FIRE TUBE STEAM BOILERS STEAM-MATIC- SG

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 Thermal efficiency reaches 95% thanks to the
saturated or superheated steam, with design optimization of heat exchange and by using our
pressure range from 12 bar up to 30 bar. Range of economizer, an equipment which can be fully
steam production is between 6000 and 25000 Kg/h. integrated into the boiler. Thermal efficiency higher
An efficient design, high-quality construction and than 95% may be achieved thanks to special solutions
an innovative control system guarantee high level by Cannon BONO.
performance and low energy costs.
Fields of application of STEAM-MATIC SG boilers are:
Models available: pulp and paper industry, food & beverage, district
heating, plastics and rubber industry, chemicals and
SG 600: up to 6.000 Kg/h petrochemical, woodworking, production of building
SG 800: up to 8.000 Kg/h material, textile industry.
SG 1000: up to 10.000 Kg/h
SG 1200: up to 12.000 Kg/h STEAM-MATIC SG boilers are marked
SG 1500: up to 15.000 Kg/h and can be produced according to the most important
SG 2000: up to 20.000 Kg/h and rigorous directives, such as:
SG 2200: up to 22.000 Kg/h - PED Directive 97/23/CE
SG 2500: up to 25.000 Kg/h - 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
Steam boilers STEAM-MATIC SG

4
 Figure 2
Steam boiler STEAM-MATIC SG functional diagram

1 Burner 6 Exhaust Gas Outlet

2 Safety Valves 7 Drain Connection
3 STEAM-MATIC Furnace 8 Fire Tubes of the 2nd Pass (*)
4 Burner Flame 9 Wet Back Water Tubes
5 Level Probes 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
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 Figure 3
to the furnace and the tubes for inspection Steam boiler STEAM-MATIC SG
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 con-
trol and management system OPTISPARK.

Customer oriented solutions

Cannon BONOs technical specialists are ca-
pable of meeting any customers request, thus
having the possibility to offer a great variety
of solutions studied specifically for the cus-
tomers needs, starting from boiler construc-
tion to type of fuel burned (especially thanks to
our know-how in designing and realizing each Figure 4
component of the boiler in Cannon BONO fac- Control panel for steam boiler STEAM-MATIC SG
tory). with OPTISPARK control and management system.

6
 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 symmet-
rical 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 re-
moving 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 pos-
sible 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.

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.

8
 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 inspection of the

second pass fire tubes from
Easy access to the rear
the frontal smoke chamber
smoke chamber from a wide
manhole

9
 2. COMPETITIVE ADVANTAGES - AUTOMATIC CONTROL AND
MANAGEMENT SYSTEM FOR INDUSTRIAL BOILER PLANTS
BONO OPTISPARK is the automatic control and manage-
ment system for industrial boilers and boiler rooms which
ensures:

CONTINUOUS AND SAFETY OPERATION Figure 8

OPERATIVE SAFETY Control and management system
ENERGY EFFICIENCY OPTISPARKs interface
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 in-
terfaceable 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 9
Automatic control and management system for in-
dustrial boiler plants OPTISPARK functional scheme.

GARC
GARC

VPS

10
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, its only indicative and may change in accordance with each
final boiler configuration. Additional data and deviations from standard are available on request.
TECHNICAL SPECIFICATIONS
Features Unit SG 600 SG 800 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 15 18 12 15 18 12 15 18 12 15 18 12 15 12 15

Min.feed water temp. C 90 90 90 90 90 90 90 90
Thermal efficiency** % 90 89,5 89 90 89,5 89 90 89,5 89 90 89,5 89 90 89,5 89 90 89,5 89 90 89,5 90 89,5

OVERALL DIMENSIONS AND CONNECTIONS

L Lenght mm 7400 7950 8350 8900 9400 10300 11000 12000
W Width mm 3250 3250 3600 3600 3750 3750 3900 4000

H Height mm 2900 2900 3250 3300 3550 3800 3800*** 3800***

Steam DN 125 125 100 150 125 100 150 150 125 150 150 150 200 150 150 200 200 200 250 200 250 200
N2
valve PN 16 40 40 16 40 40 16 40 40 16 40 40 16 40 40 16 40 40 16 40 16 40
40/ 40/ 40/ 40/ 40/ 40/ 50/ 40/ 40/ 50/ 50/ 40/ 65/ 50/ 50/ 65/ 65/ 50/ 65/ 80/ 65/ 65/
DN 65 65 65 65 65 65 80 65 65 80 80 65 100 80 80 100 100 80 100 100 100 100
N4A Safety
N4B valve outlet 25/ 25/ 40/ 25/ 25/ 40/ 25/ 25/ 40/ 25/ 25/ 40/ 25/ 25/ 40/ 25/ 25/ 40/ 25/ 25/ 25/ 25/
PN 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16

Boiler DN 40 40 40 40 40 40 40 40
N9
drain PN 16 16 16 16 16 16 16 16
N
Feed water
18A 3 3 4 4 4 5 5 6
18B line****
Reversal DN 32 32 32 32 32 32 32 32
N16 chamber
drain PN 16 16 16 16 16 16 16 16

Heavy fuel
N15 2 2 2 2 2 2 2 2
oil inlet
Natural
N17 3 4 4 4 5 5 5 6
gas inlet
Stack
N19 mm 600 600 720 720 800 850 920 920
connection
Empty weight T 17,0 17,8 18,7 20,0 21,0 22,2 23,0 24,3 25,7 26,0 27,6 29,2 32,0 34,2 36,1 38,0 41,4 43,0 39,5 42 40,5 43
Water volume at
m3 9,3 10,0 11,0 13,0 17,7 19,0 22,0 36,0
level
Full water volume m3 12,3 13,3 15,0 18,0 23,5 26,0 29,3 42,0

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 92,0 101,0
*****
Natural gas or
KW 18,5 20,0 22,0 26,0 26,0 30,0 33,0 37,0 37,0 41,0 45,0 48,5 52,0 55,5 59,0 64,0 67,0 67,0 75,0 78,0 86,0
diesel oil
Standard electric power data: 400 V/50 Hz/ 3 phases Auxiliaries voltage: 220 V

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/Nm3 (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 7E under 50C temperature. Information about heavy fuel with higher viscosity on request.

12
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, its only indicative and may change in accordance with each final boiler
configuration. Additional data and deviations from standard are available on request.
TECHNICAL SPECIFICATIONS
Features SG ECO SG ECO SG ECO SG ECO SG ECO SG ECO SG ECO SG ECO
Unit
600 800 1000 1200 1500 2000 2200 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 12 15

Min.feed water temp. C 90 90 90 90 90 90 90 90

Thermal efficiency (with
economizer)** % 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 95 94,5

OVERALL DIMENSIONS AND CONNECTIONS

L Lenght mm 7400 7950 8350 8900 9400 10300 11000 12000
W Width mm 3250 3250 3600 3600 3750 3750 3900 4000
H Height mm 2900 2900 3250 3300 3550 3800 3800*** 3800***
DN 125 125 100 150 125 100 150 150 125 150 150 150 200 150 150 200 200 200 250 200 250 200
N2 Steam valve
PN 16 40 40 16 40 40 16 40 40 16 40 40 16 40 40 16 40 40 16 40 16 40
40/ 40/ 40/ 40/ 40/ 40/ 50/ 40/ 40/ 50/ 50/ 40/ 65/ 50/ 50/ 65/ 65/ 50/ 65/ 80/ 65/ 65/
DN 65 65 65 65 65 65 80 65 65 80 80 65 100 80 80 100 100 80 100 100 100 100
N4A Safety valve
N4B outlet 25/ 25/ 40/ 25/ 25/ 40/ 25/ 25/ 40/ 25/ 25/ 40/ 25/ 25/ 40/ 25/ 25/ 40/ 25/ 25/ 25/ 25/
PN 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16

DN 40 40 40 40 40 40 40 40
N9 Boiler drain
PN 16 16 16 16 16 16 16 16

N
Feed water
18A 3 3 4 4 4 5 5 6
18B line****
Reversal DN 32 32 32 32 32 32 32 32
N16 chamber
drain PN 16 16 16 16 16 16 16 16

Liquid fuel
N15 2 2 2 2 2 2 2 2
inlet
Natural gas
N17 3 4 4 4 5 5 5 6
inlet
Stack
N19 mm 600 600 720 720 800 850 920 920
connection
Empty weight 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 42 44,5
Water volume at level m3 9,3 10,0 11,0 13,0 17,7 19,0 22,0 36,0
Full water volume m3 12,3 13,3 15,0 18,0 23,5 26,0 29,3 42,0

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 92,0 101,0
Natural gas or
KW 23,0 24,0 26,0 26,0 26,0 30,0 33,0 37,0 37,0 41,0 45,0 48,5 52,0 55,5 59,0 64,0 67,0 67,0 75,0 78,0 86,0
diesel oil
Standard electric power data: 400 V/50 Hz/ 3 phases Auxiliaries voltage: 220 V

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/Nm3 (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 7E under 50C temperature. Information about heavy fuel with higher viscosity on request.

14
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, its only indicative and may change in accordance with each final boiler configuration. Additional data
and deviations from standard are available on request.
TECHNICAL SPECIFICATIONS
Features SG PA SG PA SG PA SG PA SG PA SG PA SG PA SG PA
Unit
600 800 1000 1200 1500 2000 2200 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 12 15
Min.feed water temp. C 90 90 90 90 90 90 90 90
Thermal efficiency (with
air preheater)** % 92,5 92 91,5 92,5 92 91,5 92,5 92 91,5 92,5 92 91,5 92,5 92 91,5 92,5 92 91,5 92,5 92 92,5 92

OVERALL DIMENSIONS AND CONNECTIONS

L Lenght mm 7150 7650 7900 8400 9200 10.000 *** ***
W Width mm 3000 3000 3250 3250 3600 3.600 *** ***
Height (with
H air prehe- mm 3700 3700 4050 4050 4560 4.560 *** ***
ater)
DN 125 125 100 150 125 100 150 150 125 150 150 150 200 150 150 200 200 200 250 200 250 200
N2 Steam valve
PN 16 40 40 16 40 40 16 40 40 16 40 40 16 40 40 16 40 40 16 40 16 40
40/ 40/ 40/ 40/ 40/ 40/ 50/ 40/ 40/ 50/ 50/ 40/ 65/ 50/ 50/ 65/ 65/ 50/ 65/ 80/ 65/ 65/
DN 65 65 65 65 65 65 80 65 65 80 80 65 100 80 80 100 100 80 100 100 100 100
N4A Safety valve
N4B outlet 25/ 25/ 40/ 25/ 25/ 40/ 25/ 25/ 40/ 25/ 25/ 40/ 25/ 25/ 40/ 25/ 25/ 40/ 25/ 25/ 25/ 25/
PN 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16

DN 40 40 40 40 40 40 40 40
N9 Boiler drain
PN 16 16 16 16 16 16 16 16

N
Feed water
18A 3 3 4 4 4 5 5 6
18B line*****
Reversal DN 32 32 32 32 32 32 32 32
N16 chamber
drain PN 16 16 16 16 16 16 16 16

Heavy fuel
N15 2 2 2 2 2 2 2 2
oil inlet
Natural gas
N17 3 4 4 4 5 5 5 6
inlet
Stack
N19 mm 600 600 720 720 800 850 920 920
connection
Empty weight 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 43 45,5
Water volume at
m3 9,3 10,0 11,0 13,0 17,7 19,0 22,0 36,0
level
Full water volume m3 12,3 13,3 15,0 18,0 23,5 26,0 29,3 42,0

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 92,0 101,0
Natural gas or
KW 23,0 24,0 26,0 26,0 26,0 30,0 33,0 37,0 37,0 41,0 45,0 48,5 52,0 55,5 59,0 64,0 67,0 67,0 75,0 78,0 86,0
diesel oil
Standard electric power data: 400 V/50 Hz/ 3 phases Auxiliaries voltage: 220 V

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/Nm3 (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 7E under 50C temperature. Information about heavy fuel with higher viscosity on request.

16
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*.

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.

18
 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.

FEED WATER PROPERTIES Table 4

PARAMETERS UNIT
ACCORDING TO EN 12953 Feedwater Quality Requirements
for best STEAM-MATIC SG opera-
OPERATING PRESSURE (X) bar (= 0,1 MPa) 0,5 < X < 20 X > 20
tion and preservation
Clean, free from suspended
APPEARANCE /
solids
DIRECT CONDUCTIVITY AT 25C S/cm Not specified

pH VALUE AT 25 C (a) / > 9,2 (b) > 9,2 (b)

TOTAL HARDNESS (Ca + Mg) mmol/l < 0,01 (c) < 0,01

IRON (Fe) CONCENTRATION mg/l < 0,3 < 0,1

COPPER (Cu) CONCENTRATION mg/l < 0,05 < 0,03

SILICA (SiO2) CONCENTRATION mg/l Not specified

OXYGEN (O2) CONCENTRATION mg/l < 0,05 (d) < 0,02

OIL/GREASE CONCENTRATION
mg/l <1 <1
(see EN 12953-6)

ORGANIC SUBSTANCES CONCENTRATION / 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.

SG P&ID Elements Description

S1 Water Softener

V1 Feed Water / Condensate Tank

V2 Brine Tank

V3 Chemical Dosing Station

SG P&ID Ancillaries Symbols Meaning

LV Level Valve
LI Level Indicator
FQ Flow Indicator Totaliser
PI 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.

SG P&ID Elements Description

BDS Blowdown system (OPTION)

L1 Chimney (OPTION)

O2 Flue gas oxygen control system (OPTION)

P1 Feed water pump

P2 Second feed water pump (spare) (OPTION)

TDS 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

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
Figure 17
STEAM-MATIC SG ECO (with economizer) P&ID;
further measurements and modifications are available
on-demand.

SG P&ID Elements Description

E1 Economizer

BDS Blowdown system (OPTION)

L1 Chimney (OPTION)

O2 Flue gas oxygen control system (OPTION)

P1 Feed water pump

P2 Second feed water pump (spare) (OPTION)

TDS 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
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.

SG P&ID Elements Description

PA Air preheater

BDS Blowdown system (OPTION)

L1 Chimney (OPTION)

O2 Flue gas oxygen control system (OPTION)

P1 Feed water pump

P2 Second feed water pump (spare) (OPTION)

TDS 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
 OPTION

INSTRUMENTATION SYMBOLS
TDS
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

Functions managed by OPTISPARK system

Combustion control system

OPTION
Burner management system

Instrument air
SUPPLY LIMIT INSTRUMENTATION SYMBOLS
Interlock - burner shutdown
CANNON BONO CUSTOMER AND IDENTIFICATION ISA S-5.1
Burner

Joint

28
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

SG P&ID Ancillaries Symbols Meaning

BALL Flame alarm low levef PALL Pressure alarm low low

BE Flame scanner PCV Pressure control valve

BSLL Flame switch low level PI Pressure indicator

BV On/off actuated valve PSLL Pressure switch low low

BZ Electrical igniter TAL Temperature alarm low
FC Frequency controller TSL Temperature switch low

FV Flow valve TIC Temperature indicator controller

HV Hand valve TE Thermoelement

M Motor

Functions managed by
Autocleaner strainer
OPTISPARK system

Combustion control system

Filter Y type
(managed by OPTISPARK)

Burner management system Condensate drain

Interlock - burner shut down Sight glass

Burner Instrument air (MIN 5 bar - MAX 7)

OPTION

SUPPLY LIMIT INSTRUMENTATION SYMBOLS

CANNON BONO CUSTOMER 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 PCV Pressure control valve
BE Flame scanner PI Pressure indicator

BSLL Flame switch low level PAHH Pressure alarm high high

BV On/off actuated valve PSLL Pressure switch low low

BZ Electrical igniter TAL Temperature alarm low
FC Frequency controller TSL Temperature switch low
FV Flow valve TIC Temperature indicator controller
HV Hand valve TE Thermoelement

M Motor VSP Gas leakage test

PALL Pressure alarm low low

Functions managed by
Autocleaner strainer
OPTISPARK system

Combustion control system

Filter Y type
(managed by OPTISPARK)

Burner management system Condensate drain

Interlock - burner shut down Sight glass

Burner Instrument air (MIN 5 bar - MAX 7)

Joint OPTION

SUPPLY LIMIT INSTRUMENTATION SYMBOLS

CANNON BONO CUSTOMER AND IDENTIFICATION ISA S-5.1

32
33
 5. BOILER LAYOUT - BOILER ROOM

450 * 1500 * min.800

350
600

*
5

1500
1500

*
5600

1500

Figure 22
A sample installation
of a SG STEAM-MATIC
inside a boiler room, Chequered plate
plan view elev. 0.0 2500 800
x3
20
.Z
of
pr
500

Round bar 10

Flat bar 80X8

650
every ~2 mt.

34
 min.2000
6
min.1500

2500 min.
2

3
*
100

500

100

710

1 Steam Boiler SG
Figure 23
A sample installation of a SG 2 Water-condensate storage tank
STEAM-MATIC inside a boiler 3 Structure supporting tank
room, front view
4 Feed water treatment unit
5 Steam header
6 Chimney

35
 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 m3 per 1 MW of thermal capacity); a mini-
mum 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 spe-
cific 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 in-
staller 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.

36
Water and condensate piping
The water tank receives the condensate and treated water. The float valve controls the treated water inlet; up-
stream the float valve it is advisable to install an gate valve to allow removal of float valve for maintenance pur-
poses. 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 protect the
pump. The pipe must be as straight as possible. The height of the feed tank must assure the necessary head
to avoid 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 40-60C.

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
 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 20C for filling operation; if temperature is higher than 40C
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 wa-
ter 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.

38
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 consider-
ing 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 eco-
nomical and safe operation. Temperatures, pressure capacities shall be measured with precision and conti-
nuity 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 clean-
ing 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 ex-
treme 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.

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 con-
centration 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.

40
BOILER SHUTDOWN
When the boiler is stopped, the burner and the air fan must be put out of service following the Standards inher-
ent 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 with-
drawing 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 100C 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 Insulation of the external casing in mineral wool panels, stainless steel external lagging
LAGGING

BASE Base frame made with iron bars

Main steam valve (manual)

N.2 Pressure safety valves

Shell blow down valve (surface)

N.2 Level indicators, with shut-off valve

VALVES AND
N.2 Shell drain valves
ACCESSORIES
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)

On-off valve
WATER FEEDING
GROUP
Level regulation system with 1 pc. modulating pneumatic valve

Check valve

42
 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
TYPE OF FUEL AVAILABLE *

BURNING SYSTEM Internal gas header with multi-nozzle system

(modulating
regulation) NATURAL GAS N.2 Feeding gas train electrically actuated shut-off valves
FUEL (NG)
Feeding gas electrically actuated regulating valve

N.2 Burning ignition safety solenoid valves

Fuel pump station, complete with on/off valve

HEAVY FUEL OIL
(HFO)
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

Temperature regulation system (only heavy fuel oil)

SAFETY AND Gas leakage test- VPS (only gas fuel)
CONTROL
EQUIPMENT N.2 Max/min fuel pressure switches
FOR THE
BOILER Steam pressure transmitter

Shut-down pressure switch for max steam pressure

Automatic pressure modulating control regulator

Automatic modulating level control regulator

ELECTRIC With flexible conduits and tight terminal fittings for high mechanical resistance and water proof
WIRING sealing

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
Operators panel, burner START/STOP switch/indicator, feed pump START/STOP switch/indica-
tor, 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

OPTIONAL EQUIPMENT* - STEAM-MATIC SG

Package unit bult-in the front side of the generator structure insulation
ECONOMISER Carbon steel tube bundle made of finned tubes and elbows
(FOR HIGH
EFFICIENCY Set of headers for water inlet and outlet
UP TO 95%)
N.2 Inspection and maintenance upper doors

Vent valves

Drain valve

N.2 Temperature gauge for inlet and outlet temperature

SET OF
INSTRUMENTS
N.2 Shut-off manual valves
FOR
ECONOMISER
N.2 Pressure points

Safety valve

By pass valve (manual)

AIR Package unit bult-in the front side of the generator structure
PREHEATER
(FOR HIGH Double vertical carbon steel tubes bank, with flue gases running inside and air running outside the tubes.
EFFICIENCY
UP TO 92%) N.2 Inspection and maintenance upper doors

SECOND FEED Multi stage centrifugal pump (horizontal design)

WATER PUMP AS
SPARE (Installed
on boiler base On-off valve
frame and
connected to the
boiler skid) Check valve

FEEDING PUMP Feeding pump speed control system (drived by electrical inverter)
SPEED CONTROL
SYSTEM (available
for each pump) Feed water pressure control loop
COMBUSTION AIR
FAN SPEED Electrical inverter
CONTROL SYSTEM

SPARE FUEL PUMP Spare fuel pump (available for liquid fuel burner)

AUTOMATIC BONOOptispark industrial boilers management and control automatic system

BOILER CONTROL
Flue gas oxygen control system with separated probe
SYSTEM
OPTISPARK Control system of the air/fuel ratio (SRC) and of the supply of oxygen (electric cam)

44
 OPTIONAL EQUIPMENT* - STEAM-MATIC SG
System for 24 hour boiler operating without human presence according to
EN 12953 Directive
SAFESPARK N.2 Automatically controlled minimum level probes with periodical test, complete with switch
SYSTEM (24 HOUR)
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 Automatically controlled high level probes with periodical test, complete with switch
SYSTEM (72 HOUR)
Upgraded photocell, with automatically controlled periodical test
Automatic TDS control system
Automatic blowdown
TDS CONTROL
Automatic TDS control system (already included in SAFESPARK system 72 hour)
SYSTEM
AUTOMATIC
BLOW-DOWN SYSTEM
Automatic blowdown system (already included in SAFESPARK system 72 hour)

LADDER AND
Ladder and platform
PLATFORM

Cylindrical body in carbon steel

Set of flanged connections
Support frame in carbon steel
THERMO - PHYSI-
CAL DEAERATOR Water on-off automatic valve
(ATMOSPHERIC OR Feed water distribution system
LOW-PRESSUR- Level indicator
IZED)
Drain connection
Drain valve
Degassing tower (for low-pressurized deaerator)
WATER SOFTENER Water softening station DUPLEX type (other types on request)
CHEMICAL DOSING
Chemical dosing station (pH conditioner, oxygen scavenger)
STATION
BLOWDOWN
Blowdown vessel
VESSEL
STEAM Shell and tube configuration that heats the saturated steam coming from the cylindrical drum, exchan-
SUPERHEATER ging heat with the fumes, complete with safety valve and thermostat.
STEAM
Steam header collecting system
HEADER
Chimney complete with duct to connect boilers flue gas outlet, basaplate structure, cylindrical structure
CHIMNEY
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 produc-
tion is 5500 kg/h, we calculate the load with the following equation (feed water T = 90 C)-

5500
Load, % = * 100% Load, % =
* 100% = 92%
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
Efficiency %

93

92

91
25 50 75 100
% Load
Efficiency at 10 bar Efficiency at 13 bar Efficiency at 16 bar

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

Pm Pa T V he r hg
2 2 3
bar kg/cm bar kg/cm K C m /kg kJ/kg kcal/kg kJ/kg kcal/kg kJ/kg kcal/kg
0,050 0,051 306,05 32,9 28,191 137,7 32,9 2425 679,2 2562,7 612,1
0,100 0,102 318,95 45,8 14,674 191,8 45,8 2394,4 571,9 2586,2 617,7
0,150 0,153 327,15 54,0 10,023 225,9 54,0 2374,8 567,2 2600,7 621,2
0,200 0,204 333,15 60,0 7,65 251,5 60,1 2359,7 563,6 2611,2 623,7
0,250 0,255 338,15 65,0 6,204 272,0 65,0 2347,5 560,7 2619,5 625,7
0,300 0,306 342,25 69,1 5,229 289,3 69,1 2337,5 558,3 2626,8 627,4
0,350 0,357 345,85 72,7 4,526 304,3 72,7 2328,7 556,2 2633 628,9
0,400 0,408 349,05 75,9 3,994 317,6 75,9 2320,7 554,3 2638,3 630,2
0,450 0,459 351,85 78,7 3,577 329,6 78,8 2313,6 552,6 2643,2 631,4
0,500 0,510 354,45 81,3 3,240 340,5 81,4 2306,9 551,0 2647,4 632,4
0,6 0,612 359,05 85,9 2,732 359,9 86,0 2295,2 548,2 2655,1 634,2
0,7 0,714 363,05 89,9 2,365 376,7 90,0 2284,3 545,6 2661,0 635,6
0,8 0,816 366,65 93,5 2,087 391,7 93,6 2275,5 543,5 2667,2 637,1
0,9 0,918 369,85 96,7 1,869 405,2 96,8 2267,2 541,5 2672,4 638,3
1,0 1,020 372,75 99,6 1,694 417,5 99,8 2259,2 539,6 2676,7 639,4
0 0 1,013 1,033 373,15 100,0 1,673 419,1 100,1 2258,4 539,4 2677,5 639,5
0,05 0,051 1,063 1,084 374,55 101,4 1,601 425,0 101,5 2254,2 538,4 2679,1 639,9
0,10 0,102 1,113 1,135 375,75 102,6 1,533 430,4 102,8 2251,2 537,7 2681,6 640,5
0,15 0,153 1,163 1,186 378,25 105,1 1,471 435,8 104,1 2247,9 536,9 2683,7 641,0
0,20 0,204 1,213 1,237 379,35 106,2 1,414 440,9 105,3 2245,0 536,2 2685,8 641,5
0,30 0,306 1,313 1,339 380,55 107,4 1,312 450,5 107,6 2238,7 534,7 2689,2 642,3
0,40 0,408 1,413 1,441 382,65 109,5 1,225 459,7 109,8 2232,8 533,3 2692,5 643,1
0,50 0,510 1,513 1,543 384,75 111,6 1,149 468,5 111,9 2227,0 531,9 2695,5 643,8
0,60 0,612 1,613 1,645 386,65 113,5 1,038 476,5 113,8 2221,5 530,6 2698,0 644,4
0,70 0,714 1,713 1,747 388,55 115,4 1,024 484,4 115,7 2216,9 529,5 2701,3 645,2
0,80 0,816 1,813 1,849 390,25 117,1 0,971 491,9 117,5 2211,9 528,3 2703,8 645,8
0,90 0,918 1,913 1,951 391,95 118,8 0,923 499,1 119,2 2206,9 527,1 2705,9 646,3
1,00 1,020 2,013 2,053 393,55 120,4 0,881 505,8 120,8 2202,3 526,0 2708,0 646,8

Denomination

Pm - gauge pressure Pa - absolute pressure T temperature V - specific volume

he - specific enthalpy of water r - specific enthalpy of evaporation hg - specific enthalpy of saturated steam
of steam

47
9. APPENDIX 2. THERMODYNAMIC CHARACTERISTICS OF SATURATED STEAM

Pm Pa T V he r hg
2 2 3
bar kg/cm bar kg/cm K C m /kg kJ/kg kcal/kg kJ/kg kcal/kg kJ/kg kcal/kg
1,00 1,020 2,013 2,053 393,55 120,4 0,881 505,8 120,8 2202,3 526,0 2708,0 646,8
1,10 1,122 2,113 2,155 395,05 121,9 0,841 512,5 122,4 2198,5 525,1 2711,0 647,5
1,20 1,224 2,213 2,257 396,55 123,4 0,806 519,2 124,0 2194,3 524,1 2713,5 648,1
1,30 1,326 2,313 2,359 398,05 124,9 0,773 525,0 125,4 2190,1 523,1 2715,1 648,5
1,40 1,428 2,413 2,461 399,45 126,3 0,743 530,9 126,8 2186,3 522,2 2717,2 649,0
1,50 1,530 2,513 2,563 400,75 127,6 0,714 536,3 128,1 2181,7 521,1 2718,1 649,2
1,60 1,632 2,613 2,664 402,05 128,9 0,689 542,2 129,5 2178,8 520,4 2721 649,9
1,70 1,733 2,713 2,766 403,25 130,1 0,665 547,2 130,7 2175 519,5 2722,3 650,2
1,80 1,835 2,813 2,868 404,55 131,4 0,643 552,7 132,0 2171,3 518,6 2723,9 650,6
1,90 1,937 2,913 2,970 405,65 132,5 0,622 557,7 133,2 2167,9 517,8 2725,6 651,0
2,00 2,039 3,013 3,072 406,85 133,7 0,603 562,7 134,4 2164,6 517 2727,3 851,4
2,20 2,243 3,213 3,278 409,05 135,9 0,568 571,9 136,6 2158,3 515,5 2730,2 652,1
2,40 2,447 3,413 3,480 411,15 138,0 0,536 581,1 138,8 2152 514,0 2733,1 652,8
2,60 2,651 3,613 3,684 413,15 140,0 0,509 589,5 140,8 2146,2 512,6 2735,7 653,4
2,80 2,855 3,813 3,888 415,05 141,9 0,483 597,9 142,8 2140,3 511,2 2738,2 654,0
3,00 3,059 4,013 4,092 416,85 143,7 0,461 605,8 144,7 2134,8 509,9 2740,7 654,6
3,20 3,263 4,213 4,296 418,55 145,4 0,44 612,9 146,4 2129,4 508,6 2742,4 655,0
3,40 3,467 4,413 4,500 420,35 147,2 0,422 620,5 148,2 2124,4 507,4 2744,9 655,6
3,60 3,671 4,613 4,704 421,95 148,8 0,405 627,6 149,9 2118,9 506,1 2746,5 656,0
3,80 3,875 4,813 4,908 423,55 150,4 0,389 634,3 151,5 2114,3 505,0 2748,6 656,5
4,00 4,079 5,013 5,112 425,15 152,0 0,374 641,0 153,1 2109,3 503,8 2750,3 656,9
4,20 4,283 5,213 5,316 426,55 153,4 0,361 647,3 154,6 2104,7 502,7 2752,0 657,3
4,40 4,487 5 413 5,520 427,95 154,8 0,348 653,6 156,1 2100,1 501,6 2753,7 657,7
4,60 4,691 5,613 5,724 429,35 156,2 0,336 659,8 157,6 2095,9 500,6 2755,8 658,2
5,00 5,099 6,013 6,131 432,05 158,9 0,315 671,1 160,3 2087,1 498,5 2758,3 658,8
5,50 5,608 6,513 6,641 435,25 162,1 0,292 685,0 163,6 2077,1 496,1 2762,0 659,7
6,00 6,118 7,013 7,151 438,15 165,0 0,272 697,9 166,7 2067,4 493,8 2765,4 660,5
6,50 6,628 7,513 7,661 440,95 167,8 0,255 710,1 169,6 2058,2 491,6 2768,3 661,2
7,00 7,138 8,013 8,171 443,65 170,5 0,240 721,8 172,4 2049,0 489,4 2770,8 661,8
7,50 7,648 8,513 8,681 446,15 173,0 0,227 733,1 175,1 2040,6 487,4 2773,8 662,5
8,00 8,158 9,013 9,191 448,55 175,4 0,215 743,6 177,6 2032,3 485,4 2775,8 663,0

48
 Pm Pa T V he r hg
2 2 3
bar kg/cm bar kg/cm K C m /kg kJ/kg kcal/kg kJ/kg kcal/kg kJ/kg kcal/kg
8,50 8,667 9,513 9,700 450,85 177,7 0,204 753,6 180,0 2024,3 483,5 2777,9 663,5
9,00 9,177 10,013 10,210 453,15 180,0 0,194 763,3 182,3 2016,4 481,6 2779,6 663,9
9,50 9,687 10,513 10,720 455,25 182,1 0,185 772,9 184,6 2008,8 479,8 2781,7 664,4
10,00 10,197 11,013 11,230 457,25 184,1 0,177 782,1 186,8 2001,3 478,0 2783,4 664,8
11,00 11,217 12,013 12,250 481,15 188,0 0,163 799,3 190,9 1987,1 474,6 2786,3 665,5
12,00 12,236 13,013 13,269 464,85 191,7 0,151 815,6 194,8 1973,7 471,4 2789,2 666,2
13,00 13,256 14.013 14,289 468,25 195,1 0,141 831,1 198,5 1960,7 468,3 2791,8 666,8
14,00 14,276 15,013 15,309 471,45 198,3 0,132 845,7 202,0 1948,1 465,3 2793,9 667,3
15,00 15,296 16,013 16,328 474,55 201,4 0,124 859,6 205,3 1936,4 462,5 2795,9 667,8
16,00 16,315 17,013 17,348 477,55 204,4 0,117 872,9 208,5 1924,7 459,7 2797,6 668,2
17.00 17,335 18,013 18,368 480,35 207,2 0,110 885,5 211,5 1913,4 457,0 2798,9 668,5
18,00 18,355 19,013 19,388 483,05 209,9 0,105 897,6 214,4 1902,5 454,4 2800,1 668,8
19,00 19,374 20,013 20,407 485,65 212,5 0,100 909,4 217,2 1891,6 451,8 2801,0 669,0
20,00 20,394 21,013 21,427 488,15 215,0 0,095 921,1 220,0 1881,5 449,4 2802,6 669,4
21,00 21,414 22,013 22,447 490,45 217,3 0,090 932,0 222,6 1871,5 447,0 2803,5 669,6
22,00 22,433 23,013 23,466 492,75 219,6 0,087 942,4 225,1 1861,5 444,6 2803,9 669,7
23,00 23,453 24,013 24,486 494,95 221,8 0,083 952,9 227,6 1851,4 442,2 2804,3 669,8
24,00 24,473 25,013 25,506 497,15 224,0 0,080 963,0 230,0 1842,2 440,0 2805,2 670,0
25,00 25,493 26,013 26,525 499,25 226,1 0,077 972,6 232,3 1832,6 437,7 2805,2 670,0
26,00 26,512 27,013 27,545 501,25 228,1 0,0741 981,3 234,3 1821,6 435,0 2802,9 669,3
27,00 27,532 28,013 28,565 503,25 230,1 0,0714 990,5 236,5 1812,5 432,8 2803,0 669,4
28,00 28,552 29,013 29,585 505,15 232,0 0,0690 999,6 238,7 1803,6 430,7 2803,2 669,4
29,00 29,571 30,013 30,604 507,05 233,9 0,0667 1008,4 240,8 1794,9 428,6 2803,3 669,4
30,00 30,591 31,013 31,624 508,85 235,7 0,0645 1017,1 242,9 1786,2 426,5 2803,3 669,4

Denomination

Pm - gauge pressure Pa - absolute pressure T temperature V - specific volume

he - specific enthalpy of water r - specific enthalpy of evaporation hg - specific enthalpy of saturated steam
of 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 guaran-
tee 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 accor-
ding 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 plants field of applica-
tion 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
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

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
OIL-MATIC OMV
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
Temperature: up to 400 C

SUPERHEATED WATER BOILERS OIL-MATIC OMP

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
Thermal capacity: from 0.7 to 17 MW
Temperature: over 100 C
CTH

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. N1