugs for sensors and actuators up to a max. current of 35 A.
If required, the plug connections allow a quick and uncomplicated exchange of sensors
and actuators.
Cable Bundle
for quick and error-free cabling between terminal box and boiler control panel, with mix-up
proof connector plugs for sensors and actuators up to a max. current of 35 A.
Length of the cable bundle 10,0 m determined from the outlet point boiler at 12 o'clock
position up to control panel inlet.
Connection of the cable harness to the terminal box and to the sensors and actuators. A
function test will be carried out in the workshop.
Connection of cable harness
Cables are prepared and labelled for connecting to the boiler's terminal box.
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- menu-assisted user interface with display of the relevant parameters
- electronic compound regulation system
- operating hours meter per type of fuel
- burner startup counter per type of fuel
The burner management system is CE- as well as type-tested.
Automatic gas tightness diagnosis device for checking the tightness of the gas safety
shut-off fittings.
Speed Control with frequency converter for combustion air fan, consisting of:
- Frequency converter
- Speed controlling
- Switching devices
Application
By means of the speed control, it is possible to optimally operate the combustion air fan in
all operation ranges. High throttling losses at the air flap are avoided, thus the power
consumption is reduced.
The speed control has the following advantages:
- power saving
- noise reduction
- reduced load in the starting current system as direct resp. star-delta switching device.
Pilot Burner for venting and testing of gas valve train ,
complete with press button cock, piping and screwing.
Extension of the burner signaling
Extension of the group fault signal included in the basic equipment by additional equipment
for the transmission of the individual burner signals.
Ancillary conditions for NOx emission confirmations:
Evaluation of emissions acc. to EN 676.
averaging acc. to DIN 4702 T8.
basis for NOx: NO2 related to 3% O2 in the dry flue gas.
Emission values related to standard state.
Cable Harness for quick and error-free cabling between burner and boiler control panel for
sensors and actuators up to a max. current of 35 A.
Length of the cable harness 10,0 m determined from the outlet point boiler at 12 o'clock
position up to control panel inlet.
Silencing Hood for burner, in movable and dismountable design. Outer shell made of
corrosion resistant material, lined with temperature-proof damping material acc. to DIN
4102, faced with punched sheet. Noise reduction to sound pressure level of approx. 75
dB(A).
Delivery separately for assembly at site.
Note: Noise reduction by the attachment of a silencing hood over a burner results
exclusively from the reduction of the mechanical and flowconditioned burner noises.
The burner silencer hood is designed for positioning on the same height with the boiler.
Basic conditions for noise data:
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Determination of the noise takes place 1 m behind the burner. Noise data can only be
indicated as guide value, because the noise development also depends on the local
conditions (e.g. installation situation of the boiler and building design; flue gas routing
downstream of the boiler up to the chimney; etc.). Prerequisite for the verification of a
sound measurement is that the noise level in room is considerably below that of the burner
(min. 10 dB(A)) acc. to DIN 45635.
Workshop assembly of burner, mechanical (assembly to the boiler), including the required
assembly material as well as the assembly and installation engineering.
Dismantling of those parts which have to be delivered separately for transport reasons.
Gas regulation module GRM, consisting of:
Gas regulation module (right-hand side)
- gas pressure controller
- pressure gauge with shut-off device
- gas filter
- shut-off device
- set of connecting parts within the module
Assembly of all afore-mentioned components at the factory. Dismantling of those parts
which have to be delivered separately for transport reasons.
01.01.06
Gas meter module GMM with direct flow display, remote impulse reading possible via
reed contact and inductive transmitter.
- Meter incl. pipe connection pieces
- inlet measuring route
- connection pieces
- Thermometer, display area 0,0°C to 50,0°C.
Incorporation of the Gas meter module into the Gas regulation module.
01.01.07
Pump module PM
01.01.07.01
for continuous control of water flow, consisting of:
Feed pump with three-phase motor, suitable for supply water temperature up to 103 °C.
Designed for the boiler capacity and the boiler pressure indicated in the Technical Data
Sheet for a max. desalting rate of 5,0 % and resistances of 0.5 bar in the pressure line
which is not part of the scope of delivery.
Electric power unit, in star-delta switching, consisting of line and motor protective devices
as well as power contactor.
Fittings on suction side, consisting of:
- 1 butterfly valve(s) with manual actuation, DN100 PN16
- 1 dirt trap for installation upstream of the regulation mountings and pumps, DN100 PN16
Fittings on pressure side, consisting of:
- disc non-return valve DN40 PN40
- shut-off valve, maintenance-free with bellow seal DN40 PN40
Mounting form: globe valve
Pressure gauge on pressure side, consisting of:
- Pressure gauge
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Shrink-Wrapping for Transportation
All weather-sensitive parts shrink-wrapped or packed in plastic wrapping. Loose parts - if
necessary - to be packed in cases, cartons or other suitable type of packing. Disposal of
packing material at site.
Assembly of all afore-mentioned components at the factory. Dismantling of those parts
which have to be delivered separately for transport reasons.
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Feed water regulation module for continuous water flow control, consisting of:
Feed water regulation valve, with built-on electric servo drive, 2 free limit switches and
manual adjusting device. Complete with AC stop motor 230 V, 50 Hz.
Connection cable between feed water regulating module and Boiler control BCO,
connection is via terminals. Cable length between connection points 0,0 m.
Electric power unit, consisting of line and motor protective devices as well as power
contactors.
Function:
By means of the electronic level controller, the feed water flow is regulated via the feed
water control valve and the water level in the boiler is kept almost constant. The feed
water control valve must be installed into the feed water pressure line. The feed water
control valve opens when the water level in the boiler decreases and closes with
increasing water level.
Protective Function:
If correctly adjusted, the feed water control valve prevents operation below the minimum
flow rate which is required for cooling and lubrication of the feed pump.
Co
01.01.08
1 Drain - pump recirculation
- disc non-return valve DN25 PN40
- shut-off valve, maintenance-free with bellow seal DN25 PN40
Mounting form: globe valve
Dirt trap device, designed as:
- 1 dirt trap for installation upstream of the regulation mountings and pumps, DN40 PN40
1 Shut-off valves
- shut-off valve, maintenance-free with bellow seal DN40 PN40
Mounting form: globe valve
1 Shut-off valves
- shut-off valve, maintenance-free with bellow seal DN40 PN40
Mounting form: globe valve
Bypass Fittings , consisting of:
- shut-off valve, maintenance-free with bellow seal DN40 PN40
Mounting form: globe valve
Assembly for Feed water regulation module
with welding ends for easy local assembly close to the feed pump module or the feed
water tank.
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1 connection parts for the module.
Assembly of all afore-mentioned components at the factory. Dismantling of those parts
which have to be delivered separately for transport reasons.
Shrink-Wrapping for Transportation
All weather-sensitive parts shrink-wrapped or packed in plastic wrapping. Loose parts - if
necessary - to be packed in cases, cartons or other suitable type of packing. Disposal of
packing material at site.
refer to item 01.01
01.02.01
Boiler pressure vessel, consisting of the cylindrical boiler shell, the front and rear boiler
end, the asymmetrical flame tube located on the right-hand side which connects the boiler
ends, the internal water-cooled reversing chamber, the smoke tubes of the 2nd and 3rd
pass, the steam drying device and the connection sockets for steam extraction, pressure
safeguard, feeding, pressure measurement, water level gauge and drain, protective tube
for feed water pump control and limiter probes, inspection openings for the furnace on the
rear wall, revision openings on water and steam side, two transportation lugs and one
boiler rating plate.
Testing during manufacture:
The welding quality is monitored by means of X-ray- and ultrasonic testing. All pressurized
parts are welded and undergo an increased hydrostatic pressure test after manufacture.
The inspection facilities guarantee an optimum, cost-effective revision of the boiler. Due to
the good revision possibilities as well as the monitored production process, it is possible in coordination with local and/or national legal requirements - to achieve maximum
intervals between repeated inspection.
Mountings:
Front reversing chamber, easily accessible, for cleaning and inspection purposes on flue
gas side.
Door swivels open to the left-hand side, inner surface lined with high-quality thermal
insulation.
Flue Gas Chamber with flue gas condensate socket and inspection opening on flue gas
side, prepared for installation of the economizer.
Boiler Base Frame, sturdy profile steel construction, for even distribution of load and easy
transportation, suitable for the placement of sound absorbing pads. The boiler body is
positioned on the base frame by supports, if required with front sliding bearing.
1 Drilled Burner Plate(s), suitable for the burner
1 Refractory Lining(s), suitable for the burner
Corrosion protection paint of those Built-on accessories which are not covered by the
insulation. 2 coats of paint with one component lead- and chromate-free paint based on
modified polymer dispersions. The portion of organic solvents is below 5 weight percent.
Hoisting jacks (4 pieces), welded to the boiler supports, suitable for applying lifting
equipment (e.g. lifting cylinder, jacks). The boiler can be conveniently lifted by means of
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the hoisting jacks during bringing in, placement and leveling of the boiler, e.g. in order to
slide transport devices below the boiler supports or to remove the same.
1 Flame sight hole(s) for viewing of the flame, with sight glass clear Ø 32 mm, protective
cover, connection for cooling air and measurement.
Acceptance of the pressure vessel:
Acceptance at the workshop acc. to the European Pressure Equipment Directive PED
(97/23EC).
CE-Marking of the Pressure Vessel:
acc. to the European Pressure Equipment Directive PED (97/23EC).
Equipment boiler:
Pressure gauge manostat pipe with 3 connections G 1/2 inch A, acc. to ISO 228/1.
1 Set of Operation and Instruction Labels
Insulation of boiler shell and boiler ends with mineral wool mats and protective cladding of
structured aluminium.
Platform (with grating) for maintenance of the fittings arranged on top of the boiler.
Max. admissible surface load for accessible surfaces: 300 kg/m²
Width of Platform: 600 mm
Safety railing for platform
Equipment Boiler
Steam extraction valve, consisting of:
- shut-off valve, maintenance-free with bellow seal DN125 PN25
Mounting form: globe valve
1 x Pressure safeguard, each consisting of:
- full-stroke corner safety valve, type-accepted, DN 50 PN 40
- 3.1.B certificate for safety valve
Feed water shut-off valve consisting of:
- shut-off valve, maintenance-free with bellow seal DN40 PN40
Mounting form: globe valve
Feed water non-return valve, consisting of:
- disc non-return valve DN40 PN40
Drain shut-off valve consisting of:
- shut-off valve, maintenance-free with bellow seal DN40 PN40
Mounting form: globe valve
1 x Direct Water Level Indicator, each consisting of
- reflexion water level gauge, lockable
- Water level-blow-off tap
1 x Direct Water Level Indicator, each consisting of
- reflexion water level gauge, lockable
- Water level-blow-off tap
Pressure gauge-manostat pipe shut-off valve , consisting of:
- shut-off valve, maintenance-free with bellow seal DN20 PN25
Mounting form: globe valve
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Pressure gauge device, consisting of:
- Pressure gauge
- Pressure gauge shut-off valve
1 xSafety pressure limiting device max., consisting of:
- safety pressure limiter, CE examined
for merging into the safety chain
Combined feed water level control and limiter probe for steam boilers
equipped and certified acc. to EN 12953 Part 6, suitable for operation without permanent
supervision (BosB) for max. 72 h, consisting of:
Level control incl. electronic max. water level safeguard, consisting of:
- level transmitter (signal output 4-20mA)
- electric switching unit for feed pump control. Incorporation of the electronic switching
device into the control panel if control panel is delivered by us.
The electronic device is designed for installation into a control panel with protection class
IP54.
Low water level limiter, self-monitoring, CE-/TÜV-tested, electronic, for the limitation of
min. water level consisting of:
- limiter probe with permanent isolation supervision
- electronic switching unit to switch off burner and alarm notification. Installed in control
panel if control panel is in our scope of delivery. The electronic system is designed for
installation in a control panel with protection level IP54.
- limiter probe with permanent isolation supervision
- electronic switching unit to switch off burner and alarm notification. Installed in control
panel if control panel is in our scope of delivery. The electronic system is designed for
installation in a control panel with protection level IP54.
Separate Highest Water Level Safeguard electronic, as overfill protection for boiler water
conductivity at 25 °C = 10 µS/cm
- level transmitter
Amplifier unit for the highest water level safeguard for switching-off the boiler feed pump
and alarm signal. The electronic is designed for installation into a control panel with
protection class IP 54. Assembly into boiler control panel, if control panel is not delivered
by us.
Function
This control and limiter combination controls the water level in the boiler by means of
switching the feed pump on and off resp. by control of the feed water supply flow. Once
the highest water level is being exceeded, the feed pump is switched off. Once the lowest
permissible water level has been reached, the burner will be switched off and locked
reliably.
Workshop Assembly of the electronic switching devices into the control panel if control
panel is delivered by the contractor.
Automatic Desalting Device, consisting of:
Conductivity Measuring Device for boiler water, consisting of:
- conductivity measuring transducer with temperature compensation
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(signal output 4-20 mA)
Conductivity Control Device for boiler water, consisting of:
1 Desalting shut-off device, designed as:
- shut-off valve, maintenance-free with bellow seal DN25 PN25
Mounting form: corner valve
- desalting control valve with electric servo-drive, DN25 PN40
- Conductivity tester (manual device) for control of the water conductivity,
battery-operated, with digital display.
Application
The desalting device serves for avoiding boiler breakdowns caused by high coagulation of
the boiler water as well as for avoiding boiler damages due to excess salt concentration in
the boiler. The demand-driven drain of a portion of the boiler water minimizes the purging
rate, thus saving considerable amounts of feed water, energy and chemicals. Depending
on the fresh water consumption, the blow-down periods can be reduced and the
blow-down breaks extended.
Function
In the BCO, the boiler water conductivity which fluctuates due to thickening of the boiler
water is controlled automatically. If the conductivity exceeds a preset value, the desalting
valve opens and drains saline boiler water. A further increase of the conductivity is
recorded in the operating log . If a max. admissible limit value is reached, a fault shutdown
of the burner will take place and is recorded. In case of falling short of a minimum value
resp. in case of a burner fault shut-down, the desalting valve will close.
Automatic Blow Down Device for time dependant control of the blow down valve
control medium: compressed air/water
Pressure control medium: 4,5 - 8 bar (resp. depending on the boiler design gauge
pressure)
consisting of:
- self-closing quick shut-off blow-down valve DN40 PN40
- diaphragm drive for the blow-down valve
- BCO-software-module with digital time display and outputs for the control of the blow
down valve
- Three-way pilot valve for compressed air/water
Application
If large quantities of fresh water are fed in, there is increased precipitation of suspended
matter in the boiler because of the addition of chemicals. The suspended matter builds up
at the base of the boiler and must be blown down at regular intervals.
Function
The BCO software module with adjustable pulse and pause times controls the pilot valve
which, using compressed air, activates the membrane drive of the quick shut-off
blow-down valve.
Terminal Box
Protection class IP54, of steel sheet, powder-coating grey/structure, galvanized assembly
plate, cable entry from below. Control design in accordance with DIN-/EN-standards.
Connection of the control devices and the control panel via terminal strips in the terminal
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box. Terminal box is function-tested, 1 set of wiring diagrams inside the terminal box.
Advantages
Reading of the instruments and operating of the plant is facilitated by individual mounting
or installation of the boiler control panel. Easy and mix-up proof connection to the terminal
box by means of individually customized, coded and marked cable bundles with plug
connections on both sides.
Workshop assembly of manometer manostat pipe, terminal box and sensor technology at
the boiler (as far as inclueded in scope of delivery).
Documentation, consisting of:
Operation log
Operation log acc. to European regulations for the scope of delivery.
Quantity: 1
Language: English
Deadline: with delivery
Additional set of documents:
Quantity:
1
Language:
English
Deadline:
with delivery
Acceptance documentation
Acceptance documentation in accordance with European directives as far as required for
the supply of the boiler plant, respectively for the part concerning the delivery scope,
however without assembly drawing and PI-diagram.
Quantity: 1
Language: English
Deadline: 2 weeks after delivery date
Additional set of documents:
Quantity:
1
Language:
English
Deadline:
2 weeks after delivery date
Shrink-Wrapping for Transportation
All weather-sensitive parts shrink-wrapped or packed in plastic wrapping. Loose parts - if
necessary - to be packed in cases, cartons or other suitable type of packing. Disposal of
packing material at site.
01.02.02
refer to item 01.01.02
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refer to item 01.01.03
01.02.04
refer to item 01.01.04
01.02.05
refer to item 01.01.05
01.02.06
refer to item 01.01.06
01.02.07
refer to item 01.01.07
01.02.07.01
refer to item 01.01.07.01
01.02.08
refer to item 01.01.08
01.03
Water service module WSM-V
for storage and thermal treatment of feed water.
All essential components of the water service module are assembled as a
ready-for-connection, easily operable function unit. The water service module treats
make-up water and supplies the steam generator with thermally treated feed water.
The control of water level and feed water temperature takes place via electronic
measured-data acquisition and electric positioners, which are guided by a computer-aided
control.
Thereby precise control results are achieved which also respond well to sudden load
changes.
In the water service module, all components are well dimensioned and functionally
optimized. The internal module components are hydraulically piped, electrically wired and
pre-adjusted. Easy transportation and bringing-in of the water service module are assured.
After the assembly of connections, the water service module is ready for operation.
Feed water tank FT
with inspection opening and transportation lugs, made of steel sheet, fully electrically
welded and tightness-tested, primed on the outside, with connections for:
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01.02.03
- connection for extraction DN100
- connection for extraction DN100
- connection for extraction DN100
- connection for extraction DN100
- connection for extraction DN65
- connection for extraction DN65
- connections for drain DN40
- connection for heating-up steam DN50
- nozzle pipe for bottom heating
- connections for chemical dosing
- connections for chemical dosing
- Connection for pump idling line DN 25
- connection for negative pressure safeguard
- connection for gauge pressure protection DN125
- Socket for deaerator, welded into the feed water tank.
- connection for level transmitter
- Nozzle pipe with connection flange for condensate
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Insulation of the tank with mineral wool mats and protective cladding of structured
aluminium, without fittings and flange.
Equipment Feed Water Tank:
1 x Pressure safeguard, each consisting of:
- full-stroke corner safety valve, type-accepted, DN 125 PN 16
- 3.1.B certificate for safety valve
Min. pressure limiter, consisting of:
- disc non-return valve DN100 PN40
Fitting for drain and overfilling, consisting of:
- solenoid shut-off valve DN40 PN10
- Control for overflow protection and gauge pressure protection,
controlled by level transmitter resp. pressure transducer.
Emptying device, consisting of:
- 1 x Shut-off valve DN40 PN40
Water level regulation device for indication and regulation of the
water level in the tank, consisting of:
- differential pressure transducer
- Control of the level control of the feed water tank, controlled
by the level transmitter.
- 1 x Shut-off valve DN15 PN40
- 1 x Shut-off valve DN15 PN40
Make up water control device, consisting of:
- solenoid shut-off valve DN25 PN16
- throttleable shut-off device DN 25
Make-up water supply flow device, consisting of:
- disc non-return valve DN50 PN40
Tank pressure regulation device for indication and regulation of the tank pressure,
consisting of::
- transmitter (signal output 4 - 20 mA)
- Control for regulation controlled by pressure transducer.
Heating steam control device, consisting of:
- motorized valve with built-on positioning drive and manual adjustment, DN50 PN16
- Control for temperature regulation of feed water tank
Trickle deaeration device
Deaerator module DM consisting of:
Jacket, hood and inserts of stainless steel, material no. 1.4301, with incorporated water
distribution
system and multi-part cascade inserts, fully electrically welded.
Equipment for Deaerator module DM:
- orifice disk
Insulation of the deaerator with mineral wool mats and protective cladding of structured
aluminium, without flange.
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Shrink-Wrapping for Transportation
All weather-sensitive parts shrink-wrapped or packed in plastic wrapping. Loose parts - if
necessary - to be packed in cases, cartons or other suitable type of packing. Disposal of
packing material at site.
Condensate Supply Device for oxygenic condensate, directly returned to the tank,
consisting of:
- disc non-return valve DN40 PN40
Condensate Supply Device, for oxygen-free condensate, directly returned to the feed
water tank, consisting of:
- disc non-return valve DN65 PN40
Supporting Structure for the WSM-components, for installation on a plain, load-bearing
floor.
Water Control WCO
Enclosure type IP 54, made of steel sheet, powdercoated grey structure, galvanized
mounting plate, cable ducting from below. The switching and control devices are
assembled on a mounting plate and inside the control panel door. Wiring in the control
panel is executed by means of flexible cables in sufficiently dimensioned cable ducts. The
control devices are designed in accordance with DIN-/EN-standards. The control devices
are connected on terminal strips inside the control panel. The control panel is
function-tested, 1 set of wiring diagrams is provided inside the panel.
Equipment
- Main switch with locking device
Automation device WCO with back-lit display
Basic functions:
- level regulation
- dry-run protection feed pump
- pressure regulation of feed water tank
- temperature regulation of drain water (if BEM is supplied by us)
- control of chemical dosing device CD (if CD is supplied by us)
- control of overflow and excess pressure safeguard.
Connections (potentially coupled) provided for:
- Volt-free contact for min. temperature feed water tank
- Volt-free contact for 2nd Level (e.g. condensate pump ON/OFF).
Connection cable with multipole plug for fast, fault-free cabling between Water Control
WCO / System Control SCO and Boiler Control BCO - boiler 1. Cable length between
connection points 7,0 m.
Connection cable with multipole plug for fast, fault-free cabling between Water Control
WCO / System Control SCO and Boiler Control BCO - boiler 2. Cable length between
connection points 7,0 m.
Wiring diagrams for the scope of delivery.
Quantity: 1
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Language: English
Design: print-out
Deadline: with delivery
Additional set of documents:
Quantity:
1
Language:
English
Design:
eMail
Deadline:
with delivery
Additional set of documents:
Quantity:
1
Language:
English
Design:
eMail
Deadline:
with delivery
Documentation, consisting of:
Operating manual
Operating manual acc. to European regulations for the scope of delivery.
Quantity: 1
Language: English
Design: print-out
Deadline: with delivery
Additional set of documents:
Quantity: 1
Language: English
Design: CD-ROM
Deadline: with delivery
Water sample cooler module SCM for taking samples of boiler water, consisting of:
- cooler of stainless steel
Water sample valve, consisting of:
- 1 x Shut-off valve DN10 PN315
Water sample valve, consisting of:
- 1 x Shut-off valve DN10 PN315
- stop valve for cooling water supply
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- throttleable shut-off device DN 15
Workshop Assembly of the equipment and dismantling of those parts which have to be
delivered separately for transportation reasons.
Shrink-Wrapping WSM for Transportation
All weather-sensitive parts of the Water Service Module shrink-wrapped or packed in
plastic wrapping. Loose parts - if necessary - to be packed in cases, cartons or other
suitable type of packing.
Disposal of packing material at site.
Connection of the boiler plant to a superior control technology.
via MODBUS RTU, consisting of
Communication processor(s) with link-up possibility to superior control technology
(superior control technology is not included in this scope of supply) for transmission of
operating signals, actual process data of the boiler control and control possibilities from the
superior control technology.
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01.04
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Piping Diagram
The piping diagram is designed acc. to EN ISO 10628 and is limited to our scope of
supply.
It includes a list of all devices, fittings, measuring and control devices and pipework with
nominal diameter information, pressure stages and material as well as a recommendation
for the piping material.
Quantity: 1
Language: English
Deadline: 3 weeks within order confirmation
Execution: Hard copy (coloured, in delivery scope characteristics)
Additional set of documents:
Quantity: 1
Language: English
Deadline: 3 weeks within order confirmation
Execution: one PDF-file (black/white), one PDF-file (coloured, in delivery scope
characteristics) and onepacked DXF-file (ZIP file format) compliant to ACAD 2000 Drawing Exchange Format (coloured, in delivery scope characteristics) dispatch on
CD-ROM
Additional set of documents:
Quantity: 1
Language: English
Deadline: 3 weeks within order confirmation
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The presettings are noted in the technical information TI034
- default Modbus-address(es), baud-rate, parity und stop-bits
Extension of basic equipment for transmission of operating signals and actual process
data of the burner.
Note: If for the data transmission at site an Engineer is needed, the occuring costs will be
invoiced acc. to our conditions for delegation of personnel.
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Execution: one PDF-file (black/white), one PDF-file (coloured, in delivery scope
characteristics) and onepacked DXF-file (ZIP file format) compliant to ACAD 2000 Drawing Exchange Format (coloured, in delivery scope characteristics) dispatch by eMail
2D symbols
2D symbols for all main components.
Sent by email; one PDF file, symbols in DXF or DWG format.
01.06.04
Photographic documentation of delivery scope
Type: eMail
Deadline: with delivery
01.06.05
Labelling of loose delivered parts
Temporary labelling of loose delivered parts for clear identification of the components
according to the delivery note. Designed as PE-label with delivery note number, item
number and material number.
With metal tags fixed to the respective component.
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01.06.02
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