Technical Data INDUSTRIAL STEAM BOILERS THD-U E THSD-I E

Conservation of energy, protection of the environment.

Contents

Hoval

Section 1 1-10 THD-U E

Industrial Steam Boiler for Gas and Oil Firing

500 4000kg/h

Section 2 2-12 THSD-I E

Industrial Steam Boiler for Gas and Oil Firing

2000 20000kg/h

THD-U E
Industrial Steam Boiler for Oil and Gas Firing

Hoval

Description Design, Quality & Construction The Hoval high output steam boilers are constructed from high quality steel and are distinguished by their solid, robust and flexible design. The Hoval boiler combines ease of operation and maintenance with optimal efficiency. The boiler is designed with all necessary inspection doors and is constructed for gas or oil firing. Construction and production is according to EN12953, the Pressure Equipment Directive 97/23/EG and CE marked. An independent authorised institution carries out quality approval at our factory. The ISO 9001 certification and internal quality control ensures excellent performance and longevity of service. The client receives an economical, environmentally friendly compact unit, supplied ready for installation. THD-UE Steam Boiler The THD-UE is a three-pass flame tube/flue gas tube boiler with reverse flame tube and an inner fully water-cooled reversal chamber with finned tube wall. The boiler consists of a cylindrical shell, two endplates, gusset stay supports, the reverse flame tube with finned tube wall and single pass dimpled flue gas tubes - which increase the heat transfer (Hoval patent), with low gas side resistance. The boiler is completely electrically welded and provided with all required inspection openings. The spacious flame tube with low thermal heat release results in excellent combustion and low emissions. Large water content and steam space provides steady state operation. Efficiency of up to 89% and up to 94.5% with economiser can be achieved. 1 1 1 1 1 Boiler assembly 2 Heavy construction boiler base supports Instrument tube placed either on the right (standard) or on the left Flue gas collector with integrated horizontal flue gas connection, cleaning door and integrated relief flap Boiler door for burner mounting, thermal insulated and designed gas proof, placed on left and right hinges for the flue gas side cleaning of boiler Internal feed water distribution pipe Data plate 1-1 Valves, Fittings & Sockets Water level regulation and water level control Water level indicator (reflex type) Pressure switch for pressure regulation and supervision Pressure gauge Main steam valve Safety valve(s) Feed pump, strainer and valves Manual tds Manual double valved blowdown/drain Also available Access ladder and platform Second feed water pump Second safety valve Modulating feedwater control Automatic tds blowdown Water sample cooler Automatic timed bottom blowdown Removable cladding sections Economiser Customised control panel Remote system monitoring and controls Variable speed motor controls Hotwell and blowdown vessels Termed maintenance contracts Feed Water Quality Boiler water quality has to be respected. Detailed information can be found in the appendix. Thermal Insulation The boiler is fully insulated with 100 mm mineral wool insulation. The casing is made of 1mm thick stucco aluminum plate with neatly trimmed connections and cutouts. The flue gas collector is also thermally insulated. Control Panel The control panel is equipped with the required controls and indicators for control and supervision of the boiler and burner. Control switches, indicator lights and alarm signals are provided. The control panel is supplied to match the burner to be used. 1 1 1 Low water mark Internal steam dryer Flue gas tube cleaning kit Standard design pressures of 11 and 14 barg are available. Higher pressures can be manufactured on request.

THD-U E
Industrial Steam Boiler for Gas and Oil Firing

Hoval

Technical data THD-U E without and with economiser 500-1500 Technical data boiler without economiser (based on 10 barg working pressure) Model Steam rating Operating output Working pressure Heating surface load (nominal capacity) kg/h kW barg kg/m2 500 500 326 10 66,3 7,54 88,0 3,5 600 790 650 650 423 10 61,4 10,58 88,0 3,6 910 1076 800 800 521 10 64,0 12,50 88,0 3,9 960 1240 1000 1000 651 10 64,7 15,45 88,0 4,0 970 1332 1200 1200 781 10 61,5 19,50 88,0 4,4 1178 1470 1500 1500 977 10 61,5 24,40 88,0 4,5 1386 1965

Heating surface flue gas side (complete)* m2 *For heating surface water side approximately +15% Boiler efficiency Pressure drop flue gas side Water content operating Water content full minimum % mbar litres litres

Technical data Natural gas Model Natural gas calorific value Fuel consumption at full capacity Wet flue gas volume at 2,4% O2 Dry flue gas volume at 3% O2 Fuel heat input without economiser Fuel heat input with economiser Flue gas temperature kJ/Nm3 Nm3/h Nm /h
3

500 36,000 35 431 368 377 347 140

650 36,000 45 547 467 479 451 140

800 36,000 56 673 575 590 555 140

1000 36,000 69 842 719 737 694 140

1200 36,000 83 1010 863 888 833 140

1500 36,000 104 1262 1079 1110 1041 140

Nm3/h kW kW C

Technical data Diesel Oil (35 secs) Model Oil calorific value Fuel consumption at full capacity Wet flue gas volume at 2,7% O2 Dry flue gas volume at 3% O2 Fuel heat input without economiser Fuel heat input with economiser Flue gas temperature kJ/kg kg/h Nm3/h Nm3/h kW kW C 500 42,700 31 433 390 377 347 140 650 42,700 40 550 495 479 451 140 800 42,700 50 677 610 591 555 140 1000 42,700 62 846 762 736 694 140 1200 42,700 75 1016 914 882 833 140 1500 42,700 93 1269 1143 1102 1041 140

Technical data boiler with economiser (based on 10 barg working pressure) Model Additional output with economiser Boiler efficiency with economiser Pressure drop flue side including economiser Flue gas temperature after economiser kW % mbar C 500 24 94,0 6,5 140 650 29 94,0 6,6 140 800 32 94,0 6,9 140 1000 42 94,0 7,0 140 1200 47 94,0 7,4 140 1500 52 94,0 7,5 140

1-2

THD-U E
Industrial Steam Boiler for Oil and Gas Firing

Hoval

Technical data THD-U E without and with economiser 2000-4000 Technical data boiler without economiser (based on 10 barg working pressure) Model Steam rating Output Working pressure Heating surface load (nominal capacity) kg/h kW barg kg/m2 2000 2000 1303 10 63,0 31,74 88,0 5,2 2000 2550 2500 2500 1628 10 58,2 42,93 88,0 5,3 2575 3500 3000 3000 1953 10 57,6 52,10 88,0 5,8 2894 3840 3500 3500 2279 10 58,8 59,50 88,0 6,1 3240 4270 4000 4000 2605 10 58,9 67,90 88,0 6,8 3540 4525

Heating surface flue gas side (complete)* m2 *For heating surface water side approximately +15% Boiler efficiency Pressure drop flue gas side Water content operating Water content full minimum % mbar litres litres

Technical data fuel Natural gas Model Natural gas calorific value Fuel consumption at full capacity Wet flue gas volume at 2,4% O2 Dry flue gas volume at 3% O2 Fuel heat input without economiser Fuel heat input with economiser Flue gas temperature kJ/Nm3 Nm3/h Nm /h
3

2000 36,000 138 1683 1483 1476 1388 140

2500 36,000 184 2104 1798 1843 1735 140

3000 36,000 208 2552 2157 2211 2082 140

3500 36,000 243 2946 2517 2580 2429 140

4000 36,000 278 3366 2876 2948 2776 140

Nm3/h kW kW C

Technical data Diesel Oil (35 secs) Model Oil EL calorific value Fuel consumption at full capacity Wet flue gas volume at 2,7% O2 Dry flue gas volume at 3% O2 Fuel heat input without economiser Fuel heat input with economiser Flue gas temperature kJ/kg kg/h Nm3/h Nm3/h kW kW C 2000 42,700 124 1693 1524 1473 1388 140 2500 42,700 155 2116 1905 1846 1735 140 3000 42,700 186 2539 2286 2211 2082 140 3500 42,700 217 2962 2667 2580 2428 140 4000 42,700 249 3385 3048 2948 2776 140

Technical data boiler with economiser (based on 10 barg working pressure) Model Additional output with economiser Boiler efficiency with economiser Pressure drop flue side Flue gas temperature after economiser kW % mbar C 2000 69 94,0 8,2 140 2500 82 94,0 8,3 140 3000 105 94,0 8,8 140 3500 134 94,0 9,1 140 4000 165 94,0 9,8 140

1-3

THD-U E
Industrial Steam Boiler for Gas and Oil Firing

Hoval

Technical data THD-U E 500-4000 Dimensions and weights Model Boiler length with insulation, without burner Boiler length with Eco and insulation, without burner Boiler width with insulation, with pump Boiler height with insulation, with fittings Insulation thickness Flue gas outlet diameter
1

500 mm mm mm mm mm mm mm at 10 bar at 10 bar size quantity size quantity kg kg mm no. mm no. 2260 3300 1760 1870 100 200 350 2100 3100 420x320 1 80 2

650 2460 3500 1850 1960 100 200 350 2300 3500 420x320 1 80 2

800 2560 3550 1950 2060 100 250 350 2600 4200 420x320 1 80 2

1000 2760 3700 1950 2060 100 300 350 2900 4600 420x320 1 80 2

1200 2760 3700 2030 2140 100 300 350 3200 5000 420x320 1 80 2

1500 3340 4280 2050 2160 100 300 350 3400 5800 420x320 1 80 2

Minimum draft tube length Transport weight Operating weight flooded Manhole Inspection port

Model Boiler length with insulation, with burner Boiler length with Eco and insulation, without burner Boiler width with insulation, with pump Boiler height with insulation, with fittings Insulation thickness Flue gas outlet diameter
1

2000 mm mm mm mm mm mm mm at 10 bar at 10 bar size quantity size quantity kg kg mm no. mm no. 3810 4900 2100 2210 100 350 350 4000 6500 420x320 1 80 2

2500 3910 4900 2350 2460 100 450 350 5000 8900 420x320 1 80 2

3000 3910 4900 2500 2560 100 450 350 6000 10400 420x320 1 80 2

3500 4210 5200 2550 2640 100 450 350 7000 12000 420x320 1 80 2

4000 4410 5400 2550 2640 100 450 350 8000 13400 420x320 1 80 2

Minimum draft tube length Transport weight Operating weight flooded Manhole Inspection port

Ducting and chimney diameters to be sized for site application.

1-4

THD-U E
Industrial Steam Boiler for Gas and Oil Firing

Hoval

Design features

Three Pass Reverse Design

Reverse Flame Tube

Fin Tube Wall

Flame Tube View

Fin

Tube

1-5

THD-U E
Industrial Steam Boiler for Gas and Oil Firing

Hoval

Dimensions THD-U E without economiser

1 2 3 4 5 6 7
1 2 3

Boiler Boiler base Hinged front door Flue gas outlet Explosion/cleaning door (flue side) Inspection opening (waterside) Instrument assembly

8 9 10 11 12 13 14

tds shut off valve Steam shut off valve Safety valve(s) Water level gauges Water level control Water level alarms Feed water inlet pipework

15 16 17 18 19 20 21

Feed water valve(s)1 Bottom blow down ball valve Pressure stats Feed water pump(s)1 Electrical control panel Burner2 Flame viewing point

Optional 2nd feed water pump. Burner shown is monoblock type. Ducting and chimney diameters to be sized for site application.

Design pressure 11 and 14 bar (overpressure). Higher pressures available on request.

Dimensions incl. 100 mm insulation thickness. Transport dimensions for pressure level 11 bar.

Main dimensions THD-U E Model 500 650 800 1000 1200 1500 2000 2500 3000 3500 4000 L 2260 2460 2560 2760 2760 3340 3810 3910 3910 4210 4410 B 1760 1850 1950 1950 2030 2050 2100 2350 2500 2550 2550 B2 1625 1675 1775 1775 1875 1875 1975 2075 2225 2225 2225 B3 1460 1550 1650 1650 1730 1750 1800 2050 2150 2200 2200 H 1870 1960 2060 2060 2140 2160 2210 2460 2560 2640 2640 H2 805 850 900 900 940 950 975 1100 1150 1175 1175 H4 673 700 735 735 760 770 771 877 882 945 945 D 1210 1300 1400 1400 1480 1500 1550 1800 1900 1950 1950

Boiler base L1 1300 1500 1500 1500 1500 2200 2500 2500 2500 2800 3000 B1 850 900 1000 1000 1100 1100 1200 1300 1450 1450 1450

Flue gas connection3 H1 D1 1470 1560 1660 1660 1740 1760 1810 2060 2160 2210 2210 200 200 250 300 300 300 350 450 450 450 450

1-6

THD-U E
Industrial Steam Boiler for Gas and Oil Firing

Hoval

Technical data THD-U E with economiser

1 2 3 4 5 6 7 8
1 2 3 4

Boiler Boiler base Hinged front door Flue gas outlet Explosion/cleaning door (flue side) Inspection opening (waterside) Instrument assembly tds shut off valve

9 10 11 12 13 14 15 16

Steam shut off valve Safety valve(s) Water level gauges Water level control Water level alarms Feed water inlet pipework Feed water valve(s)1 Bottom blow down ball valve

17 18 19 20 21 22

Pressure stats Feed water pump(s)1 Electrical control panel Burner2 Flame viewing point Economiser4

Optional 2nd feed water pump. Burner shown is monoblock type. Ducting and chimney diameters to be sized for site application. Economiser can be positioned vertically.

Dimensions incl. 100 mm insulation thickness. Transport dimensions for pressure level 10 bar. *Add 100mm to H1 for crane hooks. Design pressure 11 and 14 bar (overpressure). Higher pressures available on request.

Main dimensions THD-U E Model 500 650 800 1000 1200 1500 2000 2500 3000 3500 4000 L 3300 3500 3550 3700 3700 4280 4900 4900 4900 5200 5400 B 1760 1850 1950 1950 2030 2050 2100 2350 2500 2550 2550 B2 1625 1675 1775 1775 1875 1875 1975 2075 2225 2225 2225 B3 1460 1550 1650 1650 1730 1750 1800 2050 2150 2200 2200 H 1870 1960 2060 2060 2140 2160 2210 2460 2560 2640 2640 H1 1470 1560 1660 1660 1740 1760 1810 2060 2160 2210 2210 H2 805 850 900 900 940 950 975 1100 1150 1175 1175 H4 673 700 735 735 760 770 771 877 882 945 945 D 1210 1300 1400 1400 1480 1500 1550 1800 1900 1950 1950

Boiler base L1 1300 1500 1500 1500 1500 2200 2500 2500 2500 2800 3000 B1 850 900 1000 1000 1100 1100 1200 1300 1450 1450 1450

Flue gas connection3 H3 D1 805 850 900 900 940 950 975 1100 1150 1175 1175 200 200 250 300 300 300 350 450 450 450 450

1-7

THD-U E
Industrial Steam Boiler for Gas and Oil Firing

Hoval

Technical data Installation To facilitate installation and maintenance the stated clearances should be met. Drawing indicates right hand (standard) hinged door. Minimal space refers to boiler. Depending on equipment (accessories) the minimal space needs to be reviewed according to local codes. Positioning

* 1200 Minimum

** 1200 Minimum

500 Minimum 500 Minimum

***

No air pollution through halogenated hydrocarbon (contained e.g. sprays, paints, solvents and cleaners) No large amounts of dust No high atmospheric humidity Frost-resistant and well ventilated Boiler to be installed and positioned in a weatherproof, nonhazardous and safe classified area.

Otherwise damage to the installation may occur. *300mm+ burner overall length (consider pivoting range/pivoting side) **Consider control panel, pump(s) assembly ***Flame tube length for tube witdrawal and cleaning The boiler may only be installed in rooms where air pollution through halogenated hydrocarbon can occur if sufficient measures are taken ensuring the supply of unpolluted combustion air. Boiler room dimensions can be reduced by the fitting of a shutter door or knockout panel.

Model THD-U E a (mm)

500 1850

650 2050

800 2050

1000 2050

1200 2050

1500 2750

2000 3050

2500 3050

Model THD-U E a (mm)

3000 3050

3500 3350

4000 3550

1-8

THD-U E
Industrial Steam Boiler for Gas and Oil Firing

Hoval
Installation of acoustic shroud for the burner. A substantial part of the sound caused in the combustion chamber and in the top heating surfaces is radiated from the flue outlet as sound transmitted by air. In addition to this, resonance features, depending on chimney dimensioning and inlet, may occur which are triggered by the oscillation of the combustion process. These sounds can be reduced by burner-lateral measures, e.g. changes of flame geometry, atomisation characteristics or fuel throughput. Flue gas attenuators cause a substantial sound level reduction. These should usually be tuned at low frequencies of 60 - 250 Hz. Flue gas attenuators function according to the principle of sound absorption. The kinetic energy of the exhaust gases is reduced by friction requiring an increase in chimney draft in the flue system. This has to be considered for burner sizing. The connection piece from the boiler to the flue gas sound absorber has to be gastight. The necessary space requirement of approximately 1 m for the later installation of a flue gas attenuator should already be included when planning.

Engineering Rules and regulations

The following rules and regulations have to be respected: Hoval technical information and installation guide Fire protection regulations National regulations concerning permission, installation and operation of boiler appliances. Boiler appliances have to be installed according to national laws and regulations and accessory requirements. Besides the national and local regulations the project specific circumstances of the boiler supplier have to be considered for every application. National and local rules and regulations have to be considered for the fuel supply. Fuel filters are highly recommended The operation and water analysis data is to be recorded daily in the operation booklet. Safety valve, condensate and blowdown connections must discharge to a safe place. Filters and strainers have to be cleaned periodically, especially if installed in front of control devices. The drain of the tds, blow down, drainage, etc has to be safely discharged into a blowdown vessel. All heating components and pipework are to be insulated in order to reduce radiation losses. -

Water treatment/water quality - The quality of the boiler water has to be guaranteed according to Hoval technical information and national guidelines. Hoval boilers may only be operated with treated water. The national regulations for the treatment of water apply for the values to be maintained. Required water quality: see page 1-10. The water quality has to be checked daily.

Combustion air - The supply of combustion air must be guaranteed for a safe and economic operation. There must be no possibility of the air supply being shut off. Ventilation of the boiler house has to also be provided. In the installation room no negative pressure larger than 3 N/m2 is allowed. To adhere to this demand, plan a free area for the air supply opening of at least 200 cm2, plus 2 cm2 per KW output. The aspect ratio for rectangular openings should not be more than 1.5 :1. If the opening is louvered ensure the free area is sufficient. National laws have to be respected. Boiler houses have to be fitted with relevant fresh air supply openings or ducted system. Gas boilers are not to be installed in rooms where halogen compounds occur which can enter the combustion air. -

Planning, operation and maintenance - The heating of the feed water and the degassing takes place in the feed water tank (hot well). To increase the efficiency, especially for natural gas operation, an economiser can be added to pre-heat the feed water. Pumps (especially horizontal rotary pumps and warm water/condensate pumps, NPSH pumps) need to be installed with the necessary flow and return pipework according to requirements. The installation has to be completely free of tension (antivibration proof). Feedwater tank height must satisfy the feed pump NPSH requirement.

Chimney/flue gas system - A properly designed chimney/flue arrangement must be provided to match each particular application. To achieve a smooth discharge of the exhaust gases from the boiler into the chimney, the flue connection is recommended to enter the chimney at approximately 30-45. From a length of greater than 1 m thermal insulation is necessary. Adequate provision should be made to drain off condensate from the base of the chimney ensuring condensate does not run back into the boiler smokebox.

Noise level reduction The following measures for noise level reduction are possible: Solid construction of boiler room walls, ceiling and floor, installation of silencer in fresh air supply, noise insulation for support and bracket of pipes.

1-9

THD-U E
Industrial Steam Boiler for Gas and Oil Firing

Hoval
<1 >1 < 22 >22 < 68

Boiler and feed water specifications for steam boiler plants Feed water specifications for natural circulating boilers Working pressure Properties pH-value at 25C Sum of alkaline earth elements (Ca + Mg) Conductivity at 25C Oxygen (O2) Carbon dioxide (CO2) dissolved Iron (Fe), total Copper (Cu), total Silicate acid (SiO2) Consumption of Potassium permanganate Oil, fat
1 1

bar

colourless, clear, free from suspended matter and foam >9 mmol/l dH S/cm mg/l mg/l mg/l mg/l mg/l mg/l mg/l < 0,02 < 0,112 >9 < 0,02 < 0,112 >9 < 0,01 < 0,056

see guidelines for boiler water specifications only < 0,1 < 25 < 0,02 < 25 < 0,05 < 0,01 < 0,02 < 25 < 0,03 0,005

see guidelines for boiler water only < 10 <3 < 10 <1 < 10 <1

Noted in the past at dH, changing factor: 1 mmol/l = 5,6 dH (German hardness). It is not necessary to make continuous control of the following parameters: Conductivity, Oxygen (O2), Carbon dioxide (CO2) dissolved, Iron (Fe), total, Copper (Cu), total, Silicate (SiO2), Consumption of Potassium permanganate, Oil, fat. Boiler water specifications for natural circulating boilers Working pressure Properties pH-value at 25C Sum of alkaline earth elements (Ca + Mg) Conductivity at 25C Acid capacity KS 8,2 (p-value)
3 2

bar

<1

>1 < 22

>22 < 44

colourless, clear, free from suspended matter and foam 10,5-12 mmol/l dH S/cm mmol/l mg/l mg/l mg/l mg/l mg/l mg/l < 0,02 < 0,112 < 5000* 1-12 < 25 < 150 10-20 5-10 (3-5) 10,5-12 < 0,02 < 0,112 < 5000* 1-12 < 25 < 0,05 < 100 5-10 5-10 (3-5) 10-11,8 < 0,01 < 0,056 < 2000* 0,5-6 < 25 < 0,03 < 50 5-10 3-5 --

Carbon dioxide (CO2) dissolved Iron (Fe), total Silicate acid (SiO2) Phosphate (P2O4)
4

Sodium sulphate (Na2SO3)4 (Polyamide)

1 5

Take care to maintain the allowed value of acid capacity - at this point the allowed conductivity has to be lower on many plants; for water level electrodes minimum conductivity > 5 S/cm 2 Noted in the past at dH, changing factor: 1 mmol/l = 5,6 dH (German hardness) 3 Noted in the past as p-value, changing factor: KS 8,2 = 1 according p-value = 1 4 Measurements only necessary if dosing chemicals are used which contains these values 5 It is recommended to use Amine (film producing) only instead of other dosing chemicals for boilers which have a small heating load and up to maximum 16 bar working pressure. Because of the danger of foam production overdosing is not permitted! Boiler water quality to comply with BS2486. It is not necessary to make continuous control of the following parameters: Silicate (SiO2) Important note: Hoval recommend that a water treatment specialist is employed to advise on each application and to carry out routine monitoring of the feed and boiler water to ensure it remains within specification. 1-10

Industrial steam and hot water boilers

Hoval

Boiler plant total supply package Hoval can design and supply all components for the boiler plant room including in-house manufacture of the Steam or Hot Water Boiler, Hotwells (Feedwater Tanks), Blowdown Vessels, Deaerators and Economisers where appropriate.

1-11

Industrial steam and hot water boilers

Hoval

Design of steam boiler plant

HOTWELL

1-12

STEAM BOILER

ECONOMISER

WATER TREATMENT

CONDENSATE STATION

THSD-I E
Industrial Steam Boiler for Gas and Oil Firing

Hoval

Description Design, Quality & Construction The Hoval high output steam boilers are constructed from high quality steel and are distinguished by their solid, robust and flexible design. The Hoval boiler combines ease of operation and maintenance with optimal efficiency. The boiler is designed with all necessary inspection doors and is constructed for gas or oil firing. Construction and production is according to EN12593, the Pressure Equipment Directive 97/23/EG and CE marked. An independent authorised institution carries out quality approval at our factory. The ISO 9001 certification and internal quality control ensures excellent performance and longevity of service. The client receives an economical, environmentally friendly compact unit, supplied ready for installation THSD-IE Steam Boiler The THSD-IE is a three-pass flame tube/flue gas tube boiler with an inner fully water-cooled reversal chamber with finned tube wall. The boiler consists of a cylindrical shell, two endplates, gusset stay supports, flame tube, gas reversal chamber with water cooled finned tube wall and two tube bank gas passes with low gas side resistance. The boiler is completely electrically welded and provided with all required inspection openings. The spacious flame tube with low thermal heat release results in excellent combustion and low emissions. Large water content and steam space provides steady state operation. Efficiency of up to 91% and up to 95% with economiser can be achieved. 1 1 1 1 Boiler assembly 2 Heavy construction boiler base supports Instrument tube placed either on the right (standard) or on the left Flue gas collector with integrated horizontal flue gas connection, cleaning door and integrated relief flap Boiler door for burner mounting, thermal insulated and designed gas proof, placed on left and right hinges for the flue gas side cleaning of boiler Internal feed water distribution pipe 2-1 Valves, Fittings & Sockets Water level regulation and water level control Water level indicator (reflex type) Pressure switch for pressure regulation and supervision Pressure gauge Main steam valve Safety valve(s) Feed pump, strainer and valves Manual tds Manual-double valve blowdown/drain Also available Access ladder and platform Second feed water pump Second safety valve Modulating feedwater control Automatic tds blowdown Water sample cooler Automatic timed bottom blowdown Removable cladding sections Economiser Customised control panel Remote system monitoring and controls Variable speed motor controls Hotwell and blowdown vessels Termed maintenance contracts Feed Water Quality Boiler water quality has to be respected. Detailed information can be found in the appendix. Thermal Insulation The boiler is fully insulated with 120 mm mineral wool insulation. The casing is made of 1mm thick stucco aluminum plate with neatly trimmed connections and cut-outs. The flue gas collector is also thermally insulated. Control Panel The control panel is equipped with the required controls and indicators for control and supervision of the boiler and burner. Control switches, indicator lights and alarm signals are provided. The control panel is supplied to match the burner to be used. 1 1 1 1 Data plate Low water mark Internal steam dryer Flue gas tube cleaning kit Standard design pressures of 10,13,16 and 20 barg are available. Higher pressures can be manufactured on request.

THSD-I E
Industrial Steam Boiler for Gas and Oil Firing

Hoval

Technical data THSD-I E 2000-8000 Technical data without economiser Model Steam output Operating output kg/h kW kW kW % % % % % % mbar 2000 2000 1304 1308 1311 89,8 89,3 89,0 90,2 89,7 89,3 9,0 2500 2500 1630 1635 1639 90,0 89,5 89,1 90,1 89,6 89,2 9,0 3000 3000 1956 1963 1967 89,7 89,2 89,9 89,8 89,3 89,0 10,0 4000 4000 2608 2617 2623 89,9 89,4 89,0 89,9 89,4 89,0 10,0 5000 5000 3260 3271 3278 90,2 89,7 89,3 90,2 89,7 89,3 10,0 6000 6000 3912 3925 3934 90,4 90,0 89,5 90,4 90,0 89,5 10,0 8000 8000 5216 5234 5246 89,7 89,2 89,0 89,7 89,2 89,0 10,0

at 10 barg at 13 barg at 16 barg at 10 barg at 13 barg at 16 barg at 10 barg at 13 barg at 16 barg

Boiler efficiency Natural gas

Boiler efficiency Diesel Oil (35 secs) Flue gas resistance Technical data Natural Gas Model Natural gas calorific value Fuel consumption at full capacity Flue gas volume, excess air @10% Fuel heat input

2000 kJ/Nm3 at 10 barg at 13 barg at 16 barg at 10 barg at 13 barg at 16 barg at 10 barg at 13 barg at 16 barg Nm /h Nm3/h Nm3/h
3

2500 36000 181,1 182,7 184,0 2018 2036 2050 1811 1826 1839

3000 36000 220,7 222,7 224,2 2458 2481 2498 2181 2201 2215

4000 36000 290,3 292,9 294,9 3234 3263 3285 2902 2928 2948

5000 36000 361,7 364,9 367,5 4030 4066 4094 3614 3647 3671

6000 36000 432,9 436,5 439,8 4822 4863 4899 4327 4361 4396

8000 36000 581,9 587,1 583,6 6482 6540 6501 5815 5868 5901

36000 145,3 146,7 147,7 1688 1701 1414 1453 1465 1476

Nm3/h Nm3/h Nm3/h kW kW kW

Technical data Diesel Oil (35 secs) Model Diesel Oil calorific value Fuel consumption at full capacity Flue gas volume, excess air @12% Fuel heat input at 10 barg at 13 barg at 16 barg at 10 barg at 13 barg at 16 barg at 10 barg at 13 barg at 16 barg kJ/kg kg/h kg/h kg/h Nm3/h Nm3/h Nm3/h kW kW kW 2000 42700 121,9 123,0 123,9 1647 1661 1673 1446 1458 1468 2500 42700 152,6 154,0 155,1 2061 2080 2094 1810 1825 1838 3000 42700 183,8 185,4 186,7 2482 2504 2522 2179 2199 2213 4000 42700 244,6 246,8 284,5 3304 3333 3365 2900 2926 2947 5000 42700 304,9 307,6 309,8 4117 4154 4183 3614 3647 3671 6000 42700 364,9 368,0 370,8 4928 4970 5007 4327 4361 4396 8000 42700 490,3 494,7 491,8 6621 6680 6641 5815 5868 5894

Technical data with integral economiser, fuel natural gas and low sulphur fuel oil Model Additional operating output with economiser at 10 barg at 13 barg at 16 barg kW kW kW % mbar C 2000 62 68 74 94,4 2.5 140 2500 79 88 95 94,4 2.5 140 3000 102 116 120 94,4 2.5 140 4000 131 144 156 94,4 2.5 140 5000 154 171 186 94,4 2.5 140 6000 175 194 213 94,4 2.5 140 8000 272 299 315 94,4 2.5 140

Boiler efficiency with economiser Flue gas resistance of economiser Flue gas temperature after economiser 2-2

THSD-I E
Industrial Steam Boiler for Gas and Oil Firing

Hoval

Technical data THSD-I E 10000-20000 Technical data without economiser Model Steam rating Operating output kg/h kW kW kW % % % % % % mbar 10000 10000 6520 6542 6557 89,9 89,4 89,2 89,9 89,4 89,1 11,0 12000 12000 7824 7850 7868 89,8 89,5 89,1 89,89 89,5 89,0 10,0 14000 14000 9128 9159 9180 89,8 89,4 89,0 89,9 89,5 89,0 10,0 16000 16000 10432 10467 10491 89,9 89,4 89,0 89,8 89,5 89,0 10,0 18000 18000 11736 11776 11802 89,6 89,2 89,0 89,7 89,2 89,0 11,0 20000 20000 13040 13084 13114 89,9 89,4 89,0 89,9 89,4 89,0 11,0

at 10 barg at 13 barg at 16 barg at 10 barg at 13 barg at 16 barg at 10 barg at 13 barg at 16 barg

Boiler efficiency Natural gas

Boiler efficiency Diesel Oil (35 secs) Flue gas resistance Technical data Natural Gas Model Natural gas calorific value Fuel consumption related

10000 kJ/Nm3 at 10 barg at 13 barg at 16 barg at 10 barg at 13 barg at 16 barg at 10 barg at 13 barg at 16 barg Nm /h Nm3/h Nm3/h
3

12000 36000 871,4 877,4 883,6 9707 9774 9843 8713 8771 8831

14000 36000 1016,7 1024,6 1031,7 11327 11414 11494 10165 10245 10315

16000 36000 1162,1 1171,1 1179,3 12946 13046 13137 11604 11708 11788

18000 36000 1310,0 1320,1 1329,4 14594 14706 14809 13098 13020 13291

20000 36000 1451,5 1464,5 1474,7 16170 16315 16429 14505 14635 14735

36000 725,7 732,2 728,0 8084 8156 8110 7253 7318 7351

Flue gas volume, excess air @10% Fuel heat input

Nm3/h Nm3/h Nm3/h kW kW kW

Technical data Diesel Oil (35 secs) Model Diesel Oil calorific value Fuel consumption related at 10 barg at 13 barg at 16 barg at 10 barg at 13 barg at 16 barg at 10 barg at 13 barg at 16 barg kJ/kg kg/h kg/h kg/h Nm3/h Nm3/h Nm3/h kW kW kW 10000 42700 611,5 617,0 613,6 8259 8333 8287 7253 7318 7359 12000 42700 734,3 739,5 744,7 9916 9987 10057 8703 8771 8860 14000 42700 856,8 863,5 869,7 11571 11662 11745 10154 10234 10338 16000 42700 979,3 987,0 994,0 13226 13329 13424 11617 11695 11788 18000 42700 1103,8 1112,4 1120,3 14907 15023 15129 13084 13202 13291 20000 42700 1223,2 1234,2 1245,9 16520 16667 16756 14505 14635 14735

Flue gas volume, excess air @12% Fuel heat input

Technical data with integral economiser, fuel natural gas and low sulphur fuel oil Model Additional operating output with economiser at 10 barg at 13 barg at 16 barg kW kW kW % mbar C 10000 326 366 382 94,4 2,5 140 12000 399 432 464 94,4 2,5 140 14000 465 513 557 94,4 2,5 140 16000 522 586 637 94,4 3,0 140 18000 622 686 716 94,4 3,0 140 20000 652 732 796 94,4 3,0 140 2-3

Boiler efficiency with economiser Flue gas resistance of economiser Flue gas temperature after economiser

THSD-I E
Industrial Steam Boiler for Gas and Oil Firing

Hoval

Technical data THSD-I E 2000-8000 Dimensions and weights Model Boiler length with insulation, without burner, without economiser Boiler length with economiser, without insulation, without burner Boiler width with insulation, with pump Boiler height with insulation, with fittings Insulation thickness 2000 2500 3000 4000 5000 6000 8000

mm mm mm mm mm

3750 4700 2450 2700 120 350 47,4 2750 4600 5000 5500 6000 420 x 320 1 220 x 150 2

3950 4900 2550 2800 120 450 57,3 4350 5450 6000 6500 7000 420 x 320 1 220 x 150 2

4150 5100 2600 2850 120 450 65,9 4850 6000 7000 7500 8000 420 x 320 1 220 x 150 2

4500 5450 2700 3075 120 550 88,4 5850 7250 8000 8500 9500 420 x 320 1 220 x 150 2

4950 5900 2800 3250 120 550 108,3 7200 9000 9500 10500 11500 420 x 320 1 220 x 150 2

5150 6100 2900 3400 120 650 129,2 8200 10300 11000 12000 13500 420 x 320 1 220 x 150 2

5650 6600 3100 3650 120 650 169,7 10000 12500 14500 15500 16500 420 x 320 1 220 x 150 2

Flue gas outlet diameter (ducting, and mm chimney diameters to be sized for site application Heating surface flue gas side (complete)* m2 *For heating surface water side approximately +15% Water content operating flooded litres litres kg kg kg mm

Transport weight without at 10 barg burner and without Economiser at 13 barg including accessories at 16 barg Manhole (size) (quantity) Inspection opening (size) (quantity)

mm

Design features

Three Pass Conventional Design

Flame Tube

2-4

THSD-I E
Industrial Steam Boiler for Gas and Oil Firing

Hoval

Technical data THSD-I E 10000-20000 Dimensions and weights Model Boiler length with insulation, without burner, without economiser Boiler length with economiser, without insulation, without burner Boiler width with insulation, with pump Boiler height with insulation, with fittings Insulation thickness 10000 12000 14000 16000 18000 20000

mm mm mm mm mm

6150 7050 3300 3925 120 800 211,8 14200 18000 17500 18500 19500 420 x 320 1 220 x 150 2

6550 7450 3400 4125 120 850 284,5 15900 20350 21500 21500 24000 420 x 320 1 220 x 150 2

6850 7750 3600 4350 120 950 324,9 17600 22700 25000 26000 28000 420 x 320 1 220 x 150 2

7150 8050 3700 4425 120 1000 381,3 20000 25000 28000 29000 31000 420 x 320 1 220 x 150 2

7350 8250 3800 4625 120 1000 410,7 23000 29200 30000 31000 35000 420 x 320 1 220 x 150 2

7850 8750 3900 4725 120 1000 467,6 24250 31400 33000 35000 39000 420 x 320 1 220 x 150 2

Flue gas outlet diameter mm chimney diameters to be sized for site application Heating surface flue gas side (complete)* m2 *For heating surface water side approximately +15% Water content operating flooded litres litres kg kg kg mm

Transport weight without at 10 barg burner and without Economiser at 13 barg including accessories at 16 barg Manhole (size) (quantity) Inspection opening (size) (quantity)

mm

Construction View

Mounting of the Fin tube wall

Second pass

Third pass

2-5

THSD-I E
Industrial Steam Boiler for Gas and Oil Firing

Hoval

Technical data THSD-I E 2000-8000 Fittings Model 1 Flue gas tube cleaning equipment 1 Main steam valve 10 barg 13 barg 16 barg 2000 YES DN80 DN65 DN65 DN25 10 barg 13 barg 16 barg 2500 YES DN80 DN80 DN65 DN25 3000 YES DN100 DN80 DN80 DN25 4000 YES DN100 DN100 DN80 DN25 5000 YES DN100 DN100 DN100 DN25 6000 YES DN125 DN100 DN100 DN25 8000 YES DN150 DN125 DN125 DN25 DN40/65 DN40/65 DN32/50 DN20 420 1/2" DN15 DN40 DN40 1/2"

1 Vent valve 2 Safety valves*

DN25/40 DN25/40 DN32/50 DN32/50 DN32/50 DN40/65 DN25/40 DN25/40 DN25/40 DN32/50 DN32/50 DN32/50 DN25/40 DN25/40 DN25/40 DN25/40 DN32/50 DN32/50 DN20 420 1/2" DN15 DN40 DN40 1/2" DN20 420 1/2" DN15 DN40 DN40 1/2" DN20 420 1/2" DN15 DN40 DN40 1/2" DN20 420 1/2" DN15 DN40 DN40 1/2" ON/OFF DN25 DN25 DN40 DN40 1/4" DN32 DN32 DN50 DN50 1/4" CR 2.2 CR 3.0 CR 4.0 DN32 DN32 DN50 DN50 1/4" CR 3.0 CR 4.0 CR 4.0 DN32 DN32 DN50 DN50 1/4" CR 4.0 CR 4.0 CR 5.5 DN40 DN40 DN65 DN65 1/4" CR 4.0 CR 4.0 CR 7.5 DN40 DN40 DN65 DN65 1/4" CR 5.5 CR 7.5 CR 7.5 DN20 420 1/2" DN15 DN40 DN40 1/2" DN20 420 1/2" DN15 DN40 DN40 1/2"

2 Isolation valves 2 Reflection indicators fixing centre (mm) 1 Blow down sight glass drain (screwed) 1 Desalting shut off valve 1 Blow down shut off valve 1 Blow down ball valve 1 Pressure gauge with three-way valve (screwed) Water level control type 1 Feed water valve 1 Feed water non-return valve/anti syphon valve 1 Strainer pump (suction side) 1 Ball valve pump (suction side) 1 Pressure gauge (pump) with shut off valve (screwed) 1 Feed water pump Motor rating 1 Feed water pump Motor rating 1 Feed water pump Motor rating 10 barg kW 13 barg kW 16 barg kW

DN50 DN50 DN80 DN80 1/4" CR 5.5 CR 7.5 CR 11.0

CR 2.2 CR 2.2 CR 3.0

*Safety valve number and size to be advised at contract stage subject to set pressure requirement.

2-6

THSD-I E
Industrial Steam Boiler for Gas and Oil Firing

Hoval

Technical data THSD-I E 10000-20000 Fittings Model 1 Flue gas tube cleaning equipment 1 Main steam valve 10 barg 13 barg 16 barg 10000 YES DN150 DN150 DN125 DN25 10 barg 13 barg 16 barg DN50/80 DN40/65 DN40/65 DN20 M=420 1/2" DN15 DN40 DN40 1/2" 12000 YES DN200 DN150 DN150 DN25 DN50/80 DN50/80 DN40/65 DN20 M=420 1/2" DN15 DN40 DN40 1/2" 14000 YES DN200 DN200 DN150 DN25 DN65/100 DN50/80 DN50/80 DN20 M=420 1/2" DN15 DN40 DN40 1/2" 16000 YES DN200 DN200 DN150 DN25 DN65/100 DN65/100 DN50/80 DN20 M=420 1/2" DN15 DN40 DN40 1/2" 18000 YES DN200 DN200 DN200 DN25 DN65/100 DN65/100 DN50/80 DN20 M=420 1/2" DN15 DN40 DN40 1/2" 20000 YES DN250 DN200 DN200 DN25 DN65/100 DN65/100 DN65/100 DN20 M=420 1/2" DN15 DN40 DN40 1/2"

1 Vent valve 2 Safety valve*

2 Isolation valve 2 Reflection indicators fixing centre (mm) 1 Blow down sight glass drain (screwed) 1 tds shut off valve 1 Blow down shut off valve 1 Blow down ball valve 1 Pressure gauge with three-way valve Water level control type 1 Feed water valve 1 Feed water non-return valve/anti syphon valve 1 Strainer pump (suction side) 1 Ball valve pump (suction side) 1 Pressure gauge (pump) with shut off valve 1 Feed water pump Motor rating 1 Feed water pump Motor rating 1 Feed water pump Motor rating 10 barg kW 13 barg kW 16 barg kW

MODULATING DN50 DN50 DN80 DN 80 1/4" CR 11.0 CR 11.0 CR 15.0 DN50 DN50 DN80 DN 80 1/4" CR 11.0 CR 11.0 CR 15.0 DN65 DN65 DN100 DN100 1/4" CR 11.0 CR 15.0 CR 18.5 DN80 DN80 DN125 DN125 1/4" CR 11.0 CR 15.0 CR 18.5 DN80 DN80 DN125 DN125 1/4" CR 15.0 CR 18.5 CR 18.5 DN80 DN80 DN125 DN125 1/4" CR 15.0 CR 18.5 CR 22.0

*Safety valve number and size to be advised at contract stage subject to set pressure requirement.

2-7

THSD-I E
Industrial Steam Boiler for Gas and Oil Firing

Hoval

Technical data THSD-I E without economiser

1 2 3 4 5 6 7

Boiler Boiler base Front reversal chamber Hinged front door Flue gas outlet Explosion/cleaning door (flue side) Inspection openings (water side) Instrument assembly

8 9 10 11 12 13 14 15

tds shut off valve Steam shut off valve Safety valve(s) Water level gauges Water level control Water level alarms Feed water inlet Feed water valve(s)

16 17 18 19 20 21 22 23

Bottom blow down ball valve Pressure stats Feed water pump(s) Electrical control panel Burner5 Vent valve Condensate drainage Flame viewing port
Flue gas connection6 H3 D1 1750 1825 1850 1950 2000 2100 2200 2350 2400 2500 2550 2650 2700 350 450 450 550 550 650 650 800 850 950 1000 1000 1000

Main dimensions THSD-I E Model 2000 2500 3000 4000 5000 6000 8000 10000 12000 14000 16000 18000 20000
1 2

Boiler base D 1990 2090 2140 2240 2340 2440 2640 2840 2940 3140 3240 3340 3440 L3 300 300 300 300 300 300 300 350 350 350 350 350 350 L4 700 700 700 700 700 700 700 850 850 850 850 850 850 L1 2300 2500 2700 3000 3400 3600 4100 4500 5000 5000 5500 5500 6000 L2 400 400 400 400 400 400 400 475 475 475 475 475 475 B1 1175 1225 1250 1350 1400 1450 1550 1700 1750 1850 1900 1950 2000 B2 160 160 160 160 160 160 160 200 200 200 200 200 200

L 3750 3950 4150 4500 4950 5150 5650 6150 6550 6850 7150 7350 7850

B 2450 2550 2600 2700 2800 2900 3100 3300 3400 3600 3700 3800 3900

H 2700 2800 2850 3075 3250 3400 3650 3925 4125 4350 4425 4625 4725

H1 2250 2350 2400 2550 2650 2800 2925 3200 3300 3500 3600 3700 3800

H2 1175 1225 1250 1350 1400 1450 1550 1700 1750 1850 1900 1950 2000

up to THSD-I E (4000) 100mm less up to THSD-I E (4000) 200mm less 3 up to THSD-I E (4000) 100mm less, from THSD-I E (12000) 100mm more 4 up to THSD-I E (4000) 200mm less, from THSD-I E (12000) 100mm more 5 Burner shown is monobloc type. Width/height may alter with fabricated wind box type burner. 6 Ducting and chimney diameters to be sized for site application Pos. 14 up to THSD-I E (4000) 400mm less Dimensions incl. 120 mm insulation thickness 2-8

Design pressure 10, 13 and 16 bar (overpressure) Other models available for different working pressures. Transport dimensions for pressure level 10 bar. Add 100mm to H1 for crane hooks.

THSD-I E
Industrial Steam Boiler for Gas and Oil Firing

Hoval

Technical data THSD-I E with economiser - subject to local site alterations

1 2 3 4 5 6 7

Boiler Boiler base Front reversal chamber Hinged front door Flue gas outlet Explosion/cleaning door (flue side) Inspection openings (water side) Tube assembly

8 9 10 11 12 13 14 15

tds shut off valve Steam shut off valve Safety valve(s) Water level gauges Water level control Water level alarms Feed water inlet pipework Feed water valve(s)

16 17 18 19 20 21 22 24

Bottom blow down ball valve Pressure stats Feed water pump(s) Electrical control panel Burner Vent valve Condensate drainage Economiser7

Main dimensions THSD-I E Model 2000 2500 3000 4000 5000 6000 8000 10000 12000 14000 16000 18000 20000
1 2

Boiler base D 1990 2090 2140 2240 2340 2440 2640 2840 2940 3140 3240 3340 3440 L3 300 300 300 300 300 300 300 350 350 350 350 350 350 L4 700 700 700 700 700 700 700 850 850 850 850 850 850 L1 2300 2500 2700 3000 3400 3600 4100 4500 5000 5000 5500 5500 6000 L2 400 400 400 400 400 400 400 475 475 475 475 475 475 B1 1175 1225 1250 1350 1400 1450 1550 1700 1750 1850 1900 1950 2000 B2 160 160 160 160 160 160 160 200 200 200 200 200 200

L 4700 4900 5100 5450 5900 6100 6600 7050 7450 7750 8050 8250 8750

B 2450 2550 2600 2700 2800 2900 3100 3300 3400 3600 3700 3800 3900

H 2700 2800 2850 3075 3250 3400 3650 3925 4125 4350 4425 4625 4725

H1 2250 2350 2400 2550 2650 2800 2925 3200 3300 3500 3600 3700 3800

H2 1175 1225 1250 1350 1400 1450 1550 1700 1750 1850 1900 1950 2000

Flue gas connection6 H3 D1 1750 1825 1850 1950 2000 2100 2200 2350 2400 2500 2550 2650 2700 350 450 450 550 550 650 650 800 850 950 1000 1000 1000

up to THSD-I E (4000) 100mm less up to THSD-I E (4000) 200mm less 3 up to THSD-I E (4000) 100mm less, from THSD-I E (12000) 100mm more 4 up to THSD-I E (4000) 200mm less, from THSD-I E (12000) 100mm more Pos. 14 up to THSD-I E (4000) 400mm less 5 Burner shown is monobloc type. Width/height may alter with fabricated wind box type burner 6 Ducting and chimney diameters to be sized for site application 7 Economiser can be positioned vertically.

Dimensions incl. 120 mm insulation thickness Design pressure 10, 13 and 16 bar (overpressure) Other models available for different working pressures. Transport dimensions for pressure level 10 bar. Add 100mm to H1 for crane hooks.

2-9

THSD-I E
Industrial Steam Boiler for Gas and Oil Firing

Hoval

Technical data Typical Installation To facilitate installation and maintenance the stated clearances should be met. Drawing indicates right hand (standard) hinged door Minimal space refers to boiler. Depending on equipment (accessories) the minimal space needs to be reviewed according to local codes. Positioning

* 1200 Minimum

** 1200 Minimum

500 Minimum 500 Minimum

***

No air pollution through halogenated hydrocarbon (contained e.g. sprays, paints, solvents and cleaners) No large amounts of dust No high atmospheric humidity Frost-resistant, dust free and well ventilated Boiler to be installed and positioned in a weatherproof, nonhazardous and safe classified area.

*300mm+ burner overall length (consider pivoting range/pivoting side) **Consider control panel, pump(s) assembly ***Flame tube length for tube withdrawal/cleaning

Otherwise damage to the installation may occur. The boiler may only be installed in rooms where air pollution through halogenated hydrocarbon can occur if sufficient measures are taken ensuring the supply of unpolluted combustion air. Boiler room dimensions can be reduced by the fitting of a shutter door or knockout panel.

Model THSD-I E a (mm)

2000 2800

2500 3000

3000 3200

4000 3550

5000 4000

6000 4200

8000 4700

10000 5100

Model THSD-I E a (mm)

12000 5500

14000 5800

16000 6100

18000 6300

20000 6800

2-10

THSD-I E
Industrial Steam Boiler for Gas and Oil Firing

Hoval
Installation of acoustic shroud for the burner. A substantial part of the sound caused in the combustion chamber and in the top heating surfaces is radiated from the flue outlet as sound transmitted by air. In addition to this, resonance features, depending on chimney dimensioning and inlet, may occur which are triggered by the oscillation of the combustion process. These sounds can be reduced by burner-lateral measures, e.g. changes of flame geometry, atomisation characteristics or fuel throughput. Flue gas attenuators cause a substantial sound level reduction. These should usually be tuned at low frequencies of 60 - 250 Hz. Flue gas attenuators function according to the principle of sound absorption. The kinetic energy of the exhaust gases is reduced by friction requiring an increase in chimney draft in the flue system. This has to be considered for burner sizing. The connection piece from the boiler to the flue gas sound absorber has to be gastight. The necessary space requirement of approximately 1 m for the later installation of a flue gas attenuator should already be included when planning.

Engineering Rules and regulations

The following rules and regulations have to be respected: Hoval technical information and installation guide Fire protection regulations National regulations concerning permission, installation and operation of boiler appliances. Boiler appliances have to be installed according to national laws and regulations and accessory requirements. Besides the national and local regulations the project specific circumstances of the boiler supplier have to be considered for every application. National and local rules and regulations have to be considered for the fuel supply. Fuel filters are highly recommended The operation and water analysis data is to be recorded daily in the operation booklet. Safety valve, condensate and blowdown connections must discharge to a safe place. Filters and strainers have to be cleaned periodically, especially if installed in front of control devices. The drain of the tds, blow down, drainage, etc has to be safely discharged into a blowdown vessel. All heating components and pipework are to be insulated in order to reduce radiation losses. -

Water treatment/water quality - The quality of the boiler water has to be guaranteed according to Hoval technical information and national guidelines. Hoval boilers may only be operated with treated water. The national regulations for the treatment of water apply for the values to be maintained. Required water quality: see page 2-12. The water quality has to be checked daily.

Combustion air - The supply of combustion air must be guaranteed for a safe and economic operation. There must be no possibility of the air supply being shut off. Ventilation of the boiler house has to also be provided. In the installation room no negative pressure larger than 3 N/m2 is allowed. To adhere to this demand, plan a free area for the air supply opening of at least 200 cm2, plus 2 cm2 per KW output. The aspect ratio for rectangular openings should not be more than 1.5 :1. If the opening is louvered ensure the free area is sufficient. National laws have to be respected. Boiler houses have to be fitted with relevant fresh air supply openings or ducted system. Gas boilers are not to be installed in rooms where halogen compounds occur which can enter the combustion air. -

Planning, operation and maintenance - The heating of the feed water and the degassing takes place in the feed water tank (hot well). To increase the efficiency, especially for natural gas operation, an economiser can be added to pre-heat the feed water. Pumps (especially horizontal rotary pumps and warm water/condensate pumps, NPSH pumps) need to be installed with the necessary flow and return pipework according to requirements. The installation has to be completely free of tension (antivibration proof). Feedwater tank height must satisfy the feed pump NPSH requirement.

Chimney/flue gas system - A properly designed chimney/flue arrangement must be provided to match each particular application. To achieve a smooth discharge of the exhaust gases from the boiler into the chimney, the flue connection is recommended to enter the chimney at approximately 30-45. From a length of greater than 1 m thermal insulation is necessary. Adequate provision should be made to drain off condensate from the base of the chimney ensuring condensate does not run back into the boiler smokebox.

Noise level reduction The following measures for noise level reduction are possible: Solid construction of boiler room walls, ceiling and floor, installation of silencer in fresh air supply, noise insulation for support and bracket of pipes.

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THSD-I E
Industrial Steam Boiler for Gas and Oil Firing

Hoval
<1 >1 < 22 >22 < 68

Boiler and feed water specifications for steam boiler plants Feed water specifications for natural circulating boilers Working pressure Properties pH-value at 25C Sum of alkaline earth elements (Ca + Mg) Conductivity at 25C Oxygen (O2) Carbon dioxide (CO2) dissolved Iron (Fe), total Copper (Cu), total Silicate acid (SiO2) Consumption of Potassium permanganate Oil, fat
1 1

bar

colourless, clear, free from suspended matter and foam >9 mmol/l dH S/cm mg/l mg/l mg/l mg/l mg/l mg/l mg/l < 0,02 < 0,112 >9 < 0,02 < 0,112 >9 < 0,01 < 0,056

see guidelines for boiler water specifications only < 0,1 < 25 < 0,02 < 25 < 0,05 < 0,01 < 0,02 < 25 < 0,03 0,005

see guidelines for boiler water only < 10 <3 < 10 <1 < 10 <1

Noted in the past at dH, changing factor: 1 mmol/l = 5,6 dH (German hardness). It is not necessary to make continuous control of the following parameters: Conductivity, Oxygen (O2), Carbon dioxide (CO2) dissolved, Iron (Fe), total, Copper (Cu), total, Silicate (SiO2), Consumption of Potassium permanganate, Oil, fat. Boiler water specifications for natural circulating boilers Working pressure Properties pH-value at 25C Sum of alkaline earth elements (Ca + Mg) Conductivity at 25C Acid capacity KS 8,2 (p-value)
3 2

bar

<1

>1 < 22

>22 < 44

colourless, clear, free from suspended matter and foam 10,5-12 mmol/l dH S/cm mmol/l mg/l mg/l mg/l mg/l mg/l mg/l < 0,02 < 0,112 < 5000* 1-12 < 25 < 150 10-20 5-10 (3-5) 10,5-12 < 0,02 < 0,112 < 5000* 1-12 < 25 < 0,05 < 100 5-10 5-10 (3-5) 10-11,8 < 0,01 < 0,056 < 2000* 0,5-6 < 25 < 0,03 < 50 5-10 3-5 --

Carbon dioxide (CO2) dissolved Iron (Fe), total Silicate acid (SiO2) Phosphate (P2O4)
4

Sodium sulphate (Na2SO3)4 (Polyamide)

1 5

Take care to maintain the allowed value of acid capacity - at this point the allowed conductivity has to be lower on many plants; for water level electrodes minimum conductivity > 5 S/cm 2 Noted in the past at dH, changing factor: 1 mmol/l = 5,6 dH (German hardness) 3 Noted in the past as p-value, changing factor: KS 8,2 = 1 according p-value = 1 4 Measurements only necessary if dosing chemicals are used which contains these values 5 It is recommended to use Amine (film producing) only instead of other dosing chemicals for boilers which have a small heating load and up to maximum 16 bar working pressure. Because of the danger of foam production overdosing is not permitted! Boiler water quality to comply with BS2486. It is not necessary to make continuous control of the following parameters: Silicate (SiO2) Important note: Hoval recommend that a water treatment specialist is employed to advise on each application and to carry out routine monitoring of the feed and boiler water to ensure it remains within specification. 2-12

Hoval Limited Northgate Newark Nottinghamshire NG24 1JN Tel: 01636 672711 Fax: 01636 673532 boilersales@hoval.co.uk www.hoval.co.uk

Hoval Export Austrasse 70, 9490 Vaduz Principality of Liechtenstein Tel: +423 399 2400 Fax: +423 399 2618
0805

export@hoval.co.uk www.hoval.com

By Appointment to Her Majesty The Queen Boiler Manufacturers & Engineers Hoval Limited, Newark

Hoval follows a policy of continued improvement and reserves the right to change specifications without notice. All dimensions are approximate.