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Technical Book
Fire tube steam boilers SG
2
STEAM BOILERS
STEAM-MATIC - SG
1. General Information
2. Competitive Advantages
3. Technical Specifications
4. P&ID
5. Boiler Layout
6. Installation
7. Scope of Supply
8. Appendix 1. Fuel consumption calculation
9. Appendix 2. Thermodynamic characteristics of saturated steam
10. Appendix 3. STEAM-MATIC SG special executions
11. Appendix 4. BONO ENERGIA product range
3
1. GENERAL INFORMATION
STEAM-MATIC SG fire tube steam boilers produce saturated or superheated steam, with design pressure range from 12 bar up to 30 bar. Range of steam production is between 6000 and 25000 Kg/h.
An efficient design, high-quality construction and an innovative control system guarantee high level performance and low energy costs.
Models available:
Thermal efficiency reaches 95% thanks to the optimization of heat exchange and by using our economizer, an equipment which can be fully integrated into the boiler. Thermal efficiency higher than 95% may be achieved thanks to special solutions by Cannon BONO.
Fields of application of STEAM-MATIC SG boilers are: pulp and paper industry, food & beverage, district heating, plastics and rubber industry, chemicals and petrochemical, woodworking, production of building material, textile industry.
• SG 600: up to 6.000 Kg/h
• SG 800: up to 8.000 Kg/h
• SG 1000: up to 10.000 Kg/h
• SG 1200: up to 12.000 Kg/h
• SG 1500: up to 15.000 Kg/h
• SG 2000: up to 20.000 Kg/h
• SG 2200: up to 22.000 Kg/h
• SG 2500: up to 25.000 Kg/h
STEAM-MATIC SG boilers are marked and can be produced according to the most important and rigorous directives, such as:
- PED Directive 97/23/CE
- Machinery Directive (MD) 2006/42/CE
- Gas Directive 2009/73/EC according to PED
- Low Voltage Directive (LVD) 2006/95/EC
- Electromagnetic Directive 89/336/EEC.
4
Figure 1
Steam boilers STEAM-MATIC SG
Figure 2
Steam boiler STEAM-MATIC SG functional diagram
1 Burner
2 Safety Valves
3 STEAM-MATIC Furnace
4 Burner Flame
5 Level Probes
6 Exhaust Gas Outlet
7 Drain Connection
8 Fire Tubes of the 2nd Pass (*)
9 Wet Back Water Tubes
10 Integrated Economizer (OPTIONAL)
* = the fire tubes of the second pass are mainly covering the same furnace lateral area on both sides, the smoke flow in the drawing is just for representation purposes.
5
6
2. COMPETITIVE ADVANTAGES
• Thermal efficiency up to 95% and higher
Thanks to an optimized heating surface and to the optional supply of economizers (air or water preheater).
• Better heat exchanging process
The wide heating surfaces enable a better heat exchange; these optimal conditions are granted in each of the tubes of the boiler, avoiding thermal flow unbalance and thermal stresses in the structure elements.
• Two passes are better than three
A two passes boiler has a more balanced heat transfer from the tubes to the water and less thermal stresses in the metal structure; moreover the simplicity of construction of a two passes boiler enables a total accessibility to the furnace and the tubes for inspection purposes and ordinary maintenance.
• Bigger water content volume
A bigger water volume gives to the boiler a better steam supply flexibility and stability of the steam pressure and water level.
• Bigger furnace volume
This feature permits lower thermal loads in the structure and better heat exchange, which avoids structural dilatations and lower values of the NOx emissions.
• Supply of “turn-key” boiler units
Boiler units are supplied ready for use. The boiler is supplied with feed water pumps, burning system (gaseous, diesel or heavy fuel), electric cabinet with Cannon BONO control and management system OPTISPARK.
• Customer oriented solutions
Cannon BONO’s technical specialists are capable of meeting any customer’s request, thus having the possibility to offer a great variety of solutions studied specifically for the customer’s needs, starting from boiler construction to type of fuel burned (especially thanks to our know-how in designing and realizing each component of the boiler in Cannon BONO factory).
Figure 3
Steam boiler STEAM-MATIC SG
Figure 4
Control panel for steam boiler STEAM-MATIC SG with OPTISPARK control and management system.
2. COMPETITIVE ADVANTAGES - OPTIMIZATION
-
-
-
-
TWO PASSES ARE BETTER THAN THREE
STEAM-MATIC serie SG combines the competitive advantages of a fully water cooled back side with a symmetrical configuration of tubes and plates, ensuring easy inspection operations and greater performance benefits.
The simple boiler design and the full accessibility to the fire tubes, without disassembling the burner or removing accessories (both in the frontal and back smoke chamber), make the STEAM-MATIC SG series the best solution for any steam need.
STEAM-MATIC SG furnace
A large furnace, combined with an optimized heat transfer, represent the smartest solution for the best possible thermal exchange conditions across all the tube bundle, avoiding the thermal load umbalance between the 2nd and the 3rd pass typical of a 3 pass smoke tubes boilers.
Preventing these thermal umbalance conditions means also avoiding dangerous thermal stresses in the structure of the pressure vessel itself, which are the main cause of cracks and deformations.
Moreover the rear tubes plates are exposed to a uniform thermal load.
An optimized heat transfer
In a 3 pass boiler most of the heat transfer occurs in the 2nd pass, while in the 3rd pass the transfer becomes negligible and may expose the tubes to corrosion (dew point) phenomena.
All the boilers of our STEAM-MATIC SG serie are equipped with Intensive Radiant Tubes (I.R.T) which promote:
High thermal exchange also in convection conditions
Negligible flow friction rate, with consequent modest burner fan power needed
Optimized heat flow along the entire section of the tubes
Higher speed of the flue gases even with boiler running at low rate
Figure 5
Heat transfer efficiency slope
7
The thermal flow on a three pass boiler is uneven and tends to concentrate in the central area of the smoke tubes; therefore the heat transfer becomes significantly lower, especially in the third pass.
Figure 6
Efficiency comparison between 2 and 3 smoke passes
Easy access to the burner side tubes
The STEAM MATIC SG frontal smoke chamber can be easily reached without burner disassembling, thanks to the two lateral front hinged doors. This solution allows fast and costless cleaning operations in order to preserve the optimal smokes tubes conditions.
The rear smoke chamber can be fastly inspected by means of a wide manhole which enables the operator to completely enter the chamber and inspect the rear end of the smoke tubes.
The position of the tubes themselves, allocated at both sides of the furnace, permits the operator to easily check their status.
Heat recovery system
STEAM-MATIC boilers may feature a recovery system (Economizer) integrated in the boiler structure, which can be easily and fully inspected and do not require expensive or bulky additional gas ducts, often necessary in a 3 pass design.
The economizers can be easily integrated as optional in the existing structure, which is already shaped and designed to receive them with an easy inserting operation.
8
Our SG integrated recovery system gives significant fuel savings by increasing the boiler efficiency of 4-5%, it moreover speeds up combustion in adverse conditions, such as cold furnace or rapid variation of room temperature. Installation of the air-preheater together with the economizer and other customized solutions enables STEAM-MATIC SG boiler to reach up to 99% of efficiency.
2. COMPETITIVE ADVANTAGES - BOILER CONSTRUCTION
Figure 7
Easy access spots in a STEAM-MATIC boiler SG
Easy access to the heat recovery system
Easy inspection of the second pass fire tubes from the rear smoke chamber
Easy access to the rear smoke chamber from a wide manhole
Easy inspection of the second pass fire tubes from the frontal smoke chamber
9
10
2. COMPETITIVE ADVANTAGES - AUTOMATIC CONTROL AND
MANAGEMENT SYSTEM FOR INDUSTRIAL BOILER PLANTS
BONO OPTISPARK is the automatic control and management system for industrial boilers and boiler rooms which ensures:
• CONTINUOUS AND SAFETY OPERATION
• OPERATIVE SAFETY
• ENERGY EFFICIENCY
• LOWER OWNERSHIP COSTS
• INFORMATION AVAILABILITY FOR MAINTENANCE ACTIVI-
TIES
BONO OPTISPARK is applicable to all types of boilers, new or already operating; it is suitable for any burner and it is interfaceable with any supervisory control and data acquisition
(SCADA) and any distribution control system (DCS).
The system fits any industrial process and district heating.
The human machine interface is user friendly; the touch screen operator panel is available in two sizes: 5.7’’ and
10.4’’.
Figure 8
Control and management system
OPTISPARK’s interface
Figure 9
Automatic control and management system for industrial boiler plants OPTISPARK functional scheme.
VPS
Key technical features of OPTISPARK system:
• Integrated Burner Controller BCU - (Burner Control Unit), SIL3 certified
• Burner start-up sequence management, flame protection and gas Valve Proving System
(VPS) in compliance with EN298 and EN1643
• Micrometric Gas/Air Ratio Control (GARC) in compliance with EN 12067/2
• Level regulation up to three elements with steam flow and feed water flow control
• Management of the inverter installed on the feed water pump and on the fan engine to achieve maximum energy savings and to reduce noise level
• Heat recovery management and energy-saving registration for green benefits achievement
• Integrated management of the pollutant reduction systems to the chimney (very low NOx emission)
• Oxygen and Carbon Monoxide combustion trim
• Calculation of energy saving and green benefits.
• Continuos emissions monitoring system in compliance with local legislations
• Power load sharing system between more boilers in the same boiler room
• Historical data recording, alerts and notifications via SMS
• Totalization of water and fuel consumption, steam production, boiler and pumps operation time
• Managemet of deaerators, water treatment system and auxiliary equipment
• LAN port for remote control and supervision
• BONO maintenance and service via Internet or GPRS modem
BCU
SIL 3
11
3. TECHNICAL SPECIFICATIONS - STEAM-MATIC SG
Table 1
Technical specifications and overall dimensions of steam boiler STEAM-MATIC SG. Data are refered to SG models without economizer or air preheater.
The below listed information is generalized to the entire range of models STEAM-MATIC SG, it’s only indicative and may change in accordance with each final boiler configuration. Additional data and deviations from standard are available on request.
Features
Unit
SG 600 SG 800
TECHNICAL SPECIFICATIONS
SG 1000 SG 1200 SG 1500 SG 2000 SG 2200 SG 2500
Nominal steam production
Kg/h
6000 8000 10000 12000 15000 20000 22000 25000
Design pressure* bar 12 15 18 12 15 18 12
Min.feed water temp.
°C 90 90
Thermal efficiency**
% 90 89,5 89 90 89,5 89 90
L
W
Lenght
Width mm mm
7400
3250
15
90
89,5
18
89
12
90
15
90
89,5
18
89
12
90
15
90
89,5
7950
OVERALL DIMENSIONS AND CONNECTIONS
8350 8900 9400
3250 3600 3600 3750
H
Height mm
N2
Steam valve
DN
PN
DN
N4A
N4B
Safety valve outlet
N9
Boiler drain
N
18A
18B
Feed water line****
N16
N15
N17
Reversal chamber drain
Heavy fuel oil inlet
Natural gas inlet
N19
Stack connection
Empty weight
Water volume at level
Full water volume
PN
DN
PN
Ø
DN
PN
Ø
Ø mm
T m3 m3
125
16
40/
65
25/
16
2900 2900
125 100 150 125
40 40 16 40
40/
65
25/
16
40
16
40/
65
40/
16
40/
65
25/
16
40/
65
25/
16
40
16
100
40
40/
65
40/
16
3”
32
16
2”
3”
9,3
12,3
3”
32
16
2”
4”
10,0
13,3
150
16
50/
80
25/
16
3250
150
40
40/
65
25/
16
40
16
4”
32
16
2”½
4”
600 600
17,0 17,8 18,7 20,0 21,0
720
22,2 23,0 24,3
11,0
15,0
125 150
40 16
40/
65
40/
16
50/
80
25/
16
3300
150
40
50/
80
25/
16
40
16
150
40
40/
65
40/
16
4”
32
16
2”½
4”
13,0
18,0
200
16
65/
100
25/
16
10300
3750
3800 3550
150 150 200 200 200
40 40 16 40 40
50/
80
25/
16
40
16
50/
80
40/
16
65/
100
25/
16
65/
100
25/
16
40
16
50/
80
40/
16
4”
32
16
2”½
5”
17,7
23,5
18
89
12
90
15
90
89,5
5”
32
16
2”½
5”
19,0
26,0
18
89
12
90
15
90
89,5
11000
3900
3800***
250
16
65/
100
25/
16
40
16
200
40
80/
100
25/
16
5”
32
16
2”½
5”
720 800 850
25,7 26,0 27,6 29,2 32,0 34,2 36,1 38,0 41,4 43,0 39,5
920
42
22,0
29,3
TOTAL ELECTRIC POWER
Heavy fuel oil
*****
KW 31,3 32,8 34,8 38,8 38,8 42,8 48,8 52,8 52,8 56,8 60,8 64,3 71,1 74,6 78,1 82,6 86,1
101,1
89,0 92,0
Natural gas or diesel oil
KW 18,5 20,0 22,0 26,0 26,0
Standard electric power data: 400 V/50 Hz/ – 3 phases
30,0 33,0 37,0 37,0 41,0 45,0
Auxiliaries voltage: 220 V
48,5 52,0 55,5 59,0 64,0 67,0 67,0 75,0 78,0
FUEL CONSUMPTION
Heavy fuel calorific power: 9700 kcal/kg (for actual fuel consumption calculation see Appendix 1).
Diesel fuel calorific power: 10200 kcal/kg (for actual fuel consumption calculation see Appendix 1).
Natural gas calorific power: 8500 kcal/Nm
3
(for actual fuel consumption calculation see Appendix 1).
*
Design pressure above 18 bar or below 12 bar on request.
** Thermal efficiency at 100% of the load, with water temperature 90 °C. See Figure 13 for more information.
*** Height is calculated without air fan.
**** Connection size depends on feed water pump supplier.
***** Maximum heavy fuel viscosity is 7°E under 50°C temperature. Information about heavy fuel with higher viscosity on request.
12
12 15
90
90
89,5
12000
4000
3800***
250
16
65/
100
25/
16
40
16
200
40
65/
100
25/
16
6”
32
16
2”½
6”
40,5
920
43
36,0
42,0
101,0
86,0
Figure 10
STEAM-MATIC SG steam boiler overall dimension.
More detailed information on request
13
3. TECHNICAL SPECIFICATIONS - STEAM-MATIC SG ECO (WITH ECONOMIZER)
Table 2
Technical specifications and overall dimensions of steam boiler STEAM-MATIC SG ECO. Data are refered to SG models with economizer. The below listed information is generalized to the entire range of models STEAM-MATIC SG, it’s only indicative and may change in accordance with each final boiler configuration. Additional data and deviations from standard are available on request.
Features
Unit
SG ECO
600
SG ECO
800
TECHNICAL SPECIFICATIONS
SG ECO
1000
SG ECO
1200
SG ECO
1500
SG ECO
2000
SG ECO
2200
SG ECO
2500
Nominal steam production
Kg/h 6000 8000 10000 12000 15000 20000 22000 25000
Design pressure* bar 12 15 18 12 15 18 12 15 18 12 15 18 12 15 18 12 15 18 12 15
Min.feed water temp.
Thermal efficiency (with economizer)**
L
W
H
N2
N4A
N4B
N9
Lenght
Width
Height
Steam valve
Safety valve outlet
Boiler drain
°C
90 90 90 90 90 90 90
%
95 94,5 94 95 94,5 94 95 94,5 94 95 94,5 94 95 94,5 94 95 94,5 94 95 94,5
OVERALL DIMENSIONS AND CONNECTIONS
mm mm
7400
3250
7950
3250
8350
3600
8900
3600
9400
3750
10300
3750
11000
3900 mm 2900 2900 3250 3300 3550 3800 3800***
DN
125 125 100 150 125 100 150 150 125 150 150 150 200 150 150 200 200 200 250 200
PN
16 40 40 16 40 40 16 40 40 16 40 40 16 40 40 16 40 40 16 40
DN
PN
DN
PN
40/
65
25/
16
40/
65
25/
16
40
16
40/
65
40/
16
40/
65
25/
16
40/
65
25/
16
40
16
40/
65
40/
16
50/
80
25/
16
40/
65
25/
16
40
16
40/
65
40/
16
50/
80
25/
16
50/
80
25/
16
40
16
40/
65
40/
16
65/
100
25/
16
50/
80
25/
16
40
16
50/
80
40/
16
65/
100
25/
16
65/
100
25/
16
40
16
50/
80
40/
16
65/
100
25/
16
40
16
80/
100
25/
16
N
18A
18B
Feed water line****
N16
N15
Reversal chamber drain
Liquid fuel inlet
N17
N19
Natural gas inlet
Stack connection
Empty weight
Water volume at level
Full water volume
Ø
DN
PN
Ø
Ø mm
3”
32
16
2”
3”
600
3”
32
16
2”
4”
600
4”
32
16
2”½
4”
720
4”
32
16
2”½
4”
720
4”
32
16
2”½
5”
800
5”
32
16
2”½
5”
850
5”
32
16
2”½
5”
920
T
17,6 18,4 19,3 20,6 21,6 22,8 24,0 25,3 26,7 27,0 28,6 30,2 33,2 35,4 37,3 39,4 42,8 44,4 40,9 43,4 m
3
9,3 10,0 11,0 13,0 17,7 19,0 22,0 m
3
12,3 13,3 15,0 18,0 23,5 26,0 29,3
12
95
90
6”
32
16
2”½
6”
920
15
94,5
42
36,0
44,5
42,0
16
65/
100
25/
16
12000
4000
3800***
250 200
40
65/
100
25/
16
40
16
TOTAL ELECTRIC POWER
Heavy fuel oil ***** KW
35,3 36,8 38,8 38,8 38,8 42,8 48,8 52,8 52,8 56,8 60,8 64,3 71,1 74,6 78,1 82,6 86,1 101,1 89,0 92,0
Natural gas or diesel oil
KW
23,0 24,0 26,0 26,0 26,0
Standard electric power data: 400 V/50 Hz/ – 3 phases
30,0 33,0 37,0 37,0 41,0 45,0
Auxiliaries voltage: 220 V
48,5 52,0 55,5 59,0 64,0 67,0 67,0 75,0 78,0
FUEL CONSUMPTION
Heavy fuel calorific power: 9700 kcal/kg (for actual fuel consumption calculation see Appendix 1).
Diesel fuel calorific power: 10200 kcal/kg (for actual fuel consumption calculation see Appendix 1).
Natural gas calorific power: 8500 kcal/Nm
3
(for actual fuel consumption calculation see Appendix 1).
*
Design pressure above 18 bar or below 12 bar on request.
** Thermal efficiency at 100% of the load, with water temperature 90 °C. See Figure 14 and for more information.
*** Height is calculated without air fan.
**** Connection size depends on feed water pump supplier.
***** Maximum heavy fuel viscosity is 7°E under 50°C temperature. Information about heavy fuel with higher viscosity on request.
14
101,0
86,0
Figure 11
STEAM-MATIC SG ECO steam boiler overall dimension.
Boiler is equipped with economizer for heat recovery.
15
3. TECHNICAL SPECIFICATIONS - STEAM-MATIC SG PA (WITH AIR PREHEATER)
Table 3
Technical specifications and overall dimensions of steam boiler STEAM-MATIC SG PA with air preheater. The below listed information is generalized to the entire range of models STEAM-MATIC SG PA, it’s only indicative and may change in accordance with each final boiler configuration. Additional data and deviations from standard are available on request.
Features
Unit
SG PA
600
SG PA
800
TECHNICAL SPECIFICATIONS
SG PA
1000
SG PA
1200
SG PA
1500
SG PA
2000
SG PA
2200
SG PA
2500
Nominal steam production
Design pressure*
Min.feed water temp.
Thermal efficiency (with air preheater)**
Kg/h bar
°C
%
12
92,5
6000
15
90
92
18 12
91,5 92,5
8000
15
90
92
18 12
91,5 92,5
10000
15
90
92
18 12
12000
15
90
91,5 92,5 92
18 12
91,5 92,5
15000
15
90
92
18 12
20000
15
90
91,5 92,5 92
18
91,5
12
22000
92,5
90
15
92
25000
12
92,5
90
15
92
L
W
H
Lenght
Width
Height (with air preheater) mm mm mm
7150
3000
3700
7650
3000
OVERALL DIMENSIONS AND CONNECTIONS
7900
3250
8400
3250
3700 4050 4050
***
***
***
N2
N4A
N4B
N9
Steam valve
Safety valve outlet
Boiler drain
DN
125 125 100 150 125 100 150 150 125 150 150 150 200 150 150 200 200 200 250
PN
16 40 40 16 40 40 16 40 40 16 40 40 16 40 40 16 40 40 16
DN
40/
65
40/
65
40/
65
40/
65
40/
65
40/
65
50/
80
40/
65
40/
65
50/
80
50/
80
40/
65
65/
100
50/
80
50/
80
65/
100
65/
100
50/
80
65/
100
PN
DN
PN
25/
16
25/
16
40
16
40/
16
25/
16
25/
16
40
16
40/
16
25/
16
25/
16
40
16
40/
16
25/
16
25/
16
40
16
40/
16
25/
16
25/
16
40
16
40/
16
25/
16
25/
16
40
16
40/
16
25/
16
40
16
200
40
80/
100
25/
16
250
16
65/
100
25/
16
40
16
200
40
65/
100
25/
16
N
18A
18B
Feed water line*****
N16
N15
Reversal chamber drain
Heavy fuel oil inlet
N17
N19
Natural gas inlet
Stack connection
Empty weight
Water volume at level
Full water volume
Ø
DN
PN
Ø
Ø mm m
3 m
3
3”
32
16
2”
3”
600
3”
32
16
2”
4”
600
4”
32
16
2”½
4”
720
4”
32
16
2”½
4”
720
4”
32
16
2”½
5”
800
5”
32
16
2”½
5”
850
5”
32
16
2”½
5”
920
T
18,0 18,8 19,7 21,0 22,0 23,2 24,0 25,3 27,1 27,0 28,6 30,2 35,0 37,2 39,1 40,0 43,4 45,0
41,9 44,4
9,3
12,3
10,0
13,3
11,0
15,0
13,0
18,0
17,7
23,5
19,0
26,0
22,0
29,3
43
6”
32
16
2”½
6”
920
36,0
42,0
45,5
TOTAL ELECTRIC POWER
Heavy fuel oil **** KW
35,3 36,8 38,8 38,8 38,8 42,8 48,8 52,8 52,8 56,8 60,8 64,3 71,1 74,6 78,1 82,6 86,1 101,1 89,0 92,0
Natural gas or diesel oil
KW 23,0 24,0 26,0 26,0 26,0
Standard electric power data: 400 V/50 Hz/ – 3 phases
30,0 33,0 37,0 37,0 41,0 45,0
Auxiliaries voltage: 220 V
48,5 52,0 55,5 59,0 64,0 67,0 67,0 75,0 78,0
FUEL CONSUMPTION
Heavy fuel calorific power: 9700 kcal/kg (for actual fuel consumption calculation see Appendix 1).
Diesel fuel calorific power: 10200 kcal/kg (for actual fuel consumption calculation see Appendix 1).
Natural gas calorific power: 8500 kcal/Nm
3
(for actual fuel consumption calculation see Appendix 1).
*
Design pressure above 18 bar or below 12 bar on request.
** Thermal efficiency at 100% of the load, with water temperature 90 °C.
*** Height is calculated without air fan.
**** Connection size depends on feed water pump supplier.
***** Maximum heavy fuel viscosity is 7°E under 50°C temperature. Information about heavy fuel with higher viscosity on request.
16
101,0
86,0
Figure 12
STEAM-MATIC SG PA steam boiler overall dimension.
Boiler is equipped with air preheater for heat recovery.
17
3. TECHNICAL SPECIFICATIONS - THERMAL EFFICIENCY
Figure 13 The coefficient of performance (COP) of the steam boiler STEAM-MATIC crossed with the load*.
18
Figure 14 The coefficient of performance (COP) of the steam boiler STEAM-MATIC equipped with economizer*.
* Load, % = * 100% , with T feed water at 90° C.
3. TECHNICAL SPECIFICATIONS - WATER PROPERTIES
The quality of the water constitutes one of the most important factors regarding duration, safety and reliability of the steam generator and therefore the entire thermal plant.
The “water circuit” elements are essentially comprised of:
• Unpurified water treatment system: treats the waters available, making them suitable for re-integration into the plant. The most common methods of treatment are: filters, softeners, reverse osmosis plants, demineralizers, etc.
• Thermophysical degaser: it is made up from an accumulation tank where condensate returning from the utilities and reintegration water converge. Heating takes place inside the degaser by introducing a regulated flow rate of steam. The purpose of the treatment is to eliminate the gaseous fractions dissolved in the feed water, particularly considering oxygen.
• Chemical products dosing control unit: it is made up from one or more tanks fitted with manually regulated dosing pumps, which send the chemical products into the water supply circuit. Some chemical products must be stored in a tank fitted with stirrer.
• Boiler bottom outlet and surface blowdown: they allow to keep the amount of salts dissolved and the amount of slurry inside the boiler drum within the envisioned limits. The quantity of the continuous blowdown operations is tightly linked to the percentage of total solids in the boiler water: the assistance of a laboratory specialized in the analysis of water can help in defining the real quantity and frequency of blowdown operations necessary to maintain normal concentrations.
PARAMETERS
OPERATING PRESSURE (X)
APPEARANCE
DIRECT CONDUCTIVITY AT 25°C pH VALUE AT 25 °C (a)
UNIT
FEED WATER PROPERTIES
ACCORDING TO EN 12953 bar (= 0,1 MPa)
0,5 < X < 20 X > 20
/
μS/cm
Clean, free from suspended solids
Not specified
/
> 9,2 (b) > 9,2 (b)
Table 4
Feedwater Quality Requirements for best STEAM-MATIC SG operation and preservation
TOTAL HARDNESS (Ca + Mg)
IRON (Fe) CONCENTRATION
COPPER (Cu) CONCENTRATION mmol/l mg/l mg/l
< 0,01 (c)
< 0,3
< 0,05
< 0,01
< 0,1
< 0,03
SILICA (SiO
2
) CONCENTRATION mg/l Not specified
OXYGEN (O
2
) CONCENTRATION
OIL/GREASE CONCENTRATION
(see EN 12953-6)
ORGANIC SUBSTANCES CONCENTRATION mg/l mg/l
< 0,05 (d)
< 1
< 0,02
< 1
/ See footnote (e)
(a) With copper alloys in the system the pH value shall be maintained in the range from 8.7 to 9.2.
(b) With softened water pH value >7.0 - see the manual of the boiler.
(c) If the operating pressure is <1 bar, the max total acceptable hardness should be 0.05 mmol / l.
(d) In order to observe this value at intermitted operation or operation without deareator an oxygen scavenger shall be used.
(e) Organic substances are generally a mixture of several different compounds. The composition of such mixtures and behaviour of their individual components under the conditions of boiler operation are difficul to predict. Organic substances may be decomposed to form carbonic acid or other acidic decomposition products which increase the acid conductivity and cause corrosion or deposits. They also may lead to foaming and/or priming which shall be kept as low as possible.
19
4. P&ID - STEAM-MATIC SG - BOILER ROOM
Figure 15
Boiler room general P&ID. The data processing schemes are standardized to the entire STEAM-MATIC SG range; further measurements and modifications are available on-demand.
V2
V3
S1
SG – P&ID Elements Description
Water Softener
V1 Feed Water / Condensate Tank
Brine Tank
Chemical Dosing Station
LI
FQ
PI
SG – P&ID Ancillaries Symbols Meaning
LV Level Valve
Level Indicator
Flow Indicator Totaliser
Pressure Indicator
20
INSTRUMENTATION SYMBOLS AND
IDENTIFICATION ISA S-5.1
21
4. P&ID - STEAM-MATIC SG
Figure 16
STEAM-MATIC SG P&ID. Further measurements and modifications are available on-demand.
BDS
L1
O2
P1
P2
TDS
SG – P&ID Elements Description
Blowdown system (OPTION)
Chimney (OPTION)
Flue gas oxygen control system (OPTION)
Feed water pump
Second feed water pump (spare) (OPTION)
Automatic TDS control system (OPTION)
AI
SG – P&ID Ancillaries Symbols Meaning
Alarm Indicator
AE Alarm Element
AIC Analyzer Indicator Controller
AT Analyzer Transmitter
AV Analyzer Valve
FC Flow Controller
LV Level Valve
LI Level Indicator
LAH Level Alarm High
LAHH Level Alarm High Above LAH
LAL Level Alarm Low
LALL Level Alarm Low Below LAL
LIC Level Indicator Controller
LSL Level Switch Low
LSLL Level Switch Low Below LSL
LSL/H Level Switch Low/High
LSH Level Switch High
LSHH Level Switch High Above LSH
LT Level Transmitter
M Motor
PAH Pressure Alarm High
PAHH Pressure Alarm High Above PAH
PI Pressure Indicator
PIC Pressure Indicator Controller
PSH Pressure Switch High
PSHH Pressure Switch High Above PSH
PSV Pressure Safety Valve
PT Pressure Transmitter
TAH Temperature Alarm High
TE Temperature Element
TI Temperature Indicator
TSH Temperature Switch High
22
OPTION
INSTRUMENTATION SYMBOLS
AND IDENTIFICATION ISA S-5.1
SUPPLY LIMIT
CANNON BONO CUSTOMER
Functions managed by “OPTISPARK” system
Combustion control system
Instrument air
Interlock - burner shutdown
Burner
23
4. P&ID - STEAM-MATIC SG ECO - WITH ECONOMIZER
E1
BDS
L1
O2
P1
P2
TDS
Figure 17
STEAM-MATIC SG ECO (with economizer) P&ID; further measurements and modifications are available on-demand.
SG – P&ID Elements Description
Economizer
Blowdown system (OPTION)
Chimney (OPTION)
Flue gas oxygen control system (OPTION)
Feed water pump
Second feed water pump (spare) (OPTION)
Automatic TDS control system (OPTION)
AI
SG – P&ID Ancillaries Symbols Meaning
Alarm Indicator
AE Alarm Element
AIC Analyzer Indicator Controller
AT Analyzer Transmitter
AV Analyzer Valve
FC Flow Controller
LV Level Valve
LI Level Indicator
LAH Level Alarm High
LAHH Level Alarm High Above LAH
LAL Level Alarm Low
LALL Level Alarm Low Below LAL
LIC Level Indicator Controller
LSL Level Switch Low
LSLL Level Switch Low Below LSL
LSL/H Level Switch Low/High
LSH Level Switch High
LSHH Level Switch High Above LSH
LT Level Transmitter
M Motor
PAH Pressure Alarm High
PAHH Pressure Alarm High Above PAH
PI Pressure Indicator
PIC Pressure Indicator Controller
PSH Pressure Switch High
PSHH Pressure Switch High Above PSH
PSV Pressure Safety Valve
PT Pressure Transmitter
TAH Temperature Alarm High
TE Temperature Element
TI Temperature Indicator
TSH Temperature Switch High
24
OPTION
INSTRUMENTATION SYMBOLS
AND IDENTIFICATION ISA S-5.1
SUPPLY LIMIT
CANNON BONO CUSTOMER
Functions managed by “OPTISPARK” system
Combustion control system
Instrument air
Interlock - burner shutdown
Burner
25
4. P&ID - STEAM-MATIC SG PA - WITH AIR PREHEATER
Figure 18
STEAM-MATIC SG PA (with air preheater) P&ID; further measurements and modifications are available on-demand.
PA
BDS
L1
O2
P1
P2
TDS
SG – P&ID Elements Description
Air preheater
Blowdown system (OPTION)
Chimney (OPTION)
Flue gas oxygen control system (OPTION)
Feed water pump
Second feed water pump (spare) (OPTION)
Automatic TDS control system (OPTION)
SG – P&ID Ancillaries Symbols Meaning
AI Alarm Indicator
AE Alarm Element
AIC Analyzer Indicator Controller
AT Analyzer Transmitter
AV Analyzer Valve
FC Flow Controller
LV Level Valve
LI Level Indicator
LAH Level Alarm High
LAHH Level Alarm High Above LAH
LAL Level Alarm Low
LALL Level Alarm Low Below LAL
LIC Level Indicator Controller
LSL Level Switch Low
LSLL Level Switch Low Below LSL
LSL/H Level Switch Low/High
LSH Level Switch High
LSHH Level Switch High Above LSH
LT Level Transmitter
M Motor
PAH Pressure Alarm High
PAHH Pressure Alarm High Above PAH
PI Pressure Indicator
PIC Pressure Indicator Controller
PSH Pressure Switch High
PSHH Pressure Switch High Above PSH
PSV Pressure Safety Valve
PT Pressure Transmitter
TAH Temperature Alarm High
TE Temperature Element
TI Temperature Indicator
TSH Temperature Switch High
26
TDS
OPTION
INSTRUMENTATION SYMBOLS
AND IDENTIFICATION ISA S-5.1
SUPPLY LIMIT
CANNON BONO CUSTOMER
Functions managed by “OPTISPARK” system
Combustion control system
Instrument air
Interlock - burner shutdown
Burner
27
4. P&ID - SG - NATURAL GAS BURNER
Figure 19
Natural gas combustion system P&ID. The data processing schemes are standardized to the entire
STEAM-MATIC SG range; further measurements and modifications are available on-demand.
SG – P&ID Elements Description
U10 Combustion air fan
U11 Silencer
SG – P&ID Ancillaries Symbols Meaning
BALL Flame alarm low level
BE Flame scanner
BSLL Flame switch low level
BV On/off actuated valve
BZ Electrical igniter
FC Frequency controller
FV Flow valve
M Motor
PAHH Pressure alarm high high
PALL Pressure alarm low low
PCV Pressure control valve
PI Pressure indicator
PSLL Pressure switch low low
VSP Gas leakage test
28
Functions managed by “OPTISPARK” system
Combustion control system
Burner management system
Instrument air
Interlock - burner shutdown
Burner
Joint
OPTION
SUPPLY LIMIT
CANNON BONO CUSTOMER
INSTRUMENTATION SYMBOLS
AND IDENTIFICATION ISA S-5.1
29
4. P&ID - SG - LIQUID FUEL OIL BURNER (HEAVY FUEL OIL AND DIESEL OIL)
Figure 20
Liquid fuel oil combustion system P&ID. The data processing schemes are standardized to the entire
STEAM-MATIC SG range; further measurements and modifications are available on-demand.
SG – P&ID Elements Description
U10 Combustion air fan
U11 Silencer
P10A Fuel oil pump
P10B Fuel oil pump (spare) (OPTIONAL)
E10 Fuel oil preheater
BALL Flame alarm low levef
BE Flame scanner
BSLL Flame switch low level
BV On/off actuated valve
BZ
FC
Electrical igniter
Frequency controller
FV Flow valve
SG – P&ID Ancillaries Symbols Meaning
PALL Pressure alarm low low
PCV Pressure control valve
PI Pressure indicator
PSLL Pressure switch low low
TAL
TSL
TIC
Temperature alarm low
Temperature switch low
Temperature indicator controller
HV Hand valve TE Thermoelement
M Motor
Functions managed by
“OPTISPARK” system
Combustion control system
(managed by “OPTISPARK”)
Burner management system
Interlock - burner shut down
Burner
Autocleaner strainer
Filter “Y” type
Condensate drain
Sight glass
Instrument air (MIN 5 bar - MAX 7)
OPTION
SUPPLY LIMIT
CANNON BONO CUSTOMER
INSTRUMENTATION SYMBOLS
AND IDENTIFICATION ISA S-5.1
30
31
4. P&ID - SG - NATURAL GAS + LIQUID FUEL OIL BURNER
Figure 21
The data processing schemes are standardized to the entire STEAM-MATIC SG range; further measurements and modifications are available on-demand.
SG – P&ID Elements Description
U10 Combustion air fan
U11 Silencer
P10A Fuel oil pump
P10B Fuel oil pump (spare) (OPTIONAL)
E10 Fuel oil preheater
SG – P&ID Ancillaries Symbols Meaning
BALL Flame alarm low levef
BE Flame scanner
PCV Pressure control valve
PI Pressure indicator
BSLL Flame switch low level PAHH Pressure alarm high high
BV
BZ
FC
FV
HV
M
On/off actuated valve
Electrical igniter
Frequency controller
Flow valve
Hand valve
Motor
PALL Pressure alarm low low
PSLL Pressure switch low low
TAL Temperature alarm low
TSL Temperature switch low
TIC
TE
Temperature indicator controller
Thermoelement
VSP Gas leakage test
Functions managed by
“OPTISPARK” system
Combustion control system
(managed by “OPTISPARK”)
Burner management system
Interlock - burner shut down
Burner
Autocleaner strainer
Filter “Y” type
Condensate drain
Sight glass
Instrument air (MIN 5 bar - MAX 7)
Joint
OPTION
32
SUPPLY LIMIT
CANNON BONO CUSTOMER
INSTRUMENTATION SYMBOLS
AND IDENTIFICATION ISA S-5.1
33
5. BOILER LAYOUT - BOILER ROOM
450
*
2
1500
5
* min.800
1
4
34
Figure 22
A sample installation of a SG STEAM-MATIC inside a boiler room, plan view
Chequered plate pr of
. Z 2
0x
3 elev. 0.0
650
Round bar 10
Flat bar 80X8 every ~2 mt.
2500 800
4
3
2
1
6
710
Figure 23
A sample installation of a SG
STEAM-MATIC inside a boiler room, front view
1 Steam Boiler SG
2 Water-condensate storage tank
3 Structure supporting tank
4 Feed water treatment unit
5 Steam header
6 Chimney
35
36
6. INSTALLATION
“Steam-Matic” generator is shipped ready to operate after a fire test in our factory. For installation local State regulation must be observed. Examine the boiler on arrival to control if it has suffered any damage during transport. Any damage should be notified to the carrier. The “Steam-Matic” boiler should be placed on a well leveled concrete floor.
Minimum clearance must be allowed:
- rear side min : 1,5 m. for inspection
- front side min : sufficient distance for tube cleaning and burner extraction
- left side min : 1,5 m. to allow auxiliaries control
- right side min : 0,8 m. for inspection
The boiler room will be kept clean and well ventilated (indicatively 1 m
3
per 1 MW of thermal capacity); a minimum of two opening is required to provide sufficient air for the burner and avoid excessive room temperature.
Flooring
The generator must rest on a strong and levelled floor, the floor slab must be dimensioned to support specific loads up to 25 N/cm2 and to support the total weight of the generator and its accessories in the full load condition.
The following connections are required.
Boiler piping
- Steam line to the boiler valve
- Safety valves piped to atmosphere with the same diameter as the
safety valves outlet and with adeguate supports to prevent
stress on valves.
- Bottom and surface blowdown connection piped a drain flash tank
- Water column and sight glass drain piped for blowdown
Flue gas outlet
The generator is supplied with carbon steel counterflange on the fumes exhaust connection, which the installer can use to weld the fumes pipe or the vertical flue.
The fumes connection is dimensioned to support the weight of the flue overlaying for a maximum height of 10 metres from the floor surface (considering the flue pipe realised in steel with thickness of 6 mm). Horizontal loads and moments must be avoided. For applications that do not lie within the previously described cases, consult the Bono Energia Technical Dept.
Steam connection
It shall connect the steam main valve to the steam header.
The piping must allows the thermal expansions in order to avoid stress on the valve.
If the utilities pressure is less than the generator operating pressure or if a constant pressure is required it is necessary to install a reducing valve provided with by-pass.
Water and condensate piping
The water tank receives the condensate and treated water. The float valve controls the treated water inlet; upstream the float valve it is advisable to install an gate valve to allow removal of float valve for maintenance purposes. In the tank upper section there are the vent and the condensate flanges. The over flow and blowdown connections are placed on the tank too. A filter is installed on the feed water pump suction side to pro¬tect the pump. The pipe must be as straight as possible. The height of the feed tank must assure the necessary head to a¬void pump cavitation and consequent insufficient water feed.
Oil piping (if any)
The main tank must be installed according to the Local Authority Specification.
It is necessary to heat the oil on the tank outlet to facilitate the pumping during cold seasons.
The pre-heating temperature is about 40-60°C.
Electrical tracing of heavy fuel oil lines is required to keep the oil at constant temperature while pumped.
Safety valves
Safety valve discharge has to be vented to atmosphere with a tube of same diameter than valve outlet at least following the most direct way.
The discharge pipe must be provided, at its lowest point with a condensate drain pipe and must be adequately supported and free to expand without stress on the valves.
ELECTRIC POWER CONNECTION
Connect electric line to RST terminals in boiler panel according to wiring diagram.
Check that line voltage is within + 5% of nominal value.
The general 3 phase switch, shall be provided and installed preferably outside the boiler room.
HYDRAULIC TEST
If hydraulic test is required, proceed as follows in order to prepare the generator for the hydraulic test:
- Exclude the safety valves by placing a steel disk with suitable thickness between the flanges and close the boiler valves.
- Close the pressure-switch on-off cock to prevent any damage to the internal parts.
- Remove the outlet cap from the level indicator and make the connection to the hand pump.
- Fill the generator with purified water using the boiler feed pump. Remember, in the event of a centrifugal pump, narrow the pump delivery in order to limit motor absorption. As for a single-impeller feed pump, the delivery valve must be open.
- During the filling phase vent the air through the vent valve until water flows out; then close the vent valve.
- When filling has been completed, make sure that the 3-way cock connected to the boiler manometer is open, pressurise the boiler with the centrifugal pump and then with the hand pump until the prescribed hydraulic test pressure is reached.
37
38
6. INSTALLATION
BOILER START UP
Boiler Filling
When filling the boiler, the water must appear just above the normal level (block) in a way to allow successive expansion when the water itself is heated.
At least one vent valve must be left open during the filling phase to prevent pressurisation of the boiler due to the effect of the air it contains; the operator must monitor the pressure trend carefully and stop the pump if any anomalies are detected.
Boiler must be filled slowly, in particular if water is hot, so that no dangerous stress occurs in pressure parts.
If boiler is partially filled, temperature of new water that is introduced shall be not higher or lower than 25 °C than temperature of water already present in the boiler.
Usually water temperatury should not less than 20°C for filling operation; if temperature is higher than 40°C filling must be carried out with extreme precautions.
IMPORTANT: drain levels and look at the filling to verify cleanliness and operation. For filling use only water with suitable characteristics
Preliminary operations
Before starting the boiler check that all auxiliary devices have been tested.
The following procedure is a summarised list of main controls to be carried out before starting up:
• check water level on level gauges: the level must be 30 mm over the block value
• check level gauges opening drains and looking at refilling
• check regulation valves drains and vents
• check safety valves installation and verify congruence between set point and stamp pressure of valves
• check minimum position of combustion air damper
• check all flanged connections and gaskets presence and check all bolts
• check that the man hole and the inspection hatches are closed with the bolts tightened and the gaskets in position;
• check that the requested quality of hot water is available
• check all safety logics and interblocks and check all safety instruments
ATTENTION:
if any of above checks has negative result do not start up boiler.
STARTING UP
After carrying out above operations boiler can be started up.
Burner operation and combustion shall be controlled during start up; air / fuel ratio shall be set in respect of flue gas analysis at different loads. CO content shall be limited within local law requirements.
Burner shall be ignited following relevant instructions and with strict respect of safety instructions considering also of fuel type
Boiler must be at minimum until steam flows from vent valve; from this situation is possible to closo vent valve and increase pressure.
Pressure shall be increased with burner low load.
ATTENTION:
too rapid temperature increase can create dangerous sress conditions and cause cracks
STEAM PRODUCTION
When set pressure is reached with boiler at minimum load, load can be increased and control can be set for automatic operation.
ATTENTION:
the system shall be kept continuously controlled until MCR has been reached to verify that no defects in safety system is present.
NORMAL OPERATION
When boiler begins maximum load production it is necessary to verify normal conditions for continuos economical and safe operation. Temperatures, pressure capacities shall be measured with precision and continuity and shall be compared with design figures; in particular flue gas temperature is directly associated with efficiency: an increase of this temperature is a decrease of efficiency.
An increase of pressure in combustion air / flue gas system indicate that flue gas channels are dirty and cleaning operation is urgently needed.
It is advisable to record all measures on a log book and in particular:
•
•
•
•
•
• fuel consumption flue gas analysis flue gas temperature air / flue gas pressure operation time and load any other useful note necessary to create a databank of the boiler.
39
6. INSTALLATION
During boiler operation a particular attention shall be paid to
A) Boiler water level
The normal water level in the boiler must be maintained at all times. If this is too high, water may be dragged into the steam, thus compromising its purity. If the level is too low, the boiler pipes may overheat or, in extreme cases, break. When in very low conditions, switch the fires off immediately and look for the causes of this situation before igniting again.
ATTENTION:
If level is below minimum stop immediately the burner and in any case do not refill with cold water the boiler. The furnace may explode immediately.
Levels gauges and switches shall be always perfectly efficient; level gauges shall be drained at any periodical personnel rotation to verify cleanliness.
Level gauges purge shall be carried out full opening slowly drain cocks and closing them looking at refilling: if water is drained too slowly repeat operation to purge levels from dirty.
40
B) Water treatment and continuous blow down (see also Table 4)
The chemical treatment of the feed water, the conditioning of the boiler water and the regulation of the concentration of the salts in the boiler water must be set accurately, as soon as the new boiler is used.
Blow down capacity shall be directly connected to total salt concentration in boiler water: periodical chemical analysis of boiler water are necessary to define exact capacity of blow down
C) Combustion
Efficient combustion is fundamental for good boiler operation: bad combustion can cause the production of unburned fuels, thus compromising boiler performance along with the formation of carbon deposits on the inner surfaces of the pipes with consequent dirtying (and further penalisation of performance).
Therefore combustion shall be monitored continuously.
In general good combustion is obtained with perfect air distribution in the burner: the position of the air swirler shall be correct and checked periodically.
ATTENTION:
it is absolutely necessary to respect all instructions of burner manufacturer during start up, normal operation and shut down of the burner. In particular it is always necessary to purge combustion chamber (with combustion air) before any burner start-up.
Combustion shall be optimised verifying air /fuel ratio (air excess) at any boiler and burner load. Air excess measurement can be performed by means of a flue gas oxygen content analysis; too high air excess causes efficiency reduction.
It is therefore necessary to periodically analyse the fumes released into the flue, in order to verify the correct maintenance of the operating parameters.
BOILER SHUTDOWN
When the boiler is stopped, the burner and the air fan must be put out of service following the Standards inherent the combustion system used.
Particular attention must be paid to the conditions in which the combustion system is left. When the burner has been switched off, the air fan must be left in service in order to complete cleaning of the combustion chamber and eliminate any trace of unburned fuel residues and then stopped.
The boiler must be left to cool down slowly as uniformly as possible. Accelerating cooling of the combustion chamber by allowing large masses of cold air to pass through the plant could lead to damage of the refractory materials and useless tensions in the pressurised parts.
Later, when the refractory materials have reached lower temperatures, the use of a small air flow through the burner will be allowed. At this point, the pressure in the boiler must be left to decrease naturally, without withdrawing steam or opening the valves. When the pressure has dropped below 1 bar, a vent valve can be opened.
When it is necessary to empty the boiler, boiler water temperature shall be below 100°C before openig boilers drains.
ATTENTION: before opening drains check if vent valve is opened to avoid vacuum condition in the boiler.
When the boiler has been fully drained inernal inspection can be performed.
41
7. SCOPE OF SUPPLY - STANDARD EQUIPMENT
STANDARD EQUIPMENT - STEAM-MATIC SG
Cylindrical furnace fitted with expansion joints up to model SG 1200 (corrugated type from model SG
1500)
Shell equipped with manholes, inspection and cleaning doors, flanged doors, steam outlet branch
BOILER
PRESSURE VESSEL
Moisture separator
Front and rear tube plates dished type, butt-welded to the shell and the furnace
Smoke tubes expanded and welded to the tube plates, internal turbulator system
Flanged connection for self-supporting stack, with counterflange
Water tube reversing chamber with upper and lower headers welded to the rear tube plate
INSULATION AND
EXTERNAL
LAGGING
BASE
Insulation of the external casing in mineral wool panels, stainless steel external lagging
Base frame made with iron bars
VALVES AND
ACCESSORIES
Main steam valve (manual)
N.2 Pressure safety valves
Shell blow down valve (surface)
N.2 Level indicators, with shut-off valve
N.2 Shell drain valves
N.2 Reversal chamber blow down valves
Flue gases thermoelement at the stack base
Flue gases sampling point at the stack base
Rear flame sight hole
Multi stage centrifugal pump (horizontal design)
WATER FEEDING
GROUP
On-off valve
Level regulation system with 1 pc. modulating pneumatic valve
Check valve
42
BURNING SYSTEM
(modulating regulation)
STANDARD EQUIPMENT - STEAM-MATIC SG
Burner box
Flame scanner
Observation port for flame control
Air swirler
Combustion air fan
Burning ignition torch
Natural gas pressure gauge
Internal gas header with multi-nozzle system
NATURAL GAS
FUEL (NG)
N.2 Feeding gas train electrically actuated shut-off valves
Feeding gas electrically actuated regulating valve
N.2 Burning ignition safety solenoid valves
HEAVY FUEL OIL
(HFO)
Fuel pump station, complete with on/off valve
Preheating station steam-electrical thermoregulation system
DIESEL OIL (DO) Fuel pump station, complete with on/off gate valve
Burner management system for burner ignition and flame control BMS (safety automatic device)
Safety pressure switch for minimum air combustion pressure
SAFETY AND
CONTROL
EQUIPMENT
FOR THE
BOILER
Temperature regulation system (only heavy fuel oil)
Gas leakage test- VPS (only gas fuel)
N.2 Max/min fuel pressure switches
Steam pressure transmitter
Shut-down pressure switch for max steam pressure
Automatic pressure modulating control regulator
ELECTRIC
WIRING
Automatic modulating level control regulator
With flexible conduits and tight terminal fittings for high mechanical resistance and water proof sealing
Steel cabinet, oven painting, front door, IP54 protection
ELECTRIC PANEL
Power section, main switch and door locking device, magneto-thermal switches to protect each power user, tropicalized power contactors
Control auxiliary section, ignition and flame control panel, alarms and shut-down logic, alarm horn contacts, auxiliaries protection fuses
Operators panel, burner START/STOP switch/indicator, feed pump START/STOP switch/indicator, alarms acknowledgement with lamps
* dual fuel burning systems are available (NG + HFO, NG + DO) and include the burning system equipment above listed for each fuel type.
43
7. SCOPE OF SUPPLY - OPTIONAL EQUIPMENT
ECONOMISER
(FOR HIGH
EFFICIENCY
UP TO 95%)
SET OF
INSTRUMENTS
FOR
ECONOMISER
OPTIONAL EQUIPMENT* - STEAM-MATIC SG
Package unit bult-in the front side of the generator structure insulation
Carbon steel tube bundle made of finned tubes and elbows
Set of headers for water inlet and outlet
N.2 Inspection and maintenance upper doors
Vent valves
Drain valve
N.2 Temperature gauge for inlet and outlet temperature
N.2 Shut-off manual valves
N.2 Pressure points
Safety valve
By pass valve (manual)
AIR
PREHEATER
(FOR HIGH
EFFICIENCY
UP TO 92%)
Package unit bult-in the front side of the generator structure
Double vertical carbon steel tubes bank, with flue gases running inside and air running outside the tubes.
N.2 Inspection and maintenance upper doors
SECOND FEED
WATER PUMP AS
SPARE (Installed on boiler base frame and connected to the boiler skid)
Multi stage centrifugal pump (horizontal design)
On-off valve
Check valve
FEEDING PUMP
SPEED CONTROL
SYSTEM (available for each pump)
COMBUSTION AIR
FAN SPEED
CONTROL SYSTEM
SPARE FUEL PUMP
Feeding pump speed control system (drived by electrical inverter)
Feed water pressure control loop
Electrical inverter
Spare fuel pump (available for liquid fuel burner)
AUTOMATIC
BOILER CONTROL
SYSTEM
«OPTISPARK»
BONO Optispark industrial boilers management and control automatic system
Flue gas oxygen control system with separated probe
Control system of the air/fuel ratio (SRC) and of the supply of oxygen (electric cam)
44
«SAFESPARK»
SYSTEM (24 HOUR)
OPTIONAL EQUIPMENT* - STEAM-MATIC SG
System for 24 hour boiler operating without human presence according to
EN 12953 Directive
N.2 Automatically controlled minimum level probes with periodical test, complete with switch
Automatically controlled high level probes with periodical test, complete with switch
Upgraded photocell, with automatically controlled periodical test
System for 72 hour boiler operating without human presence according to
EN 12953 Directive
N.2 Automatically controlled minimum level probes with periodical test, complete with switch
“SAFESPARK”
SYSTEM (72 HOUR)
Automatically controlled high level probes with periodical test, complete with switch
Upgraded photocell, with automatically controlled periodical test
Automatic TDS control system
Automatic blowdown
TDS CONTROL
SYSTEM
AUTOMATIC
BLOW-DOWN SYSTEM
Automatic TDS control system (already included in “SAFESPARK” system 72 hour)
Automatic blowdown system (already included in “SAFESPARK” system 72 hour)
LADDER AND
PLATFORM
Ladder and platform
THERMO - PHYSI-
CAL DEAERATOR
(ATMOSPHERIC OR
LOW-PRESSUR-
IZED)
Cylindrical body in carbon steel
Set of flanged connections
Support frame in carbon steel
Water on-off automatic valve
Feed water distribution system
Level indicator
Drain connection
Drain valve
Degassing tower (for low-pressurized deaerator)
WATER SOFTENER
Water softening station DUPLEX type (other types on request)
CHEMICAL DOSING
STATION
BLOWDOWN
VESSEL
Chemical dosing station (pH conditioner, oxygen scavenger)
Blowdown vessel
STEAM
SUPERHEATER
STEAM
HEADER
Shell and tube configuration that heats the saturated steam coming from the cylindrical drum, exchanging heat with the fumes, complete with safety valve and thermostat.
Steam header collecting system
CHIMNEY
Chimney complete with duct to connect boiler’s flue gas outlet, basaplate structure, cylindrical structure shell and anchor points to fix wool panels for insulation
* complete list of all available components on request
45
8. APPENDIX 1. FUEL CONSUMPTION CALCULATION
We assume that we have to calculate natural gas fuel consumption for the production of 5500 kg/h of saturated steam, working pressure is 13 bar, the fire tube steam boiler is a STEAM-MATIC SG 600 with economizer. Feed water temperature is 90 °C.
As nominal steam production of the fire tube steam boiler STEAM-MATIC SG 600 is 6000 kg/h, while actual steam production is 5500 kg/h, we calculate the load with the following equation (feed water T = 90 °C)-
5500
6000
According the graphic regarding the coefficient of performance (COP) of the steam boiler STEAM-MATIC SG
ECO, equipped with economizer crossed with load (see Figure 14), we define that COP is 94,7%.
96
95
94
93
92
91
25 50
Efficiency at 10 bar
% Load
Efficiency at 13 bar
75
Efficiency at 16 bar
100
In accordance with heat balance equation Q = M steam * (hg-he)/3600, where:
Q – heat needed to achieve saturated steam production with the above indicated characteristics (watt);
M steam - steam production (t/h); hg – enthalpy of saturated steam at the above indicated steam pressure and water temperature (kcal/kg); he – enthalpy of feeding water at the above indicated water temperature (kcal/kg);
According to the table of thermodynamic characteristics of water and saturated steam (Appendix 2), we define value hg under 13 bar pressure gauge and he with 90 °C.
Actual useful thermal load is defined by the relation:
Q actual useful = 5 500 * (666,8 – 90,0) = 3 172 400 kcal/h.
Total thermal power in the burner is defined by the equation:
Q burner = Q actual useful / (COP,%/100),
Q burner = 3 172 400/(94,7/100) = 3 349 947 kcal/h.
Fuel heat capacity of natural gas is 8500 kcal/Nm3.
We define fuel consumption per hour of natural gas under normal conditions from the relation:
3 349 947/8 500 = 394 Nm3/h.
46
9. APPENDIX 2. THERMODYNAMIC CHARACTERISTICS OF SATURATED STEAM
0,10
0,15
0,20
0,30
0,40
0,50
0,60
0,70
0,80
0,90
1,00 bar
Pm kg/cm
2
0,400
0,450
0,500
0,6
0,7
0,8
0,9
0
0,05
1,0
0 1,013
0,051 1,063 bar
0,050
0,100
0,150
0,200
0,250
0,300
0,350
0,102
0,153
0,204
0,306
0,408
0,510
0,612
0,714
0,816
0,918
1,020
1,113
1,163
1,213
1,313
1,413
1,513
1,613
1,713
1,813
1,913
2,013
1,543
1,645
1,747
1,849
1,951
2,053
0,816
0,918
1,020
1,033
1,084
1,135
1,186
1,237
1,339
1,441
Pa kg/cm
2
0,051
0,102
0,153
0,204
0,255
0,306
0,357
0,408
0,459
0,510
0,612
0,714
T
K
306,05
318,95
327,15
333,15
338,15
342,25
345,85
349,05
351,85
354,45
359,05
363,05
366,65
369,85
93,5
96,7
372,75 99,6
373,15 100,0
374,55 101,4
75,9
78,7
81,3
85,9
89,9
°C
32,9
45,8
54,0
60,0
65,0
69,1
72,7
375,75 102,6
378,25 105,1
379,35 106,2
380,55 107,4
382,65 109,5
384,75 111,6
386,65 113,5
388,55 115,4
390,25 117,1
391,95 118,8
393,55 120,4
1,149
1,038
1,024
0,971
0,923
0,881
2,087
1,869
1,694
1,673
1,601
1,533
1,471
1,414
1,312
1,225
6,204
5,229
4,526
3,994
3,577
3,240
2,732
2,365
V m
3
/kg
28,191
14,674
10,023
7,65
111,9
113,8
115,7
117,5
119,2
120,8
93,6
96,8
99,8
100,1
101,5
102,8
104,1
105,3
107,6
109,8 he kcal/kg
32,9
45,8
54,0
60,1
65,0
69,1
72,7
75,9
78,8
81,4
86,0
90,0
430,4
435,8
440,9
450,5
459,7
468,5
476,5
484,4
491,9
499,1
505,8
317,6
329,6
340,5
359,9
376,7
391,7
405,2
417,5
419,1
425,0 kJ/kg
137,7
191,8
225,9
251,5
272,0
289,3
304,3 r hg kJ/kg kcal/kg kJ/kg kcal/kg
2425 679,2 2562,7 612,1
2394,4 571,9 2586,2 617,7
2374,8 567,2 2600,7 621,2
2359,7 563,6 2611,2 623,7
2347,5 560,7 2619,5 625,7
2337,5 558,3 2626,8 627,4
2328,7 556,2 2633 628,9
2320,7 554,3 2638,3 630,2
2313,6 552,6 2643,2 631,4
2306,9 551,0 2647,4 632,4
2295,2 548,2 2655,1 634,2
2284,3 545,6 2661,0 635,6
2275,5 543,5 2667,2 637,1
2267,2 541,5 2672,4 638,3
2259,2 539,6 2676,7 639,4
2258,4 539,4 2677,5 639,5
2254,2 538,4 2679,1 639,9
2251,2 537,7 2681,6 640,5
2247,9 536,9 2683,7 641,0
2245,0 536,2 2685,8 641,5
2238,7 534,7 2689,2 642,3
2232,8 533,3 2692,5 643,1
2227,0 531,9 2695,5 643,8
2221,5 530,6 2698,0 644,4
2216,9 529,5 2701,3 645,2
2211,9 528,3 2703,8 645,8
2206,9 527,1 2705,9 646,3
2202,3 526,0 2708,0 646,8
Denomination
Pm - gauge pressure he - specific enthalpy of water
Pa - absolute pressure r - specific enthalpy of evaporation of steam
T – temperature V - specific volume hg - specific enthalpy of saturated steam
47
9. APPENDIX 2. THERMODYNAMIC CHARACTERISTICS OF SATURATED STEAM
4,00
4,20
4,40
4,60
5,00
5,50
6,00
6,50
7,00
7,50
8,00
2,40
2,60
2,80
3,00
3,20
3,40
3,60
3,80
1,40
1,50
1,60
1,70
1,80
1,90
2,00
2,20 bar
1,00
Pm kg/cm
2
1,020
1,10
1,20
1,30
1,122
1,224
1,326
1,428
1,530
1,632
1,733
1,835
1,937
2,039
2,243
4,079
4,283
4,487
4,691
5,099
5,608
6,118
6,628
7,138
7,648
8,158
2,447
2,651
2,855
3,059
3,263
3,467
3,671
3,875
5,112
5,316
5,520
5,724
6,131
6,641
7,151
7,661
8,171
8,681
9,191
3,480
3,684
3,888
4,092
4,296
4,500
4,704
4,908
Pa kg/cm
2
2,053
2,155
2,257
2,359
2,461
2,563
2,664
2,766
2,868
2,970
3,072
3,278
6,513
7,013
7,513
8,013
8,513
9,013
4,413
4,613
4,813
5,013
5,213
5 413
5,613
6,013
2,713
2,813
2,913
3,013
3,213
3,413
3,613
3,813
4,013
4,213 bar
2,013
2,113
2,213
2,313
2,413
2,513
2,613
T
K °C
393,55 120,4
395,05 121,9
396,55 123,4
398,05 124,9
399,45 126,3
400,75 127,6
402,05 128,9
403,25 130,1
404,55 131,4
405,65 132,5
406,85 133,7
409,05 135,9
411,15 138,0
413,15 140,0
415,05 141,9
416,85 143,7
418,55 145,4
420,35 147,2
421,95 148,8
423,55 150,4
425,15 152,0
426,55 153,4
427,95 154,8
429,35 156,2
432,05 158,9
435,25 162,1
438,15 165,0
440,95 167,8
443,65 170,5
446,15 173,0
448,55 175,4
0,374
0,361
0,348
0,336
0,315
0,292
0,272
0,255
0,240
0,227
0,215
0,536
0,509
0,483
0,461
0,44
0,422
0,405
0,389
0,743
0,714
0,689
0,665
0,643
0,622
0,603
0,568
V m
3
/kg
0,881
0,841
0,806
0,773
163,6
166,7
169,6
172,4
175,1
177,6
148,2
149,9
151,5
153,1
154,6
156,1
157,6
160,3
130,7
132,0
133,2
134,4
136,6
138,8
140,8
142,8
144,7
146,4 he kcal/kg
120,8
122,4
124,0
125,4
126,8
128,1
129,5
685,0
697,9
710,1
721,8
733,1
743,6
620,5
627,6
634,3
641,0
647,3
653,6
659,8
671,1
547,2
552,7
557,7
562,7
571,9
581,1
589,5
597,9
605,8
612,9 kJ/kg
505,8
512,5
519,2
525,0
530,9
536,3
542,2 r hg kJ/kg kcal/kg kJ/kg kcal/kg
2202,3 526,0 2708,0 646,8
2198,5 525,1 2711,0 647,5
2194,3 524,1 2713,5 648,1
2190,1 523,1 2715,1 648,5
2186,3 522,2 2717,2 649,0
2181,7 521,1 2718,1 649,2
2178,8 520,4 2721 649,9
2175 519,5 2722,3 650,2
2171,3 518,6 2723,9 650,6
2167,9 517,8 2725,6 651,0
2164,6 517 2727,3 851,4
2158,3 515,5 2730,2 652,1
2152 514,0 2733,1 652,8
2146,2 512,6 2735,7 653,4
2140,3 511,2 2738,2 654,0
2134,8 509,9 2740,7 654,6
2129,4 508,6 2742,4 655,0
2124,4 507,4 2744,9 655,6
2118,9 506,1 2746,5 656,0
2114,3 505,0 2748,6 656,5
2109,3 503,8 2750,3 656,9
2104,7 502,7 2752,0 657,3
2100,1 501,6 2753,7 657,7
2095,9 500,6 2755,8 658,2
2087,1 498,5 2758,3 658,8
2077,1 496,1 2762,0 659,7
2067,4 493,8 2765,4 660,5
2058,2 491,6 2768,3 661,2
2049,0 489,4 2770,8 661,8
2040,6 487,4 2773,8 662,5
2032,3 485,4 2775,8 663,0
48
bar
8,50
9,00
Pm kg/cm
8,667
2 bar
9,513
9,177 10,013
Pa kg/cm
2
9,700
10,210
9,50 9,687 10,513
10,00 10,197 11,013
11,00 11,217 12,013
12,00 12,236 13,013
13,00 13,256 14.013
10,720
11,230
12,250
13,269
14,289
14,00 14,276 15,013
15,00 15,296 16,013
16,00 16,315 17,013
17.00
17,335 18,013
18,00 18,355 19,013
19,00 19,374 20,013
20,00 20,394 21,013
21,00 21,414 22,013
22,00 22,433 23,013
23,00 23,453 24,013
15,309
16,328
17,348
18,368
19,388
20,407
21,427
22,447
23,466
24,486
24,00 24,473 25,013
25,00 25,493 26,013
26,00 26,512 27,013
27,00 27,532 28,013
28,00 28,552 29,013
29,00 29,571 30,013
30,00 30,591 31,013
25,506
26,525
27,545
28,565
29,585
30,604
31,624
T
K °C
450,85 177,7
453,15 180,0
455,25 182,1
457,25 184,1
481,15 188,0
464,85 191,7
468,25 195,1
471,45 198,3
474,55 201,4
477,55 204,4
480,35 207,2
483,05 209,9
485,65 212,5
488,15 215,0
490,45 217,3
492,75 219,6
494,95 221,8
497,15 224,0
499,25 226,1
501,25 228,1
503,25 230,1
505,15 232,0
507,05 233,9
508,85 235,7
0,100
0,095
0,090
0,087
0,083
0,080
0,077
0,0741
0,0714
0,0690
0,0667
0,0645
0,163
0,151
0,141
0,132
0,124
0,117
0,110
0,105
V m
3
/kg
0,204
0,194
0,185
0,177
845,7
859,6
872,9
885,5
897,6
909,4
921,1
932,0
942,4
952,9 kJ/kg
753,6
763,3
772,9
782,1
799,3
815,6
831,1
963,0
972,6
981,3
990,5
999,6
1008,4
1017,1
202,0
205,3
208,5
211,5
214,4
217,2
220,0
222,6
225,1
227,6 he kcal/kg
180,0
182,3
184,6
186,8
190,9
194,8
198,5
230,0
232,3
234,3
236,5
238,7
240,8
242,9 r hg kJ/kg kcal/kg kJ/kg kcal/kg
2024,3 483,5 2777,9 663,5
2016,4 481,6 2779,6 663,9
2008,8 479,8 2781,7 664,4
2001,3 478,0 2783,4 664,8
1987,1 474,6 2786,3 665,5
1973,7 471,4 2789,2 666,2
1960,7 468,3 2791,8 666,8
1948,1 465,3 2793,9 667,3
1936,4 462,5 2795,9 667,8
1924,7 459,7 2797,6 668,2
1913,4 457,0 2798,9 668,5
1902,5 454,4 2800,1 668,8
1891,6 451,8 2801,0 669,0
1881,5 449,4 2802,6 669,4
1871,5 447,0 2803,5 669,6
1861,5 444,6 2803,9 669,7
1851,4 442,2 2804,3 669,8
1842,2 440,0 2805,2 670,0
1832,6 437,7 2805,2 670,0
1821,6 435,0 2802,9 669,3
1812,5 432,8 2803,0 669,4
1803,6 430,7 2803,2 669,4
1794,9 428,6 2803,3 669,4
1786,2 426,5 2803,3 669,4
Denomination
Pm - gauge pressure he - specific enthalpy of water
Pa - absolute pressure r - specific enthalpy of evaporation of steam
T – temperature V - specific volume hg - specific enthalpy of saturated steam
49
10. APPENDIX 3. STEAM-MATIC SG SPECIAL EXECUTIONS
This section is dedicated to special executions of STEAM-MATIC SG firetube steam boilers, showing few examples of the great variety of solutions that BONO can provide to the customer. These are clear examples of the attention paid to the customers’ needs and the high level of quality standards and customization of the design and production of industrial steam boilers by BONO ENERGIA.
Figure 24
3D model of a special execution of a supplied STEAM-MATIC SG fire tube steam boiler. The particularity of the equipment is its capacity to guarantee more than 99% efficiency rate; this is possible due to the condensation
technology introduced. The result of this solution is the optimization of the combustion fumes’ temperature (avoiding acid condensation at the chimney) and the production of steam and hot water at a proper temperature according to the brewing processes.
50
Figure 25
Picture of the supplied STEAM-MATIC SG fire tube steam boiler, with an effective steam capacity of 20 ton/h at 15 bar, with efficiency rate above 99%. Field of application is a brewery, the boiler can be fuelled with natural gas, heavy fuel oil and a combination of natural gas and biogas, which is produced during the processes.
51
10. APPENDIX 3. STEAM-MATIC SG SPECIAL EXECUTIONS
Figure 26
3D drawings of STEAM-MATIC SG steam boilers, 20 t/h, 15 bar fuelled with natural gas and heavy fuel oil. Each one of the three boilers is complete with air preheaters, to achieve thermal efficiency up to 93%, and heat exchanger, to produce superheated water from steam. The supply includes deaerator and water treatment plant. This customized thermal plant’s field of application is district heating.
52
53
11. APPENDIX 4. BONO ENERGIA PRODUCT RANGE
STEAM BOILERS
» UNI-MATIC UM
FLASH COIL STEAM GENERATORS
Applications: food & beverage, textile industry, plastics and rubber industry, woodworking, laundries
Pressure: up to 12 bar
» STEAM-MATIC SM and SG
FIRE TUBE STEAM BOILERS beverage, district heating, plastics and rubber industry, chemicals and petrochemical industry, textile
UNI-MATIC UM
» CLAJTUB CTD
WATER TUBE STEAM BOILERS petrochemical industry, power generation utilities, sugar refineries
» HRSG
HEAT RECOVERY STEAM GENERATORS pharmaceutical, district heating, cogeneration, textile
From gas turbine: from 3 to 15 MW (el.),
STEAM-MATIC SG
CLAJTUB CTD
54
THERMAL FLUID HEATERS
» OIL-MATIC OMV
THERMAL FLUID HEATERS, MULTI-COIL
TECHNOLOGY
Applications: typography, cosmetics industry, wood & paper, chemical industry, petrochemical
Thermal capacity: 0.2 to 6 MW
Fluid temperature: up to 350 °C
» OIL-MATIC OMP
THERMAL FLUID HEATERS, MULTITUBULAR
Applications: pharmaceutical, petrochemical
Thermal capacity: from 1.7 to 17 MW
Temperature: up to 350 °C
» OIL-MATIC HTH
HIGH TEMPERATURE THERMAL FLUID
HEATERS
Applications: district heating, oil & gas, others
Thermal capacity: from 2 to 35 MW
OIL-MATIC OMV
SUPERHEATED WATER BOILERS
» CTH
MULTITUBULAR SUPER HEATED WATER
GENERATORS
Applications: district heating and others
Thermal capacity: up to 40 MW
package: up to 80 MW - field erected
Temperature: over 100 °C, up to 260 °C
» SM-ASA, SG-ASA
FIRE TUBE SUPERHEATED WATER BOILERS
Applications: district heating and others
Temperature: over 100 °C
CTH
OIL-MATIC OMP
55
DISCLAIMER: All the data presented in this technical book are indicative and subject of changing due to product customization and innovation processes.
They must be considered by the user only at the first stage of product selection; CANNON BONO declines any responsibility for wrong usage of mentioned data and invites the user to contact our commercial department for further details.
Bono Energia S.p.A
Via Resistenza 12 - 20068 Peschiera Borromeo (Mi) - Italy
Phone +39 0255302848 - Fax +39 025471955 www.bono.it
Ed. N°1
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