TECHNICAL ECONOMIC OFFER

ICI Caldaie Spa SC AQUATERM SRL

TECHNICAL OFFER

TECHNICAL ECONOMIC OFFER

ICI Caldaie Spa SC AQUATERM SRL

TECHNICAL PROPOSAL

TECHNICAL ECONOMIC OFFER

ICI Caldaie Spa SC AQUATERM SRL

PRODUCT LIST
GX 3500
Main features
The GX steam generator with three smoke ways is a
monobloc unit with excellent performance and with original
technical solutions, designed and constructed to give
maximum guarantee of reliability, durability, and management.
The generator is horizontal, 3 smoke ways, passing flame,
wetback semi-stationary type
Some of the product's main features are related below:
- P265GH UNI EN 10028/2 and P275NH UNI EN 10028/3
quality steel boiler body welded and tested with methods
approved and labeled CE in accordance with the PED 97
/23/EC directive
- horizontal combustion chamber with single pass flame,
with corrugated section for models beginning with GX2500
- wetback combustion produce reversal chamber, supported
and connected to a socket of 500 mm diameter with manhole
function
- Tube plates with drilled holes into which tubes are expanded
and welded. The tube plates are completely dished after
heating and butt welded thus avoiding t-butt welds
- the shell with flanged PN 16 or PN 40 EN 1092-1
connections for equipment operation; equipped with manhole
and hand holes, and lifting eye bolts.
- P235GH UNI EN 10216/2-10217/2 smoke tubes welded to
tube plates, without Turbolators
- front smoke box made from steel sheet , thermally insulated
with refractory materials with a high aluminum content,
equipped with two flat separated doors, lined in ceramic fiber
and rotating on a double-jointed hinges; complete with
refractory cone to suit burner
- rear smoke box made from steel sheet , thermally insulated
with refractory materials with a high aluminum content
equipped with two flat separated doors, equipped with
cleaning hatch , chimney connection, buffer for access to the
combustion chamber , light flame with guillotine closing
- support built form carbon steel sections able to support the
entire unit.
- embossed metal sheet upper walkway for accessories service, parts located above the boiler
- high density, mineral wool mattress, adequate thickness thermal insulation , with round embossed aluminum case.
- suitability for liquid or gaseous fuels, for a steam production from 1700 to 25000 kg/h
- Supplied accessories needed for automatic operation with mechanical and hydraulic assembly for all equipment and
certifications ,also in compliance with the PED 97 /23/EC Directive
- Electrical wiring converging to a single Boiler Houseized control panel, having silicone insulated wires inserted in PVC
protective pockets all subjected to final functionality test

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ICI Caldaie Spa SC AQUATERM SRL

Standard equipment:
Steam accessory group contains:
- steam stop valve
- 2 spring safety valves
- 2 level indicators with direct reflection
- 2 shut-off valve groups and drain indicator
Monitoring instrumentation manifold, containing:
- large dial 3 way test valve manometer
- limit pressure gauge
- manual reset safety pressure gauge
- 2 vertical multistage centrifugal pumps suitable for 120C water
- 3 shut-off valves, powered at flow start
- 2 pump suction filter
- 3 non return valves
Blow down unit containing:
- purge shut-off valve
- male connection quick exhaust valve with manual lever
- automatic conductivity probe level regulator containing:
- pump start up probe
- pump shut-off probe
- 1 alarm and burner block probe for low level
- 2 alarm and burner block probe for low level
Boiler electric command panel, IP 55 400V/3 +N/ 50Hz electrical protection, composed of:
- main switch
- pump/main switch (off-manual-automatic)
- burner switch
- pump 1 selector
- level regulation relay
- low level 1 alarm relay with manual reset
- low level 2 alarm relay with manual reset
- high pressure light and alarm reset button
- low level 1 pressure light and alarm reset button
- low level 2 pressure light and alarm reset button
- alarm siren

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OVERALL DIMENSIONS

PRODUCT TECHNICAL DATA TABLE

Feature
Maximum heat output
Maximum heat input
Steam production
Design pressure
Hydraulic test pressure
Efficiency at 100% load
Flue gas resistance
Total water volume
Water volume up to working level

U.M.
kW
kW
kg/h
bar
bar
%
mbar
l
l

Value
4070
4522
6000
12
22,5
90,00
10,5
11940
9725

Heating surface
H - Height
L - Width
P - Length
N1 - Steam stop valve size
Total weight (mass)
Electrical power supply
Nominal frequency

mq
mm
mm
mm
DN
kg
V
Hz

127,00
3600
2900
5600
125
14500
3/N~ 400
50

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ICI Caldaie Spa SC AQUATERM SRL

MODULATING FEED WATER SYSTEM 2 PUMPS

With this system, the water level is maintained by a PID controller regulating the speed of the feed pumps. The
modulating level control is available for both the duty and standby pump.
The feed water flow rate is smoothly matched to the steam demand, thus avoiding cycling of the steam output which
occurs with on/off control.
A modulating feed water system is always recommended to be used when and economizer is fitted for always
guaranteeing a minimum water circulation, thus improving the economizer performance.
STANDARD EQUIPMENT
- 1 capacitance probe with preamplifier for continuous level control
- 2 frequency converters (inverters) integrated in both feed pumps
- 1 electronic level controller in the main control panel

OVERALL DIMENSIONS

(1)

Capacitance probe with preamplifier

(2)
(3)
(4)
(5)

Probe chamber
Inverter integrated in the duty feed pump
Electronic level controller in the main control panel
Inverter integrated in the standby feed pump

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ICI Caldaie Spa SC AQUATERM SRL

GSS 72/2
Generalities
Comprehensive security system, designed and built to ensure the overall operation
safety of steam generators, in line with the new CE directive concerning the conduction
without supervisor for 72 continuous hours. Supplied system, (EC certificate by
Notified Body as a whole in accordance with the European Directive 97/23/EC), consists
of an equipment series electrically and hydraulically assembled and tested at our
establishment, and more specifically:

A.

Auto controlled security level containing:

- 2 low level security probes, mechanically and electrically independent, mounted directly in the boiler body, with manual
reconnection with self-test, complete with relay burner unit
- connections and electrical controls in general control panel of the boiler
- mechanical and electrical assembly
This system, provided as an alternative to series low level probes, is able to ensure with absolute certainty that boiler
level does not drop dangerously below allowed value.
Consists of 2 "fail safe" type probes connected to 2 distinct level electronic relays with self-diagnosis function, able to
indicate:
- water absence below stated level ;
- loss of insulation within the probe;
- failure situation within the device (self-test);
- connection interruption between the probe and the device; in accordance with EN 12953-9 point 5.4.8 . In the event of
an operation, the system gives an audio-visual alarm and permanently stops the generator.
The generator restore operation will be carried out only after manual reset and error elimination by the operator. The
supplied system, fully assembled to the generator is tested, and is in accordance with main European directives:
- Low Voltage Directive 2006/95 CE
- Directive EMC 2004/108 CE
- Directive PED 97/23/CE.

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ICI Caldaie Spa SC AQUATERM SRL

B. Pressure security unit containing:

- "Fail Safe", manual reinsertion safety pressure switch , complete with burner unit relay
- connections and electrical controls in general control panel of the boiler
- mechanical and electrical assembly

B. Salinity control unit (TDS) containing:

- conductivity probe
- salinity regulation and control unit
- purging system, electric or pneumatic complete with shut-off valves.
- electrical controls in general control panel of the boiler
- mechanical and electrical assembly
TDS control system limits the salt and mineral levels dissolved in boiler water within permitted manufacturer values, thus
avoiding any risk of entrainment due to high salinity levels and minimizing the amount of purge required and associated
costs.
The system conducts measurements continuously, just below evaporation surface, the electrical conductivity of boiler
water whose value is related to dissolved salts concentration. The output value is compared with the input value.
If this value is found higher, the purging valve opens until the value drops below the set point.

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ICI Caldaie Spa SC AQUATERM SRL

C. Automatic sludge removal unit, able to prevent the accumulation of sludge in the boiler body composed of:
- 2 way pneumatic valve made of steel, with the lever for manual operation.
- PLC for adjusting opening frequency and duration
- compressed air electrovalve
- connections and electrical controls in general control panel of the boiler
- mechanical and electrical assembly
The automatic bottom purging unit prevents unnecessary purging duplication or omission verifiable with the manual
system.
This system allows sludge accumulated at the bottom of the generator to be regularly and automatically evacuated
through a cyclical opening in the purge valve.
Purging interval and duration are set by the user based on boiler water characteristics as indicated in the generator
technical manual.
The system requires compressed air availability.

D. High level safety probe, mounted directly in the boiler body

Kit designed to prevent an excessive increase of water level inside the boiler.
Upon reaching the set level, the system intervenes by stopping the supply pump and indicating the event with an audible
alarm.
Alarm resetting and pump restart automatically occur once normal level in the boiler is restored.

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ICI Caldaie Spa SC AQUATERM SRL

E. Boiler control panel certified for safety chain management, complete with PLC and operator panel able to monitor,
status signals and alarm view :
- inserted generator
- control panel power supply
- generator pressure view
- hot water level view (optional)
- modulate supply management predisposition (optional)
- burner view
- water supply pump status view
- steam high pressure security block
- water low level security block
- salinity alarm
- operation burner
- burner block
- cumulative alarm signal system

F.

Sample cooler, mounted directly in the boiler body

In order to make sure that the generator is operating within the parameters of conductivity,water samples must be
analyzed In order to obtain accurate and safe samples, it is essential that there is adequate cooling in order to condense
any rising steam before sample acquisition.
The cooler reduces water temperature up to 25 C making it ready for an immediate sampling.

All provided material, with particular regard to electrical panel and electrical system, is made in accordance with
European Regulations in force, more specifically:
- Directive 97/23/CE
- Directive 2006/95/CE
- Directive 2004/108/CE
- European Guide Lines 8/15 and 9/20
- Norm EN 12953
- Norm EN 50156-1
The whole system will be labeled CE as a whole in accordance with European Directive 97/23/EC and test conducted at
your establishment with functional parameter setting.

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TECHNICAL ECONOMIC OFFER

ICI Caldaie Spa SC AQUATERM SRL

Products Detail

Qty

GX 3500
HIGH PRESSURE 3 PASS STEAM BOILER
Maximum heat output: 4070 kW
Steam production: 6000 kg/h
Design pressure: 12 bar

HAMWORTHY ERD15
NATURAL GAS-HEAVY OIL DUAL FUEL ROTARY CUP BURNER
Complete with Variable Speed fan control.
Fitted at factory to the boiler above.

MODULATING FEED WATER SYSTEM

BY MEANS OF 2 DUTY/STANDBY PUMPS WITH INVERTER

GSS 72/2
GLOBAL SAFETY SYSTEM
Complete with data transmission system ModBus RTU on RS 485 port

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ICI Caldaie Spa SC AQUATERM SRL

OPERATING CONDITIONS
INSTALLATION CONDITIONS AND OPERATION
-positioning

internal

-min/max room temperature

-10 / +40

-installation altitude

m s.l.m

<1000

-type of electrical distribution system

TN-S

-max. fluctuation of voltage +/-

10

-max. fluctuation of the electrical frequency

bar

4-10

+/-pneumatic service supply

Unless otherwise specified in the offer, the aforementioned conditions are considered in the completion of supply.
WATER CHARACTERISTICS (STEAM BOILERS)
The values listed below in the following tables are extracted from tables 5.1, 5.2, figure 5.1, 5.2 in EN 12953-10
(requirements concerning the quality of water supply and the water in the boiler).
Even for biolers that are not covered by the aforementioned provision it is however necessary to adopt at least the
indicated limits and however, to refer to the specialised companies that manage selecting the type of treatment to be
carried out on the basis of a thorough analysis of the water available. Many failures and sometimes serious accidents are
caused by the use of water with non compliant characteristics.
WATER SUPPLY - THRESHOLD VALUES (feed water)
Table 1
Characteristics

Unit of measurement

Pressure [ 20 bar ]

Appearance

Clear, limpid, without foam, suspended solids

Direct conductivity at 25 C

mS/cm

< 6000

pH at 25C

---

> 9,2

Total hardness (Ca + Mg)

mmol/l

< 0,01

Iron (Fe)

mg/l

< 0,3

Copper (Cu)

mg/l

< 0,05

Silica (SiO2)

mg/l

See table 1.1

Oxygen(O2 )(2)

mg/l

< 0,05

Oily substances

mg/l

<1

Concentration of organic substances

------

Note 1

OPERATING WATER - THRESHOLD VALUES

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ICI Caldaie Spa SC AQUATERM SRL

Table 2
Characteristics

Unit of measurement

Pressure [ 20 bar ]

Appearance

Clear, limpid, without foam, suspended solids

Direct conductivity at 25 C

mS/cm

< 6000 *

pH at 25 C

------

10,5 I 12

Total alkalinity

mmol/l

1 I 15

Silica (SiO2 )

mg/l

See table 1.1

Phosphate (PO4 )

mg/l

10 I 30

Organic substances

------

Note 1

* The threshold value is reduced to 3000 S/cm where there is a steam superheater. In addition, the conductivity needs to
be higher than 250 S/cm for the proper functioning of the level regulator.
Note 1. Organic substances are generally a mixture of various residues. The composition of these mixtures and the
behaviour of the various components during boiler operation are difficult to predict. Organic substances can be
decomposed to form carbonic acid or other silica decomposition products that increase the conductivity of acid and
cause corrosion or deposits.
Note 2. These values are valid assuming the presence of a thermal deaerator. In the absence of the deaerator, it is
appropriate, however, to raise the temperature of the water contained in the tank to at least 80C (see Chap. 2.3
Supply) to reduce the content of dissolved gases (O2 e CO2). It is, in any case, appropriate to use chemical conditioning
to de-oxygenate the water supply completely and to minimise the corrosive CO2 effects.
Table 1.1
Alkalinity

Silica

0,5 mmol/l

80 mg/l

5 mmol/l

105 mg/l

10 mmol/l

135 mg/l

15 mmol/l

160 mg/l

WARRANTY
INDUSTRIAL RANGE - BOILER WARRANTY
ICI CALDAIE SpA herewith warrants the body of steam boilers during 36 months from delivery date. Accessories are
guaranteed at the same conditions of our subcontractors and anyway not more than 12 months from delivery date. If
during the warranty period, any of the goods is found defective by our technicians, ICI CALDAIE SpA will be responsible
to replace the defective part and will supply it to the buyer as soon as possible. Warranty excludes labor costs, travel
expenses and any applicable subsistence charges. Warranty also excludes breakdowns caused by incorrect installation,
neglect, misuse, accident or failure to operate the boiler in accordance with the manufacturers instructions. Special
attention should be given to the feed water characteristics, which must comply with the parameters shown in the manual
and in the following tables.

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