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Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

korra-energi Bosch Industriekessel GmbH


TT-CH/PAI
Cairo Nürnberger Str. 73
EGYPT 91710 Gunzenhausen
www.bosch-industrial.com

Amr Kamel, 2/6/2020


Phone: +2 03 5833301, Fax: +2 03 5823514
catec@catecegypt.com, Our ref.: Al Jamjoom Pharma Plant - El Obour
City, Qalubia, Egypt

Thank you for your Enquiry

Customer number: 4900596


Our Project No.: 191103/8; 377
Our Offer No.: 1169073653-377
External offer number:

Dear Sir or Madam,

With reference to your inquiry, please find enclosed our detailed


quotation.

Our quotation is based on the attached Sales and Delivery Conditions


and is without obligation until final confirmation.
For detailed information on the special advantages of the design and
equipment of our boiler systems and boiler house components, please
refer to the detailed description as well as the enclosed leaflets.

Technical details such as capacity rates, consumption values and


dimensions are available in the technical data sheets and specification
sheets.

Should you require further explanations and expert technical advice,


please do not hesitate to contact us.

Yours sincerely,
Registered Office: Gunzenhausen, Registration Court: Amtsgericht Ansbach HRB 87 - USt-IdNo.: DE 131 937 341 Managing Directors: Wai-
Cheong Tsang, Pablo Catalán Morros HypoVereinsbank AG - BLZ: 765 200 71, Kto. 2906880, IBAN: DE70765200710002906880, BIC:
HYVEDEMM406 Commerzbank AG - BLZ: 760 800 40, Kto. 119675300, IBAN: DE73760800400119675300, BIC: DRESDEFF760 BOSCH and
Logo are Trademarks of Robert Bosch GmbH, Germany
Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

2/6/2020
Seite 2 von 59

CATEC
Eng. Amr Kamel
Senior Sales Manager

Enclosures
Price Summary
Technical Data
Description and Scope of Delivery
Sales and Delivery Conditions
Leaflets and Specification Sheets
Directive water conditions
Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

Price Summary
Position Description Amount Unit price Total net price
01 Steam boiler plant 1
01.01 UNIVERSAL UL-S-IE4000X13 (4000 1 210,370.25 210,370.25
kg/hr)
01.01.01 Boiler and equipment 1
01.01.02 Flue gas heat exchanger ECO 1 1 (18,532.63)
01.01.03 Boiler control panel 1
01.01.04 Dual firing 1
01.01.05 Gas regulation module 1
01.01.06 Gas meter module 1 (6,921.00)
01.01.07 Pump module PM 1
01.01.07.01 Pump module 2
01.01.08 Steam flow measurement 1 (4,385.44)
01.01.09 Heat exchanger with flue gas 1 (24,798.40)
condensation
01.02 UNIVERSAL UL-S-IE4000X13 (4000 1 210,459.08 210,459.08
kg/hr)
01.02.01 Boiler and equipment 1
01.02.02 Flue gas heat exchanger ECO 1 1 (18,535.96)
01.02.03 Boiler control panel 1
01.02.04 Dual firing 1
01.02.05 Gas regulation module 1
01.02.06 Gas meter module 1 (6,921.00)
01.02.07 Pump module PM 1
01.02.07.01 Pump module 2
01.02.08 Steam flow measurement 1 (4,385.44)
01.02.09 Heat exchanger with flue gas 1 (24,798.40)
condensation
01.03 UNIVERSAL UL-S-IE4000X13 (4000 1 209,657.52 209,657.52
kg/hr)
01.03.01 Boiler and equipment 1
01.03.02 Flue gas heat exchanger ECO 1 1 (18,388.59)
01.03.03 Boiler control panel 1
01.03.04 Dual firing 1
01.03.05 Gas regulation module 1
01.03.06 Gas meter module 1 (6,921.00)
01.03.07 Pump module PM 1
01.03.07.01 Pump module 2
01.03.08 Steam flow measurement 1 (4,385.44)
01.03.09 Heat exchanger with flue gas 1 (24,082.29)
condensation
01.04 Water service module WSM-V 1 69,012.30 69,012.30
01.05 Make-up water distribution and 1 924.86 924.86
control for heat exchanger
01.06 Water treatment module WTM-DM 1 23,132.79 23,132.79
01.07 Steam distributor SD 1 15,241.56 15,241.56
01.10 Documentation, extended version 1 4,924.96 4,924.96
01.10.01 Piping diagram 1
01.10.02 2D boiler house layout plan 1
01.10.03 Data medium for Documentation, 1
extended version
01.10.04 Photographic documentation of 1
Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

delivery scope
01.10.05 Labeling of loosely delivered parts 1
05 Freight charges for the scope of 1 87,500.00 87,500.00
delivery
07 MEC Remote 1 958.13 958.13

Total CIF – Alexandria Seaport price 832,181.44


Final Discount 20% 166,436.29
Final CIF – Alexandria Seaport price 665,745.15
All quoted prices in Euro.
Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

Technical data
Position Description
Attribute Unit Value
General Data

Country of destination - Egypt


Location - indoors
Assembly and operating conditions - free of frost, dust as
well as dripping water
Erection altitude max. about sea level m 100
Ambient temperature min. °C 10
Ambient temperature max. °C 40
Voltage V 380
Voltage fluctuations max. (+/-) % 5
Neutral conductor - yes
Earth connection - yes
Frequency Hz 50
Max. frequency fluctuations (+/-) % 1
Direct switching up to kW 5.5
Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

Position Description
Attribute Unit Value
01 Steam boiler plant

Medium - Saturated steam


Direct, electrical conductivity in the feed water - containing salt > 30
µS/cm
Water quality - acc. to Operating
Manual "Directive water
condition" B002
Fuel - Gas / Natural Gas H
Fuel standard - DVGW G260
Net calorific value (rated to 0 °C / 1013 mbar) kWh/Nm 10.35
(gas) ³
Gas flow pressure on gas regulation module mbar 108
inlet (+ 5% / - 0%)
gas temperature °C 15.00
All details ref. to the O2-contents in the dry % 2.10
smoke gas of
Fuel - LFO / Light fuel oil EL
Fuel standard - (DIN 51603 T1)
Net calorific value (rated to 0 °C) (oil) kWh/kg 11.89
Max. viscosity mm²/s 6
Reference temperature for viscosity (oil) °C 20
All details ref. to the O2-contents in the dry % 2.70
smoke gas of
01.01 UNIVERSAL UL-S

Boiler type - 4,000


Steam capacity (nominal load) kg/h 4,000
Max. design pressure bar 13.0
Trip pressure safety valve bar 13.0
Mean working gauge pressure bar 10.0
Trip pressure safety pressure limiter bar 12.4
Cold water test pressure bar 24.70
Nominal heating area m² 80.00
Feed water temperature °C 103
Operation side - right-hand side
Category (DGRL) - IV
01.01.01 Boiler and equipment

Nominal diameter flue gas connection DN 400


(DIN24151, DIN24154)
Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

Position Description
Attribute Unit Value
Water content up to low-water l 5,930
Steam capacity from and at 212 °F kg/h 4,158
Gross thermal capacity (nominal load) kW 2,608
Efficiency gas % 94.4
calculation of efficiency (gas) - in accordance with the
basic principles of EN
12953 part 11 – indirect
method
Efficiency oil % 94.4
Calculation of efficiency (oil) - in accordance with the
basic principles of EN
12953 part 11 – indirect
method
Total burner capacity (gas) kW 2,764
Total burner capacity (oil) kW 2,762
Norm volume flow fuel (gas) m³/h 267
Mass flow fuel (oil) kg/h 232
Radiation loss gas (TI 005/01) % 0.47
Radiation loss oil (TI 005) % 0.47
Norm volume flow moist smoke gas (gas) m³/h 3,178
Norm volume flow moist smoke gas (oil) m³/h 3,142
Mass flow moist smoke gas (gas) kg/h 3,945
Mass flow moist smoke gas (oil) kg/h 4,059
Flue gas loss approx. (in accordance with the % 5.2
basic principles of EN 12953 Part 11) (gas)
Flue gas loss approx. (in accordance with the % 5.1
basic principles of EN 12953 Part 11) (oil)
Flue gas temperature approx. (gas) °C 143
Flue gas temperature approx. (oil) °C 143
Furnace volume load (gas) MW/m³ 1.1
Furnace volume load (oil) MW/m³ 1.1
Heating surface on burner side m² 80.0
Total resistance on heating gas side of boiler mbar 9.70
in operation with gas (based on altitude)
Total resistance on heating gas side of boiler mbar 9.70
in operation with oil fuel (based on altitude)
Total resistance on heating gas side includes - Boiler with ECO
Maximum permissible local flue gas pressure mbar 0.00
at the limit of supply
Minimum permissible local flue gas pressure at mbar -1.00
the limit of supply
Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

Position Description
Attribute Unit Value
Transportation weight boiler body approx. kg 11,212
Total weight boiler body (full) approx. +/- 2% kg 19,189
Material of insulation cladding - ALU Stucco
Insulation thickness min. mm 100
Thickness of insulation cladding mm 0.60
Mounting place terminal box - Boiler front - top left (10
o'clock position)
01.01.02 Flue gas heat exchanger ECO 1

Cold water test pressure bar 56.00


Outlet direction of flue gas connection - to top
Thermal capacity of economizer in operation kW 149
with gas
Thermal capacity of economizer in operation kW 142
with oil
Flue gas temperature approx. (gas) °C 143
Flue gas temperature approx. (oil) °C 143
Heating surface ECO m² 65
Water throughput (gas) kg/h 3,991
Water throughput Eco (oil) kg/h 3,438
Water outlet temperature (gas) °C 135
Water outlet temperature (oil) °C 134
Resistance on water side mbar 63
Insulation thickness min. mm 100
01.01.03 Boiler control panel

Extra space in the boiler control panel % 20


Width control panel mm 800
Height control panel mm 1,800
Depth control panel mm 400
Installed load kW 16.06
Base height mm 100
Maximum site protection must be A 50.00
Display size Touch Panel - 9"
Cable harness feeder at the boiler (o´clock) - 12
Cable harness length m 20.00
Total weight control panel kg 330.00
Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

Position Description
Attribute Unit Value
01.01.04 Dual firing

Emission evaluation according to - EN 267/676


Temperature of aspirated air °C 25.00
Burner brand - Weishaupt
Type of control (gas) - Continuous modulating
Type of control (oil) - Maximum-/Middle-/Low
firing rate
Assembly side of gas fitting - right-hand side
Type of burner - monobloc
Type designation burner - WM-GL30/2-A ZM-T
Turn down ratio burner (gas) - 6.10
Turn down ratio burner (oil) - 3.00
Rated capacity engine(s) (electrical) kW 10.00
Sound pressure level burner without sound db(A) 85
insulation
Weight burner kg 179
Separate medium for ignition - not required
General characteristics of fuel - free of bubbles and
filtered
Max. permissible particle size - < 100 µm
Min. required oil pressure before burner resp. bar -0.30
burner pump station
Max. required oil pressure before burner resp. bar 5.00
burner pump station
Max. fuel temperature before burner oil pump: °C 90
01.01.05 Gas regulation module

Assembly side of gas fitting - right-hand side


Gas flow pressure at inlet of gas regulation mbar 108
module
Max. possible standard volume flow m³/h 271
Nominal diameter gas shut-off valve DN 50
Max. permissible gas flow pressure of the gas mbar 500
regulation module (safeguarding pressure of
gas transfer station)
Operating/transport weight gas regulation kg 17.07
module +/- 4%
01.01.06 Gas meter module

Type gas consumption meter - QA 250


Measurement range Q min. (operating m³/h) m³/h 20.00
Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

Position Description
Attribute Unit Value
Measurement range Q max. (operating m³/h) m³/h 400.00
Operating/transport weight gas meter module kg 28.71
+/- 4%
01.01.07 Pump module PM

Min. required positive suction head mm 995


Type of control feed pump - Continuous with
frequence-controlled
pump
01.01.07.01 Pump module

Cable length boiler control cabinet - feed pump m 20.00


module
Pump manufacturer - Grundfos
Type designation feed pump - CRE 5-29 X
Rated capacity engine(s) (electrical) kW 4.00
Dispatch weight pump module +/- 4% kg 90
Operating weight pump module +/- 2% kg 100
01.01.08 Steam flow measurement

Design pressure bar 10.00


Design mass flow kg/h 4,000.00
01.01.09 Heat exchanger with flue gas condensation

Trip temperature of temperature monitor °C 90.00


Capacity in operation with gas (energy saving kW 120
with flue gas condensation) approx.
Capacity in operation with oil (energy saving kW 0
with flue gas condensation) approx.
Efficiency with flue gas condensation (gas) % 98.8
Efficiency with flue gas condensation (oil) % 94.4
Flue gas temperature approx. (gas) °C 93
Flue gas temperature approx. (oil) °C 143
Water circulation - make-up water
temperature water outlet ECO (gas) °C 58
Temperature water outlet Flue gas heat °C 10
exchanger (oil) approx.
Volume flow condensate flue gas heat l/h 94.73
exchanger max.
Resistance on water side mbar 10
Resistance on waterside at max. volume flow mbar 218
Water inlet temperature flue gas heat °C 10.00
exchanger
Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

Position Description
Attribute Unit Value
Design volume flow of water for flue gas m³/h 2.2
condensator
Design volume flow of water for flue gas m³/h 10.0
condensator max.
Nominal diameter flue gas connection DN 400
(DIN24151, DIN24154)
Resistance on heating gas side - ECO (fuel mbar 2.5
gas) (based on altitude)
Dispatch weight ECO approx. kg 538
Operating weight Eco approx. kg 593
01.02 UNIVERSAL UL-S

Boiler type - 4,000


Steam capacity (nominal load) kg/h 4,000
Max. design pressure bar 13.0
Trip pressure safety valve bar 13.0
Mean working gauge pressure bar 10.0
Trip pressure safety pressure limiter bar 12.4
Cold water test pressure bar 24.70
Nominal heating area m² 80.00
Feed water temperature °C 103
Operation side - left-hand side
Category (DGRL) - IV
01.02.01 Boiler and equipment

Nominal diameter flue gas connection DN 400


(DIN24151, DIN24154)
Water content up to low-water l 5,930
Steam capacity from and at 212 °F kg/h 4,158
Gross thermal capacity (nominal load) kW 2,608
Efficiency gas % 94.4
calculation of efficiency (gas) - in accordance with the
basic principles of EN
12953 part 11 – indirect
method
Efficiency oil % 94.4
Calculation of efficiency (oil) - in accordance with the
basic principles of EN
12953 part 11 – indirect
method
Total burner capacity (gas) kW 2,764
Total burner capacity (oil) kW 2,762
Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

Position Description
Attribute Unit Value
Norm volume flow fuel (gas) m³/h 267
Mass flow fuel (oil) kg/h 232
Radiation loss gas (TI 005/01) % 0.47
Radiation loss oil (TI 005) % 0.47
Norm volume flow moist smoke gas (gas) m³/h 3,178
Norm volume flow moist smoke gas (oil) m³/h 3,142
Mass flow moist smoke gas (gas) kg/h 3,945
Mass flow moist smoke gas (oil) kg/h 4,059
Flue gas loss approx. (in accordance with the % 5.2
basic principles of EN 12953 Part 11) (gas)
Flue gas loss approx. (in accordance with the % 5.1
basic principles of EN 12953 Part 11) (oil)
Flue gas temperature approx. (gas) °C 143
Flue gas temperature approx. (oil) °C 143
Furnace volume load (gas) MW/m³ 1.1
Furnace volume load (oil) MW/m³ 1.1
Heating surface on burner side m² 80.0
Total resistance on heating gas side of boiler mbar 9.70
in operation with gas (based on altitude)
Total resistance on heating gas side of boiler mbar 9.70
in operation with oil fuel (based on altitude)
Total resistance on heating gas side includes - Boiler with ECO
Maximum permissible local flue gas pressure mbar 0.00
at the limit of supply
Minimum permissible local flue gas pressure at mbar -1.00
the limit of supply
Transportation weight boiler body approx. kg 11,212
Total weight boiler body (full) approx. +/- 2% kg 19,197
Material of insulation cladding - ALU Stucco
Insulation thickness min. mm 100
Thickness of insulation cladding mm 0.60
Mounting place terminal box - Vorderer Kesselbereich
rechts oben ( 2 Uhr
Position)
01.02.02 Flue gas heat exchanger ECO 1

refer to item 01.01.02


01.02.03 Boiler control panel

Extra space in the boiler control panel % 20


Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

Position Description
Attribute Unit Value
Width control panel mm 800
Height control panel mm 1,800
Depth control panel mm 400
Installed load kW 16.06
Base height mm 100
Maximum site protection must be A 50.00
Display size Touch Panel - 9"
Cable harness feeder at the boiler (o´clock) - 12
Cable harness length m 20.00
Total weight control panel kg 332.00
01.02.04 Dual firing

refer to item 01.01.04


01.02.05 Gas regulation module

refer to item 01.01.05


01.02.06 Gas meter module

refer to item 01.01.06


01.02.07 Pump module PM

refer to item 01.01.07


01.02.07.01 Pump module

refer to item 01.01.07.01


01.02.08 Steam flow measurement

refer to item 01.01.08


01.02.09 Heat exchanger with flue gas condensation

refer to item 01.01.09


01.03 UNIVERSAL UL-S

refer to item 01.01


01.03.01 Boiler and equipment

Nominal diameter flue gas connection DN 400


(DIN24151, DIN24154)
Water content up to low-water l 5,930
Steam capacity from and at 212 °F kg/h 4,158
Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

Position Description
Attribute Unit Value
Gross thermal capacity (nominal load) kW 2,608
Efficiency gas % 94.4
calculation of efficiency (gas) - in accordance with the
basic principles of EN
12953 part 11 – indirect
method
Efficiency oil % 94.4
Calculation of efficiency (oil) - in accordance with the
basic principles of EN
12953 part 11 – indirect
method
Total burner capacity (gas) kW 2,764
Total burner capacity (oil) kW 2,762
Norm volume flow fuel (gas) m³/h 267
Mass flow fuel (oil) kg/h 232
Radiation loss gas (TI 005/01) % 0.47
Radiation loss oil (TI 005) % 0.47
Norm volume flow moist smoke gas (gas) m³/h 3,178
Norm volume flow moist smoke gas (oil) m³/h 3,142
Mass flow moist smoke gas (gas) kg/h 3,945
Mass flow moist smoke gas (oil) kg/h 4,059
Flue gas loss approx. (in accordance with the % 5.2
basic principles of EN 12953 Part 11) (gas)
Flue gas loss approx. (in accordance with the % 5.1
basic principles of EN 12953 Part 11) (oil)
Flue gas temperature approx. (gas) °C 143
Flue gas temperature approx. (oil) °C 143
Furnace volume load (gas) MW/m³ 1.1
Furnace volume load (oil) MW/m³ 1.1
Heating surface on burner side m² 80.0
Total resistance on heating gas side of boiler mbar 9.70
in operation with gas (based on altitude)
Total resistance on heating gas side of boiler mbar 9.70
in operation with oil fuel (based on altitude)
Total resistance on heating gas side includes - Boiler with ECO
Maximum permissible local flue gas pressure mbar 0.00
at the limit of supply
Minimum permissible local flue gas pressure at mbar -1.00
the limit of supply
Transportation weight boiler body approx. kg 11,210
Total weight boiler body (full) approx. +/- 2% kg 19,188
Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

Position Description
Attribute Unit Value
Material of insulation cladding - ALU Stucco
Insulation thickness min. mm 100
Thickness of insulation cladding mm 0.60
Mounting place terminal box - Boiler front - top left (10
o'clock position)
01.03.02 Flue gas heat exchanger ECO 1

refer to item 01.01.02


01.03.03 Boiler control panel

refer to item 01.02.03


01.03.04 Dual firing

refer to item 01.01.04


01.03.05 Gas regulation module

refer to item 01.01.05


01.03.06 Gas meter module

refer to item 01.01.06


01.03.07 Pump module PM

refer to item 01.01.07


01.03.07.01 Pump module

refer to item 01.01.07.01


01.03.08 Steam flow measurement

refer to item 01.01.08


01.03.09 Heat exchanger with flue gas condensation

refer to item 01.01.09


01.04 Water service module WSM-V

Supply steam pressure bar 10.00


Steam supply line safeguarded at bar 13.00
Design temperature (deaeration) °C 103
Safety valve trigger pressure feed water tank bar 0.50
Deaeration capacity kg/h 8,143
Designed for a system performance of kg/h 8,000
Max. O2-content mg/l 0.02
Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

Position Description
Attribute Unit Value
Tank material - V2A (1.4301)
Material of insulation cladding - ALU Stucco
Mean working gauge pressure bar 0.2
Cold water test pressure bar 2.00
Water content (in operation) l 3,500
Insulation thickness mm 100.00
Type designation deaeration - DM 10
Connected power - control panel of feed water kW 0.8
treatment
Width control panel mm 600
Height control panel mm 600
Depth control panel mm 250
Mass flow of oxygen-free condensate (average kg/h 0
flow)
Mass flow of oxygen-free condensate kg/h 0
(minimum flow)
Temperature of oxygen-free condensate °C 0
Pressure of oxygen-free condensate bar 0.00
Mass flow of oxygenic condensate (average kg/h 3,800
flow)
Mass flow of oxygenic condensate (minimum kg/h 0
flow)
Temperature of oxygenic condensate °C 90
Pressure of oxygenic condensate bar 0.00
Mass flow heating-up steam kg/h 543
Mass flow vapour steam kg/h 41.00
Mass flow make-up water kg/h 4,316
Make-up water temperature min. °C 10
Min. required make-up water pressure bar 1.00
Maximum supply pressure for make-up water bar 6.00
Type of expansion and cooling - BEM 450
Size (total content) of the expansion vessel l 450
Temperature cooling water °C 10.00
Size (total content) of the dosing tank l 75
Type of deaerator - Cascade deaerator
Type WSM - WSM-V 8.0
Tank size (total volume) l 5,000
Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

Position Description
Attribute Unit Value
Content feed water tank l 5,000.00
Type electrical cabinet (WCO) - AE1054.500
Dispatch weight WSM kg 1,978
Operating weight WSM +/- 2% kg 5,914
Maximum weight WSM +/- 2% kg 8,042
01.06 Water treatment module WTM-DM

Total hardness °d 10.00


Carbon hardness °d 3.00
Max. capacity m³/h 10.00
Water temperature min. °C 5.00
Water temperature max. °C 30.00
Transport weight WTM +/-4% kg 878
Operating weight WTM +/-2% kg 2,085
Raw water pre-pressure min. bar 3.2
Raw water pre-pressure max. bar 6.0
01.07 Steam distributor SD

Steam capacity (nominal load) kg/h 8,000


Max. design pressure bar 13.0
Mean working gauge pressure bar 10.0
External diameter mm 323.90
Cold water test pressure bar 22.00
Length mm 4,738.00
Dispatch weight steam distributor (without kg 398
fittings)
Weight steam distributor kg 793
Maximum weight steam distributor +/-2% kg 1,156
(100% filled)
07 MEC Remote

Type of connection MEC Remote - LAN (DSL)


08 Connection of control to control system at site

Type of data transfer - Industrial Ethernet S7


Communication via
TCP/IP
Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

Description of delivery scope


01 Steam boiler plant

01.01 UNIVERSAL UL-S


for the generation of saturated steam.
Suitable for the combustion of fuels acc. to data sheet.
For technical data, please refer to the attached technical data sheets, for
further information to the current leaflets and specification sheets.

01.01.01 Boiler pressure vessel, consisting of the cylindrical boiler shell, the front
and rear boiler end, the asymmetrical flame tube located on the right-
hand side which connects the boiler ends, the internal water-cooled
reversing chamber, the smoke tubes of the 2nd and 3rd pass, the steam
drying device and the connection sockets for steam extraction, pressure
safeguard, feeding, pressure measurement, water level gauge and drain,
protective tube for feed water pump control and limiter probes, inspection
openings for the furnace on the rear wall, revision openings on water and
steam side, two transportation lugs and one boiler rating plate.
Testing during manufacture:
The welding quality is monitored by means of X-ray- or ultrasonic testing.
All pressurized parts are welded and undergo an increased hydrostatic
pressure test after manufacture.
The inspection facilities guarantee an optimum, cost-effective revision of
the boiler. Due to the good revision possibilities as well as the monitored
production process, it is possible - in coordination with local and/or
national legal requirements - to achieve maximum intervals between
repeated inspection.

Mountings:
Front reversing chamber, easily accessible, for cleaning and inspection
purposes on flue gas side.
Door swivels open to the left-hand side, inner surface lined with high-
quality thermal insulation.
Flue Gas Chamber with flue gas condensate socket and inspection
opening on flue gas side, prepared for installation of the economizer.
Boiler Base Frame, sturdy profile steel construction, for even distribution
of load and easy transportation, suitable for the placement of sound
absorbing pads. The boiler body is positioned on the base frame by
supports, if required with front sliding bearing.
1 Drilled Burner Plate(s), suitable for the burner

1 Refractory Lining(s), suitable for the burner

Corrosion protection paint of those Built-on accessories which are not


covered by the insulation. 2 coats of paint with one component lead- and
chromate-free paint based on modified polymer dispersions. The portion
of organic solvents is below 5 weight percent.
1 Flame sight hole(s) for viewing of the flame, with sight glass clear Ø 32
mm, protective cover, connection for cooling air and measurement.
Acceptance of the pressure vessel:
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242 Abdel salam Aref St.,
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Acceptance at the workshop acc. to the European Pressure Equipment


Directive PED (2014/68/EU).
CE-Marking of the Pressure Vessel:
acc. to the European Pressure Equipment Directive PED (2014/68/EU).

Equipment boiler:
Pressure gauge manostat pipe with 3 connections G 1/2 inch A, acc. to
ISO 228/1.
Smoke Tube Cleaning Device
Cleaning rod with hand grip and screw-on wire brush attachments,
matching the diameters of the boiler smoke tubes. Regular cleaning of
the smoke tubes is a prerequisite for avoiding corrosions on flue gas side
resp. for safeguarding trouble-free burner operation, achieving the full
efficiency and consequently
lower operating costs.
1 Set of Operation and Instruction Labels

Insulation of boiler shell and boiler ends with mineral wool mats and
protective cladding of structured aluminium.
Platform (with grating) for maintenance of the fittings arranged on top of
the boiler.
Max. admissible surface load for accessible surfaces: 3 kN/m²
Width of Platform: 600 mm
Safety railing for platform
Ladder with non-skid steps.
Max. admissible loads for:
stairs: 150 kg individual load
Equipment Boiler
Steam extraction valve, consisting of:
- shut-off valve, maintenance-free with bellow seal DN80 PN25
Mounting form: globe valve
Pressure safeguard, each consisting of:
- full-stroke corner safety valve, type-accepted, DN 40 PN 40
Pressure safeguard, each consisting of:
- full-stroke corner safety valve, type-accepted, DN 40 PN 40
Feed water shut-off valve consisting of:
- shut-off valve, maintenance-free with bellow seal DN40 PN40
Mounting form: globe valve
Feed water non-return valve, consisting of:
- disc non-return valve DN40 PN40
Drain shut-off valve consisting of:
- shut-off valve, maintenance-free with bellow seal DN40 PN40
Mounting form: globe valve
Direct Water Level Indicator, each consisting of
- Water level indicator with transparent indicator with mica washer,
closeable
- Water level-blow-off tap
Direct Water Level Indicator, each consisting of
- Water level indicator with transparent indicator with mica washer,
closeable
- Water level-blow-off tap
- Trans-illumination device for transparency displays of the
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water level indicator


Pressure gauge-manostat pipe shut-off valve, consisting of:
- shut-off valve, maintenance-free with bellow seal DN20 PN25
Mounting form: globe valve
Pressure gauge device, consisting of:
- Pressure gauge
- Pressure gauge shut-off valve
Safety pressure limiting device max., consisting of:
- safety pressure limiter, CE examined
for merging into the safety chain

Combined feed water level control and limiter probe for steam boilers
equipped and certified acc. to EN 12953 Part 6, suitable for operation
without permanent supervision (BosB) for max. 72 h, consisting of:
Level control incl. electronic max. water level safeguard, consisting of:
- level transmitter (signal output 4-20mA)

 electric switching unit for feed pump control. Incorporation of the


electronic switching device into the control panel if control panel is
delivered by us. The electronic device is designed for installation
into a control panel with protection class IP54.

Low water level limiter, self-monitoring, CE-/TÜV-tested, electronic, for the


limitation of min. water level consisting of:
- limiter probe with permanent isolation supervision
- electronic switching unit to switch off burner and alarm notification.
Installed in control panel if control panel is in our scope of delivery. The
electronic system is designed for installation in a control panel with
protection level IP54.
- limiter probe with permanent isolation supervision
- electronic switching unit to switch off burner and alarm notification.
Installed in control panel if control panel is in our scope of delivery. The
electronic system is designed for installation in a control panel with
protection level IP54.
Function
This control and limiter combination controls the water level in the boiler
by means of switching the feed pump on and off resp. by control of the
feed water supply flow. Once the highest water level is being exceeded,
the feed pump is switched off. Once the lowest permissible water level
has been reached, the burner will be switched off and locked reliably.
Workshop Assembly of the electronic switching devices into the control
panel if control panel is delivered by the contractor.
Automatic Desalting Device, consisting of:
Conductivity Measuring Device for boiler water, consisting of:
- conductivity measuring transducer with temperature
compensation
(signal output 4-20 mA)
Conductivity Control Device for boiler water, consisting of:
1 Desalting shut-off device, designed as:
- shut-off valve, maintenance-free with bellow seal DN25 PN25
Mounting form: corner valve
- desalting control valve with electric servo-drive, DN25
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CATEC
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P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

PN40
- Conductivity tester (manual device) for control of the
water conductivity, battery-operated, with digital display.
Application
The desalting device serves for avoiding boiler breakdowns caused by
high coagulation of the boiler water as well as for avoiding boiler
damages due to excess salt concentration in the boiler. The demand-
driven drain of a portion of the boiler water minimizes the purging rate,
thus saving considerable amounts of feed water, energy and chemicals.
Depending on the fresh water consumption, the blow-down periods can
be reduced and the blow-down breaks extended.
Function
In the boiler control panel, the boiler water conductivity which fluctuates
due to thickening of the boiler water is controlled automatically. If the
conductivity exceeds a preset value, the desalting valve opens and drains
saline boiler water. A further increase of the conductivity is recorded in
the operating log . If a max. admissible limit value is reached, a fault
shutdown of the burner will take place and is recorded. In case of falling
short of a minimum value resp. in case of a burner fault shut-down, the
desalting valve will close.
Automatic Blow Down Device for time dependent control of the blow down
valve
control medium: compressed air/water
Pressure control medium: 4,5 - 8 bar (resp. depending on the boiler
design gauge pressure)
consisting of:
- self-closing quick shut-off blow-down valve DN40 PN40
- diaphragm drive for the blow-down valve
- software-module with digital time display and outputs for the control of
the blow down valve
Application
If large quantities of fresh water are fed in, there is increased precipitation
of suspended matter in the boiler because of the addition of chemicals.
The suspended matter builds up at the base of the boiler and must be
blown down at regular intervals.
Function
The software module with adjustable pulse and pause times controls the
magnetic valve which, using compressed air, activates the membrane
drive of the quick shut-off blow-down valve.
Terminal Box
Protection class IP54, of steel sheet, powder-coating grey/structure,
galvanized assembly plate, cable entry from below. Control design in
accordance with DIN-/EN-standards. Connection of the control devices
and the control panel via terminal strips in the terminal box. Terminal box
is function-tested, 1 set of wiring diagrams inside the terminal box.
Advantages
Reading of the instruments and operating of the plant is facilitated by
individual mounting or installation of the boiler control panel. Easy and
mix-up proof connection to the terminal box by means of individually
customized, coded and marked cable bundles with plug connections on
both sides.
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CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

Workshop assembly of manometer manostat pipe, terminal box and


sensor technology at the boiler (as far as included in scope of delivery).
Documentation, consisting of:
Operating manual
Operating manual acc. to European regulations for the scope of delivery.
Quantity: 3
Language: English
Design: print-out
Deadline: with delivery
Additional set of documents:
Quantity: 1
Language: English
Design: CD-ROM
Deadline: with delivery
Operation log
Operation log acc. to European regulations for the scope of delivery.
Quantity: 1
Language: English
Deadline: with delivery
Additional set of documents:
Quantity:
1
Language:
English
Deadline:
with delivery

Acceptance documentation
Acceptance documentation in accordance with European directives as far
as required for the supply of the boiler plant, respectively for the part
concerning the delivery scope, however without assembly drawing and
PI-diagram.
Quantity: 3
Language: English
Deadline: 2 weeks after delivery date
Additional set of documents:
Quantity:
1
Language:
English
Deadline:
2 weeks after delivery date

Seaworthy packing of the boiler in wooden case, execution according to


HPE-regulations.

01.01.02 Flue gas heat exchanger ECO - integrated


for saving energy and reducing CO2 by reduction of the flue gas
temperature by means of feed water.
Design acc. to European Pressure Equipment Directive PED
(2014/68/EU), suitable for high-pressure steam boilers.
Heat Exchanger , welded design, for installation onto the rear flue gas
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CATEC
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242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

chamber, with connection for water inlet, water outlet and drainage incl.
inspection opening on flue gas side.
Highly efficient heat transfer based on the counterflow principle.
Heat exchanger tubes with fully welded fins for optimizing the heat
transfer.
The heat exchanger casing consists of a sturdy welded construction of
steel sheet. It is stiffened against flue gas vibrations and pressure-tight.
Function
In the flue gas heat exchanger, heat is retrieved from the (warmer) boiler
flue gas, in which (cooler) feed water flows through the heat exchanger
tubes and the temperature of the flue gas is reduced. The energy gained
in this way gives a higher boiler efficiency and therefore lower fuel
consumption and lower emissions of air pollutants such as carbon dioxide
or nitrogen oxide.
Equipment Heat Exchanger
Venting valve, designed as:
- shut-off valve, maintenance-free with bellow seal DN20 PN40
Mounting form: globe valve
Drain valve, designed as:
- shut-off valve, maintenance-free with bellow seal DN20 PN40
Mounting form: globe valve
Temperature indicator for water outlet, designed as:
- Thermometer, display area 0.00°C to 250.00°C.
Temperature indicator for water inlet, designed as:
- Thermometer, display area 0.00°C to 250.00°C.
Shut-off device on water side, consisting of:
- shut-off valve, maintenance-free with bellow seal DN40 PN40
Mounting form: globe valve
Shut-off device on water side, consisting of:
- shut-off valve, maintenance-free with bellow seal DN40 PN40
Mounting form: globe valve
Pressure safeguard, before ECO designed as:
- full-stroke corner safety valve, type-accepted, DN 20 PN 40
Pressure safeguard behind ECO, designed as:
- full-stroke corner safety valve, type-accepted, DN 20 PN 40
Pressure gauge device, on inlet consisting of:
- Pressure gauge
- Pressure gauge shut-off valve
Pressure gauge at outlet, consisting of:
- Pressure gauge
- Pressure gauge shut-off valve
Automatic Flue Gas Temperature Control,
consisting of:
Motorized three-way regulator valve, with built-on electric servo drive,
manual adjusting device, packings, screws and nuts. Complete with AC
stop motor 230 V, 50 Hz. Certificate of final testing acc. to EN 10204.
Electric power unit, consisting of line and motor protective devices as well
as power contactors.
Flue gas temperature sensor
1 Temperature sensor (Pt 100) with welded sleeve R 1/2" for local
installation into the flue gas line (distance 3 x D from the heat exchanger).
- Temperature transducer for proportional provision of signal 0/4-20 mA
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CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

1 electrical temperature controller in the BCO, incl. digital display of set


and actual value of flue gas temperature down-stream of the heat
exchanger, incl. automaticset value change-over in case of dual fuel
burners
1 control unit for automatic and manual operation
1 connection to the burner control
The above-mentioned flue gas temperature control device will be
incorporated into the boiler control panel, if the control panel is delivered
by us.
Function
If the flue gas temperature downstream of the heat exchanger drops too
low:
part of or the complete feed water stream will be bypassed at the heat
exchanger via a three-way valve with electric servo drive in case of
control on water side until the pre-adjusted flue gas temperature
downstream of the heat exchanger is reached in order to avoid
undercuttings of the dew point in the subsequent flue gas system.
Due to the subsequent flue gas system, the energy saving potential of the
heat exchanger can be utilized only partly, depending on the boiler
capacity.
In case of dual fuel burners gas/oil, a min. flue gas temperature
corresponding to the subsequent flue gas paths can be automatically
applied to each type of fuel via the set-value changeover.

Flue gas temperature display device


for display of the flue gas temperature upstream of the Flue gas heat
exchanger in the display and operating unit of the boiler control BCO,
consisting of:
- Temperature transducer for proportional provision of signal 0/4-20 mA

Insulation of the flue gas heat exchanger, the flue gas chamber and the
flue gas exchanger housing with mineral wool mats - 100 mm thick - and
protective cladding of structured aluminium.
Insulation of the connection line on water side between the heat
exchanger and the boiler without fittings and flanges.
Connection line for connecting the feed water nozzle on the boiler to the
connection for the water outlet on the heat exchanger.
Piping for a closable heat exchanger design.
The acceptance procedure for the lines is carried out at the factory in
accordance with European Pressure Equipment Directive 2014/68/EU
(PED).
Cover panel with welded on flue gas connection socket
Flue gas connection socket DN 400 with counterflange, packing, nuts and
bolts.
Assembly of all afore-mentioned components at the factory. Dismantling
of those parts which have to be delivered separately for transport
reasons.

01.01.03 Boiler Control Panel for Boiler control BCO


Enclosure type IP 54, made of steel sheet, powder coated grey structure,
galvanized mounting plate, cable ducting from below. The switching and
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CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
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control devices are assembled on a mounting plate and inside the control
panel door. Wiring in the control panel is executed by means of flexible
cables in sufficiently dimensioned cable ducts. The control devices are
designed in accordance with DIN-/EN- standards. The control devices are
connected on terminal strips inside the control panel. The control panel is
function-tested, 1 set of wiring diagrams is provided inside the panel.
The marking of the electrical operating equipment in the wiring diagrams
is made in accordance with DIN EN 81346- 2.

Control Panel Fan, consisting of:


Filter fan and outlet filter for reduction of the temperature inside the
control panel by means of cooler ambient temperature.
Assemblies:

 Main switch with locking device

- Main switch with locking device


Control Transformer acc. to EN 60204-1 for the generation of the control
voltage 230 VAC. Incorporated and wired in the switch box, control
voltage grounded one-way
- Main switch with locking device
Control Transformer acc. to EN 60204-1 for the generation of the control
voltage 230 VAC. Incorporated and wired in the switch box, control
voltage grounded one-way
Additional connections (potentially coupled) provided for:

 emergency cut-out
 external alarm buzzer
 contact of the feed water pump contactor for the control of a
dosing pump (combination product or oxygen scavenger)

Automation device BCO with touch-sensitive touchscreen colour display


Industrially proven hardware from the range of stored-program controls
are applied in the Boiler Control BCO. The complete control software is
stored on a memory card provided with the device. A graphic TFT-display
with touch-sensitive interface serves as display and operating unit.
Operating signals and process value archive are stored on a multi-media
card included in the delivery scope.

Basic functions:

 Load control

- level control

 Low load control


 Boiler operation hours meter
 Burner operation hours meter
 Registration of number of burner starts
 Clear text display of operation and fault signals, signal history on
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P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

500 signals with time recording (Coming, Going, Acknowledging)


and all relevant operation data at the time
 Intuitive, menu-driven operation by means of the touch-sensitive
graphic display
 Display of all operation-relevant measured values and conditions

INDUSTRIAL ETHERNET connection, consisting of:


1 communication processor with connection possibility to a superior
control (superior control is not in scope of delivery) via RJ45-connection.
The RJ45-plug is delivered loosely.

Condition Monitoring basic


CMbasic is an analysis and evaluation system integrated in the BCO
boiler control. It gathers, analyses and evaluates system operating
statistics and parameters, consumption values, and measurements, and
uses a traffic light-style display to clearly show the results. It detects,
evaluates and notifies the user, in good time, of increased wear or
uneconomical operation of the boiler system.
Scope of delivery:
Temperature-recording device at boiler outlet on flue gas side
Software module integrated in boiler control
Scope of functions
-Displays operating hours; frequency of starts; cold starts as a function of
time
-Detects unfavourable start-up conditions
-Detects contamination on water and flue gas side
-Detects unwanted condensation
-Generates service notifications
-Displays boiler load profiles as a function of time
-In steam boilers where the fittings are controlled electrically, highlights
energy losses from blow-down and desalting
-Displays measurements as actual values at time of delivery and as a
function of time
-Representation of the digital volume meters with additional reset
function, which are includedin the scope of deliveryand displayed in the
control panel
Intended use
CMbasic gives customers the option of monitoring the efficiency and
correct
operation of their system. In this way CMbasic makes a positive
contribution to
system availability and to ensuring consistently high system efficiency.
Heating device HD via burner - pressure-controlled - acc. to Fig. 2 of TI
019, consisting of:
1 software program module with timer incorporated in the control panel
BCO
Application
To achieve faster availability of the boiler and to avoid corrosion when
inactive and from cold starts, this is kept at a lowered pressure level.

Function
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CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

This device can be used to set an additional lower switching pressure for
the burner. Normal operation or heat maintenance operation can be
manually selected using a selection menu in the BCO control panel. The
timer can be programmed with switching times to allow automatic
switching between heat maintenance and normal operation. In heat
maintenance operation, the burner's output is limited to low load and the
burner switching frequency is reduced. If there is a controlled steam
extraction valve, it is closed during heat maintenance operation.
Normal operation (release of vapour valve)
Automatic feed pump switch-over (pressure and time)
for two feed pumps. The required electric control is part of the delivery
scope and completely wired in the control panel.

MEC Remote
- key switch for disrupting the internet connection of MEC Remote

Wiring diagrams for the scope of delivery.


Quantity: 3
Language: English
Design: print-out
Deadline: with delivery
Additional set of documents:

Quantity:
1
Language:
English
Design:
in PDF on CD-ROM
Deadline:
with delivery

Cable Harness
for quick and error-free cabling between terminal box and boiler-/ plant
components with mix-up proof connection plugs for sensors and
actuators up to a max. current of 35 A.
If required, the plug connections allow a quick and uncomplicated
exchange of sensors and actuators.
Cable Bundle
for quick and error-free cabling between terminal box and boiler control
panel, with mix-up proof connector plugs for sensors and actuators up to
a max. current of 35 A.
Length of the cable bundle 20.00 m determined from the outlet point
boiler at 12 o'clock position up to control panel inlet.

Connection of the cable harness to the terminal box and to the sensors
and actuators. A function test will be carried out in the workshop.

Connection of cable harness


Cables are prepared and labelled for connecting to the boiler's terminal
box.
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CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

01.01.04 Firing Equipment, equipped acc. to EN 267/EN 676 for positive furnace
pressure, consisting of:
1 Burner(s) incl.
- ignition device
- fuel atomizing device
- fuel-air-ratio device
- double fuel safety shut-off fitting, per fuel type
Load Control, consisting of:
- transmitter (signal output 4 - 20 mA)
Combustion air fan, mounted on burner, with motor.

Burner Management System


Microprocessor-assisted burner control for gas-, oil- or dual fuel burners,
incl. flame supervision for continuous operation acc. to EN 12953
- plain text display of operational and fault messages
- diagnostic memory for 10 fault signals incl. time specification
- menu-assisted user interface with display of the relevant parameters
- electronic compound regulation system
- operating hours meter per type of fuel
- burner startup counter per type of fuel
The burner management system is CE- as well as type-tested.
Automatic gas tightness diagnosis device for checking the tightness of the
gas safety shut-off fittings.
Voltage-free contact Burner operating created through the installation of
additional control devices and electrical connection in the control panel.
Function according to the open circuit system as operation or fault signal.
Wiring up to the terminals in the control panel for external signal and
control function. Contact load max. 5 A.
Speed Control with frequency converter for combustion air fan, consisting
of:
- Frequency converter
- Speed controlling
- Switching devices
Application
By means of the speed control, it is possible to optimally operate the
combustion air fan in all operation ranges. High throttling losses at the air
flap are avoided, thus the power consumption is reduced.
The speed control has the following advantages:
- power saving
- noise reduction
- reduced load in the starting current system as direct resp. star-delta
switching device.

Oil consumption meter


Shut-Off Device incl. oil filter. In case of separate burner oil pump without
oil filter. Complete with safety valve and limit switch. To be mounted next
to the burner as initial shut-off device for the oil supply to the burner.
Suitable for connection to a two-pipe- or an oil ring line supply system.

Burner Oil Pump incl. oil pressure controller. In case of separate burner oil
pump, one additional oil filter included.
Automatic Switch-Off Device for burner oil pump during gas operation.
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242 Abdel salam Aref St.,
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This additional device serves for reducing the wear-and-tear on the oil
pump, thus extending the pump's service-life.
Automatic Fuel Switch-Over Device
for change-over from gas to oil operation and vice versa. Control for fuel
change-over via volt-free contact from an external system, consisting of:
Selection switch for automatic device gas/oil operation from an external
system.
Device completely wired with the boiler control.
Pilot Burner for venting and testing of gas valve train,
complete with press button cock, piping and screwing.
Basic conditions for noise data:
Determination of the noise takes place 1 m behind the burner. Noise data
can only be indicated as guide value, because the noise development
also depends on the local conditions (e.g. installation situation of the
boiler and building design; flue gas routing downstream of the boiler up to
the chimney; etc.). Prerequisite for the verification of a sound
measurement is that the noise level in room is considerably below that of
the burner (min. 10 dB(A)) acc. to DIN 45635.

Cable Harness for quick and error-free cabling between burner and boiler
control panel for sensors and actuators.
Length of the cable harness 20.00 m determined from the outlet point
boiler at 12 o'clock position up to control panel inlet.

Workshop assembly of burner, mechanical (assembly to the boiler),


including the required assembly material as well as the assembly and
installation engineering.
Dismantling of those parts which have to be delivered separately for
transport reasons.

01.01.05 Gas regulation module GRM, consisting of:


Gas regulation module (right-hand side)
- shut-off device
- gas filter
- gas pressure controller
- expansion joint
- set of connecting parts within the module
- set of stainless steel supports for floor assembly
Assembly of all afore-mentioned components at the factory. Dismantling
of those parts which have to be delivered separately for transport
reasons.

Shrink-Wrapping for Transportation


All weather-sensitive parts shrink-wrapped or packed in plastic wrapping.
Loose parts - if necessary - to be packed in cases, cartons or other
suitable type of packing. Disposal of packing material at site.

01.01.06 Gas meter module GMM with direct flow display, remote impulse reading
possible via reed contact and inductive transmitter.
- Meter incl. pipe connection pieces
- inlet measuring route
- connection pieces
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- Thermometer, display area 0.00°C to 50.00°C.


Gas flow converter (temperature- and pressure compensated)
Measuring device, consisting of:
- transmitter (signal output 4 - 20 mA)
- temperature transducer
- Temperature transducer for proportional provision of signal 0/4-20 mA
- BCO/SCO-Software for calculation of the gas standard
cubic meter
Application:
The gas meter module GMM records operation-m³. The integrated
software unit transfers the operation-m³ recorded by the gas meter
module GMM (Vb) into standard-m³ (Vn ) while considering gas
temperature and gas pressure and provides the following figures on the
BCO/SCO-display:
- total reading mb³ or mn ³, not resettable
- total reading mb³ or mn ³, resettable
- current measured value in mn ³
- current measured value in mb ³
- gas temperature in °C
- gas pressure in bar
Function:
The gas pressure and the gas temperature are collected by means of
separate sensors in the gas line. As another input signal, the gas flow in
operating-m³ as volume-proportional 4-20 mA-signal is provided to the
software module. The conversion to standard cubic meters is effected by
means of these values. The conversion is done acc. to DIN 1343.
Connection cable between Gas meter module GMM and Boiler control
BCO, connection is via terminals. Cable length between connection
points 31.00 m.
Incorporation of the Gas meter module into the Gas regulation module.

01.01.07 Pump module PM

01.01.07.01 for continuous control of water flow, consisting of:


Feed pump with frequency-controlled motor, suitable for water supply
temperature of up to 103 C, min. required positive suction head
according to the attached technical data sheet.
Designed for the boiler capacity and the boiler pressure indicated in the
Technical Data Sheet for a max. desalting rate of 4.64 % and resistances
of 0.5 bar in the pressure line which is not part of the scope of delivery.
Connection cable between pump module and control panel, connection
via terminals. Cable length between connection points 20.00 m.
Fittings on suction side, consisting of:
- 1 butterfly valve(s) with manual actuation, DN65 PN16
- 1 dirt trap for installation upstream of the regulation
mountings and pumps, DN65 PN16
Fittings on pressure side, consisting of:
- disc non-return valve without feather, DN32 PN40
Installation in vertical piping with flow direction from bottom to top
- shut-off valve, maintenance-free with bellow seal DN32 PN40
Mounting form: globe valve
Pressure gauge on pressure side, consisting of:
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Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
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- Pressure gauge
Pressure monitoring for automatic Feed pump switch-over, consisting of
- safety pressure limiter, CE examined

Shrink-Wrapping for Transportation


All weather-sensitive parts shrink-wrapped or packed in plastic wrapping.
Loose parts - if necessary - to be packed in cases, cartons or other
suitable type of packing. Disposal of packing material at site.
Assembly of all afore-mentioned components at the factory. Dismantling
of those parts which have to be delivered separately for transport
reasons.

01.01.08 Steam Flow Measurement


Measuring device consisting of:
- Flow measuring sensor, DN80 PN40,
- with internal temperature compensation
- with display and control unit
- incl. gaskets and screws for assembly
- Assembly set
- software unit in the BCO/SCO for calculation of the steam
flow
Connection cable for steam volume measurement, connection is via
terminals. Cable length between connection points 20.00 m.
Application
The flow measurement system measures the mass flow continuously and
precisely.
Function
Flow measurement according to the vortex measuring principle. The
measuring principle is based on the Karman vortex street. It includes the
flow calculation from volumetric flow to mass with the help of the steam
temperature.
Note:
The measurement range given in the technical specification of 260 kg/h
to 7,706 kg/h applies to a design pressure of 10.00 bar. If the
measurement range is not met, there can be discrepancies when
displaying or accumulating the steam volume.

01.01.09 Flue gas heat recovery system for additional heat recovery from the flue
gases during condensation operation, consisting of:
- Economiser, welded design, with stainless steel plain
tube bundle, transportation
lugs and supports for transport and installation of the flue
heat exchanger.
- Flue gas connection socket including inspection openings
on flue gas side
with counterflange, packing, screws and bolts
Function:
In the flue gas heat exchanger, heat is recovered from the boiler flue
gases by means of water flowing through the heat exchanger pipes. In
this respect, the (cooler) water is heated up by the (warmer) boiler flue
gases while simultaneously reducing the waste gas temperatures. The
energy recovered during this process leads to an increase of the boiler
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242 Abdel salam Aref St.,
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efficiency and thus to a reduction of the fuel consumption as well as the


waste gas emission.
Due to the optimum heat recovery it must be considered in the
subsequent flue gas system that - dependent on the boiler capacity -
temperatures below the design temperature according to the technical
data sheet occur.

The boiler efficiency including flue gas condensation indicated in the


technical data results from the ratio of useful heat and heat applied
(burner capacity in relation to the calorific value Hi).

Note:
The volume flow rate condensate calculated for the flue gas heat
exchanger amounts to 94.73 l/h. The accruing flue gas condensate which
occurs during the utilization of flue gas condensation must be neutralized
in accordance with local regulations due to its low pH-value.

Insulation of the flue gas heat exchanger with mineral wool mats -
thickness 100 mm - and protective cladding of structured aluminium.

Equipment Heat Exchanger


Set of Valves, Water Inlet, consisting of:
Venting valve, designed as:
- shut-off valve, maintenance-free with bellow seal DN20 PN40
Mounting form: globe valve
Shut-off valve, consisting of :
- shut-off valve, maintenance-free with bellow seal DN40 PN16
Mounting form: globe valve
Pressure safeguard, before ECO designed as:
- full-stroke corner safety valve, type-accepted, DN 20 PN 16
Temperature indicator for water inlet, designed as:
- Thermometer, display area 0.00°C to 120.00°C.

Flow Monitor for monitoring of the heat exchanger minimum water flow.
If the control panel is delivered by us the heat exchanger will be
bypassed after falling short of the preset minimum water flow, designed
as:
- Flow rate monitor, DN15
Drain valve, designed as:
- shut-off valve, maintenance-free with bellow seal DN20 PN40
Mounting form: globe valve

Set of Valves Water Outlet; consisting of:


Temperature monitor,
1 temperature sensor with weld-in coupling R 1/2" for assembly at site
into the water outlet line (space: 3 x D from heat exchanger), designed
as:
- Temperature transducer for proportional provision of signal 0/4-20 mA
Shut-off valve, consisting of :
- Ball valve, spindle seal PTFE, DN40 PN40
Type: stainless steel
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242 Abdel salam Aref St.,
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Pressure gauge at outlet, consisting of:


- Pressure gauge
- Pressure gauge shut-off valve
Safety Temperature Limiter, design as surface-mounting thermostat

Set of fittings for additional water distribution to the flue gas heat
exchanger with flue gas condensation,
comprising:

- motorized ball valve DN32 PN64


- throttleable shut-off device DN 32
Flue Gas Bypass integrated, with flue gas flap, suitable for manual
adjustment or for assembly of an electrical servo-drive.
Electrical servo drive for flue gas control flap, consisting of:
- Electrical servo drive for actuation of the flue gas control flap.
- control unit for automatic and manual operation
The above-mentioned control unit will be incorporated into the boiler
control panel, if the control panel is delivered by us.
Function:
With the control unit the complete flue gas stream will be by-passed at
the heat exchanger via the incorporated flue gas bypass in case of
control on flue gas side.
Granulate Neutralisation
for the neutralisation of acidic flue gas condensate from condensing
boilers, consisting of:
- compact neutralisation plant with deposit zone for the
separation of solid matter and other impurities in the flue
gas condensate; with neutralisation granulate fill and
condensate water collection zone
- 5 m hose
- neutralisation agents 25 kg (starter filling)
- 1 pack pH-measuring strips
In normal operation the condensate water is dammed up on a level of 90
mm above the installation level of the plant. For discharge of the
condensing water a drain connection must be available. This connection
must allow an inlet without backwater. If no inlet on ground level is
available, a waste water lifting device has to be installed on the
downstream side.
Function:
The acidic flue gas condensate runs into the deposit zone of the
neutralisation plant and flows through the granulate filling. This causes
the granulate to solubilize and the condensate is neutralized.

01.02 refer to item 01.01

01.02.01 Boiler pressure vessel, consisting of the cylindrical boiler shell, the front
and rear boiler end, the asymmetrical flame tube located on the right-
hand side which connects the boiler ends, the internal water-cooled
reversing chamber, the smoke tubes of the 2nd and 3rd pass, the steam
drying device and the connection sockets for steam extraction, pressure
safeguard, feeding, pressure measurement, water level gauge and drain,
protective tube for feed water pump control and limiter probes, inspection
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openings for the furnace on the rear wall, revision openings on water and
steam side, two transportation lugs and one boiler rating plate.
Testing during manufacture:
The welding quality is monitored by means of X-ray- or ultrasonic testing.
All pressurized parts are welded and undergo an increased hydrostatic
pressure test after manufacture.
The inspection facilities guarantee an optimum, cost-effective revision of
the boiler. Due to the good revision possibilities as well as the monitored
production process, it is possible - in coordination with local and/or
national legal requirements - to achieve maximum intervals between
repeated inspection.

Mountings:
Front reversing chamber, easily accessible, for cleaning and inspection
purposes on flue gas side.
Door swivels open to the left-hand side, inner surface lined with high-
quality thermal insulation.
Flue Gas Chamber with flue gas condensate socket and inspection
opening on flue gas side, prepared for installation of the economizer.
Boiler Base Frame, sturdy profile steel construction, for even distribution
of load and easy transportation, suitable for the placement of sound
absorbing pads. The boiler body is positioned on the base frame by
supports, if required with front sliding bearing.
1 Drilled Burner Plate(s), suitable for the burner

1 Refractory Lining(s), suitable for the burner

Corrosion protection paint of those Built-on accessories which are not


covered by the insulation. 2 coats of paint with one component lead- and
chromate-free paint based on modified polymer dispersions. The portion
of organic solvents is below 5 weight percent.
1 Flame sight hole(s) for viewing of the flame, with sight glass clear Ø 32
mm, protective cover, connection for cooling air and measurement.
Acceptance of the pressure vessel:
Acceptance at the workshop acc. to the European Pressure Equipment
Directive PED (2014/68/EU).
CE-Marking of the Pressure Vessel:
acc. to the European Pressure Equipment Directive PED (2014/68/EU).

Equipment boiler:
Pressure gauge manostat pipe with 3 connections G 1/2 inch A, acc. to
ISO 228/1.
Smoke Tube Cleaning Device
Cleaning rod with hand grip and screw-on wire brush attachments,
matching the diameters of the boiler smoke tubes. Regular cleaning of
the smoke tubes is a prerequisite for avoiding corrosions on flue gas side
resp. for safeguarding trouble-free burner operation, achieving the full
efficiency and consequently
lower operating costs.
1 Set of Operation and Instruction Labels

Insulation of boiler shell and boiler ends with mineral wool mats and
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242 Abdel salam Aref St.,
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protective cladding of structured aluminium.


Platform (with grating) for maintenance of the fittings arranged on top of
the boiler.
Max. admissible surface load for accessible surfaces: 3 kN/m²
Width of Platform: 600 mm
Safety railing for platform
Ladder with non-skid steps.
Max. admissible loads for:
stairs: 150 kg individual load
Equipment Boiler
Steam extraction valve, consisting of:
- shut-off valve, maintenance-free with bellow seal DN80 PN25
Mounting form: globe valve
Pressure safeguard, each consisting of:
- full-stroke corner safety valve, type-accepted, DN 40 PN 40
Pressure safeguard, each consisting of:
- full-stroke corner safety valve, type-accepted, DN 40 PN 40
Feed water shut-off valve consisting of:
- shut-off valve, maintenance-free with bellow seal DN40 PN40
Mounting form: globe valve
Feed water non-return valve, consisting of:
- disc non-return valve DN40 PN40
Drain shut-off valve consisting of:
- shut-off valve, maintenance-free with bellow seal DN40 PN40
Mounting form: globe valve
Direct Water Level Indicator, each consisting of
- Water level indicator with transparent indicator with mica washer,
closeable
- Water level-blow-off tap
Direct Water Level Indicator, each consisting of
- Water level indicator with transparent indicator with mica washer,
closeable
- Water level-blow-off tap
- Trans-illumination device for transparency displays of the
water level indicator
Pressure gauge-manostat pipe shut-off valve, consisting of:
- shut-off valve, maintenance-free with bellow seal DN20 PN25
Mounting form: globe valve
Pressure gauge device, consisting of:
- Pressure gauge
- Pressure gauge shut-off valve
Safety pressure limiting device max., consisting of:
- safety pressure limiter, CE examined
for merging into the safety chain

Combined feed water level control and limiter probe for steam boilers
equipped and certified acc. to EN 12953 Part 6, suitable for operation
without permanent supervision (BosB) for max. 72 h, consisting of:
Level control incl. electronic max. water level safeguard, consisting of:
- level transmitter (signal output 4-20mA)

 electric switching unit for feed pump control. Incorporation of the


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electronic switching device into the control panel if control panel is


delivered by us. The electronic device is designed for installation
into a control panel with protection class IP54.

Low water level limiter, self-monitoring, CE-/TÜV-tested, electronic, for the


limitation of min. water level consisting of:
- limiter probe with permanent isolation supervision
- electronic switching unit to switch off burner and alarm notification.
Installed in control panel if control panel is in our scope of delivery. The
electronic system is designed for installation in a control panel with
protection level IP54.
- limiter probe with permanent isolation supervision
- electronic switching unit to switch off burner and alarm notification.
Installed in control panel if control panel is in our scope of delivery. The
electronic system is designed for installation in a control panel with
protection level IP54.
Function
This control and limiter combination controls the water level in the boiler
by means of switching the feed pump on and off resp. by control of the
feed water supply flow. Once the highest water level is being exceeded,
the feed pump is switched off. Once the lowest permissible water level
has been reached, the burner will be switched off and locked reliably.
Workshop Assembly of the electronic switching devices into the control
panel if control panel is delivered by the contractor.
Automatic Desalting Device, consisting of:
Conductivity Measuring Device for boiler water, consisting of:
- conductivity measuring transducer with temperature
compensation
(signal output 4-20 mA)
Conductivity Control Device for boiler water, consisting of:
1 Desalting shut-off device, designed as:
- shut-off valve, maintenance-free with bellow seal DN25 PN25
Mounting form: corner valve
- desalting control valve with electric servo-drive, DN25
PN40
- Conductivity tester (manual device) for control of the
water conductivity, battery-operated, with digital display.
Application
The desalting device serves for avoiding boiler breakdowns caused by
high coagulation of the boiler water as well as for avoiding boiler
damages due to excess salt concentration in the boiler. The demand-
driven drain of a portion of the boiler water minimizes the purging rate,
thus saving considerable amounts of feed water, energy and chemicals.
Depending on the fresh water consumption, the blow-down periods can
be reduced and the blow-down breaks extended.
Function
In the boiler control panel, the boiler water conductivity which fluctuates
due to thickening of the boiler water is controlled automatically. If the
conductivity exceeds a preset value, the desalting valve opens and drains
saline boiler water. A further increase of the conductivity is recorded in
the operating log . If a max. admissible limit value is reached, a fault
shutdown of the burner will take place and is recorded. In case of falling
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242 Abdel salam Aref St.,
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short of a minimum value resp. in case of a burner fault shut-down, the


desalting valve will close.
Automatic Blow Down Device for time dependent control of the blow down
valve
control medium: compressed air/water
Pressure control medium: 4,5 - 8 bar (resp. depending on the boiler
design gauge pressure)
consisting of:
- self-closing quick shut-off blow-down valve DN40 PN40
- diaphragm drive for the blow-down valve
- software-module with digital time display and outputs for the control of
the blow down valve
Application
If large quantities of fresh water are fed in, there is increased precipitation
of suspended matter in the boiler because of the addition of chemicals.
The suspended matter builds up at the base of the boiler and must be
blown down at regular intervals.
Function
The software module with adjustable pulse and pause times controls the
magnetic valve which, using compressed air, activates the membrane
drive of the quick shut-off blow-down valve.
Terminal Box
Protection class IP54, of steel sheet, powder-coating grey/structure,
galvanized assembly plate, cable entry from below. Control design in
accordance with DIN-/EN-standards. Connection of the control devices
and the control panel via terminal strips in the terminal box. Terminal box
is function-tested, 1 set of wiring diagrams inside the terminal box.
Advantages
Reading of the instruments and operating of the plant is facilitated by
individual mounting or installation of the boiler control panel. Easy and
mix-up proof connection to the terminal box by means of individually
customized, coded and marked cable bundles with plug connections on
both sides.

Workshop assembly of manometer manostat pipe, terminal box and


sensor technology at the boiler (as far as included in scope of delivery).
Documentation, consisting of:
Additional set of documents:
Quantity: 1
Language: English
Design: CD-ROM
Deadline: with delivery
Operation log
Operation log acc. to European regulations for the scope of delivery.
Quantity: 1
Language: English
Deadline: with delivery
Additional set of documents:
Quantity:
1
Language:
English
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CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
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Deadline:
with delivery

Acceptance documentation
Acceptance documentation in accordance with European directives as far
as required for the supply of the boiler plant, respectively for the part
concerning the delivery scope, however without assembly drawing and
PI-diagram.
Quantity: 3
Language: English
Deadline: 2 weeks after delivery date
Additional set of documents:
Quantity:
1
Language:
English
Deadline:
2 weeks after delivery date

Seaworthy packing of the boiler in wooden case, execution according to


HPE-regulations.

01.02.02 refer to item 01.01.02

01.02.03 Boiler Control Panel for Boiler control BCO


Enclosure type IP 54, made of steel sheet, powder coated grey structure,
galvanized mounting plate, cable ducting from below. The switching and
control devices are assembled on a mounting plate and inside the control
panel door. Wiring in the control panel is executed by means of flexible
cables in sufficiently dimensioned cable ducts. The control devices are
designed in accordance with DIN-/EN- standards. The control devices are
connected on terminal strips inside the control panel. The control panel is
function-tested, 1 set of wiring diagrams is provided inside the panel.
The marking of the electrical operating equipment in the wiring diagrams
is made in accordance with DIN EN 81346- 2.

Control Panel Fan, consisting of:


Filter fan and outlet filter for reduction of the temperature inside the
control panel by means of cooler ambient temperature.
Assemblies:

 Main switch with locking device

- Main switch with locking device


Control Transformer acc. to EN 60204-1 for the generation of the control
voltage 230 VAC. Incorporated and wired in the switch box, control
voltage grounded one-way
- Main switch with locking device
Control Transformer acc. to EN 60204-1 for the generation of the control
voltage 230 VAC. Incorporated and wired in the switch box, control
voltage grounded one-way
Additional connections (potentially coupled) provided for:
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 emergency cut-out
 external alarm buzzer
 contact of the feed water pump contactor for the control of a
dosing pump (combination product or oxygen scavenger)

Automation device BCO with touch-sensitive touchscreen colour display


Industrially proven hardware from the range of stored-program controls
are applied in the Boiler Control BCO. The complete control software is
stored on a memory card provided with the device. A graphic TFT-display
with touch-sensitive interface serves as display and operating unit.
Operating signals and process value archive are stored on a multi-media
card included in the delivery scope.

Basic functions:

 Load control

- level control

 Low load control


 Boiler operation hours meter
 Burner operation hours meter
 Registration of number of burner starts
 Clear text display of operation and fault signals, signal history on
500 signals with time recording (Coming, Going, Acknowledging)
and all relevant operation data at the time
 Intuitive, menu-driven operation by means of the touch-sensitive
graphic display
 Display of all operation-relevant measured values and conditions

INDUSTRIAL ETHERNET connection, consisting of:


1 communication processor with connection possibility to a superior
control (superior control is not in scope of delivery) via RJ45-connection.
The RJ45-plug is delivered loosely.

Condition Monitoring basic


CMbasic is an analysis and evaluation system integrated in the BCO
boiler control. It gathers, analyses and evaluates system operating
statistics and parameters, consumption values, and measurements, and
uses a traffic light-style display to clearly show the results. It detects,
evaluates and notifies the user, in good time, of increased wear or
uneconomical operation of the boiler system.
Scope of delivery:
Temperature-recording device at boiler outlet on flue gas side
Software module integrated in boiler control
Scope of functions
-Displays operating hours; frequency of starts; cold starts as a function of
time
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-Detects unfavourable start-up conditions


-Detects contamination on water and flue gas side
-Detects unwanted condensation
-Generates service notifications
-Displays boiler load profiles as a function of time
-In steam boilers where the fittings are controlled electrically, highlights
energy losses from blow-down and desalting
-Displays measurements as actual values at time of delivery and as a
function of time
-Representation of the digital volume meters with additional reset
function, which are includedin the scope of deliveryand displayed in the
control panel
Intended use
CMbasic gives customers the option of monitoring the efficiency and
correct
operation of their system. In this way CMbasic makes a positive
contribution to
system availability and to ensuring consistently high system efficiency.
Heating device HD via burner - pressure-controlled - acc. to Fig. 2 of TI
019, consisting of:
1 software program module with timer incorporated in the control panel
BCO
Application
To achieve faster availability of the boiler and to avoid corrosion when
inactive and from cold starts, this is kept at a lowered pressure level.

Function
This device can be used to set an additional lower switching pressure for
the burner. Normal operation or heat maintenance operation can be
manually selected using a selection menu in the BCO control panel. The
timer can be programmed with switching times to allow automatic
switching between heat maintenance and normal operation. In heat
maintenance operation, the burner's output is limited to low load and the
burner switching frequency is reduced. If there is a controlled steam
extraction valve, it is closed during heat maintenance operation.

Bus connection cable with plug (plugs delivered separately) for


connection of Boiler control BCO boiler control panels. Cable length
between connection points 20.00 m.
Normal operation (release of vapour valve)
Automatic feed pump switch-over (pressure and time)
for two feed pumps. The required electric control is part of the delivery
scope and completely wired in the control panel.

Wiring diagrams for the scope of delivery.


Quantity: 3
Language: English
Design: print-out
Deadline: with delivery
Additional set of documents:

Quantity:
Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
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1
Language:
English
Design:
in PDF on CD-ROM
Deadline:
with delivery

Cable Harness
for quick and error-free cabling between terminal box and boiler-/ plant
components with mix-up proof connection plugs for sensors and
actuators up to a max. current of 35 A.
If required, the plug connections allow a quick and uncomplicated
exchange of sensors and actuators.
Cable Bundle
for quick and error-free cabling between terminal box and boiler control
panel, with mix-up proof connector plugs for sensors and actuators up to
a max. current of 35 A.
Length of the cable bundle 20.00 m determined from the outlet point
boiler at 12 o'clock position up to control panel inlet.

Connection of the cable harness to the terminal box and to the sensors
and actuators. A function test will be carried out in the workshop.

Connection of cable harness


Cables are prepared and labelled for connecting to the boiler's terminal
box.

01.02.04 refer to item 01.01.04

01.02.05 refer to item 01.01.05

01.02.06 refer to item 01.01.06

01.02.07 refer to item 01.01.07

01.02.07.01 refer to item 01.01.07.01

01.02.08 refer to item 01.01.08

01.02.09 refer to item 01.01.09

01.03 refer to item 01.01

01.03.01 refer to item 01.02.01

01.03.02 Flue gas heat exchanger ECO - integrated


for saving energy and reducing CO2 by reduction of the flue gas
temperature by means of feed water.
Design acc. to European Pressure Equipment Directive PED
(2014/68/EU), suitable for high-pressure steam boilers.
Heat Exchanger , welded design, for installation onto the rear flue gas
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chamber, with connection for water inlet, water outlet and drainage incl.
inspection opening on flue gas side.
Highly efficient heat transfer based on the counterflow principle.
Heat exchanger tubes with fully welded fins for optimizing the heat
transfer.
The heat exchanger casing consists of a sturdy welded construction of
steel sheet. It is stiffened against flue gas vibrations and pressure-tight.
Function
In the flue gas heat exchanger, heat is retrieved from the (warmer) boiler
flue gas, in which (cooler) feed water flows through the heat exchanger
tubes and the temperature of the flue gas is reduced. The energy gained
in this way gives a higher boiler efficiency and therefore lower fuel
consumption and lower emissions of air pollutants such as carbon dioxide
or nitrogen oxide.
Equipment Heat Exchanger
Venting valve, designed as:
- shut-off valve, maintenance-free with bellow seal DN20 PN40
Mounting form: globe valve
Drain valve, designed as:
- shut-off valve, maintenance-free with bellow seal DN20 PN40
Mounting form: globe valve
Temperature indicator for water outlet, designed as:
- Thermometer, display area 0.00°C to 250.00°C.
Shut-off device on water side, consisting of:
- shut-off valve, maintenance-free with bellow seal DN40 PN40
Mounting form: globe valve
Shut-off device on water side, consisting of:
- shut-off valve, maintenance-free with bellow seal DN40 PN40
Mounting form: globe valve
Pressure safeguard, before ECO designed as:
- full-stroke corner safety valve, type-accepted, DN 20 PN 40
Pressure safeguard behind ECO, designed as:
- full-stroke corner safety valve, type-accepted, DN 20 PN 40
Pressure gauge device, on inlet consisting of:
- Pressure gauge
- Pressure gauge shut-off valve
Pressure gauge at outlet, consisting of:
- Pressure gauge
- Pressure gauge shut-off valve
Automatic Flue Gas Temperature Control,
consisting of:
Motorized three-way regulator valve, with built-on electric servo drive,
manual adjusting device, packings, screws and nuts. Complete with AC
stop motor 230 V, 50 Hz. Certificate of final testing acc. to EN 10204.
Electric power unit, consisting of line and motor protective devices as well
as power contactors.
Flue gas temperature sensor
1 Temperature sensor (Pt 100) with welded sleeve R 1/2" for local
installation into the flue gas line (distance 3 x D from the heat exchanger).
- Temperature transducer for proportional provision of signal 0/4-20 mA
1 electrical temperature controller in the BCO, incl. digital display of set
and actual value of flue gas temperature down-stream of the heat
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exchanger, incl. automaticset value change-over in case of dual fuel


burners
1 control unit for automatic and manual operation
1 connection to the burner control
The above-mentioned flue gas temperature control device will be
incorporated into the boiler control panel, if the control panel is delivered
by us.
Function
If the flue gas temperature downstream of the heat exchanger drops too
low:
part of or the complete feed water stream will be bypassed at the heat
exchanger via a three-way valve with electric servo drive in case of
control on water side until the pre-adjusted flue gas temperature
downstream of the heat exchanger is reached in order to avoid
undercuttings of the dew point in the subsequent flue gas system.
Due to the subsequent flue gas system, the energy saving potential of the
heat exchanger can be utilized only partly, depending on the boiler
capacity.
In case of dual fuel burners gas/oil, a min. flue gas temperature
corresponding to the subsequent flue gas paths can be automatically
applied to each type of fuel via the set-value changeover.

Flue gas temperature display device


for display of the flue gas temperature upstream of the Flue gas heat
exchanger in the display and operating unit of the boiler control BCO,
consisting of:
- Temperature transducer for proportional provision of signal 0/4-20 mA

Insulation of the flue gas heat exchanger, the flue gas chamber and the
flue gas exchanger housing with mineral wool mats - 100 mm thick - and
protective cladding of structured aluminium.
Insulation of the connection line on water side between the heat
exchanger and the boiler without fittings and flanges.
Connection line for connecting the feed water nozzle on the boiler to the
connection for the water outlet on the heat exchanger.
Piping for a closable heat exchanger design.
The acceptance procedure for the lines is carried out at the factory in
accordance with European Pressure Equipment Directive 2014/68/EU
(PED).
Cover panel with welded on flue gas connection socket
Flue gas connection socket DN 400 with counterflange, packing, nuts and
bolts.
Assembly of all afore-mentioned components at the factory. Dismantling
of those parts which have to be delivered separately for transport
reasons.

01.03.03 refer to item 01.02.03

01.03.04 refer to item 01.01.04

01.03.05 refer to item 01.01.05


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Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
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01.03.06 refer to item 01.01.06

01.03.07 refer to item 01.01.07

01.03.07.01 refer to item 01.01.07.01

01.03.08 refer to item 01.01.08

01.03.09 Flue gas heat recovery system for additional heat recovery from the flue
gases during condensation operation, consisting of:
- Economiser, welded design, with stainless steel plain
tube bundle, transportation
lugs and supports for transport and installation of the flue
heat exchanger.
- Flue gas connection socket including inspection openings
on flue gas side
with counterflange, packing, screws and bolts
Function:
In the flue gas heat exchanger, heat is recovered from the boiler flue
gases by means of water flowing through the heat exchanger pipes. In
this respect, the (cooler) water is heated up by the (warmer) boiler flue
gases while simultaneously reducing the waste gas temperatures. The
energy recovered during this process leads to an increase of the boiler
efficiency and thus to a reduction of the fuel consumption as well as the
waste gas emission.
Due to the optimum heat recovery it must be considered in the
subsequent flue gas system that - dependent on the boiler capacity -
temperatures below the design temperature according to the technical
data sheet occur.

The boiler efficiency including flue gas condensation indicated in the


technical data results from the ratio of useful heat and heat applied
(burner capacity in relation to the calorific value Hi).

Note:
The volume flow rate condensate calculated for the flue gas heat
exchanger amounts to 94.73 l/h. The accruing flue gas condensate which
occurs during the utilization of flue gas condensation must be neutralized
in accordance with local regulations due to its low pH-value.

Insulation of the flue gas heat exchanger with mineral wool mats -
thickness 100 mm - and protective cladding of structured aluminium.

Equipment Heat Exchanger


Set of Valves, Water Inlet, consisting of:
Venting valve, designed as:
- shut-off valve, maintenance-free with bellow seal DN20 PN40
Mounting form: globe valve
Shut-off valve, consisting of :
- shut-off valve, maintenance-free with bellow seal DN40 PN16
Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

Mounting form: globe valve


Pressure safeguard, before ECO designed as:
- full-stroke corner safety valve, type-accepted, DN 20 PN 16
Temperature indicator for water inlet, designed as:
- Thermometer, display area 0.00°C to 120.00°C.

Flow Monitor for monitoring of the heat exchanger minimum water flow.
If the control panel is delivered by us the heat exchanger will be
bypassed after falling short of the preset minimum water flow, designed
as:
- Flow rate monitor, DN15
Drain valve, designed as:
- shut-off valve, maintenance-free with bellow seal DN20 PN40
Mounting form: globe valve

Set of Valves Water Outlet; consisting of:


Temperature monitor,
1 temperature sensor with weld-in coupling R 1/2" for assembly at site
into the water outlet line (space: 3 x D from heat exchanger), designed
as:
- Temperature transducer for proportional provision of signal 0/4-20 mA
Shut-off valve, consisting of :
- Ball valve, spindle seal PTFE, DN40 PN40
Type: stainless steel
Pressure gauge at outlet, consisting of:
- Pressure gauge
- Pressure gauge shut-off valve
Safety Temperature Limiter, design as surface-mounting thermostat

Set of fittings for additional water distribution to the flue gas heat
exchanger with flue gas condensation,
comprising:

- motorized ball valve DN32 PN64


- throttleable shut-off device DN 32
Flue Gas Bypass integrated, with flue gas flap, suitable for manual
adjustment or for assembly of an electrical servo-drive.
Electrical servo drive for flue gas control flap, consisting of:
- Electrical servo drive for actuation of the flue gas control flap.
- control unit for automatic and manual operation
The above-mentioned control unit will be incorporated into the boiler
control panel, if the control panel is delivered by us.
Function:
With the control unit the complete flue gas stream will be by-passed at
the heat exchanger via the incorporated flue gas bypass in case of
control on flue gas side.

01.04 Water service module WSM-V


for storage and thermal treatment of feed water.
All essential components of the water service module are assembled as a
ready-for-connection, easily operable function unit. The water service
module treats make-up water and supplies the steam generator with
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CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

thermally treated feed water.


The control of water level and feed water temperature takes place via
electronic measured-data acquisition and electric positioners, which are
guided by a computer-aided control.
Thereby precise control results are achieved which also respond well to
sudden load changes.
In the water service module, all components are well dimensioned and
functionally optimized. The internal module components are hydraulically
piped, electrically wired and pre-adjusted. Easy transportation and
bringing-in of the water service module are assured. After the assembly
of connections, the water service module is ready for operation.
Feed water tank FT
with nozzle pipe for bottom heating, inspection opening, made of
stainless steel, fully electrically welded and tightness-tested.
Transportation lug
Insulation of the tank with mineral wool mats and protective cladding of
structured aluminium.
Equipment Feed Water Tank:
Pressure safeguard, each consisting of:
- full-stroke corner safety valve, type-accepted, DN 100 PN 16
Min. pressure limiter, consisting of:
- disc non-return valve DN50 PN40
Fitting for drain and overfilling, consisting of:

 solenoid shut-off valve DN40 PN10

- Control for overflow protection and gauge pressure


protection,
controlled by level transmitter resp. pressure transducer.
Emptying device, consisting of:
- Shut-off valve DN40 PN20
Water level regulation device for indication and regulation of the
water level in the tank, consisting of:
- differential pressure transducer
- Control of the level control of the feed water tank,
controlled
by the level transmitter.
- Shut-off valve DN15 PN40
Make up water control device, consisting of:

 solenoid shut-off valve DN25 PN16

 solenoid shut-off valve DN25 PN16

- throttleable shut-off device DN 25


- throttleable shut-off device DN 25
Make-up water supply flow device, consisting of:
- disc non-return valve DN50 PN40
Min. flow regulation for make-up water,
for keeping up the min. flow of the make-up water for the heat exchanger,
consisting of:
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CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

 solenoid shut-off valve DN25 PN16

- throttleable shut-off device DN 25


Tank pressure regulation device for indication and regulation of the tank
pressure,
consisting of::
- transmitter (signal output 4 - 20 mA)
- Control for regulation controlled by pressure transducer.
Heating steam control device, consisting of:
- motorized regulation valve with built-on positioning drive and manual
adjustment, DN40 PN16
- Control for temperature regulation of feed water tank

Cascade deaeration device


Deaerator module DM consisting of:
Jacket, hood and inserts of stainless steel, material no. 1.4301, with
incorporated water distribution
system and multi-part cascade inserts, fully electrically welded.
Equipment for Deaerator module DM:
- orifice disk
Insulation of the deaerator with mineral wool mats and protective cladding
of structured aluminium, without flange.

Shrink-Wrapping for Transportation


All weather-sensitive parts shrink-wrapped or packed in plastic wrapping.
Loose parts - if necessary - to be packed in cases, cartons or other
suitable type of packing. Disposal of packing material at site.
Condensate Supply Device for oxygenic condensate, directly returned,
consisting of:
- disc non-return valve DN32 PN40
Pressure monitoring device consisting of:
- Pressure gauge
- Pressure gauge shut-off valve
Direct Temperature indicator, consisting of:
- Thermometer, display area 0.00°C to 120.00°C.

Feed water temperature monitoring via SPC (Stored Program Control),


consisting of:
- Temperature transducer for proportional provision of signal 0/4-20 mA
- software for indication of the temperature in the control
panel
Overflow fitting, without auxiliary power,
consisting of:
- 1 positioning valve and control drive incl. control cable
with expansion vessel, DN80 PN25
Impulsleitung (lose für bauseitige Montage)

Function:
The trigger pressure of the overflow fitting is preset below the triggering
pressure of the safety valve in order to avoid permanent blow off of the
safety valve through returning high pressure condensate.
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CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

Vapour Vent Valve with electrical drive, for assembly into the vapour line
after the
deaerator, consisting of:
- electrically regulated fitting
- motorized ball valve DN32 PN64
Function
The electrically controlled vapour valve opens with start and closes at
stop of the deaeration plant. Energy losses while stand-still are reduced.
Control of vapour valve with module or plant control panel if included in
scope of delivery.
Supporting Structure for the WSM-components, for installation on a plain,
load-bearing floor.

Water Control WCO


Enclosure type IP 54, made of steel sheet, powdercoated grey structure,
galvanized mounting plate, cable ducting from below. The switching and
control devices are assembled on a mounting plate and inside the control
panel door. Wiring in the control panel is executed by means of flexible
cables in sufficiently dimensioned cable ducts. The control devices are
designed in accordance with DIN-/EN-standards. The control devices are
connected on terminal strips inside the control panel. The control panel is
function-tested, 1 set of wiring diagrams is provided inside the panel.
Equipment
Control Transformer acc. to EN 60204-1 for the generation of the control
voltage 230 VAC. Incorporated and wired in the switch box, control
voltage grounded one-way
- Main switch with locking device

Control Panel Fan, consisting of:


Filter fan and outlet filter for reduction of the temperature inside the
control panel by means of cooler ambient temperature.
PLC WCO with 3 "FSTN LCD Display, Black and White with key
operation
Basic features:
- Level control
- Dry-running protection feed pump
- Temperature control feedwater tank
- Drain water temperature control (upon delivery of the BEM by us)
- Control chemical dosing (upon delivery of the CD by us).

Communication module FOR Industrial Ethernet connection, consisting

Communications processor with connectivity to a higher-level control (I &


C is not included) for transmitting operational messages, the current
process data from the plant control via a RJ45 port means Industrial
Ethernet with application protocol passive S7 communication (server)
over TCP / IP

- The RJ connector is included


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CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

- Default IP address (es), router address, subnet mask,


transport protocol, application protocol
Potential-Free Contact WCO of automation units with operation and text
display. Function as fault signal acc. to the operating current principle.
Wiring up to the terminals in the control panel for external signaling and
control function. Contact load max. 5 A.
- Volt-free contact for min. temperature feed water tank
- Volt-free contact for 2nd Level (e.g. condensate pump
ON/OFF).
Connection cable with multipole plug for fast, fault-free cabling between
Water Control WCO / System Control SCO and Boiler Control - boiler 1.
Cable length between connection points 20.00 m.
Connection cable with multipole plug for fast, fault-free cabling between
Water Control WCO / System Control SCO and Boiler Control - boiler 2.
Cable length between connection points 20.00 m.
Connection cable with multipole plug for fast, fault-free cabling between
Water Control WCO / System Control SCO and Boiler Control - boiler 3.
Cable length between connection points 20.00 m.

Wiring diagrams for the scope of delivery.


Quantity: 3
Language: English
Design: print-out
Deadline: with delivery
Additional set of documents:

Quantity:
1
Language:
English
Design:
in PDF on CD-ROM
Deadline:
with delivery

Documentation, consisting of:


Operating manual
Operating manual acc. to European regulations for the scope of delivery.
Quantity: 3
Language: English
Design: print-out
Deadline: with delivery
Additional set of documents:
Quantity: 1
Language: English
Design: CD-ROM
Deadline: with delivery

Blow-down, expansion and cooling module BEM


for the expansion and cooling of all temperature-conveying waters in the
steam boiler plant to duct inlet temperature (approx. 30-40 °C, adjustable
in accordance with local regulations).
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CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

Tank with inspection opening, connections for venting, waste water,


drainage water, cooling water, emptying, designed as mixing cooler,
made of steel sheet, fully electrically welded and tightness-tested, tank
supports, two transportation lugs and manufacturer plate.

Corrosion protection paint of those Built-on accessories which are not


covered by the insulation. 2 coats of paint with one component lead- and
chromate-free paint based on modified polymer dispersions. The portion
of organic solvents is below 5 weight percent.
Protection against contact with protective cladding of structured
aluminium.
Equipment:
Emptying device, consisting of:
- Shut-off valve DN25 PN32
Pressure monitoring device consisting of:
- Pressure gauge
Temperature regulation device for display and control of the temperature
of the medium in the expansion vessel, consisting of:
- Temperature transducer for proportional provision of signal 0/4-20 mA
(If the plant control panel is delivered by us, the display
and the control is included)
Cooling water control device, consisting of:

 solenoid shut-off valve DN25 PN16

- throttleable shut-off device DN 25


Control for cooling device, controlled by the temperature transducer.
Direct Temperature indicator, consisting of:
- Thermometer, display area 0.00°C to 120.00°C.
Blending device
Mixing valve for admixing softened make-up water to the cooling water,
designed as:
- automatic mixing valve DN32
Function:
By means of a mixing valve, an exactly defined amount of softenend
make-up water will be added to the raw water which is used as cooling
water, in order to avoid that the max. admissible total hardness of the
cooling water acc. to the operating instructions will be exceeded.

Chemical dosing device CD for storage, supply and dosing of liquid


protection chemicals, with the exception of Hydrazine. The main
components of the dosing device are assembled to form a ready-to-
install, easily operable function unit.
- 1 dosing tank with incorporated suction lance
- 1 dosing pump with control cable, built onto the dosing
tank
- 1 non-return valve
- 1 dosing lance
- 5m dosing hose
The chemicals and the required analysis kits must be provided locally in
due time.
Control for chemical dosing device CD, controlled by the level regulation
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CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

of the feed water tank resp. the boiler feed pump.

Chemical dosing device CD for storage, supply and dosing of liquid


protection chemicals, with the exception of Hydrazine. The main
components of the dosing device are assembled to form a ready-to-
install, easily operable function unit.
- 1 dosing tank with incorporated suction lance
- 1 dosing pump with control cable, built onto the dosing
tank
- 1 non-return valve
- 1 dosing lance
- 5m dosing hose
The chemicals and the required analysis kits must be provided locally in
due time.
Water sample cooler module SCM for taking samples of boiler water,
consisting of:
- cooler of stainless steel
Water sample valve, consisting of:
- Shut-off valve DN10 PN315
Water sample valve, consisting of:
- Shut-off valve DN10 PN315
- stop valve for cooling water supply
- throttleable shut-off device DN 15
Workshop Assembly of the equipment and dismantling of those parts
which have to be delivered separately for transportation reasons.
Shrink-Wrapping WSM for Transportation
All weather-sensitive parts of the Water Service Module shrink-wrapped
or packed in plastic wrapping. Loose parts - if necessary - to be packed in
cases, cartons or other suitable type of packing.
Disposal of packing material at site.
Seaworthy packing of the water service module in wooden case,
execution according to HPE-regulations.
Parts removed from the boiler for shipping purposes will be packed,
unless otherwise specified, in cardboard boxes.

01.05 Make-up water distribution


for controlling the distribution of the make-up water to the heat exchanger
to optimize heat recovery.

Set of fittings for the bypass


consisting of:
- motorized ball valve DN32 PN64
- throttleable shut-off device DN 32
In loose sections for on-site installation into the on-site make-up water
line.

01.06 Water treatment module WTM


The main components of the water treatment module are assembled to
form a function unit, ready for connection and for easy operation. Via an
ion exchanger, the water softening module generates water with a
hardness of 0° dH. In the water treatment module, all components are
well dimensioned and functionally optimized. The internal module
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CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

components are hydraulically pipe connected, electrically wired and pre-


adjusted. Easy transportation and bringing-in of the water softening
module are assured. After the assembly of connections for raw water,
make-up water, waste water and power, the water treatment module is
ready for operation.
Softener, double aggregate with flow-dependent control, consisting of:
- 2 exchanger tanks with GFK-shell, incl. nozzle system
- 2 fillings of ion exchanger material
- 1 control head incl. cover for fully automatic regeneration with electric
control
unit, incl. operation switches, display, incl. power connection cable and
plug
with earth contact
- 1 salt tank with cover and integrated brine system
- 1 contact water meter
- 1 fine filter with initial filter insert, control via removable glass cover.
- 1 system isolator incl. screw joint and packings, acc. to DIN 1988,
DVGW-tested.
Base Frame for the WTM components, for installation on a level, bearing
ground.
Assembly, electrical wiring and function test of all above mentioned
components in the workshop. Dismantling of those parts which have to be
delivered separately for transport reasons.
Shrink-Wrapping for Transportation
All weather-sensitive parts shrink-wrapped or packed in plastic wrapping.
Loose parts - if necessary - to be packed in cases, cartons or other
suitable type of packing. Disposal of packing material at site.
Seaworthy packing of the water softening in wooden case, execution
according to HPE-regulations.
Parts removed from the boiler for shipping purposes will be packed,
unless otherwise specified, in cardboard boxes.

Due to missing raw water analysis, we have quoted for a water softening
plant for the design of which we have assumed raw water data based on
iron-free (smaller 0,2 mg/l) and manganese-free (smaller 0,05 mg/l)
drinking or service water with a max. total hardness of 10 °dH (German
degrees) (1.79 mmol/l), a carbonate hardness of 3 °dKH (1.07 mmol/l) as
well as a conductivity of 500 µS/cm. For the condensate rate, we have
assumed 0.00 kg/h. The water treatment plant requires 3 - 6 bar raw
water supply pressure, a max. service temperature of 30 °C is admitted.
As these are only assumed values, our quoted price is a budget price,
only and might have to be revised after receipt of a detailed analysis of
the raw water available at site which will be necessary for the final layout
of the water treatment plant.
Filling of the salt tank with locally provided regenerating salt has to be
done in due time.

01.07 Steam distributor


CE marking in accordance with the European Pressure Equipment
Directive PED (2014/68/EU), for distribution of steam mass flow to
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CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

different consumers an separation of the residual humidity.


The steam distributor is made of steel sheet, completely electrically
welded and pirmed outside, not insulated.
Fastening device for mounting on the floor.
Equipment:
- nozzle for manostat tube [DN 20 PN 16]
- nozzle for residual drain [DN 20 PN 16]
- nozzle for condensate trap [DN 20 PN 16]
- nozzle [DN 125 PN 16]
- nozzle [DN 125 PN 16]
- nozzle [DN 125 PN 16]
- nozzle [DN 65 PN 16]
- nozzle [DN 100 PN 16]
- nozzle [DN 80 PN 16]
- nozzle [DN 80 PN 16]
- nozzle [DN 80 PN 16]
- nozzle [DN 50 PN 16]
- nozzle [DN 50 PN 16]
- nozzle [DN 65 PN 16]

Accessories:
Pressure gauge device, consisting of:
- Pressure gauge
- Pressure gauge shut-off valve
Shut-off valve for residual drain, consisting of:
- shut-off valve, maintenance-free with bellow seal DN20 PN40
Mounting form: globe valve
Shut-off valve for condensate trap (inside), consisting of:
- shut-off valve, maintenance-free with bellow seal DN20 PN40
Mounting form: globe valve
Shut-off valve for condensate trap, consisting of:
- shut-off valve, maintenance-free with bellow seal DN20 PN40
Mounting form: globe valve
Condensate trap, consisting of:
- condensate trap DN20 PN40
- disc non-return valve DN20 PN40
Equipment for outlet branch, consisting of:
- shut-off valve, maintenance-free with bellow seal DN125 PN16
Mounting form: globe valve
- disc non-return valve DN125 PN40
Equipment for outlet branch, consisting of:
- shut-off valve, maintenance-free with bellow seal DN125 PN16
Mounting form: globe valve
- disc non-return valve DN125 PN40
Equipment for outlet branch, consisting of:
- shut-off valve, maintenance-free with bellow seal DN125 PN16
Mounting form: globe valve
- disc non-return valve DN125 PN40
- shut-off valve, maintenance-free with bellow seal DN65 PN16
Mounting form: globe valve
Equipment for outlet branch, consisting of:
- shut-off valve, maintenance-free with bellow seal DN100 PN16
Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

Mounting form: globe valve


Equipment for outlet branch, consisting of:
- shut-off valve, maintenance-free with bellow seal DN80 PN16
Mounting form: globe valve
Equipment for outlet branch, consisting of:
- shut-off valve, maintenance-free with bellow seal DN80 PN16
Mounting form: globe valve
Equipment for outlet branch, consisting of:
- shut-off valve, maintenance-free with bellow seal DN80 PN16
Mounting form: globe valve
Equipment for outlet branch, consisting of:
- shut-off valve, maintenance-free with bellow seal DN50 PN16
Mounting form: globe valve
Equipment for outlet branch, consisting of:
- shut-off valve, maintenance-free with bellow seal DN50 PN16
Mounting form: globe valve
Equipment for outlet branch, consisting of:
- shut-off valve, maintenance-free with bellow seal DN65 PN16
Mounting form: globe valve
Documentation, consisting of:
Operating manual
Operating manual acc. to European regulations for the scope of delivery.
Quantity: 3
Language: English
Design: print-out
Deadline: with delivery
Additional set of documents:
Quantity: 1
Language: English
Design: CD-ROM
Deadline: with delivery

01.08 Functions of connection of boiler plant to superior control technology

01.10.01 Piping Diagram


The piping diagram is designed acc. to EN ISO 10628 and is limited to
our scope of supply.
Quantity: 3
Language: English
Deadline: 3 weeks within order confirmation
Execution: Hard copy (coloured, in delivery scope characteristics)
A dimensioned key for all fittings (given as a list of fittings), MSR devices
(given as a list of measuring points) and piping is included.
In the list of fittings are listed all the fittings with details of the nominal
diameter, nominal pressure, manufacturer, manufacturer's type
designation, connection and material.
In the list of measuring points are listed all the MSR devices with details
of the nominal diameter, manufacturer, manufacturer's type designation,
connection and measurement range.
Additional set of documents:
Quantity: 1
Language: English
Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

Deadline: 3 weeks within order confirmation


Execution: one PDF-file (black/white), one PDF-file (coloured, in delivery
scope characteristics) and onepacked DXF-file (ZIP file format) compliant
to ACAD 2000 - Drawing Exchange Format (coloured, in delivery scope
characteristics) dispatch on CD-ROM

01.10.02 2D-boiler house layout drawing


Positioning proposal of the boiler and boiler plant components acc. to
product requirements.
Quantity: 3
Language: English
Deadline: 3 weeks within order confirmation
Execution: Hard copy
Additional set of documents:
Quantity: 1
Language: English
Deadline: 3 weeks within order confirmation
Execution: one PDF-file and onepacked DXF-file (ZIP file format)
compliant to ACAD 2000 - Drawing Exchange Format (coloured, in
delivery scope characteristics) dispatch on CD-ROM.

01.10.04 Photographic documentation of delivery scope


Type: eMail
Deadline: with delivery

01.10.05 Labelling of loose delivered parts


Temporary labelling of loose delivered parts for clear identification of the
components according to the delivery note. Designed as PE-label with
delivery note number, item number and material number.
With metal tags fixed to the respective component.

04 Seaworthy packing:
Where present, the following items shall be packed in a case:
Boiler
Degassing system
Softening system
Steam accumulator
Condensate service module
ECO SA 1/5
Superheater
All accessories shall be prepared for stowing in containers.
If the accessories are to be packed in cases as well, an additional
agreement must be made for this purpose.

05 Delivery CIF Alexandria Seaport


according to Incoterms 2010.

07 MEC Remote
for remote access to the boiler control panel or system control panel via
the internet.
Router for MEC Remote
VPN router for remote access to boiler control panel BCO / system
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CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

control panel SCO via the internet portal www.mec-remote.com,


parameterized and installed in a control panel in order to be connected
to a internet connection on site or a customer network via DSL Router or
dial-up in a mobile phone network via the optional available UMTS radio
module.
Costs of connection for data transmission are not included in the price of
the device. We recommend the acquisition of an unlimited plan.
Scope of delivery router
- VPN router ERT50
- microSD card incl. router software
- implementation of plant data into MEC portal
If MEC Remote will be connected to a customer network, the router's IP
address in the network needs to be indicated to the responsible project
officer at the latest 10 working days after the order confirmation arrival.
Otherwise the router will be configured with DHCP on the WAN side. The
connection to the internet needs to be established according to TI043.
Function
In order to successfully set up a data connection to the MEC Remote
portal (www.mec-remote.com), an online registration needs to be
completed. This way you acquire the customer's access to the MEC
Remote portal including remote access to all connected plants, server
provision to visualize the connected boiler control panels and system
control panels and automatic software and security updates for the VPN
router.
After the successful registration you furthermore gain the option to
receive fast and professional help by BOSCH specialized staff -
irrespective of the plant location. In case of incidents, extensive remote
diagnosis can be created, parameter can be adjusted end even errors in
the program sequence of the control can be identified and cleared.

The online registration can be found here: http://www.bosch-


industrial.com/mec-registration.

08 Connection of the boiler plant to a superior control technology.

via Industrial Ethernet with application protocol passive S7-communication


(server) via TCP/IP
e.g. from OPC-Server provided by the customer.
Communication prozessor(s) with link-up possibility to superior control
(superior control is not in scope of delivery) for transfer of operating
messages, actual process data of the boiler control and control
possiblities from the superior control.

The presettings and notes are indicated in the technical information


TI034:
- preset IP-address(es), router address, subnet mask, transport protocol,
application protocol
The exact functions can be found in the section
Functions of connection of boiler plant to superior control technology
of this description.

Note: If for the data transmission at site an Engineer is needed, the


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CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
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occuring costs will be invoiced acc. to our conditions for delegation of


personnel.
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CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

CONDITIONS OF SALE AND DELIVERY

All delivers and services, assembly work and repairs are governed by these conditions and
by any separate contractual agreements. Any terms of purchase of the buyer which deviate
from these shall not become part of the contract even on acceptance of the order. Unless
otherwise agreed, a contract comes about when the order is confirmed in writing by the
seller.

Validity of the offer


Our offer and the prices in our offer are valid for a period of 3 months, calculated from the
date of the offer. After this date, a probable price increment of 6 % for the following year is to
be considered.

Object of the delivery and performance


The object of the delivery and performance according to the specification described in this
offer.
The scope of our delivery and performance is completely and finally specified in this offer.
Further details and delivery limitations will become clear from these Conditions of Sale and
Delivery.

Method of payment
Total amount of order by a divisible and irrevocable letter of credit, opened through and
confirmed by one of the below mentioned banks and free of any charges for the seller:
- HypoVereinsbank AG - account no. 2906880, bank code: 765 200 71,
IBAN: DE70765200710002906880, BIC: HYVEDEMM406
- Commerzbank AG - account no. 119675300, bank code: 760 800 40,
IBAN: DE73760800400119675300, BIC: DRESDEFF760

The L/C must be payable in Germany at sight against presentation of the usual shipping
documents or a warehouse receipt to the bank. The letter of credit must be in accordance
with UCP 2006, ICC-publication no. 600. The validity period of the L/C must exceed the
delivery time by one month for shipping plus 21 days for negotiation.

Conditions of delivery
The delivery will be CIF Alexandria Seaport.

Transport conditions
If transport is included in the order, this will be carried out solely in accordance with the
general conditions of carriage valid at the time, such as the General German Conditions of
Carriage (ADSp, publ. 2003) issued by Bundesverband Spedition und Logistik e.V..

Any claims by the seller against the dispatch company are assigned to the buyer, who
accepts this assignment.

Delivery time ex works


Approx 18 weeks Ex-Works delivery.

Storage and maintenance costs


If the customer defaults on acceptance, the customer shall bear the costs incurred by us, in
particular for storage (also by third parties). For each day of delay, the customer shall
reimburse us for lump-sum costs amounting to 0.025% of the net order value as well as a
one-off lump-sum expense amounting to 1% of the net order value, unless we can prove to
the customer that we incurred higher actual costs.
Thermotechnology

CATEC
Consulting And Technical Engineering Co.
P.O.BOX 114 Elsaray
242 Abdel salam Aref St.,
Loran - Alexandria, Egypt

Warranty period
The boiler system specified here is covered by a warranty period of 12 months from
commissioning, at the latest 18 months from readiness for delivery.
We generally recommend to close a maintenance service contract, to ensure an optimal
operation of the plant.

Legal Documents and Conditions of Terms


The General Terms and Conditions of Sale, Delivery and Payment of Bosch Industriekessel
GmbH, Gunzenhausen together with data protection notices shall apply exclusively. You can
find these on our website at: www.bosch-industrial.com/terms.