Technical Specification 92835016 - 02 040516 PDF

technical specification
no. 92-8350-16 / 02
dated 04.05.16
page 1/27
ITEM 1 GEKAKONUS THERMOMAT THZ-S 20 H (HORIZONTAL)
The GEKAKONUS-thermomat is a forced circulation heater of three-pass design for organic
high temperature heat transfer media on mineral- or synthetic basis. It consists of a
cylindrical combustion chamber, formed by closely bended pipes.
The combustion chamber is dimensioned large in regard to diameter and length, so that,
based on the special firing equipment, the flame can completely burn out with sufficient
distance to the walls of the furnace. This construction guarantees that there is no danger of
thermal fluid overheating and damage when operating the heater according to specifications
and selecting GEKAKONUS-recommended heat transfer media. A further coil, surrounding
the combustion chamber, forms the convective heating surfaces.
Both coils are mounted without strain in a gastight heater-shell, so that they are free to
expand, independent from the operating conditions. The space between inner an outer coil
forms the second pass and the space between heater shell and outer coil the third pass. The
thermal fluid temperature is monitored in both coils.
The thermal oil flows from the return flow connection (inlet), located at the bottom of heater,
into both tubings parallel upwards to the outlet (outlet). By this operating method the heat
transfer medium will be treated gently and during the start-up phase an easy and quick
degassing is possible. No gas pockets in the tubing can develop.
The heater cover plate can be opened and closed easily by means of quickacting locks for
inspection or required cleaning of the complete coil-system.
Manufacturing in accordance with:
EC- Machine Directive 98/37/EC, EC- Pressure Equipment Directive 97/23/EC,
UVV/ Operational Reliability Regulation (BetrSichV),
DIN 4754 "Heat conducting equipment with organic heat transfer media",
DIN EN 25817 Arc- welded joints in steel, ass. group C and
DIN 8562 .Welding of containers.
Standard equipment:
on the outlet header:
2 orifice for flow indication and monitoring, mounted be

tween two flanges, for easy maintenance and checking
1 pocket for temperature-sensor
1 connection with flange DN 25, DIN 2633 for vent- and
safety valve
on the inlet header:
1 pocket for temperature-sensor

1 U-shaped tube for manometer
flue gas connection piece:
1 pocket for flue gas temperature sensor
no. 92-8350-16 / 02
dated 04.05.16
page 2/27
TECHNICAL SPECIFICATION
Type
Design
Temperature difference
Heat output
Outlet temperature
Inlet temperature
Circulation rate - normal
Circulation rate -minimum
Heat transfer medium
acc. to DIN 51522
Heating surface
Heater content
Test pressure
Design pressure
Firing efficiency
Pressure test
Quality of tubes
In- and outlet-connection
Flue gas outlet
Heater frame
:
:
:
:
:
:
:
:
THZ-S 20 H
horizontal
30 C
2.326 kW (2.000.000 kcal/h)
260 C
230 C
140 m3/h
125 m3/h
:
:
:
:
:
:
:
:
:
:
:
Heater shell
BP Transcal N or equivalent
90,5 m2
1981 litres
25 bar
10 bar
approx. 87 % (based on 250C outlet temp.)
coldwater pressure test with certificate by TV
St 37.8I, material no. 1.0315
flange PN 40, DIN 2635
round, with counter flange
metal surface hand-derusted, grease and dustfree
1x
base coat corrosion protective with
1-component zincphosphate-colour
dry film thickness approx. 35 my
tone: RAL 6011 reseda green
2x
top coat weatherproof, glossy with
synthetic resin-varnish paint on alkyd
resin base
dry film thickness approx. 70 my
tone: RAL 7001 - silver-grey
metal surface hand-derusted, grease and dustfree
2x
top coat heat-resisting with siliconaluminium colour
tone: silver-light
ITEM 1.1 HEAT INSULATION OF BOILER SHELL

The boiler shell is surrounded by a heat insulation of mineral wool and protected by a casing
of structured aluminium sheet.
This insulation is suitable for indoor installation only. The insulation thickness is designed for
a max. surface temperature of 50C above ambient temperature.
no. 92-8350-16 / 02
dated 04.05.16
page 3/27
ITEM 1.2 HINGED HEATER COVER
The heater cover is fixed with hinges on the heater shell. Therefore it is possible the heater
cover easily swing. By the easily way the heater cover to open is quickly sufficient access to
combustion chamber possible. Necessary inspections and cleaning works in the combustion
chamber and on the flue gas passes can be done relative without problems.
ITEM 2 DESIGN BY PRESSURE EQUIPMENT DIRECTIVE 97/23/EC
GEKAKONUS-heater are preliminary calculated by pressure vessel rules AD 2000 Germany
and will be tested during and after completion of manufacturing by notified body TV SD
Industrie Service GmbH (Identification number 0036). This test is documented by the TV
SD Industrie Service GmbH with a certificate.
Manufacturing according Pressure Equipment Directive 97/23/EC Module G, category IV.
Calculation and manufacturing according to foreign codes and acceptance by foreign
supervision organizations (e.g. BS, LROS, AS, Stoomwezen, Vincotte, STDB etc.) can be
supplied.
The additional costs for manufacturing and acceptance by foreign supervision organizations
(special design, special costs for manufacturing and acceptance tests) must be invoiced
according to the additional expenditure.
ITEM 3 HEATER FITTINGS FOR STAND-BY OPERATION
2 pcs. manual stop valves DN 150, PN 40
1 pc. non return flap DN 150, PN 16
TECHNICAL SPECIFICATION:
Casing material
Connections
Nominal width
Nominal pressure
:
:
:
:
1. 0619+N (steel cast)

weld on ends
DN 150
PN 40
no. 92-8350-16 / 02
dated 04.05.16
page 4/27
ITEM 4 SAFETY MOUNTINGS
According to DIN 4754 the GEKAKONUS- heater is classified as pressure vessel.
Corresponding to the pressure vessel-regulation TRB any pressure vessel which can be
locked to the expansion space must be equipped with a safety valve, see DIN 4754, page 9,
picture A.2.
Safety valve:
Type
Adjusting pressure
Nominal bore in-/outlet
Nominal pressure in-/outlet
Component test mark
Casing material
Number of
:
:
:
:
:
:
proportional-spring-safety valve, cornertype closed cap, heat resisting spring

10 bar
DN 25/ DN 40
PN 40/ PN 16
TV SV 97-663/22,5/D/G/0,74/10 bar
GGG 40.3
1
Vent valve:
For a quick venting of GEKAKONUS- heater during start-up and after each refilling we
deliver a vent valve on the outlet. The installation occurs in the outlet pipe. During the
continuous operation of GEKAKONUS- heater this valve remains closed.
Type
Casing material
Connections
Nominal bore
Number of
:
:
:
:
straight-way shut-off valve with metal

bellow-type sealing in special design with
safety gland
1.0619+N (steel cast)
weld-on ends PN 40
DN 25
1
Manometer for pressure indication on the inlet (0-40 bar).

Numer of
no. 92-8350-16 / 02
dated 04.05.16
page 5/27
ITEM 5 CONTROL SYSTEM AND SMALL AUXILIARY FITTINGS
The control elements and the temperature limiters are integrated into the switchboard. The
temperature sensors, as well as the flow safety device are mounted at the appropriate
places of the GEKAKONUS- Heater.
The burner regulation will be caused through an universal process controller, whose output
signal controls the position of the burner. The signal input occur through a 2 x Pt 100, which
is mounted in the outlet header.
Principally the heat transfer plant may be putting into operation only under staff supervision.
An automatically commissioning of the plant through an automatic short- out of the flow
control, remote control and/ or a timer is only permissible, if this process is allowed by the
public authority, who is responsible for the operation place of the plant.
During the automatical putting into operation the capacity of the burner is due to safety
reasons limited in the low load range. A temperature sensor in the inlet header of the heater
measures the inlet temperature. The capacity of the burner is by a combined contact in the
process controller limited on low load range. At an inlet temperature 100 C the limitation
of the burner capacity and the bridging of flow limitation will be disconnected. After enabling
of the low load limitation the burner can operate in the full range of capacity.
Additionally to the above mentioned process the minimal flow will be checked at the flow
control of the heater through a second contact. Independent of the inlet temperature of the
thermal oil the minimal flow must be always available for the automatic start. If no minimal
flow is available the automatic start of the burners won't be occurred.
Are the above mentioned conditions not to be effected, a fault interruption and also a burner
lock will be occurred. An further switch- on can only occur after elimination of the fault and
unblocking.
After switch- off the prime circulation pump (s), the pump wake can be activated by turn on
the switch pump wake in the switchboard. It will be signalled through a control lamp in the
switch board. The wake time is dependent on the inlet temperature and switching-off by
reaching 100 C.
2 pcs. Differential pressure- gauge with two micro switchers as flow safety device
for flow monitoring of each coil
2 pcs. Vent- valve combination for flow safety device
2 pcs. Temperature sensors 2x Pt 100 for outlet- and inlet measurement of
temperature (JUMO)
1 pc. Temperature sensor 2x Pt 100 for flue gas measurement of temperature
(JUMO)
no. 92-8350-16 / 02
dated 04.05.16
page 6/27
ITEM 6 FREESTANDING - SWITCHBOARD
The freestanding- switchboard consists of a solid dust- tight sheet steel casing. The front
side is fitted with a swing-door. The switchboard contains all equipment, wirings, relays,
fuses, terminals etc. for the power- and control-circuit. The necessary switches, control
buttons, signal lamps and indicator instruments are installed in the switchboard-door. The
equipment is wired ready to operate.
The inlet- and outlet temperature of the heat transfer medium is measured and announced
at the process controller. The burner controller controls and checks the faultless course of
the burner. The process controller controls the capacity of the burner.
The monitor equipment is in a safety circuit cascaded. In case of addressing of one of these
elements the firing is disconnected. The trouble is announced audibly and optically by a
GEKAKONUS- trouble indication type Siemens-LOGO with P+I- diagram.
The burner and the circulating pump are turned on/ switched off at the switchboard. The
functions of the individual, to the operation absolutely necessary aggregates are optically
announced through signal lamps.
Every three-phase motor is protected by an overload relay and circuit breakers or NH- fuse.
The bringing of the power line to the switchboard as well as the connection are provided by
the client/customer way.
Design
Country of erection
Protective system
DIN 40050 (IEC 144)
Power supply
Type of current
Control supply
Frequency
fluctuation voltage / frequency
max. adm. ambient temperature
Inscription
Motor starters
Indications
:
:
:
:
:
:
:
:
:
:
Flow chart
General alarm
Main switch
:
:
switchboard material
Burner control
Painting
Number
:
:
:
: VDE 0100 and DIN EN 50156-1

: Vietnam
IP 54
380 Volt
3 phases, 1 PEN
220 Volt
50 cps
+ / - 5 % max.
45 C
English
from 7,5 kW motor capacity star-delta
optical indication for the
operational and trouble-process
diagrammatic view of the heater
with trouble indication type Siemens-LOGO
audible signal
manually activated switch for interruption of the
main current supply
contactor/ relay/ button/ signal lamp
maker Moeller / ABB
modulating
RAL 7035 - light grey
1
no. 92-8350-16 / 02
dated 04.05.16
page 7/27
INTERNAL EQUIPMENT:
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
Control transformer 380 V / 220 V

Universal electronic compact process controller DICON TOUCH
with inlet- and outlet temperature display according DIN 3440
Burner control with tested burner operation
Operation time counter for burner integrated in Siemens-LOGO
Horn for the audible fault message
COMBINATION:
1 pc.
1 pc.
3 pc.
2 pcs.
1 pc.
Safety temperature limiter STBOw (0-350 C) for the thermal safeguard of

the tube system
Flue gas temperature limiter STBOw (20-500 C) for the thermal
safeguard of the flue gas duct
Thermometer 2 x Pt 100 for the temperature display and arrangement
Level switch at the expansion vessel for the protection of a least filling in the
system
Emergency stop push bottom with emergency stop relay (ISO 13850/ EN
418) at the switchboard
ITEM 6.1 INSTRUMENTATION ASSEMBLY-PRE-WIRING

The freestanding switchboard can be set up near the GEKAKONUS- heater. The electric
connection occurs by marked ILME- industry plug-in connector.
The maximum distance from the boiler is 10 m.
All instrumentation e.g. transmitter, electrodes and switches are installed at the boiler. The
electrical wiring between switchboard and instrumentation is completely pre-wired. The
wiring is installed on cable trays. The cable trays are fixed with a distance to the insulation
cladding so that the wiring has no contact to the cladding of insulation. All wirings are
connected with the terminals in the terminal box, the transmitter and switches.
The power supply to the switchboard and to all other electrical devices which are not
installed at the GEKAKONUS- Heater have to be provided by the customer.
E.g. level control switch on expansion tank, pumps, filling/discharge- pump on the sump tank
and electrical limit position switch on the quick-closing valve.
For the transport resp. the installation at site, the wiring - as far as necessary - is marked
and disconnected from the terminals of the switchboard resp. the burner and the
instrumentation.
The electrical installation is in accordance with the valid specifications VDE.
no. 92-8350-16 / 02
dated 04.05.16
page 8/27
ITEM 6.2 SPECIAL DESIGN / POTENTIAL-FREE CONTACTS / ANALOGUE SIGNALS
TO PLC
For monitoring of some relevant operation data of the boiler following input/output are
provided:
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
general heater trouble alarm - signal from GEKAKONUS- switchboard to PLC

heater ready for operation - signal from GEKAKONUS- switchboard to (in stand-by
position) PLC
reset safety chain / reset heater
burner in operation - signal from GEKAKONUS-switchboard to central control panel
burner fault - signal from GEKAKONUS-switchboard to central control panel
temperature too high - burner switching-off - signal from GEKAKONUS-switchboard
to PLC
minimum level expansion tank - burner switching-off - signal from GEKAKONUSswitchboard to PLC
flow rate too less - burner switching-off - signal from GEKAKONUS- switchboard
to PLC
emergency stop - burner switching-off - signal from PLC to
GEKAKONUS- switchboard
primary circulation pump (run/trip) signal to PLC
flue gas exit temperature high signal to PLC burner switching off.
4 20 mA analogue signal (outlet temperature) to PLC
4 20 mA analogue signal (inlet temperature) to PLC
All electrical wires are connected with the terminals in the switchboard.
The electrical cables from the GekaKonus switchboard to the external PLC must be installed
on site by the customer.
no. 92-8350-16 / 02
dated 04.05.16
page 9/27
ITEM 7 CIRCULATION PUMP - 140 m3/H
When operating a GEKAKONUS- thermomat, a circulation pump is required for the forced
circulation of the heat transfer medium. For this low-lift centrifugal pumps acc. to DIN 24255
are being used.
The delivery head of the circulation pump, based on the nominal circulation rate, has to be
determined with regard to the requirement of overcoming the flow resistance of heater,
connecting pipes, fittings and heat consumers.
The circulation pump is mounted, ready for operation, with coupling, coupling cover and
electrical motor on a base plate. Counter flanges, screws, nuts, gaskets and the electrical
connection wires are only included when the compact design forms part of the project.
Manufacturer
:
Type
:
Design
:
max. adm. operation temperature
:
max. adm. operation pressure
:
Capacity
:
Delivery head
:
Net positive suction head (NPSH) minimum:
Motor output
:
Revolutions
:
Protective system DIN 40050 (IEC 144)
:
Operating voltage
:
Frequency
:
Shaft sealing
:
Seal cooling
:
Connections
:
KSB
ETANORM SYT 80-250
centrifugal pump, 1-stage
350 C
10 bar
140 m3/h
80 m.l.c.
4,14 m.l.c.
37 kW
2.900 min-1
IP 55
380 Volt
50 cps
mechanical seal
not required
ITEM 7.1 FITTINGS FOR THE CIRCULATION PUMP -DN 150

The pump-fittings are provided for easier cleaning of the strainer and inspection or
maintenance works on the pump - unless the heat transfer oil must be drained from the
complete plant. When using these fittings only the heat transfer oil between the two stopvalves must be drained for inspection- or cleaning purposes of the pump.
SCOPE OF SUPPLY:
2 pcs straight-way stop valves with metal-bellow-type sealing in special design
and safety stuffing box
1 pc strainer in Y-form
2 pcs manometer with manometer stop-valve and U-tube (-1/+9 bar)
1 pc drain valve DN 20
1 pc non return flap
Casing material
Connections
Nominal width
Nominal pressure
:
:
:
:
1. 0619 +N (steel cast)

weld on ends
DN 150
PN 40
no. 92-8350-16 / 02
dated 04.05.16
page 10/27
ITEM 8 STAND-BY CIRCULATION PUMP - 140 m3/H
When operating a GEKAKONUS- thermomat, a circulation pump is required for the forced
circulation of the heat transfer medium. For this low-lift centrifugal pumps acc. to DIN 24255
are being used.
The delivery head of the circulation pump, based on the nominal circulation rate, has to be
determined with regard to the requirement of overcoming the flow resistance of heater,
connecting pipes, fittings and heat consumers.
The circulation pump is mounted, ready for operation, with coupling, coupling cover and
electrical motor on a base plate. Counter flanges, screws, nuts, gaskets and the electrical
connection wires are only included when the compact design forms part of the project.
Manufacturer
:
Type
:
Design
:
:
:
Capacity
:
Delivery head
:
Motor output
:
Revolutions
:
:
Operating voltage
:
Frequency
:
Shaft sealing
:
Seal cooling
:
Connections
:
KSB
ETANORM SYT 80-250
350 C
10 bar
140 m3/h
80 m.l.c.
4,14 m.l.c.
37 kW
2.900 min-1
IP 55
380 Volt
50 cps
mechanical seal
not required
ITEM 8.1 FITTINGS FOR THE STAND-BY CIRCULATION PUMP -DN 150
SCOPE OF SUPPLY:
1 pc non return flap
Casing material
Connections
Nominal width
Nominal pressure
:
:
:
:
1. 0619 +N (steel cast)

weld on ends
DN 150
PN 40
no. 92-8350-16 / 02
dated 04.05.16
page 11/27
ITEM 8.2 COMPACT DESIGN OF CIRCULATION PUMPS AS A UNIT
The elements of the items circulation pump and fittings for the circulation pump are mounted
on one frame and connected among each other.
The pumps are interconnected at inlet side via one inlet header.
The connecting pipeline with fittings between circulation pumps and heaters shall mounted
and adjusted at site. This pipeline between heaters and pump-group is not subject of the
offer.
Fittings, flanges and electrical connecting wires are included as well as far as these are
required for the shop-assembly.
The execution is exept thermal insulation of the pipeline. The top coat of the pipeline and
fittings based on heat resisting aluminium- bronze, and the base plate with ton RAL 7001.
As far as possible necessary, the installed elements are disassembled for the transport.
no. 92-8350-16 / 02
dated 04.05.16
page 12/27
ITEM 9 BURNER- MFO/HSD/NATURAL GAS- CONTROL- MODULATING
The burner is to fire liquid or gaseous fuels. It is designed in accordance with the valid rules
of engineering in the European Community and - up to special cases - it is CE- productand/or DIN CERTCO certified.
The burner specified by GEKAKONUS is only to be use, in order to ensure an optimal
operation between burner and steam generator.
The requirements with respect to the fuels are listed below.
For outdoor erection the burner incl. fittings have to be protected against direct atmospheric
effects (sun, rain, snow etc.) by suitable covers. The burner incl. fittings are applicable at
ambient temperature of min. -15C up to max. +40C. However at operation of burner resp.
commissioning it has to be observed that according to the ambient temperature different
excess air values occur.
For adjustment of burner capacity at the first commissioning and for the following inspections
of furnace a direct gas quantity measuring by a gas counter is required. Generally our offer
does not include a gas counter, except an extra item is shown below. The output of the firing
unit will reduce with increasing height of erection.
Manufacturer
Type
Type of control
:
:
:
Nominal bore fittings (NB)

Design
Fuel
Type of gas
Fuel oil
Fuel oil viscosity
Emission
:
:
:
:
:
:
:
Calorific value gas

Calorific value fuel oil
Max. permissible gas supply pressure
before the shut off valve
Projected permissible gas supply pressure
before the shut off valve
Gas temperature
Fuel consumption gas
Fuel consumption fuel oil
Combustion air temperature
Burner motor
Electrical preheater
Protective system of all electrical parts
acc. DIN 40050 (IEC 144)
Installation altitude
Fuel oil supply pressure min./max.
Fuel oil supply temperature min./max.
:
:
Weishaupt
RGMS 40/2 - A ZM - NR
modulating / Gas ratio 5,3
modulating / Oil ratio 2,6
DN 65
blast burner/high pressure atomizer
gas / fuel oil acc. to DIN 51603
LPG
medium fuel oil or diesel oil, FO N2B
180 mm2/s at 50 C (max.)
NOx < 850 mg/nm in the flue gas if
N2 content in the fuel oil is < 3000 mg/kg
24,0 kWh/Nm3
11,24 kWh/kg
300 mbar
:
:
:
:
:
:
:
300 mbar
20 C (max.)
111 Nm3/h (at full load)
238 kg/h (at full load)
50 C (max.)
7,0 kW
13,2 kW (EV2D)
:
:
:
:
IP 54
up to 500 m above sea level
1,0/5,0 bar
65/90 C
With the offered burner can be only used the specified fuel acc. the technical
specification with the calorific value and viscosity. GEKAKONUS must be informed if
other fuels are to be used to check the specification for the possible application.
If the orderer and/or customer use another fuel as specified, GEKAKONUS does not
take over any guarantee for the operation of the boiler.
no. 92-8350-16 / 02
dated 04.05.16
page 13/27
ITEM 9.1 BURNER ACCESSORIES - GAS FITTINGS
The above listed fittings are required for a regular operation of the gas burner.
A test burner must only be installed in cases of a firing capacity of > than 350 kW. In case of
lower outputs this test burner is not part of our supply.
For adjustment of burner during commissioning of plant, a gas flow meter must be provided
by customer.
So far a gas flow meter is NOT included in our scope of supply.
Nominal bore fittings (NB) : DN 65
SCOPE OF SUPPLY:
1 pc
1 pc
1 pc
1 pc
1 pc
1 pc
ball valve
gas filter
manometer with push-button cock
test burner with push-button cock
compensator
gas pressure controller low pressure type DN 65
ITEM 9.2 MAGNETIC COUPLING

These standard-dual-fuel burners are fitted with a fuel pump for atomization purposes of the
fuel oil. We recommend for operation with gas to automatically separate the fuel pump from
the drive shaft by means of a magnetic coupling. This magnetic coupling protects the fuel
pump against unnecessary wear.
ITEM 9.3 BURNER ACCESSORIES - FUEL OIL
2 pcs fuel hoses (not heated), DN 20, length 1.300
1 pc manometer with ball stop (0 - 40 bar) for test purposes of the fuel-pump pressure
1 pc fuel oil filter
ITEM 9.4 BURNER ASSEMBLY
The burner is mounted to the GEKAKONUS steam-generator ready for commissioning. All
electrical lines between burner and switchboard are mounted and wired. As far as
necessary, the burner and the installed connections are dismantled and marked for transport
resp. re-installation. The dismantled parts must be re-mounted on site by the customer.
no. 92-8350-16 / 02
dated 04.05.16
page 14/27
ITEM 10 HOT OIL EXPANSION TANK (ONLY FABRICATION DRAWING)
Heat transfer fluid plants must be equipped with an expansion vessel so that the increase in
volume of the heat transfer medium between cold- and hot-condition of the plant can be
collected. The expansion vessel is a cylindrical vessel with dished end that is constructed
and manufactured according to the principles for pressure vessels and the specifications
according to DIN 4754.
All connections are constructed with nozzle with welded ends. The nominal width and the
required amount of the nozzles are calculated to DIN 4754 and the thermal output of the
heater resp. the plant.
Construction sizes according to the valid dimension sheet. Special design can be agreed.
The standard type is fitted with:
2 pcs level control switch for the lowest and highest adm. liquid level (included in the offer)
maker: Fischer
1 set flange connections as per data sheet
TECHNICAL SPECIFICATION
Type
Volume
Design code
Approval
Materials
:
:
:
:
:
A 500 RL/0
17.000 litres
manufacturer standard, no pressure part
works certificate
ASTM materials equivalent to DIN
At an outlet temperature of 300 C this content is sufficient for the total plant content
(heater-, piping- and heat consumer content) of abt. 49.000 litres
SADDLE SUPPORTINGS / HOT OIL EXPANSION TANK
The standard expansion vessel is not fitted with saddle supportings. But in case that it is
required or highly functional for the installation, the expansion vessel is fitted with the saddle
supportings, which are welded on the vessel.
Number of saddle supportings
Material
:
:
2
ASTM Material equivalent to St 37
no. 92-8350-16 / 02
dated 04.05.16
page 15/27
ITEM 11 HOT OIL STORAGE TANK (ONLY FABRICATION DRAWING)
Heat transfer fluid plants with a content of more than 1.000 litres must be provided with a
stationary sump tank. We recommend plants with a content of less than 1000 litres to be
equipped with a sump tank as well. The tank should be able to contain - at least - the major
content of the unit part with its own shut- off device.
The sump tank is a cylindrical vessel with dished ends, which is constructed according to the
rules of pressure vessels (AD 2000- regulation works) and manufactured according to DIN
4754.
All connections are constructed with nozzle with welded ends. Nominal width and amount of
the nozzles are designed according to DIN 4754 and the heat capacity of the heater resp.
the plant.
Construction dimensions according to the valid dimension sheet. Special design can be
agreed.
The standard type is fitted with:
1 set
connections as per data sheet
Type
Volume
Design code
Approval
Materials
:
:
:
:
:
SA 200 /0
20.200 liters
manufacturer standard, no pressure part
works certificate
ASTM materials equivalent to DIN
SADDLE SUPPORTINGS / SUMP TANK

The standard sump tank is not fitted with saddle supportings. But in case that it is required or
highly functional for the installation, the sump tank is fitted with the saddle supportings,
which are welded on the tank.
Number of saddle supportings
Material
:
:
2
ASTM equivalent to St 37
no. 92-8350-16 / 02
dated 04.05.16
page 16/27
ITEM 12 BOOSTER CIRCULATION PUMP - 10 m3/H
The booster circulation pump is mounted, ready for operation, with coupling, coupling cover
and electrical motor on a base plate. Counter flanges, screws, nuts, gaskets and the
electrical connection wires are only included when the compact design forms part of the
project.
Manufacturer
:
Type
:
Design
:
:
:
Capacity
:
Delivery head
:
Discharge pressure
:
Motor output
:
Revolutions
:
:
Operating voltage
:
Frequency
:
Shaft sealing
:
Seal cooling
:
Connections
:
KSB
HPKL 40-315
350 C
24 bar
10 m3/h
128 m.l.c.
10 bar
2,95 m.l.c.
18,5 kW
2.900 min-1
IP 55
380 Volt
50 cps
mechanical seal
not required
ITEM 12.1 FITTINGS FOR THE BOOSTER CIRCULATION PUMP -DN 50

SCOPE OF SUPPLY:
Casing material
Connections
Nominal width
Nominal pressure
:
:
:
:
1.0619+N
weld on ends
DN 50
PN 40
no. 92-8350-16 / 02
dated 04.05.16
page 17/27
ITEM 12.2 COMPACT DESIGN OF BOOSTER CIRCULATION PUMP AS A UNIT
The elements of the items booster circulation pump and fittings for the booster circulation
pump are mounted on one frame and connected among each other.
Fittings, flanges and electrical connecting wires are included as well as far as these are
required for the shop-assembly.
The execution is exept thermal insulation of the pipeline. The top coat of the pipeline and
fittings based on heat resisting aluminium- bronze, and the base plate with ton RAL 7001.
As far as possible necessary, the installed elements are disassembled for the transport.
no. 92-8350-16 / 02
dated 04.05.16
page 18/27
ITEM 13 ELECTRICAL FILLING/DISCHARGE-PUMP
For filling and draining of thermal oil plant, an electrical operated gear pump is being
provided.
The gear pump is mounted to the drain tank and equipped with a valve combination and the
required pipe connections.
The installation is consisting of a combination of 2 valves, 1 strainer and 2 opening, which
in normal case are closed with thread plugs.
TECHNICAL SPECIFICATION: (VALVES)
Casing material
Connections
Nominal width
Nominal pressure
:
:
:
:
1.0619+N
weld on ends
DN 20
PN 40
The mode of operation of gear pump can happen in two directions of rotation. According to
the direction of rotation of pump and depending of the specific valve position and the opening or closing of the 2 openings, the plant can be drained or filled as described below:
The power supply for the electrical filling/discharge-pump is istalled in the switchboard, only
if the sump tank is included in the scope of supply by GEKAKONUS.
Filling of plant
A)
with the gear pump from the drain tank into the plant
B)
with the gear pump from an external vessel into the plant
C)
with the gear pump from an external vessel into the drain tank
Draining of plant
D)
with the gear pump into the drain tank
E)
with the gear pump into an external vessel
F)
with the gear pump from the drain tank into an external vessel
Design
Brand
Type
Function
Pump capacity
Delivery head
Viscosity max.
Operating temperature, max. admissible
Drive
Motor output
Revolutions
Protective system
Connection to the plant
Thread plug
:
:
:
:
:
:
:
:
:
:
:
:
:
:
gear pump
SCHERZINGER
450
right-/left-handed operation
2500 litres/hr
30 m. l.c.
220 mm/s
300 C at constant operation
e-motor (not for hazardous area use)
1,5 kW
1450 min -1
IP 54
welding socket pieceDN 1/ DN 1
R 3/4"
Function
Protective system /casing

Power supply
Frequency
Electrical performance
:
:
:
:
on/off
right-/left-handed operation
IP 54
220 Volt
50 cps
VDE 0100 and VDE 0116
ELECTRICAL CONTROL:
no. 92-8350-16 / 02
dated 04.05.16
page 19/27
ITEM 14 SAMPLING COOLER
In accordance with German Guideline VDI 3033, the operator of a heat transfer system in
compliance with DIN 4754 shall be obligated to analyze the serviceability of the thermal oil at
least once a year.
Sampling of the thermal oil must be at a thermal oil temperature less then 100 C.
Equipment and containers used for sampling must be clean in order to prevent any
contamination of the sample and erroneous analysis results caused by same.
For the sampling of the thermal oil must be used the sampling cooler
Scope of supply:
as per drawing no. 154589
The sampling cooler must be firmly installed in the feed line near the heater. Operation shall
be permitted only through suitable measures and by specially trained personnel. After the
sampling procedure has been concluded, it must be ascertained through suitable measures
that no uncontrolled discharge of thermal oil occurs. Sampling must be performed under
risk-free conditions and must be performed such that the analysis data for thermal oil are not
affected. Such effect would occur in a heated system if the sample were drawn into an open
container, permitting the highly evaporative thermal oil components to escape during
sampling. Sampling must therefore be performed using a sampling cooler.
no. 92-8350-16 / 02
dated 04.05.16
page 20/27
ITEM 15 COMMISSIONING (START- UP) / SERVICE
Assistance for assemble of the burner, electrical wiring and for start-up of the heater/ boiler
one of our service engineers will be delegated.
Requirement for the start-up is a completely assembled heater/ boiler plant, ready for startup, filled-up with a suitable thermal oil or at steam plants with properly treated water and
connected to all supply and heat consumer systems.
Essentially the following jobs must have been done by customer prior to the arrival of our
engineer:
completely installed piping system

all heat consumers are mounted ready for operation
all energy supply as e. g. current, water, compressed air, fuel (fuel oil or gas) are
connected to the boiler system and the heat consumers and are ready for start-up
chimney for boiler is installed and connected to the boiler.
The heat transfer medium e.g. thermal oil or water must be available in suitable quality and
quantity for the filling of the system. At thermal oil plants, compared to the system content of
plant, a surplus of approx. 200 up to 400 litres thermal oil must be available.
At steam plants boiler water for min. 4-times filling must be available.
For start-up must be secured that min. 80 % of max. boiler output can be transferred
continuously to the heat consumers.
The commissioning by our engineer is consisting of following works:
Visual control of piping installation and - if necessary - information for elimination of

systems faults
Control of electrical function of plant parts which were delivered by GekaKonus
Filling of plant with thermal oil resp. water. To carry out this job customer will support
our engineer by 2 persons from his staff (free of charge)
Ventilation of plant
Heat-up of plant in compliance with the operating instructions for burner, pump and
boiler
Adjustment of burner to optimum combustion values
Test run for plant in compliance with the operating instructions
Instruction of operating personnel and handing over of plant to the customer
During the entire start-up time customer will provide 1 person from his staff (free of charge)
in order to support our engineer.
For start-up following conditions will be agreed. The daily rates are including wages and
reimbursement.
no. 92-8350-16 / 02
dated 04.05.16
page 21/27
COSTS FOR HOTEL WITHIN THE COUNTRY AND DURING THE TRAVELLING WILL BE
PAID BY CUSTOMER, WITHOUT CHARGING GEKAKONUS FOR THESE.
Daily rate for each day of absence from our factory based on 10 daily working hours. The
daily rate based for the working days MONDAY to SATURDAY.
1.150,00
All Sundays, all legal holidays in Germany as well as the 24th December and the 31st
December are impossible. The daily rate for commissioning (start- up) / service on these
days increases of 100 %.
We are estimating a required period of 12 days (incl. 4 days travelling) for the
commissioning of this plant.
We ask for your understanding that an advance payment covering the mentioned estimated
period will be necessary.
Waiting periods for which we are not responsible will be charged at above stated daily rate.
Charging results temporary in advance for the estimated period:
11 daily rates of 1.150,00

1 daily rate for Sunday of 2.300,00
Flight costs
for 2-way ticket business class
excess baggage (e.g. tool chest
measuring equipment if necessary)
necessary costs for journey
e.g. Visa, travel to and from the airport
in Germany, car parking, phone etc.
Total costs temporary in advance
:
:
12.650,00
2.300,00
4.780,00
850,00
20.580,00
The final amount will be invoiced when the order is finalized. In case the assistance
and commissioning period is shorter as the estimated period the costumer get an
adequate credit note. In case the assistance and commissioning period is extended
over the estimated period GekaKonus will than invoice the rates and costs for the
additional used time.
The travel expenses within the country will be paid by the customer, without charging
GekaKonus for these.
In case start-up will be delayed for reasons not represented by GekaKonus, for the waiting
period the a. m. daily rates for the time exceeding will be calculated.
no. 92-8350-16 / 02
dated 04.05.16
page 22/27
ITEM 16 FUEL OIL RING MAIN SYSTEM
ITEM 16.1 MFO PUMP STATION WITH TWO PUMPS (RING MAIN SYSTEM)
The fuel oil pump is used for the fuel oil supply to the burner. The pump must be installed
near the fuel oil tank. The design is suitable for the installation at the ground.
SCOPE OF SUPPLY:
2 pcs.
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
Ball valve (suction side)

3 way ball valve (pressure side)
Strainer
Pressure gauge (suction side)
Pressure gauge (pressure side)
Vent plug
Pump unit consisting of:
2 screw spindle pump complete with motor with relief valve
Separate oil tray
Electrical pressure switch
Heating cartridge, 220W
TECHNICAL SPEZIFICATION:
Type
Brand
Medium
Viscosity max.
Throughput pressure max.
Relief valve, test pressure
Capacity max.
Power supply
Pump motor
Motor output
Protective system of all electrical parts
acc. DIN 40050 (IEC 144)
Revolution
Connections
:
:
:
:
:
:
:
:
:
:
DKC 900
Kral
MFO
180 cst at 50 C
7 bar
7 bar
912 l/h
3 x 380 V
electrical, not explosion proof
0,55 kW
:
:
:
IP 55
2.900 min-1
SAE 1
ELECTRICAL CONTROL OF MFO FILLING PUMP STATION

The equipment for the electrical control of the fuel oil pump is integrated in the switchboard
of the heater/steam boiler.
The electrical connections between the switchboard, the fuel oil pump station and the
pressure switch must carried out by customer.
no. 92-8350-16 / 02
dated 04.05.16
page 23/27
ITEM 16.2 AIR-/ GAS SEPARATOR
Gas and air bubbles occur in the return oil flowing back from the pressure-regulating valve in
the burner pump and also from the oil regulator. These bubbles can be entrained by velocity
of the oil to subsequently cause burner faults.
The bubbles can however be re-directed, and prevented from being re-entrained by the
air/gas separator and returned through the ring main return to the tank. Thus are avoided
burner faults.
The installation of the air/gas separator in the ring main must be in horizontal ITEMition.
Arrange burner suction and return connections vertically upwards.
Type
Throughput quantity
Connection ring main
Connection nozzle
Number
:
:
:
:
:
BG 2
2000 l/h (max)
DN 40
welding end
2
ITEM 16.3 PRESSURE REGULATING VALVE

The pressure- regulating valve in the ring main is used for holding the ring main pressure
(pressure on suction side of the burner pump) and the admissible pressure constant.
The pressure- regulating valve must be suitable for the full displacement capacity of the ring
pump.
Type
Ring main pressure
Ring main temperature
Number
:
:
:
:
FDR 20
2 - 6 bar
60 - 70 C
1
ITEM 16.4 PRESSURE GAUGE

For the adjustment of the pressure- regulating valve and check of the fuel oil pressure a
pressure gauge with shut-off valve must be mounted in the ring main.
Pressure gauge- display range
Number
:
:
0-6 bar
1
no. 92-8350-16 / 02
dated 04.05.16
page 24/27
ITEM 16.5 SHUT OFF COMBINATION WITH SAFETY RELIEF VALVE

For the separation of the fuel oil main system to the burner a shut off combinations is
necessary. By activating this shut off combination, the burners`s inlet and return line will be
blocked simultaneously.
At closed shutt off combinations the electrical safety circuit in the switchboard of the
heater/steam boiler is interrupted by limit switch.
A safety valve in the return line protect in a danger situation at closed shutt off combinations
the fuel oil hoses and the ring main against pipeline break.
In the electrical safety circuit of the heater/steam boiler in the switchboard the function of the
electrical limit switch is integrated. It is guaranteed, that the burner at closed shut off
combinations can be not taken into operation.
The electrical connections between the switch board, shut off combinations and the limit
switch must carried out by customer.
Nominal bore
Nominal pressure
Safety valve- test pressure
Limit switch
:
:
:
:
DN 20
PN 10
1,8 bar
3 A, 230/240 V, IP 65
ITEM 16.6 LINE HEATING

The electrical heating cable is used to be heated the fuel piping. As line heating for oil lines
required approx. 2 m heating cable for each m of pipe to be heated.
Maximum surface temperature is 160 C. The heating cable consists of silicon coat with
reinforcement made of galvanized steel wire mesh.
Cold connection ends
Heating cable - length
Pipe to be heated - length
Capacity
Power supply
Frequency
:
:
:
:
:
:
2 pcs., 500 mm length

4 x 10 m
5m
356 Watt
380 V
50 cps
SCOPE OF SUPPLY:
Hose clip for attachment of the heating cable on the ring main,
Dimension
:
9 mm, 25 m length
Number
:
8
Hose fastener for hose slip, approx. 3 pieces per meter
Number
:
pcs.
Temperature controller with attachment sensor
Type
:
GAT/7 HC AN 67 403
Display range
:
10-90 C
The temperature controller with attachment sensor must be mounted one suitable place in
the ring main system.
no. 92-8350-16 / 02
dated 04.05.16
page 25/27
ELECTRICAL CONTROL OF THE LINE HEATING
The equipment for the electrical control of the line heating is integrated in the switchboard of
the heater/steam boiler.
The electrical connections between the switchboard and the line heating must carried out by
customer.
The parts mentioned above under ITEM 16 are not mounted on the burner. This parts
must be mounted at the place of the GekaKonus heater respectively steam generator
near to the heater respectively steam generator. Assembling of piping and electrical
installation must be carried out by customer. The execution occurs according to the
valid installation plan. The necessary material for installation is not included in the
scope of supply.
no. 92-8350-16 / 02
dated 04.05.16
page 26/27
ITEM 17 ADDITIONAL INSTRUMENTS AND CONTROL
SCOPE OF SUPPLY:
2 pcs. Temperature sensor 2 x Pt 100 for temperature measurement at
expansion tank and thermal oil outlet line (lose delivery)
2 pcs. Temperature indication at the switch board with analoque signal 4-20mA
to customer PLC
1 pc. ESD push button activation from customer PLC
1 pc. Flue gas temperature analogue signal 4-20mA fom switch board to customer PLC
1 pc. Switch board modification for parallel operation
no. 92-8350-16 / 02
dated 04.05.16
page 27/27
ITEM 18 ENGINEERING/ DOCUMENTATION
Complete documentation off all in the scope of supply listed components and component
parts.
Number of documentation : 3
Language
: english
Delivery date
: with main order
For the planning of the heat generation plant, as described in our offer, following service is
included:
Packing list
Wiring diagram, terminal- and cable duct plan
Dimensional- and data sheets for all supplied components
Description of plant
Instruction and maintenance manual, instruction for putting
into operation
TV Acceptance Certificate acc. PED 97/23/EC
Strength Calculation
Material Certificates
SUPPLYING EXCLUSIONS
Following listed service and components, which are eventuelly necessary for a proper
operation, are not included in the scope of our offer.
Assembly of the plant at location site

Putting into operation
Thermal insulation of tubes, vessels, apparatus and fittings
Fittings at burner side
Fittings air- and flue gas side
Foundation, calculation of foundation and fastening material
Electrical connection and cabling main current feeding/ current distribution
Steel construction
Compenator on circulation pumps
Wet back design (unknow, so excluded)
Siemens S7 with touch screen
Double acting mechanical seal for pumps
Instruments and electrical motors suitable for hazardous area operation
Expansion- and sump tank
Fuel oil tank
Heat transfer oil
Piping, thermal-, burner- and fuel side
Performance record
Chimney with connecting branches and flue gas joining pipes
All masonry, cutting and earthmoving work
All connecting pipe lines, length compensators, tigh and loose supports, fittings for the
pipe system

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technical specification

2 orifice for flow indication and monitoring, mounted be

on the inlet header:

1 pocket for temperature-sensor

flue gas connection piece:

1 pocket for flue gas temperature sensor

ITEM 1.1 HEAT INSULATION OF BOILER SHELL

1. 0619+N (steel cast)

proportional-spring-safety valve, cornertype closed cap, heat resisting spring

straight-way shut-off valve with metal

Manometer for pressure indication on the inlet (0-40 bar).

: VDE 0100 and DIN EN 50156-1

Control transformer 380 V / 220 V

Safety temperature limiter STBOw (0-350 C) for the thermal safeguard of

ITEM 6.1 INSTRUMENTATION ASSEMBLY-PRE-WIRING

general heater trouble alarm - signal from GEKAKONUS- switchboard to PLC

ITEM 7.1 FITTINGS FOR THE CIRCULATION PUMP -DN 150

1. 0619 +N (steel cast)

1. 0619 +N (steel cast)

Nominal bore fittings (NB)

Calorific value gas

ITEM 9.2 MAGNETIC COUPLING

connections as per data sheet

SADDLE SUPPORTINGS / SUMP TANK

ITEM 12.1 FITTINGS FOR THE BOOSTER CIRCULATION PUMP -DN 50

Protective system /casing

completely installed piping system

Visual control of piping installation and - if necessary - information for elimination of

11 daily rates of 1.150,00

Ball valve (suction side)

ELECTRICAL CONTROL OF MFO FILLING PUMP STATION

ITEM 16.3 PRESSURE REGULATING VALVE

ITEM 16.4 PRESSURE GAUGE

ITEM 16.5 SHUT OFF COMBINATION WITH SAFETY RELIEF VALVE

ITEM 16.6 LINE HEATING

2 pcs., 500 mm length

Assembly of the plant at location site

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