Generadores de fluido termico Calderas de vapor.

Ingenieria

PIROBLOC, S.A. P.I. Santiga Av. Castell de Barber, 31 08210 Barbera del Valls (Barcelona) Tel. 00 34 937 189 064 Fax 00 34 902 908 812 E-mail: info@pirobloc.com www.pirobloc.com

THERMAL FLUID BOILER PIROBLOC, S.A. 1- Introduction

The thermal fluid boilers from PIROBLOC, fulfill the effective directive European of devices to pressure D.E. 97/23/CE (category I) and with the Regulation of Apparatuses to Pressure and Complementary Technical Instructions of the Industry and Energy. The design of these generators is based on the most renowned construction codes such as the EN13445. All the materials which are used in the construction of the boilers, bear the Original Quality Certificate, nevertheless PIROBLOC, S.A. performs a further checking on the mechanical and chemical features, in an independent laboratory, which allows to secure the complete reliability of the product. The welding process and the welding personnel is duly approved by a Cooperating Entity to the Administration. The user receives full documentation proving all these approvals together with the corresponding Quality Control Dossier. In the same also the Certificates for the Original Quality Control are contained.

Generadores de fluido termico Calderas de vapor. Ingenieria

PIROBLOC, S.A. P.I. Santiga Av. Castell de Barber, 31 08210 Barbera del Valls (Barcelona) Tel. 00 34 937 189 064 Fax 00 34 902 908 812 E-mail: info@pirobloc.com www.pirobloc.com

2- Description
The thermal fluid heater, in vertical execution, without any adjusted or preset level, with automatic operation and indirect supervision, provides heat by means of liquid or gaseous fuels. These heaters have cylindrical cover, (4) and (5), and they are prepared to increase the temperature of the thermal fluid that circulates through two concentric coils, by means of the combustion of liquid or gaseous combustibles in a burner. This burner is located and fixed in the upper flat lid (12). There is a rockwool isolation (10) between both covers, providing therefore a minimum structural loss and also avoiding harmful burnings through involuntary contact with the boiler. Item list: 1. Internal coil 2. Coil lid 3. Combustion chamber lid 4. Internal cover 5. External cover 6. Connecting flanges 7. Bottom combustion chamber 8. Bottom isolation 9. Kaowool 10. Isolation 11. UPN contour 12. Boiler lid 13. External coil 14. Closing combustion chamber The burner flame is projected towards the combustion chamber, then depending on the adjustment of the combustion, it will strike the ceramic bed that closes the fireplace (7), changing then the sense so that the combustion gases go up at high speed and with turbulence, between both coils until reaching the upper conic lid (2), at that stage their sense will get again descending, until they are exhausted by the chimney which is situated on the lower edge of the covers. The coils (1 and 13) may be of one, two or three steps, depending on the model, being essential the high speed in the circulation of the thermal fluid, in order to obtain a good heat transmission and also to avoid the "cracking" of the said fluid. These coils are manufactured in stretched steel without any welding St. 35.8.1 special for boilers, according to DIN 17175, thickness according to DIN 2440. The circulation of the thermal fluid is done initially through the outer coil (there where heat is transmitted almost only by convection), passing later on to the internal coil (where heat is transmitted almost exclusively by radiation), obtaining then an excellent energetic result.

Generadores de fluido termico Calderas de vapor. Ingenieria

PIROBLOC, S.A. P.I. Santiga Av. Castell de Barber, 31 08210 Barbera del Valls (Barcelona) Tel. 00 34 937 189 064 Fax 00 34 902 908 812 E-mail: info@pirobloc.com www.pirobloc.com The slightly conic lid, contains a detachable, moving part and a fixed part. This last one, that means the fixed part, serves as closure to the smoke passage between the coils and disposes of the corresponding holes for the passage of the coil pipes which are connected to the general collector, being connected to the circuit by means of flanges (6). The detachable, moving part closes the combustion chamber, and is where the burner is attached. Easily this part can be taken out, providing an easy access to the combustion chamber for the necessary maintenance works. The external lid is flat and has the proper fastening tabs for transporting the boiler, facility that is possible in the higher standard models. Also there is the possibility provided for fastening the boiler to the UPN profiles that are located in the bottom (11).

Generadores de fluido termico Calderas de vapor. Ingenieria

PIROBLOC, S.A. P.I. Santiga Av. Castell de Barber, 31 08210 Barbera del Valls (Barcelona) Tel. 00 34 937 189 064 Fax 00 34 902 908 812 E-mail: info@pirobloc.com www.pirobloc.com

3- The heating circuit

A standard type circuit of thermal fluid, as the one shown on the included drawing, is formed by: - The thermal fluid boiler or generator - The circulating pump - The collecting tank - The expansion tank - The consuming equipments - The pipes, valves and accessories Its operating diagram is as follows : The thermal fluid is suctioned by the circulating pump (3) through the pipe (1) and the valve and filter (2), after it is introduced in the generator (4). The thermal fluid flows out of the boiler passing through the valve (5) and through the general net (6), reaching the different consuming points (8), controlled by means of automatic valves. These automatic valves can be of two or three tracks, the working temperature in the equipment is therefore precisely regulated by them. Each consuming equipment can be independent of the general net thanks to manual valves that are installed in each line (7). Once the heat is "placed" in the consumer equipment, the fluid will return to the collecting bottle (9), there, in all PIROBLOC i n s tallations AUTOMATICALLY the installation will be drained and goes back again to the circulating pump in order to restart the cycle. The valve (18), operates as general "by pass" to the circuit. These valves may be of mechanical drive (ballasted valve) or of electrical or pneumatic drive (automatic valve).

Generadores de fluido termico Calderas de vapor. Ingenieria

PIROBLOC, S.A. P.I. Santiga Av. Castell de Barber, 31 08210 Barbera del Valls (Barcelona) Tel. 00 34 937 189 064 Fax 00 34 902 908 812 E-mail: info@pirobloc.com www.pirobloc.com When heated, the thermal fluid gets expanded, by decreasing its density (see thermal fluid features). So. f.e. at 200C we get a volumetric increase of approx. 18% and at 300C of 30%. The expansion tank (11) should have sufficient capacity so that it is not filled up totally, when the thermal fluid of the whole installation is at the highest temperature, while at room temperature the expansion compensating pipe (10) should not remain without oil, causing therefore the failure of the circulating pump, which would remain unprimed. Further on, this tank is also used for making the AUTOMATIC drainage of the circuit. Effectively, when the thermal fluid passes through the collecting bottle (9), the humidity and the gases will be detached and they are brought through pipe (10) to the expansion tank, where they are either condensed or they are exhausted through pipe (12) to the collecting tank (13). It is a closed circuit, for this reason there is a thermal fluid pillow installed, in the collecting or gathering tank, which absorbs the pressures and underpressures which could arise in the circuit, during operation. The siphon (14) avoids also the air entrance to the collecting tank. The humidity will only be present during the start up of the installation, precisely at this moment the connection of the expansion tank and the collecting tank should be avoided, as this fact would cause the storage of humidity in the collecting tank , and this of course could also cause its later entrance again in the circuit when this tank is filled up. During the operation, only the gases that are generated by heating up the thermal fluid, will be drained automatically. The gathering tank has, besides the function of being the pillow for the gases, also the function of absorbing the fluid of the installation for the complete drainage of the same, when any repair or maintenance works have to be done. It should be situated in the lowest place of the installation, either on the surface or embedded. The refilling and drainage group (16), enables to carry out these operations from cans (18) to the tank or to circuit and reverse, by changing the valves (17). Some consuming points could have recirculation groups (19) when uniform or very precise temperatures in the product are needed (around +/-1C).

Generadores de fluido termico Calderas de vapor. Ingenieria

PIROBLOC, S.A. P.I. Santiga Av. Castell de Barber, 31 08210 Barbera del Valls (Barcelona) Tel. 00 34 937 189 064 Fax 00 34 902 908 812 E-mail: info@pirobloc.com www.pirobloc.com

4- Controls and securities

The PIROBLOC boilers and installations accomplish the relevant present norms :

Directive 97/23/CE relative to the Pressure Equipments. Regulations for Pressure Equipments and Complementary Technical Instructions. UNE 9-310-92 Norm for "Heat transmitting installations by means of liquids other than water". DIN 4754 Heat Transfer systems operationg with organic heat transfer media Atmospheric Environmental Protective Rules and complementary dispositions.

Besides, all the installations made by PIROBLOC satisfy also all the dispositions and laws corresponding to the Municipality and/or Autonomous Community where the installation has to take place. On the included drawing, the securities and controls of the installation are shown. The operating and security elements are indicated in blue color. In green color are the control elements and in red color the safety elements. The boiler and installation securities and controls are: Visual level in the collecting tank (LI) Temperature security pyrometers for the thermal fluid and the smokes in chimney (TAH) Electric level for minimum in the expansion tank (LSL) Manometers for boiler entrance and exit (PI) and temperature intake (TI) Thermal relays for motor protection Differential pressure switch (dPSL) Maximum pressure switch (PAH) Operating pyrometer (TIC) Flame control (BAL) Safety stop Hour safety Acoustic warning

Generadores de fluido termico Calderas de vapor. Ingenieria

PIROBLOC, S.A. P.I. Santiga Av. Castell de Barber, 31 08210 Barbera del Valls (Barcelona) Tel. 00 34 937 189 064 Fax 00 34 902 908 812 E-mail: info@pirobloc.com www.pirobloc.com Following we will observe in detail the function of each one: - Pyrometers for the first and second flame (operating pyrometer) (TIC) They send information (temperature) to the electric panel with respect to the heat demands of the equipment. Operating and control elements. - Pyrometer for max. oil temperature (TAH) Warns about a possible failure on different elements, which could cause a considerable increase on the thermal fluid temperature. Safety element which locks the burner. - Pyrometer for max. smoke temperature (TAH) Detects a too high increase of the combustion gases temperature by the boiler (chimney) exhaust, due to failure in any control element. Safety element which locks the burner. - Differential pressure switch (dPSL) Detects a faulty circulation of the thermal fluid, due to insufficient pressure between the entrance and the outlet of the boiler. Safety element, which locks the burner. - Maximum pressure switch Detects a faulty circulation of the thermal fluid, due to an increase in the pressure, which is delivered by the circulating pump. Safety element, which locks the burner. - Acoustic warning Acts in front of any kind of safety, in order to inform on the same. Safety element. - Thermal relays They serve as protection to the pump motors and to the burner fan. Operating and safety elements. - Cooling timer (safety stop) Prevents that the circulating pump of the thermal fluid is disconnected before a preadjustment time has elapsed, avoiding tightness at high temperatures, which could be harmful to the oil load. Operating and safety element. - Hour safety timer Obliges to make periodical inspections (every two hours) by the personnel in charge, to verify the state of the equipment. Safety element. - Visual level (LI) Allows to observe the fluid quantity inside the installation. Control element. - Electric Level (LSL) This element inhibits start up of the equipment when thermal fluid is missing in the installation. Safety element. - Manometers (PI) and thermometers (TI) Pressure and temperature indicators at boiler entrance and exit, informing on the correct circulation of the thermal fluid. Control elements.

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Generadores de fluido termico Calderas de vapor. Ingenieria

PIROBLOC, S.A. P.I. Santiga Av. Castell de Barber, 31 08210 Barbera del Valls (Barcelona) Tel. 00 34 937 189 064 Fax 00 34 902 908 812 E-mail: info@pirobloc.com www.pirobloc.com Other standard elements, belonging to the own function of any burner are : - Electrovalve for the first and the second flame They allow a greater or smaller quantity flow of the combustible, depending on the needs of the equipment. Operating and control elements. - Safety electrovalve Cuts the flow of combustible off, when there is no demand on it, at the same time as the electrovalve for the first and second flame, acting as safety for those. Safety element. - Burner control Element that is indicating all steps that the burner has to follow. Operating and safety element. - Ultra-violet cell, or ionization probe (Flame control) (BAL) Light detecting, therefore detection of flame forming, indicating that combustion has started, informing on false ignitions. Safety and control element.

Generadores de fluido termico Calderas de vapor. Ingenieria

PIROBLOC, S.A. P.I. Santiga Av. Castell de Barber, 31 08210 Barbera del Valls (Barcelona) Tel. 00 34 937 189 064 Fax 00 34 902 908 812 E-mail: info@pirobloc.com www.pirobloc.com

5- Instructions for start-up

The first start-up of the boiler and the installation will be done by a specialized PIROBLOC technician, who will also give instructions and train about the correct use, the personnel in charge of operating the equipment. Before the routine start-up, following points will have to be checked: 1) Verify the correct filling of the installation, observing that the luminous signal of Oil level, in the electric panel is out, once the voltage has been connected. Also the visual level installed on the expansion tank, will have to be checked. 2) Verify that the manometer readings installed at the pump drive and boiler exit, indicate the usual static level, corresponding approx. to 0.08 times the value of the geometric height of the expansion tank. 3) Verify that all the valves are positioned in the desired and correct position. 4) Verify the correct state of the combustible feeding installation. 5) Verify the correct set-point selection in the temperature regulators for the thermal fluid of the boiler and of the automatic valves. 6) Verify the correct set-point selection in the thermal fluid temperature limiters and for the smokes. 7) Checking of the correct adjustment of the differential pressure switch. 8) Checking of the correct adjustment of the thermal relays. Some of these operations (7) and (8), are not precisely necessary, if the person in charge of the boiler is always the same one. However, when there takes place a shift change, variations may happen in the operating state, if these are not passed on to the entering person in charge, misalignments may occur. Once these operations have been done, you may proceed to start up the thermal fluid circulating pump, observing that the dynamic pressures in the impulsion manometers of the pump and the boiler exit must be the usual ones for start up. These are higher pressures than those of the installation in normal operation, having in mind the variation of the physical changes in the thermal fluid regarding with the temperature. The burner is connected as soon as the circulating pump is in normal operation. This one cannot be connected without the operating presence of the circulating pump, existing a lock-in. The installations do not require any special care during normal operation. However checking of the pressures and the temperatures is necessary, when relieving the timer after the obligatory stop (every two hours). When labor day is ending, the cooling circuit MUST be connected, in order to avoid stopping at high temperature as this may damage the thermal fluid load, causing a quicker degradation of the same.

Generadores de fluido termico Calderas de vapor. Ingenieria

PIROBLOC, S.A. P.I. Santiga Av. Castell de Barber, 31 08210 Barbera del Valls (Barcelona) Tel. 00 34 937 189 064 Fax 00 34 902 908 812 E-mail: info@pirobloc.com www.pirobloc.com

6- Maintenance 6.1 Preventive maintenance

Besides the special instructions given in each section concerning the pump and the burner, periodically following reduced maintenance steps should be taken into account and performed in order to dispose always of the best working conditions of the boiler and of the installation in general : - Daily 1) As already mentioned before, checking of the oil level in the expansion tank. If there is not sufficient oil inside, it must be filled up, until reaching about 1/3 of the tank. This operation must always be done when the installation is IN COLD condition. 2) Verify the consumption of the pump motor. 3) Verify the temperature of the smokes. - Weekly 1) Checking of the correct function and the state of all the electrical material, connections and devices. automatic

2) Verify the pyrometers, either by means of a mercury thermometer, or by means of the electrical signal readings that the controller receives. Please keep in mind, that in those installations with thermocouple type (FeKonst), to the indicated value on the table, the room temperature has to be added. - Quarterly 1) Analysis of the combustion. 2) Partial emptying in order to check the correct function of the electric level in the expansion tank. 3) Check the circuit safety devices ( acoustic warning, differential pressure switch, temperature limiters, etc.). - Every semester 1) Extraction of a thermal fluid sample and analysis of the same. The most convenient point for this extraction lays in the emptying-filling up circuit, rejecting the fluid that is inside this circuit. - Yearly 1) At least once, a PIROBLOC technician or any other competent person, should make an overhaul, following the norms stated in the prevailing Rules for Pressure Equipments. 2) Cleaning and internal overhaul.

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Generadores de fluido termico Calderas de vapor. Ingenieria

PIROBLOC, S.A. P.I. Santiga Av. Castell de Barber, 31 08210 Barbera del Valls (Barcelona) Tel. 00 34 937 189 064 Fax 00 34 902 908 812 E-mail: info@pirobloc.com www.pirobloc.com

6.2. - Corrective maintenance

The most frequent failures in a thermal fluid installation, are related to the burner and the pump. These failures are already described in the corresponding section herewith. On the other hand, normally a thermal fluid boiler or installation does not have failures, due to their simple ness the maintenance functions are just as easy to carry out. However, some possible failures, peculiar to the circuit, could be :

FAILURE

CAUSE
Thermal fluid filter is dirty

SOLUTION
Sieve cleaning. Pass an entire process in cold, closing previously the suction valves of the pump and drive

Pressure oscillations. Cavitation

Lack of thermal fluid in the Proceed to fill up in cool state installation Proceed to automatic drainage of the installation, very slowly increasing the working temperature after 100C The installation contains humidity onwards. Try to find out how the humidity could enter into the installation (exchangers) and solve the problem Degradation of the thermal fluid Analysis of a sample and change the thermal fluid if load necessary. Make a circuit cleaning

Locking due to the temperatures of the smokes or due to security

Working temperature increases, Modify according the temperature adjustments of the whereas the other adjustments smokes and the safety do not increase Casual modification of adjustments the Proceed to adjust new values

Degradation of the thermal fluid Analysis of a sample and change the thermal fluid if load necessary. Make a circuit cleaning Dirt inside the boiler Boiler inside cleaning Degradation of the thermal fluid Analysis of a sample and change the thermal fluid if load necessary. Make a circuit cleaning Important leakages installation Change of the set-point in the Check the sealing and tightness of the circuit Check the sealing and tightness of the circuit Readjust the set-point

Frequently filling-up of the thermal fluid

Leakage in a secondary circuit

The pressure switch is locked

Proceed to automatic drainage of the installation, increasing very slowly the working temperature after Humidity in the circuit 100C onwards. Try to find out how the humidity could enter into the installation (exchangers) and solve the problem Degradation of the thermal fluid Analysis of a sample and change the thermal fluid if load necessary. Make a circuit cleaning Change in the hydraulic circuit Check the operating point of the pump (enlargement)

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