Boilers KSV “Generation” 1–12 MW

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Purpose.

KSV “Generation” boilers with capacity 1 to 12 MW – sectional hot-water three-pass boilers. The first boiler pass is formed by fire tube and backfire chamber. The second and the third boiler pass are formed by gas tube of the convection part of the boiler. KSV “Generation” sectional hot-water boilers are designed for efficient heating of and hot-water supply for industrial, community and residential buildings as well as for the production facilities. Boilers are used in stationary and modular boiler houses.


Technical data:

Parameter	KSV-1,0	KSV-2,0	KSV-3,0	KSV-5,0	KSV-8,0	KSV-12,0
Heat efficiency, MW	1,0 (0,86)	2,0 (1,72)	3,0 (2,58)	5,0 (4,3)	8,0 (6,88)	12,0 (10,2)
Efficiency, %	92	92	92	92	92	92
Inlet/outlet water temperature, ºC	115/70	115/70	115/70	115/70	115/70	115/70
Hydraulic resistance, MPa (kgf/cm2), max	0,01 (0,1)	0,01 (0,1)	0,01 (0,1)	0,01 (0,1)	0,01 (0,1)	0,01 (0,1)
Aerodynamic resistance, Pa	555	687	560	670	820	1820
Max water operation pressure, MPa	0,6 (6)	0,6 (6)	0,6 (6)	0,6 (6)	0,6 (6)	0,6 (6)
Fuel	natural and accompanying gas, liquid fuel
Boiler volume, m3	3,50	5,31	7,60	11,40	18,80	23,6
Boiler heating surface, m2	37,57	68,69	96,26	138,74	216,38	367,2
Closure external surface (heat insulation) temperature, ºC, max	45	45	45	45	45	45
Content in smoker gas, max: СО	60	60	60	60	60	60
NO2	80	80	80	80	80	80
Overall dimensions, m, max: length	4,25	4,66	4,94	5,25	6,02	7,4
width	1,78	2,3	2,49	3,05	3,0	3,25
height	1,93	2,28	2,65	2,98	3,40	3,6
Boiler weight, max, kg	4400	6200	11000	14500	20000	28600

Unit complete:

Unit complete consists of the boiler itself and automated burner. Control instrumentation and locking safety fittings are supplied together with the boiler house. On request the boiler can be complete with boiler automation set.

KSV «Generation» boiler structure and operation:

Boiler consists of the body, front cover, smoke gas offtake, supports, heat insulation and decorative top shell.
Boiler body (1) – cylindrical, includes combustion chamber, front (5) and rear (3) tube sheets, convection gas duct (4), front backfire chamber (6) and external ring.

Combustion chamber is a cylinder made in a way of fire tube (2) and rear backfire chamber (8), rear tube sheet (3). The burner flange is welded to the front wall.

Combustion chamber head and rear tube sheet form a flexible system compensating the fire tube extension.
Boiler convection gas duct is made of seamless smoke tubes (4). Tubes are grouped and welded to the tube sheets. The clearances between the smoke pipe units permit cleaning and inspection.


Boiler case is made of the sheet steel. On the case there are:

• Return water intake elbow (10)
• Direct water offtake elbow (12)
• Drain connection (13)
• Explosion valve (14)

Frontal double-leaf cover (8) is made of sheet steel with refractory filling. Under the smoke exhauster (15) the explosion valve (14) is mounted. It is lined inside and equipped with springs and sight port.

The front cover has a sealing which provides an equal torque of cover bolts to boiler body.

The boiler has light type heat insulation.

Mineral fiber sheets resisting temperature up to 300-500ºC are used for thermal insulation.  Insulation thickness is 100mm. Insulation layer is covered with decorative aluminum or galvanized shell with decorative polymer coating.

Burner flare is arranged horizontally along the furnace centre line.

Smoke gases while reached the backfire chamber, enter the smoke fire tubes of the first pass of the convection unit and forwarded to the boiler front.
In the front chamber smoke gases make 180º turn and are forwarded to the collecting box and further to the chimney.
Water is delivered to the boiler through the inlet elbow (10) at the rare part of the boiler. Screen between boiler body and convection unit widens the mixing zone of cold return water and hot boiler water.

The turbulators volumetric mixing of original design increase the efficiency and decrease aerodynamic resistance of the smoke gas inside convection pipes.
Water is discharged from the boiler to the system through the outlet elbow in the front part of the boiler.

Boiler overall and connecting dimensions

Boiler designation	А*	B	C	D	E	F	G	H	I	J	K	L	M	N	O	P	Dy1	Dy2	Power (mW)
KSV–1,0	4,85	4,34	4,16	0,78	2,5	1,35	1,92	0,96	1,7	0,52	1,52	0,22	0,13	0,5	1,29	1,72	0,08	0,05	1,0
KSV–2,0	5,54	4,66	4,38	0,78	2,4	1,63	2,24	1,0	2	0,6	2,0	0,3	0,10	0,55	1,49	2,18	0,1	0,07	2,0
KSV–3,0	6,0	4,65	4,55	0,78	2,8	1,71	2,55	0,66	2,3	0,52	2,3	0,3	0,15	0,69	1,85	2,45	0,13	0,08	3,0
KSV–5,0	6,43	5,5	4,48	0,94	2,95	1,84	2,95	0,61	2,73	0,27	2,3	0,33	0,10	1,63	2,21	3,05	0,15	0,15	5,0
KSV–8,0	6,75	5,5	5,30	1,0	3,8	0,82	3,3	0,9	3,7	0,45	3,5	0,6	0,20	0,75	2,50	3,6	0,15	0,1	8,0
KSV–12,0	9,22	7,43	7,05	0,82	4,7	2,4	3,62	1,11	3,55	0,71	3,04	0,92	0,12	1,03	2,62	3,21	0,2	0,2	12,0

Note: dimensions are given in meters

Instrumentation

On the return water elbow the pressure gage and thermometer (from the boiler set) are mounted.

The direct water offtake elbow is equipped with thermometer and pulse sockets to connect the instruments of the burner automation. On the gas offtake duct the thermometer (from the boiler set) is installed to measure smoke gases temperature. Boilers are supplied with automated blow burner fueled with gas, liquid or combined fuel according to the Customer specifications. Burners can be operated with negative pressure as well as with forced aspiration


Location and mounting

The boiler is to be mounted in separate rooms in accordance to the SNiP 2.01.02-85 regulations.

Boiler is mounted according to the “Operation and safety instructions for boilers with air pressure 0.7 kgf/cm, hot water boilers and water heaters with heating temperature max 115°С” and boiler house project documentation.

The boiler has two supports to mount it either directly on the boiler floor or on the foundation. One support is to be fixed and the other is to be free for shifting.

© 2008 "The Generation Industrial Group".