Thermal Fluid Heaters Oil-Matic 2 Thermal Fluid Heaters Series Oil-Matic

Technical Book Thermail FluidHeatersOMV

THERMAL FLUID HEATERS OIL-MATIC 2 THERMAL FLUID HEATERS SERIES OIL-MATIC

1. General Information about Thermal Fluid Heaters 2. Technical Highlights 3. Competitive Advantages 4. Technical Characteristics and Overall Dimensions 5. P&ID 6. Thermal Oil Circuit Layout 7. Thermal Oil System Elements 8. Installation 9. Thermal Fluid Brands & Types 10. Scope of Supply 11. Appendix 1. OIL-MATIC OMV Special Executions 12. Appendix 2. BONO ENERGIA Product Range

3 1. GENERAL INFORMATION

Thermal fluid heathers of the series OIL-MATIC, OIL-MATIC OMV fields of application are typically: type OMV, guarantee a power capacity range typographies, cosmetics, pulp and paper industry, between 200.000 Kcal/h and 5.000.000 Kcal/h, with chemical and petrochemical industry, oil a maximum working temperature of 350 °C. transportation devices, food&beverage, bitumen industry, textile and packaging industry. Models of the series OIL-MATIC include: OIL-MATIC heaters are supplied as packaged • OMV 200: up to 0,2 MW, 200.000 Kcal/h. units, complete with all necessary equipment and • OMV 300: up to 0,5 MW, 300.000 Kcal/h. ready to be connected to site utilities; the selection • OMV 400: up to 0,7 MW, 400.000 Kcal/h. of the oil circulation pumps, expansion tank • OMV 600: up to 0,9 MW, 600.000 Kcal/h. and oil storage tank is strictly depending on the • OMV 800: up to 0,2 MW, 800.000 Kcal/h. system type, anyway our technical and commercial • OMV 1000: up to 1,2 MW, 1.000.000 Kcal/h. specialists are available to select and quote the • OMV 1250: up to 1,5 MW, 1.250.000 Kcal/h. proper equipment case by case. • OMV 1500: up to 1,7 MW, 1.500.000 Kcal/h. • OMV 2000: up to 2,3 MW, 2.000.000 Kcal/h. As an optional, air preheater can be purchased • OMV 2500: up to 2,9 MW, 2.500.000 Kcal/h. additionally to the oil heater. Preheater enables • OMV 3000: up to 3,5 MW, 3.000.000 Kcal/h. the boiler to increase efficiency reaching 90% at • OMV 4000: up to 4,7 MW, 4.000.000 Kcal/h. full load. • OMV 5000: up to 5,8 MW, 5.000.000 Kcal/h. OIL-MATIC model OMV is available both in vertical and horizontal versions; OMV compact design is also suitable for small plants, although always guaranteeing high quality performances. OIL-MATIC OMV heaters 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.

Figure 1 Thermal Fluid Heaters series OIL- MATIC, type OMV, with ladder and platform.

4 Figure 2 Thermal Fluid Heater OIL-MATIC – OMV AIR

FUEL

OIL OUTLET

BURNER FLAME

OIL INLET EXHAUST GAS

1 OIL-MATIC coil 5 Thermal Oil Inlet 2 Heater’s body 6 Thermal Oil Outlet 3 Upper cover 7 Thermal Oil Drain 4 Burner 8 Thermal Oil inner coil/furnace

5 2. TECHNICAL HIGHLIGHTS

At first glance, thermal fluid heaters of different equipment producers may appear the same. Deeply analyzing their characteristics it is clear that OIL-MATIC OMV has outstanding technical features. OIL-MATIC OMV heaters can be used with a wide range of thermal fluids (both minerals and synthetics) and are available in a wide range of sizes, from 0,2 MW up to 5.8 MW. Thanks to its easy design OIL-MATIC OMV series has found a large and successful application in many heating processes.

OMV Design OMV design consists in a well proportioned heating surfaces dimensioning, where both the sections, radiant and convective, are designed according to recent up-to-date design formulas, taking into consideration of several critical process data such as heat flow density, specific thermal load per unit, max. recommended bulk and max. film temperature. Depending on the thermal output, OMV heaters employ up to 4 concentric coils, containing up to 7 pipes in parallel (see Figure 3); the extended convective section ensures a higher exploiting of the hot gases, a gradual heat exchange rate and reduced thermal stresses in the whole structure.

Figure 3. OIL-MATIC OMV seamless spiral heating coils

Thanks to our innovative design, the OMV range also ensures :

• Longer fluid life cycle • High safety margin during operation with thermal fluid temperature close to the maximum recommended bulk temperature. • Reduced carbon coating and carbon sooty formation at the film layer. • Uniform thermal fluid circulation velocity in each coil. • An innovative and reliable design of tube suspension ensures a free thermal expansion. • Thanks to the correct combination between wide surfaces (radiant and convective) and different fluid speed and flows, OMV ensures lower heat flow if compared with other design, with evident benefits in terms of lower tube wall and fluid film temperatures.

Multi Coil Design Properties OMV heater employs several coils pipe seamless type, having a reduced section in order to ensure higher fluid velocity and, consequently, a reduced Delta T between mass and wall fluid temperature. Thanks to the particular restricted section of the coil the fluid in OMV heater circulates in turbulent flow and the fluid speed at any point is in a status of continuous undergoing changes both in magnitude and direction; this implies a more balanced heat flow and increased heat transfer properties.

Moderate Delta Temperature between bulk and film In our OMV the fluid flow is in turbulent condition, which is enough to ensure flat temperature profile and a reduced difference between film and bulk temperature along the entire circuit.

6 Figure 4 Right side partially turbulent condition The fluid film, in this thermal flow condition, has a temperature of 30÷35°C higher than the bulk one and this situation leads to a fast flow degradation. Although only a part of the whole fluid volume is present in the film layer, if the fluid temperature exceeds the max. recommended value (as very often happens in the inner coil, called the radiant section), the whole volume of fluid is quickly involved in a larger degradation rate. The rate of degradation generally doubles with an increase of temperature of 10°C. The film temperature is not the only one to be controlled in this process, also the bulk temperature must be under control. A cracking event occurs in a coil heater when the fluid velocity (and consequently the turbulence) decreases and the thermal fluid remains in prolonged contact with the heated surfaces. Even though the bulk temperature may not change so evidently the film temperature can rise very quickly leading to cracking.

Figure 4 Left side turbulent condition This is the best operating condition peculiar of our OMV Coil Heater De- sign, characterized by a reduced difference of temperature between the film and the bulk.

Design of Heaters The fundamental principles.

In order to minimize the degradation rates when using mineral oils Figure 4 above 600° F (316°C), users should take extra care with a proper heat- Heat exchange in the oil pipes depending on oil speed er selection in terms of combustion chamber dimension choice. A larger volume combustion chamber allows more space around the burner, which minimizes the radiant energy reaching the coil surface. The same thing could be said regarding the space between the coils.

The radiant section is the area of the tubing that actu- ally faces the flame; depending on geometry and design, up to 70% of the total heat is transferred in the radiant section. The resulting localized heat flow can be three times the average in the entire heater, with film temperatures ex- ceeding the average fluid temperature by 150° F (83°C) or even more. In some heaters, the maximum recommended film temperature of a fluid can be exceeded even if the average temperature is largely within limits. OIL-MATIC employs a new coil design, which, if combined with the fluid’s turbulent flow, guarantees excellent heat transfer conditions and the best fluid temperature profile, as per recommendation of all the fluid suppliers. The fluid’s high turbulence and velocity rates in the radiant section prevent the formation of fluid stagnation ar- eas that might lead to boiling and hot spot phenomena and, consequently, rapid fluid degradation. Figure 5 Thermal fluid velocity in a OIL-MATIC heater 7 2. TECHNICAL HIGHLIGHTS

Moreover higher flow velocity in the coils enables to control the fluid itself with simpler control devices, which are not recommended on heaters with lower flow circulation speed, for the same thermal degradation prevention reasons.

Reduced Fluid Degradation Rate The reduced fluid degradation rate is achieved thanks to the homogeneous heat flow. On the con- trary, single or dual coil heater design (or fluid flow connected in parallel arrangements) are charac- terised by a wide unbalanced condition between the inner and outer coil where the difference in temperature both film and bulk can be over 35°C from the set point with a consequent reduced safety margin.

In OMV Heaters circulates only thermal fluids in liquid phase This condition allows a balanced heat transfer rate between the sections in order to ensure: • High fluid velocity in radiation section. Figure 6 • Reduced fluid degradation rate. Degradation rate vs Operating temperature • Maximum exploiting of the flue gases and high heat transfer rate also in the convection section. • Gradual fluid temperature increases in radiation section and in countercurrent to the gases in order to avoid any thermal shock.

Figure 7 Thermal oil heater series OIL-MATIC, type OMV, horizontal version 8 3. COMPETITIVE ADVANTAGES

• Two versions: vertical and horizontal.

• Wide choice of sizes. Our wide range allows our customers to define the proper capacity in accordance to their usage needs.

• Maximum efficiency and high reliability, with air preheater OMV can reach thermal efficiency up to 92%

• Multi coil design. Lower thermal stresses of the pressure vessel and higher prevention against fluid overheating.

• Easy maintenance. The upper cover facilitates inspection and cleaning of the combustion chamber and the internal parts of the steam generator.

• Easy-to-use and reliable automatic combustion regulation. Two-stages version: the regulation of air/fuel ratio is progressive and realized through on/off valves fitted on the fuel feeding lines; modulating version: realized Figure 8 through an electronic control system Thermal Fluid Heater OIL-MATIC – OMV, with acting on the burner output by means of a operator’s control panel modulating air/fuel servomotor.

• Compact design and high performance Thanks to its concentric multi-coil construction, OIL-MATIC has a large heating surface, nonetheless the compact design of the heater guarantees a better heat exchange.

Figure 9 Thermal Fluid Heater OIL-MATIC – OMV coils 9 4. TECHNICAL CHARACTERISTICS AND OVERALL DIMENSIONS: OIL-MATIC OMV

Table 1. Technical characteristics of thermal oil heater series OIL-MATIC type OMV. Characteristics of this table are generalized to the entire range of models OIL-MATIC. Additional data and deviations from standard are available on request. THERMAL FLUID HEATER SERIES OIL-MATIC, TYPE OMV MODELS OMV OMV OMV OMV OMV OMV OMV OMV OMV OMV OMV OMV OMV Unit 200 300 400 600 800 1000 1250 1500 2000 2500 3000 4000 5000 Mcal/h 200 300 400 600 800 1000 1250 1500 2000 2500 3000 4000 5000 Thermal capacity MW 0,2 0,3 0,5 0,7 0,9 1,2 1,5 1,7 2,3 2,9 3,5 4,7 5,8 Efficiency at 100 % of the load* % 87 87 87 87 88 88 88 88 88 88 88 88 88 Efficiency at 75 % of the load* % 87,5 87,5 87,5 87,5 88,5 88,5 88,5 88,5 88,5 88,5 88,5 88,5 88,5 Max. thermal fluid temperature °C 350 350 350 350 350 350 350 350 350 350 350 350 350 Pressure drop fluid side ΔP bar 1,0 1,0 0,6 1,3 1,1 1,4 0,7 1,1 0,8 1,5 1,5 2,0 2,0 Max ΔT between outlet and inlet temp. °C 30 30 30 30 30 33 40 40 40 40 40 50 50 OVERALL DIMENSIONS AND CONNECTIONS L Lenght mm 1250 1400 1620 1620 1880 1880 2020 2020 2120 2420 2470 2635 2800 W Width mm 1200 1300 1380 1380 1600 1600 1790 1790 1950 2140 2330 2665 3000 H Height mm 2050 2050 2450 2710 3350 3350 3420 3420 4000 4350 4600 5360 6120 N1 Thermal oil inlet flange DN 50 65 80 80 100 100 125 125 125 150 150 150 200 N2 Thermal oil outlet flange DN 50 65 80 80 100 100 125 125 125 150 150 150 200 N3 Thermal oil drain flange DN 20 20 20 20 25 25 25 25 25 25 25 25 25 N4 Natural gas inlet DN/PN 3/4" 1" 1" 1"1/2 1"1/2 2" 2" 2" 50/16 50/16 50/16 80/16 100/16 N6 Liquid fuel inlet DN/PN 1/2’’ 1/2’’ 1/2’’ 1/2’’ 3/4’’ 3/4’’ 1”1/2 1”1/2 1”1/2 2” 2” 2” 1/2 2” 1/2 N5 Stack diameter mm 164 220 314 314 400 400 400 400 400 470 470 535 600 Thermal oil volume in the boiler l 75 96 165 165 418 418 670 670 1070 1083 1530 2250 2970 Boiler empty weight t 1,1 1,4 1,6 1,7 2,7 2,7 3,3 3,3 4,4 5,7 7,2 10,6 14 TYPE OF BURNER (REGULATION STAGES)** Heavy fuel oil burner stages 1 stage 2 stages 2 stages or modulating modulating Natural gas fuel stages 1 stage 2 stages 2 stages or modulating modulating Diesel oil burner stages 1 stage 2 stages 2 stages or modulating modulating FUEL CONSUMPTION*** Min. gas pressure mbar 50 50 50 50 100 100 100 100 100 150 150 300 300 Nat. gas (100% of the load) Nm3/h 27,0 40,6 54,1 81,1 107,0 133,7 167,1 200,5 267,4 334,2 401,1 534,8 668,4 Nat. gas (75% of the load) Nm3/h 20,2 30,3 40,3 60,5 79,8 99,7 124,6 149,6 199,4 249,3 299,1 398,8 498,5 Diesel oil (100% of the load) l/h 22,5 33,8 45,1 67,6 89,1 111,4 139,3 167,1 222,8 278,5 334,2 445,6 557,0 Diesel oil (75% of the load) l/h 16,8 25,2 33,6 50,4 66,5 83,1 103,9 124,6 166,2 207,7 249,3 332,3 415,4 Heavy fuel oil (100% of the load) kg/h 23,7 35,5 47,4 71,1 93,7 117,2 146,4 175,7 234,3 292,9 351,5 468,6 585,8 Heavy fuel oil (75% of the load) kg/h 17,7 26,5 35,3 53,0 69,9 87,4 109,2 131,1 174,7 218,4 262,1 349,5 436,8 FUEL CALORIFIC POWER Heavy fuel oil*** kcal/kg 9700 Natural gas kca l/Nm3 8500 Diesel oil kcal/kg 10200 INSTALLED TOTAL ELECTRIC POWER (400V 3Ph+N) Heavy fuel oil KW 4,2 6,0 6,0 9,6 19,4 20,9 20,9 31,6 31,6 35,7 35,7 47,6 59,5 Nat. gas or diesel oil KW 0,4 0,5 0,7 1,5 1,5 2,2 4,6 4,6 10,2 15,3 15,3 20,4 25,5 THERMAL OIL CIRCULATION PUMP CHARACTERISTICS***** Flow rate m3/h 20 20 25 40 60 60 65 75 105 125 150 165 205 Pump head m 40404040404040404045455050 Installed total electric power KW 5,5 5,5 5,5 7,5 11 11 11 15 15 22 22 22 30 Power consumption KW 2,3 2,3 2,8 4,5 6,8 6,8 7,4 8,5 11,9 16,0 19,2 20,5 25,5 10 Figure 10 OIL-MATIC OMV overall dimensions, vertical version H W

* Efficiency calculated at thermal oil temperature 250 °C ** Indicated data of models’ burner regulation system are standard. Modulating regulation system for other models on request *** Fuel consumption calculated at thermal oil temperature 250 °C **** heavy fuel oil max viscosity considered is 7°E at 50°C, please ask for higher viscosities. ***** Typical application thermal oil circulation pump data; Bono Energia technical office will propose the most suitable solution according to customer’s needs L and plant’s characteristics (lenght of the thermal circuit, oil pressure drop in the system) 11 4. TECHNICAL CHARACTERISTICS AND OVERALL DIMENSIONS: OIL-MATIC OMV HORIZONTAL VERSION

Table 2. Overall dimensions and connections of thermal oil heater series OIL-MATIC type OMV, HORIZONTAL VERSION. Characteristics are generalized to the entire range of models OIL-MATIC. Additional data and deviations from standard are available on-demand. THERMAL FLUID HEATER SERIES OIL-MATIC, TYPE OMV HORIZONTAL VERSION MODELS OMV OMV OMV OMV OMV OMV OMV OMV OMV OMV OMV OMV OMV Unit 200 300 400 600 800 1000 1250 1500 2000 2500 3000 4000 5000 Mcal/h 200 300 400 600 800 1000 1250 1500 2000 2500 3000 4000 5000 Thermal capacity MW 0,2 0,3 0,5 0,7 0,9 1,2 1,5 1,7 2,3 2,9 3,5 4,7 5,8 Efficiency at 100 % of the load* % 87 87 87 87 88 88 88 88 88 88 88 88 88 Efficiency at 75 % of the load* % 87,5 87,5 87,5 87,5 88,5 88,5 88,5 88,5 88,5 88,5 88,5 88,5 88,5 Max. thermal fluid temperature °C 350 350 350 350 350 350 350 350 350 350 350 350 350 Pressure drop fluid side ΔP bar 1,0 1,0 0,6 1,3 1,1 1,4 0,7 1,1 0,8 1,5 1,5 2,0 2,0 Max ΔT between outlet and inlet temp. °C 30 30 30 30 30 33 40 40 40 40 40 50 50 OVERALL DIMENSIONS AND CONNECTIONS L Lenght mm 2050 2050 2450 2710 3350 3350 3420 3420 4000 4350 4600 5360 6120 W Width mm 1450 1450 1740 1740 1900 1900 2150 2150 2350 2490 2750 2875 3000 H Height mm 1390 1390 1390 1390 1680 1680 1810 1810 1960 2330 2380 2590 2800 N1 Thermal oil inlet flange DN 50 65 80 80 100 100 125 125 125 150 150 150 200 N2 Thermal oil outlet flange DN 50 65 80 80 100 100 125 125 125 150 150 150 200 N3 Thermal oil drain flange DN 20 20 20 20 25 25 25 25 25 25 25 25 25 N4 Natural gas inlet DN/PN 3/4" 1" 1" 1"1/2 1"1/2 2" 2" 2" 50/16 50/16 50/16 80/16 100/16 N6 Liquid fuel inlet DN/PN 1/2’’ 1/2’’ 1/2’’ 1/2’’ 3/4’’ 3/4’’ 1”1/2 1”1/2 1”1/2 2” 2” 2” 1/2 2” 1/2 N5 Stack diameter mm 164 220 314 314 400 400 400 400 400 470 470 535 600 Thermal oil volume in the boiler l 75 96 165 165 418 418 670 670 1070 1083 1530 2250 2970 Boiler empty weight t 1,2 1,5 1,7 1,8 2,8 2,8 3,4 3,4 4,5 5,8 7,3 10,7 14 TYPE OF BURNER (REGULATION STAGES)** Heavy fuel oil burner stages 1 stage 2 stages 2 stages or modulating modulating Natural gas fuel stages 1 stage 2 stages 2 stages or modulating modulating Diesel oil burner stages 1 stage 2 stages 2 stages or modulating modulating FUEL CONSUMPTION*** Min. gas pressure mbar 50 50 50 50 100 100 100 100 100 150 150 300 300 Nat. gas (100% of the load) Nm3/h 27,0 40,6 54,1 81,1 107,0 133,7 167,1 200,5 267,4 334,2 401,1 534,8 668,4 Nat. gas (75% of the load) Nm3/h 20,2 30,3 40,3 60,5 79,8 99,7 124,6 149,6 199,4 249,3 299,1 398,8 498,5 Diesel oil (100% of the load) l/h 22,5 33,8 45,1 67,6 89,1 111,4 139,3 167,1 222,8 278,5 334,2 445,6 557,0 Diesel oil (75% of the load) l/h 16,8 25,2 33,6 50,4 66,5 83,1 103,9 124,6 166,2 207,7 249,3 332,3 415,4 Heavy fuel oil (100% of the load) kg/h 23,7 35,5 47,4 71,1 93,7 117,2 146,4 175,7 234,3 292,9 351,5 468,6 585,8 Heavy fuel oil (75% of the load) kg/h 17,7 26,5 35,3 53,0 69,9 87,4 109,2 131,1 174,7 218,4 262,1 349,5 436,8 FUEL CALORIFIC POWER Heavy fuel oil*** kcal/kg 9700 kca l Natural gas 8500 Nm3 Diesel oil kcal/kg 10200 INSTALLED TOTAL ELECTRIC POWER (400V 3Ph+N) Heavy fuel oil KW 4,2 6,0 6,0 9,6 19,4 20,9 20,9 31,6 31,6 35,7 35,7 47,6 59,5 Nat. gas or diesel oil KW 0,4 0,5 0,7 1,5 1,5 2,2 4,6 4,6 10,2 15,3 15,3 20,4 25,5 THERMAL OIL CIRCULATION PUMP CHARACTERISTICS***** Flow rate m3/h 20 20 25 40 60 60 65 75 105 125 150 165 205 Pump head m 40 40 40 40 40 40 40 40 40 45 45 50 50

Installed total electric power KW 5,5 5,5 5,5 7,5 11 11 11 15 15 22 22 22 30

Power12 consumption KW 2,3 2,3 2,8 4,5 6,8 6,8 7,4 8,5 11,9 16,0 19,2 20,5 25,5 Figure 11 OIL-MATIC OMV overall dimensions, horizontal version.

L H

* Efficiency calculated at thermal oil temperature 250 °C ** Indicated data of models’ burner regulation system are standard. Modulating regulation system for other models on request *** Fuel consumption calculated at thermal oil temperature 250 °C **** heavy fuel oil max viscosity considered is 7°E at 50°C, please ask for higher viscosities. ***** Typical application thermal oil circulation pump data; Bono En- ergia technical office will propose the most suitable solution according to customer’s needs and plant’s characteristics (lenght of the thermal circuit, oil pressure drop in the system) W

13 4. TECHNICAL CHARACTERISTICS AND OVERALL DIMENSIONS: OIL-MATIC OMV PA

Table 3. Technical characteristics of thermal oil heater series OIL-MATIC type OMV PA. OMV PA version is available only from model OMV 800. Characteristics of this table are generalized to the entire range of models OIL-MATIC with air preheater. Additional data and deviations from standard are available on-demand.

THERMAL FLUID HEATER SERIES OIL-MATIC, TYPE OMV PA MODELS OMV PA OMV PA OMV PA OMV PA OMV PA OMV PA OMV PA OMV PA OMV PA Unit 800 1000 1250 1500 2000 2500 3000 4000 5000 Mcal/h 800 1000 1250 1500 2000 2500 3000 4000 5000 Thermal capacity MW 0,9 1,2 1,5 1,7 2,3 2,9 3,5 4,7 5,8 Efficiency at 100 % of the load* % 92 92 92 92 92 92 92 92 92 Efficiency at 75 % of the load* % 92,5 92,5 92,5 92,5 92,5 92,5 92,5 92,5 92,5 Max. thermal fluid temperature °C 350 350 350 350 350 350 350 350 350 Pressure drop fluid side ΔP bar 1,1 1,4 0,7 1,1 0,8 1,5 1,5 2,0 2,0 Max ΔT between outlet and inlet temp. °C 30 33 40 40 40 40 40 50 50 OVERALL DIMENSIONS AND CONNECTIONS L Lenght mm 3250 3250 3600 3600 3800 4500 4600 5400 5400 W Width mm 1600 1600 1750 1750 1950 2150 2550 2950 2950 H Height mm 3250 3450 3500 3500 3600 4000 4200 5300 6100 N1 Thermal oil inlet flange DN 100 100 125 125 125 150 150 150 200 N2 Thermal oil outlet flange DN 100 100 125 125 125 150 150 150 200 N3 Thermal oil drain flange DN 25 25 25 25 25 25 25 25 25 N4 Natural gas inlet DN/PN 1"1/2 2" 2" 2" 50/16 50/16 50/16 80/16 100/16 N6 Liquid fuel inlet DN/PN 3/4’’ 3/4’’ 1”1/2 1”1/2 1”1/2 2” 2” 2” 1/2 2” 1/2 N5 Stack diameter mm 400 400 400 400 400 470 470 535 600 Thermal oil volume in the boiler l 418 418 670 670 1070 1083 1530 2250 2970 Boiler empty weight t 3,7 3,7 4,8 4,8 5,9 7,8 9,4 15 20 TYPE OF BURNER (REGULATION STAGES)*** Heavy fuel oil burner stages *** Natural gas fuel stages 2 stages or modulating modulating Diesel oil burner stages *** FUEL CONSUMPTION**** Min. gas pressure mbar 100 100 100 100 100 150 150 300 300 Nat. gas (100% of the load) Nm3/h 102,3 127,9 159,8 191,8 255,8 319,7 383,6 511,5 639,4 Nat. gas (75% of the load) Nm3/h 76,3 95,4 119,2 143,1 190,8 238,5 286,2 381,6 476,9 Diesel oil (100% of the load) l/h 85,3 106,6 133,2 159,8 213,1 266,4 319,7 426,3 532,8 Diesel oil (75% of the load) l/h 63,6 79,5 99,4 119,2 159,0 198,7 238,5 318,0 397,5 Heavy fuel oil (100% of the load) kg/h 89,6 112,1 140,1 168,1 224,1 280,1 336,2 448,2 560,3 Heavy fuel oil (75% of the load) kg/h 66,9 83,6 104,5 125,4 167,2 209,0 250,8 334,4 417,9 FUEL CALORIFIC POWER Heavy fuel oil***** kcal/kg 9700 Natural gas kca l/Nm3 8500 Diesel oil kcal/kg 10200 INSTALLED TOTAL ELECTRIC POWER (400V 3Ph+N) Heavy fuel oil KW 19,4 20,9 20,9 31,6 31,6 35,7 35,7 47,6 59,5 Nat. gas or diesel oil KW 1,5 2,2 4,6 4,6 10,2 15,3 15,3 20,4 25,5 THERMAL OIL CIRCULATION PUMP CHARACTERISTICS****** Flow rate m3/h 60 60 65 75 105 125 150 165 205 Pump head m 40 40 40 40 40 45 45 50 50 Installed total electric power KW 11 11 11 15 15 22 22 22 30 Power consumption KW 6,8 6,8 7,4 8,5 11,9 16,0 19,2 20,5 25,5 14 Figure 12 OIL-MATIC OMV PA with air preheater overall dimensions. H W

* Efficiency calculated at thermal oil temperature 250 °C *** For technical reason we recommend natural gas burner. For other fuel please refer to technical office. **** Fuel consumption calculated at thermal oil temperature 250 °C ***** heavy fuel oil max viscosity considered is 7°E at 50°C, please ask for higher viscosities. ****** Typical application thermal oil circulation pump data; Bono Energia technical office will propose the most suitable solution according to customer’s needs and plant’s characteristics (lenght of the thermal circuit, oil pressure drop in the system)

15 4. TECHNICAL CHARACTERISTICS: THERMAL EFFICIENCY

87 Efficiency % Efficiency

84 Figure 13 The coefficient of performance (COP) of the thermal fluid heater OIL-MATIC (from model OMV 800), crossed with the load. The maximum efficiency with the three reference temperatures is reached at 75% of the load.

91 Efficiency % Efficiency

88 Figure 14 The coefficient of performance (COP) of the thermal fluid heater OIL-MATIC (from model OMV 800)equipped with an air preheater (PA), crossed with the load. The maximum efficiency with the three reference temperatures is reached at 75% of the load.

16 Figure 15 Thermal oil heater OIL-MATIC type OMV, with operator’s panel

Figure 16 Thermal oil heaters OIL-MATIC type OMV PA with air preheater installed, to achieve high efficiency

17 5. P&ID - BOILER ROOM (WITH ATMOSPHERIC EXPANSION TANK)

18 Figure 17 OMV – P&ID Elements Description A P&ID sample for an oil circuit containing an OIL-MATIC heater, a single wall oil storage tank, OMV Thermal Oil Heater OMV an atmospheric expansion tank, a circuit loading P1 Loading Pump pump and two oil circulation pumps. Modifications or other deviations from standard P2 Oil Circulation Pump are available upon demand. P3 Oil Circulation Pump (spare) T1 Oil Storage Tank U1 Utilities V1 Atomspheric Expansion Tank SUPPLY LIMIT

CANNON BONO CUSTOMER OMV – P&ID Symbols Meaning

LI Level Indicator

LSLL Level Switch Belove Low INSTRUMENTATION SYMBOLS

M Motor AND IDENTIFICATION ISA S-5.1 PDSL Pressure Differential Switch Low PDAL Pressure Differential Alarm Low PI Pressure Indicator QE Electrical Panel TAH Temperature Alarm High TAHH Temperature Alarm High Above TAH TE Temperature Element TI Temperature Indicator TIC Temperature Indicator Controller TISL Temperature Indicator Switch Low TLH Temperature Level High TSH Temperature Switch High TSHH Temperature Switch High Above TSH TV Temperature Valve

19 5. P&ID - BOILER ROOM (WITH PRESSURIZED EXPANSION TANK)

20 OMV – P&ID Elements Description B1 Thermal Oil Heater OMV Figure 18 A P&ID sample for an oil circuit containing P1 Loading Pump an OIL-MATIC heater, a double wall oil storage tank, a pressurized expansion P2 Oil Circulation Pump tank, a circuit loading pump and an oil P3 Oil Circulation Pump (spare) circulation pump. Modifications or other deviations from T1 Oil Storage Tank standard are available upon demand. U1 Utilities V1 Pressurized Expansion Tank

OMV – P&ID Symbols Meaning SUPPLY LIMIT LAL Level Alarm Low CANNON BONO CUSTOMER LI Level Indicator

LSLL Level Switch Below Low

M Motor INSTRUMENTATION SYMBOLS

PAL Pressure Alarm Low AND IDENTIFICATION ISA S-5.1 PDSL Pressure Differential Switch Low PDAL Pressure Differential Alarm Low PI Pressure Indicator PSHH Pressure Switch Above High PSL Pressure Switch Low PSV Pressure Safety Valve QE Electrical Panel TAH Temperature Alarm High TAHH Temperature Alarm High Above TAH TE Temperature Element TI Temperature Indicator TIC Temperature Indicator Controller TISL Temperature Indicator Switch Low TLH Temperature Level High TSH Temperature Switch High TSHH Temperature Switch High Above TSH TV Temperature Valve

21 5. P&ID - MODULATING BURNING SYSTEM (NATURAL GAS)

OMV – P&ID Elements Description Figure 19 Natural gas combustion modulating system P&ID. U10 Combustion air fan The data processing schemes are standardized to the entire OIL-MATIC OMV range; further measurements U11 Strainer and modifications are available on-demand.

OMV – P&ID Ancillaries Symbols Meaning

BAL Flame alarm low level

BE Flame scanner BSL Flame switch low level

BV On/off actuated valve

BZ Electrical igniter

FV Flow valve M Motor PAL/H Pressure alarm high

PCV Pressure control valve

PDSL Pressure differential switch low

PDAL Pressure differential alarm low

PI Pressure indicator PSH Pressure switch high PSL Pressure switch low VSP Gas leakage test (from OMV 800)

VSPAL Gas leakage test alarm high (from OMV 800)

Burner management system

Interlock - burner shutdown SUPPLY LIMIT INSTRUMENTATION SYMBOLS

Burner CANNON BONO CUSTOMER AND IDENTIFICATION ISA S-5.1

Flexible Joint

Autocleaner Strainer

22 *$6/($.$*( 7(67

23 5. P&ID - MODULATING BURNING SYSTEM, LIQUID FUEL (HEAVY FUEL OIL OR DIESEL OIL)

OMV – P&ID Elements Description Figure 20 Fuel oil combustion modulating system P&ID E10 Fuel oil preheater (may be heavy fuel oil or diesel oil). The data processing schemes are standardized P10 Fuel oil feed pump* to the entire OIL-MATIC OMV range; further measurements and modifications are available on-demand. U10 Combustion air fan

OMV – P&ID Ancillaries Symbols Meaning BAL Flame alarm low level BE Flame scanner BSL Flame switch low level BV On/off actuated valve BZ Electrical igniter FC Frequency controller FV Flow valve M Motor PI Pressure indicator TAL Temperature alarm low TSL Temperature switch low TIC Temperature indicator controller TE Thermoelement

Burner management system

Interlock - burner shutdown SUPPLY LIMIT INSTRUMENTATION SYMBOLS

Burner CANNON BONO CUSTOMER AND IDENTIFICATION ISA S-5.1

Autocleaner strainer

* Spare fuel oil feed pump on request

24 25 5. P&ID - MODULATING BURNING SYSTEM, DUAL FUEL (NATURAL GAS + LIQUID FUEL)

OMV – P&ID Elements Description Figure 21 E10 Fuel oil preheater Natural gas + liquid fuel oil dual fuel modulating combustion system P&ID. P10 Fuel oil feed pump* The data processing schemes are standardized to the entire OIL-MATIC OMV range; further U10 Combustion air fan measurements and modifications are available on-demand. U11 Strainer

OMV – P&ID Ancillaries Symbols Meaning BAL Flame alarm low levef

BE Flame scanner Burner management system BSL Flame switch low level BV On/off actuated valve Interlock - burner shutdown BZ Electrical igniter Burner FC Frequency controller FV Flow valve Autocleaner strainer M Motor

PAL/H Pressure alarm high Flexible Joint PCV Pressure control valve

PDSL Pressure differential switch low SUPPLY LIMIT INSTRUMENTATION SYMBOLS

PDAL Pressure differential alarm low CANNON BONO CUSTOMER AND IDENTIFICATION ISA S-5.1 PI Pressure indicator

PSH Pressure switch high

PSL Pressure switch low

TAL Temperature alarm low TSL Temperature switch low TIC Temperature indicator controller TE Thermoelement

VSP Gas leakage test (from OMV 800)

VSPAL Gas leakage test alarm high (from OMV 800)

* Spare fuel oil feed pumpon request

26 27 6. THERMAL OIL CIRCUIT LAYOUT

Figure 22 Typical thermal oil circuit layout, with thermal oil heater OMV, skid with two pumps, thermal oil expansion tank and thermal oil storage tank

4 1

28 7 5

1 Thermal Oil Heater OMV

2 Chimney

3 Oil Circulation Pump

4 Reserve Oil Circulation Pump

5 Thermal Oil Expansion Tank

6 Thermal Oil Storage Tank

7 Gear Pump

29 7. THERMAL OIL SYSTEM ELEMENTS

This section is dedicated to the equipment that is part of the thermal oil circuit. Having a high-profile know- how in the technology of the thermal fluid heaters, Bono Energia technical office can easily recommend and offer the best solution according to the customer’s needs.

A thermal oil system, besides one or more thermal oil heater, usually comprise:

• A thermal oil storage tank; it can be installed above ground with a storage basin or underground (a double-wall construction is required with the second option). The design volume is usually 1.5 times the total volume of oil in the plant. The tank must be assembled as required by the applicable standards, being especially careful to prevent fire outbreaks. If possible, it is preferable that the point of installation be below the minimum level of the plant, so that the thermal oil is drained spontaneously. It’s possible to drain the thermal oil when its temperature is lower than the one projected for the tank (usually room temperature);

• An expansion vessel to absorb fluid dilation: its capacity is usually about 1/3 of the total fluid contained in the plant. The expansion vessel can be either atmospheric or pressurized. The expansion vessel must be positioned so that the minimum pressure required by the suction pump inlet is guaranteed (NPSHr). The connecting line between the expansion vessel and the oil circuit must not be stoppable. The expansion vessel (and the connecting line) usually do not need to be insulated, because the temperature of the oil must be contained as much as possible in order to prevent oxidization of the thermal fluid when it comes into contact with the air. The atmosphere in contact with the oil can for this purpose be made inert with nitrogen, for this reason the vessel should be located in a safe area;

• A thermal fluid transfer pump (reversible) that can load and unload the plant;

• One or more user machines equipped with their own regulator and valve to adjust user heat capacity, to ensure oil circulation within the heater even if a heat request is missing; user heat capacity should be regulated in order to have the same thermal oil flow rate through the heater. A three-way valve can be used for this purpose. The valve can be a diverter or mixer-diverter valve.

• One or more circulation pumps which must be sized so as to ensure the flow of thermal oil required by the heater. The prevalence must overcome all frictions of the heater, valves, line, and connected utilities. Oil flow rate to the heater must in all operating conditions not be less than the one decided in the order, so as to ensure the oil lasts and that the heater is preserved intact and cracking is prevented. The electric circuit of the circulation pump is usually connected to the burner’s circuit so that if the motor trips, the burner is automatically disabled. Heater’s control panel is capable of managing the motor trip signal, even if circulation pumps are not supplied by Bono Energia.

30 7. THERMAL OIL SYSTEM ELEMENTS: GEAR PUMP OVERALL DIMENSIONS

Figure 23 OIL-MATIC OMV thermal oil gear pump overall dimensions and connections. Thermal oil gear pump selection depends on the total amount of oil in the circuit; Bono Energia technical office will propose the most suitable solution according to customer’s needs and plant’s characteristics (lenght of the thermal circuit, oil pressure drop in the system) H

L W

THERMAL OIL CIRCULATION GEAR PUMP

Unit PO 60 PO 100 PO 150 PO 250 PO 300

L Lenght mm 324 334 369 385 426 W Width mm 136 136 153 153 171 H Height mm 177 177 195 195 216 1 Thermal oil inlet DN/PN 3/4’’ 3/4’’ 3/4’’ 1’’ 1’’ 2 Thermal oil outlet DN/PN 3/4’’ 3/4’’ 3/4’’ 1’’ 1’’ Capacity l/h 600 1000 1500 2000 3000 Pump thrust m 25 Motor power kW 0,37 0,55 0,75 1,1 1,5

31 7. THERMAL OIL SYSTEM ELEMENTS: CIRCULATION PUMP SKID OVERALL DIMENSIONS - SINGLE PUMP

Typical application thermal oil circulation skid overall dimensions and connections; Bono Energia technical office will propose the most suitable solution according to customer’s needs and plant’s characteristics (lenght of the thermal circuit, oil pressure drop in the system)

Figure 24 OIL-MATIC OMV thermal oil circulation pump skid overall dimensions and connections. H

L W

THERMAL OIL CIRCULATION PUMP SKID DIMENSIONS AND CONNECTIONS (ONE PUMP SKID) OMV OMV OMV OMV OMV OMV OMV OMV OMV Unit OMV 200OMV 300OMV 400OMV 600 800 1000 1250 1500 2000 2500 3000 4000 5000

L Lenght mm 1400 1400 1500 1500 2000 2000 2450 2450 2550 2700 2700 3100 3100 W Width mm 400 400 400 500 500 500 600 600 600 600 600 600 600

H Height mm 1400 1400 1600 1600 1800 1800 1900 1900 2200 2550 2550 3000 3000 1 Base 2 Thermal oil circulation pumps DN 65 65 80 80 100 100 125 125 125 150 150 200 200 3 Thermal oil inlet connections PN 16 16 16 16 16 16 16 16 16 16 16 16 16 DN 65 65 80 80 100 100 125 125 125 150 150 200 200 4 Thermal oil outlet connection PN 16 16 16 16 16 16 16 16 16 16 16 16 16 DN 20 20 20 20 25 25 25 25 25 25 25 25 25 5 Thermal oil drain connection PN 16 16 16 16 16 16 16 16 16 16 16 16 16 J Antivibration Joints F Strainers

32 7. THERMAL OIL SYSTEM ELEMENTS: CIRCULATION PUMP SKID OVERALL DIMENSIONS - TWO PUMPS

Figure 25 OIL-MATIC OMV thermal oil circulation pump skid overall dimensions and connections.

THERMAL OIL CIRCULATION PUMP SKID DIMENSIONS AND CONNECTIONS (TWO PUMPS) OMV OMV OMV OMV OMV OMV OMV OMV OMV Unit OMV 200OMV 300OMV 400OMV 600 800 1000 1250 1500 2000 2500 3000 4000 5000 L Lenght mm 1400 1400 1500 1500 2000 2000 2450 2450 2550 2700 2700 3100 3100

W Width mm 1050 1050 1050 1300 1300 1300 1600 1600 1600 1600 1600 1600 1600 H Height mm 1650 1650 1850 1900 2100 2100 2300 2300 2600 2950 2950 3400 3400 1 Base 2 Thermal oil circulation pumps DN 65 65 80 80 100 100 125 125 125 150 150 200 200 3 Thermal oil inlet connections PN 16 16 16 16 16 16 16 16 16 16 16 16 16 DN 65 65 80 80 100 100 125 125 125 150 150 200 200 4 Thermal oil outlet connection PN 16 16 16 16 16 16 16 16 16 16 16 16 16 DN 65 65 65 65 65 65 65 65 65 65 65 65 65 5 Expansion line connection PN 16 16 16 16 16 16 16 16 16 16 16 16 16 DN 15 15 15 15 15 15 15 15 15 15 15 15 15 6 Vent connection PN 16 16 16 16 16 16 16 16 16 16 16 16 16 DN 20 20 20 20 25 25 25 25 25 25 25 25 25 7 Thermal oil drain connection PN 16 16 16 16 16 16 16 16 16 16 16 16 16 J Antivibration Joints F Strainers

33 7. THERMAL OIL SYSTEM ELEMENTS: ATMOSPHERIC EXPANSION TANKS

Table 4 Atmospheric expansion tank dimensions, vertical version*. Usually the volume of the expansion tank should be approximately 35% of the total amout of thermal oil in the circuit.

Oil Expansion Tank Atmospheric Type - ATM (Vertical version*)

Model VEO VEO VEO VEO VEO VEO VEO VEO VEO ATM 300 ATM 600 ATM 1000 ATM 1500 ATM 2000 ATM 3000 ATM 4000 ATM 5000 ATM 6000 Nominal capacity liters 300 600 1000 1500 2000 3000 4000 5000 6000 Diameter mm 600 800 900 1100 1270 1500 1500 1600 1800 Shell height mm 1000 1050 1500 1500 1500 1500 2000 2260 3020 Total height mm 1660 1800 2200 2200 2200 2310 2810 3030 3800 A) Inspection hole diameter mm 400 400 400 400 400 400 400 450 450 B) Overflow DN 32 50 50 50 50 50 65 65 65 F) Tank vent DN 15 25 25 25 25 25 25 25 25 G) Expansion DN 32 50 50 50 50 50 65 65 65 H) Total drain connection DN 25 40 40 40 40 40 40 40 40 I) Local Drain DN 15 15 15 15 15 15 15 15 15 L) Connection to vent header DN 25 25 25 25 25 25 25 25 25

Figure 26 Atmospheric expansion tank, vertical version

* horizontal version is also available on request 34 7. THERMAL OIL SYSTEM ELEMENTS: PRESSURIZED EXPANSION TANKS

Table 5. Pressurized expansion tanks dimensions - Vertical version*. Usually the volume of the expansion tank should be approximately 30% of the total amout of thermal oil in the circuit.

Oil Expansion Tank Pressurized Type - (Vertical version*) Model VEO VEO VEO VEO VEO VEO VEO VEO VEO P 300 P 600 P 1000 P 1500 P 2000 P 3000 P 4000 P 5000 P 6000 Nominal capacity liters 300 600 1000 1500 2000 3000 4000 5000 6000 Diameter mm 550 800 800 950 1100 1250 1400 1600 1700 Shell height mm 1050 1050 1500 1700 1700 2000 2000 2000 2500 Total height mm 1600 1900 2100 2700 2700 3200 3700 4200 4700 A) Inspection hole diameter mm 400 400 400 400 400 400 400 400 400 F) Tank vent DN 15 25 25 25 25 25 25 25 25 G) Expansion DN 32 50 50 50 50 50 65 65 65 H) Total Drain DN 25 40 40 40 40 40 40 40 40 I) Local Drain DN 15 15 15 15 15 15 15 15 15 L) Connection to vent header DN 25 25 25 25 25 25 25 25 25 P1) Nitrogen pressurization DN 15 15 15 15 15 15 15 15 15 PSV) Safety valve inches 1/2’’ 1/2’’ 1/2’’ 1/2’’ 1/2’’ 1/2’’ 1/2’’ 1/2’’ 1/2’’

Figure 27 Pressurized expansion tank, vertical version

* horizontal version is also available on request 35 7. THERMAL OIL SYSTEM ELEMENTS: THERMAL FLUID DUAL WALL STORAGE TANKS

Table 6 Dual wall storage tank dimensions

Thermal Fluid Storage Tank – dual wall - VEO Model VEO VEO VEO VEO VEO VEO VEO VEO VEO VEO 1000 2000 4000 5000 6000 8000 10000 12000 15000 20000 Dual wall storage tank capacity liters 1000 2000 4000 5000 6000 8000 10000 12000 15000 20000 L) Length mm 1500 1800 2050 2500 3500 4050 4000 4200 5000 5000 Tank diameter (Ø) mm 1100 1300 1600 1600 1600 1600 1900 1900 2200 2350 A) Overflow DN 32 40 40 50 50 50 50 65 65 65 B) Vent (Ø) inch ½” ¾” ¾” ¾” ¾” ¾” ¾” 1” 1” 1” C) Inlet (Ø) inch 2” 2” 2” 2” 2” 2” 2” 2” 2” 2” D) Pump suction (Ø) inch 1” 1 ¼ “ 1 ¼ “ 1 ¼ “ 1 ½ “ 1 ½ “ 1 ½ “ 2” 2” 2” F) Drain (Ø) inch ¾” ¾” ¾” ¾” ¾” ¾” ¾” ¾” ¾” ¾” Wall thickness mm 4 4 4 4 4 4 4 4 4 4 Empty weight Kg 450 770 960 1090 1230 1640 2290 2430 3390 3850 DIAMETER

Figure 28 Dual wall storage tank

36 7. THERMAL OIL SYSTEM ELEMENTS: THERMAL FLUID STORAGE TANKS Table 7 Single wall storage tank dimensions Thermal Fluid Storage Tank – single wall Model VEO VEO VEO VEO VEO VEO VEO VEO VEO VEO 1000 2000 4000 5000 6000 8000 10000 12000 15000 20000 Single wall storage tank capacity liters 1000 2000 4000 5000 6000 8000 10000 12000 15000 20000 L) Length mm 1500 1800 2050 2500 3500 4050 4000 4200 5000 5000 Tank diameter (Ø) mm 1100 1500 1600 1600 1600 1600 1900 1900 2200 2350 A) Overflow DN 32 40 40 40 50 50 50 65 65 65 B) Vent (Ø) inch ½” ¾” ¾” ¾” ¾” ¾” ¾” 1” 1” 1” C) Inlet (Ø) inch 2” 2” 2” 2” 2” 2” 2” 2” 2” 2” D) Pump suction DN 25 32 32 32 40 40 40 50 50 50 F) Drain DN 15 15 15 15 20 20 20 20 20 20 Wall thickness mm 3 4 4 4 4 4 5 5 5 5 Empty weight Kg 220 410 550 580 650 810 1250 1350 1630 1790 Saddle dimensions SL) Saddle length mm 650 900 1100 1100 1100 1100 1300 1300 1400 1500 SD) Saddle distance mm 800 950 1100 1300 1800 2100 2100 2150 2600 2600 SW) Saddle width mm 100 160 160 200 200 200 200 200 200 200 DIAMETER

Figure 29 Single wall storage tank

37 8. INSTALLATION

GENERAL COMMENTS

To operate at its best, the Generator must be installed correctly and must be operated and checked in accordance with the instructions provided in the manual

The Generator is supplied as a completely operational monoblock unit. The Generator must be installed upon a rigid level base, preferably on a concrete slab, in a place that gives personnel adequate access to the equipment. Good ventilation is essential to supply a quantity of air sufficient for combustion and a suitable temperature for the normal functioning of the electrical devices (the temperature must not exceed 35-40°C). The premises housing the boiler must have at least two entrances for air that are always open. One entrance must be as close as possible to the fan. The height of the boiler room must be sufficient to allow personnel to gain access to the burner. THE GENERATOR MUST NOT BE INSTALLED IN THE OPEN UNDER A ROOF ! UNLESS IT HAS BEEN CONSTRUCTED FOR THIS PURPOSE. CONNECTIONS TO BE CARRIED OUT • Chimney pipe for smoke • Oil pipes • Pipes to discharge oil from the generator • Connection pipes to the expansion chamber • Feeding pipes for combustible material • Electric power to the board

DURING INSTALLATION FIRST MAKE THE HYDRAULIC CONNECTIONS AND ! THEN THE ELECTRIC CONNECTIONS CHIMNEY The chimney pipe must not have a diameter that is smaller than that of the boiler exit connection and its height must conform to the provisions in force. In every case throttling or localized flow resistance must be avoided as this may inhibit the proper functioning of the Generator.

OIL PIPING Make the connections between the generator outlet, the installation delivery and the return pipes to the intake connection of the circulation pump. Install a filter in front of the circulation pump to hold back any impurities. The diameter of the pipes must not be less than that of the boiler connection; to limit flow resistance there must not be any narrowing of the pipes nor must there be any corners. In order to limit heat loss along the pipes we recommend covering them with an insulating material.

The oil pipe connection is supplied with a flange. In the designing stage the manufacturer did not provide for any load on these connections. Accordingly, any type of mechanical strain due to the weight of the pipes or expansion stress must ! be avoided. If this is not possible an expansion joint and/or suitably sized supports must be provided. PIPING AND CONNECTIONS TO THE EXPANSION CHAMBER Run a pipe from the pump intake pipes (return from the installation) and connect it to the expansion chamber. This pipe must be as straight as possible and counter-slopes and traps must be avoided. Moreover, all the breather pipes of the installations must be channelled into the expansion chamber.

38 ELECTRICAL CONNECTIONS Always refer to the enclosed wiring diagram. • Check that the tension and the frequency correspond to that indicated in the enclosed wiring diagram. • The customer is responsible for the connection and installation of the power cable. The electrical installation must be carried out in a workmanlike manner in accordance with EN 60204. • Always install a differential magnetothermic switch of adequate amperage “upstream” of the power line.

OPERATIONS TO FILL AND EMPTY THE INSTALLATION Fill the generator and the installation as follows: • Ensure that all the following valves are open: • Service on-off valves • Oil circulation pump on-off valves (if a reserve circulation pump is installed the on-off valves of this pump must also be open) • Boiler and installation relief valves and the expansion chamber atmospheric relief valves (VEO). • Storage tank relief valve • Check that the expansion chamber draining valves are closed. • At this point, check that the direction of rotation of the transfer pump is that for intake and not vice-versa. • Start the transfer pump and commence filling the plant, from the bottom to the top to facilitate the expul- sion of air. As soon as the level of oil in the expansion chamber has reached the minimum level on the visual indicator, stop the pump and close the following valves: • Generator exhaust valves • Service outlet valves • Expansion chamber exhaust valves • Oil transfer and reserve circulation pump on-off valves The air valves must remain open Proceed to bleed the oil circulation pump using the plug located on the shaft support. If required, grease the bearings of the pump and the motor and check the alignment of the connection joint by turning the pump by hand. Start the pump and check the direction of rotation. Check the absorption of the motor. The oil pump must be made to operate for a certain amount of time before lighting the burner - in any event until no further varia- tions in pressure are noted on the oil inlet and outlet gauges of the generator. After the burner has been lit at the minimum setting, maintain an oil temperature gradient that does not exceed 60-70°C for each hour of operation.

When a temperature of 120-130°C has been reached carry out the following operations: • Stop the oil circulation pump and close all the breathers of the generator (the breathers of the expansion chamber and the storage tank must always remain open). • Drain any condensate in the expansion chamber • Re-start the pump and the burner at the minimum setting and thereafter bring the oil temperature to the maximum working value. • If drops in pressure due to cavitations of the pump occur, it is necessary to stop the burner and to bleed the installation by opening the vent located at the highest point of the installation, whilst the pump is operating, until the inlet and outlet pressure from the generator stabilizes.

N.B. To restore the oil level in the expansion chamber it is necessary to: open the transfer pump isolating valve open the expansion chamber exhaust valve start the oil transfer pump and load the chamber to the cold working level stop the pump close the expansion chamber exhaust valve close the oil transfer pump isolating valve.

39 9. THERMAL FLUID BRANDS & TYPES - MINERAL FLUIDS

This section is dedicated to the thermal fluid selection. The type of thermal oil should be chosen according to the maximum working temperature, considering that under normal working conditions film temperature is approximately 20 °C higher than bulk temperature For example: Max working temperature = 260 °C; Δ T Film - Bulk = 20 °C T Film = 280 °C

Table 8 Typical characteristics of a suitable mineral fluid to be used in our OMV series.

Characteristic Unit Value of suggested mineral oil

Max. working temperature °C 300 Pour point temperature °C -10 Viscosity at 40°C cSt 20 Flash point temperature COC (VA) °C 220 Specific weight at 15°C Kg/dm3 0,86 Specific weight at 250°C Kg/dm3 0,68 Specific heat at 15°C KJ/Kg K 2,0 Specific heat at 250°C KJ/Kg K 2,8 Vapor pressure mbar 80

Table 9 Mineral fluids brands and types.

Supplier Brand Oil type PETRO-CANADA CALFLO ESSO ESSOTHERM 500 AGIP ALARIA 3 BP TRANSCAL LT-N MOBIL MOBILTHERM 605 SHELL THERMIA B

40 9. THERMAL FLUID BRANDS & TYPES - SYNTHETHIC FLUIDS

Table 10 Typical characteristics of a suitable synthetic fluid to be used in our OMV series.

Value of suggested Value of suggested synthetic Characteristic Unit synthetic oil (liquid phase) oil (vapor phase) Max. working temperature °C 345 400 Pour point temperature °C -32 +12 Viscosity at 40°C cSt 29,64 2,48 Flash point temperature COC (VA) °C 170 110 Specific weight at 20°C Kg/dm3 1,008 1,064 Specific weight at 300°C Kg/dm3 0,808 0,818 Specific heat at 20°C KJ/Kg K 1,560 1,540 Specific heat at 300°C KJ/Kg K 2,570 2,314 Vapor pressure at 200°C kPa 2,23 24,00 Vapor pressure at 300°C kPa 30 239

Table 11 Synthetic fluids brands and types.

Supplier Brand Oil type SOLUTIA THERMINOL 55 / THERMINOL 66 / THERMINOL VP1 DOW DOWTHERM Q DOW SYLTHERM 800 DOW DOWTHERM A

41 10. SCOPE OF SUPPLY - STANDARD EQUIPMENT

STANDARD EQUIPMENT - OIL-MATIC OMV Set of concentric tangent coils made of carbon steel tubes THERMAL OIL HEATER PRESSURE VESSEL Spiral coil tubular screen on the upper furnace (from OMV 800) Carbon steel heater shell containing the coils Removable cover for inspection Flanged connection for stack with counterflange included REFRACTORIES Refractory material INSULATION AND Insulation of the external casing in mineral wool panels EXTERNAL LAGGING Stainless steel external lagging BASE Base frame made with iron bars VALVES AND Set of thermal fluid inlet and outlet pressure gauges ACCESSORIES Set of thermal fluid inlet and outlet thermocouples Burner box Flame scanner Burning ignition device Observation port for flame control Air swirler Combustion air fan BURNING SYSTEM Natural gas pressure gauge - Monoblock (with integrated air fan) Internal gas header with multi-nozzle system NATURAL GAS - Dual block (with FUEL (NG) N.2 Feeding gas train electrically actuated shut-off valves separated air fan) Feeding gas electrically actuated regulating valve

Fuel pump station, complete with on/off valve HEAVY FUEL OIL (HFO) Preheating station electrical thermoregulation system

DIESEL OIL (DO) Fuel pump station, complete with on/off gate valve TYPE OF FUEL AVAILABLE*

Cycle programming panel for burner ignition and flame control (safety automatic device)

BURNING CONTROL Safety pressure switch for minimum air combustion pressure AND SAFETY Gas leakage test - VPS (only for natural gas fuel, from model OMV 800) EQUIPMENT Temperature switches for fuel temperature regulation (only for heavy fuel oil) N.2 Max/min gas pressure switches (for gas fuel only) Steel cabinet, oven painting, front door, IP54 protection Power section, main switch and door locking device, magneto-thermal switches to protect each power user, tropicalized power contactors ELECTRIC PANEL Control auxiliary section, ignition and flame control panel, alarms and shut-down logic, alarm horn contacts, auxiliaries protection fuses

Burner START/STOP switch/indicator, alarms acknowledgement with lamps Alarm panel (from model OMV 800) N.2 Thermoelements for inlet/outlet thermal fluid temperature detection Heater inlet thermal fluid indicator (digital electronic type) THERMAL OIL HEATER Heater outlet thermal fluid regulator, digital electronic type SAFETY EQUIPMENT Safety differential pressure switch for inadequate thermal fluid circulation Automatic thermal oil pump switch off system (from model OMV 800) Burner interlock for thermal fluid circulation for pump motor trip ELECTRIC WIRING With flexible conduits and tight terminal fittings for high mechanical resistance and water proof sealing

42 * dual fuel burning systems are available (NG + HFO, NG + DO) and include the burning system equipment above listed for each fuel type. 10. SCOPE OF SUPPLY - OPTIONAL

OPTIONAL EQUIPMENT - OIL-MATIC OMV Tube bank with flue gases running inside and air running outside the tubes

AIR PRE-HEATER (FOR EFFICIENCY UP TO 92%) Rectangular section shape casing FROM MODEL OMV 800 Mineral wool insulation, external covering made of stainless steel Inspection and maintenance bottom door COMBUSTION AIR FAN SPEED CONTR. SYSTEM Electrical inverter SPARE FUEL PUMP (FOR LIQUID FUEL BURNER) Spare fuel pump THERMAL OIL CIRCULATION PUMP Single stage centrifugal pump N.2 On-off valves Strainer COMMON SKID FOR N.2 Pressure indicators OIL CIRCULATION PUMP (FOR ONE PUMP) N.2 Antivibration connection (for antivibration joints and for press. indicators) Magneto-thermal swich for motor pump control (star-triangle connection from 18,5 kW) Piping and fittings N. 4 On-off valves N. 2 Strainers COMMON SKID FOR N. 4 Pressure indicators TWO OIL CIRCULATION PUMPS N. 4 Antivibration connection (for antivibration joints and for press. indicators) N. 2 Magneto-thermal swiches for motor pump control (star-triangle connection from 18,5 kW) Piping and fittings Body of the tank OIL STORAGE TANK Set of saddles (SINGLE WALL) Set of flange connections Body of the tank

OIL STORAGE TANK Manometer (DOUBLE WALL) Pump suction check valve Set of flanged connections Body of the tank Level indicator

OIL EXPANSION TANK Inspection hole (ATMOSPHERIC TYPE) Low level switch Temperature indicator Set of flanged connections Body of the tank Level indicator Inspection hole OIL EXPANSION TANK Low level switch (PRESSURIZED TYPE) Thermometer Safety valve Pressure switch Thermal fluid loading pump OIL LOADING PUMP Pump electrical starter (integrated in the electrical panel) BONO Optispark industrial boilers management and control automatic system

AUTOMATIC BOILER CONTROL SYSTEM Burner management system (BCU) «OPTISPARK» (FROM MODEL OMV 1000) Flue gas oxygen control system with separated probe Control of the air/fuel ratio (GARC) and of the supply of oxygen (electric cam) THERMAL OIL DEAERATOR Thermal oil deaerator 43 LADDER AND PLATFORM Ladder and platform

11. APPENDIX 1. OIL-MATIC OMV SPECIAL EXECUTIONS

This section is dedicated to special executions of OIL-MATIC OMV thermal fluid heaters, 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 30 Thermal oil heater OIL-MATIC OMV equipped with two circulation pumps, installed in the same skid. This heater is equipped with air preheater to achieve thermal efficiency up to 92%.

Figure 31 View of an OIL-MATIC OMV customized electrical panel. This boiler was highly customized, with an explosion-proof construction, according to ATEX Directive. Another peculiar aspect of the boiler is the fuel burnt, which is hydrogen sul-

phide ( H2S )

44 Figure 32 In this special execution, three circulation pumps are installed on a single skid. This is a special execution available for special projects, in this case two pumps plus are installed with a reserve one, whose use can be splitted for two boilers

Figure 33 Three OIL-MATIC OMV thermal oil heaters. These heaters’ field of application is Oil & Gas; the fuel burnt is a combination of diesel oil and hydrogen sulphite, another example of our expertise and know-how in combustion technologies, which ensures highly customized solutions.

45 11. APPENDIX 1. OIL-MATIC OMV SPECIAL EXECUTIONS

Figure 34 A P&ID sample for two OIL-MATIC heaters, an oil storage tank, an expansion tank, a circuit loading pump and three circulation pumps. In this application A P&ID sample for two OIL-MATIC heaters, an oil storage tank, an expansion tank, a circuit loading pump and three circulation pumps. In this application In this application there are two independent thermal oil circuits, with different Δ T. Moreover in this customized solution the circuits have two different flow rates, thus guarateeing each consumer’s request.This P&ID was designed for a highly customized project and represents an indicative solution, please ask for available modifications.

SUPPLY LIMIT INSTRUMENTATION SYMBOLS OPTION CANNON BONO CUSTOMER AND IDENTIFICATION ISA S-5.1 46 OMV – P&ID Elements Description OMV – P&ID Symbols Meaning

B1-B2 Thermal Oil Heater OMV LI Level Indicator TE Temperature Element

H1 Thermal Oil Header (from plant) M Motor TIC Temperature Indicator Controller H2 Thermal Oil Header (to plant) PDSL Pressure Differential Switch Low TISL Temperature Indicator Switch Low L1 Chimney PDAL Pressure Differential Alarm Low TLH Temperature Level High P1-P2-P3 Oil Circulation Pumps P4 Second Circuit Pump PI Pressure Indicator TSH Temperature Switch High P5 Oil Loading Pump QE Electric TSHH Temperature Switch High Above TSH T1 Oil Storage Tank TAH Temperature Alarm High TV Temperature Valve U1 Utilities TAHH Temperature Alarm High Above TAH V1 Atmospheric Expansion Tank 47 12. APPENDIX 2. BONO ENERGIA PRODUCT RANGE

STEAM BOILERS » UNI-MATIC UM FLASH COIL STEAM GENERATORS Applications: food & beverage, textile industry, plastics and rubber industry, woodworking, laundries Steam production: from 0.3 to 3 t/h Pressure: up to 12 bar

UNI-MATIC UM » STEAM-MATIC SM and SG FIRE TUBE STEAM BOILERS Applications: pulp and paper industry, food & beverage, district heating, plastics and rubber industry, chemicals and petrochemical industry, textile Steam production: from 1 to 25 t/h Pressure: from 12 to 30 bar

» CLAJTUB CTD WATER TUBE STEAM BOILERS Applications: chemical processes, refinery, petrochemical industry, power generation utilities, sugar refineries Steam production: up to 180 t/h Pressure: up to 80 bar Temperature: up to 480 °C STEAM-MATIC SG

» HRSG HEAT RECOVERY STEAM GENERATORS Applications: paper mill, chemical and pharmaceutical, district heating, cogeneration, textile Steam production: up to 40 MW From gas turbine: from 3 to 15 MW (el.), from engine: from 3 to 20 MW (el.)

CLAJTUB CTD CLAJTUB CT

48 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 OIL-MATIC OMV 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 Temperature: up to 400 °C

SUPERHEATED WATER BOILERS » CTH MULTITUBULAR SUPER HEATED WATER OIL-MATIC OMP 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 Thermal capacity: from 0.7 to 17 MW Temperature: over 100 °C

CTH

49 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