Omv en

OIL-MATIC
THERMAL FLUID HEATERS
Technical Book Thermail Fluid Heaters OMV
THERMAL FLUID HEATERS SERIES
OIL-MATIC
1. General Information about Thermal Fluid Heaters

2. Technical Highlights
3. Competitive Advantages
4. Technical Characteristics and Overall Dimensions
5. P&ID
6. Thermal Oil Circuit Layout
7. Thermal Oil System Elements
8. Installation
9. Thermal Fluid Brands & Types
10. Scope of Supply
11. Appendix 1. OIL-MATIC OMV Special Executions
12. Appendix 2. BONO ENERGIA Product Range
1. GENERAL INFORMATION
Thermal fluid heathers of the series OIL-MATIC,

type OMV, guarantee a power capacity range
between 200.000 Kcal/h and 5.000.000 Kcal/h, with
a maximum working temperature of 350 C.
OIL-MATIC OMV fields of application are typically:

typographies, cosmetics, pulp and paper industry,
chemical and petrochemical industry, oil
transportation devices, food&beverage, bitumen
industry, textile and packaging industry.
Models of the series OIL-MATIC include:
OMV 200: up to 0,2 MW, 200.000 Kcal/h.

OMV 300: up to 0,5 MW, 300.000 Kcal/h.
OMV 400: up to 0,7 MW, 400.000 Kcal/h.
OMV 600: up to 0,9 MW, 600.000 Kcal/h.
OMV 800: up to 0,2 MW, 800.000 Kcal/h.
OMV 1000: up to 1,2 MW, 1.000.000 Kcal/h.
OMV 1250: up to 1,5 MW, 1.250.000 Kcal/h.
OMV 1500: up to 1,7 MW, 1.500.000 Kcal/h.
OMV 2000: up to 2,3 MW, 2.000.000 Kcal/h.
OMV 2500: up to 2,9 MW, 2.500.000 Kcal/h.
OMV 3000: up to 3,5 MW, 3.000.000 Kcal/h.
OMV 4000: up to 4,7 MW, 4.000.000 Kcal/h.
OMV 5000: up to 5,8 MW, 5.000.000 Kcal/h.
OIL-MATIC heaters are supplied as packaged

units, complete with all necessary equipment and
ready to be connected to site utilities; the selection
of the oil circulation pumps, expansion tank
and oil storage tank is strictly depending on the
system type, anyway our technical and commercial
specialists are available to select and quote the
proper equipment case by case.
As an optional, air preheater can be purchased
additionally to the oil heater. Preheater enables
the boiler to increase efficiency reaching 90% at
full load.
OIL-MATIC model OMV is available both in vertical
and horizontal versions; OMV compact design is
also suitable for small plants, although always
guaranteeing high quality performances.
OIL-MATIC OMV heaters are marked
and can be produced according to the most
important and rigorous directives, such as:
- PED Directive 97/23/CE
- Machinery Directive (MD) 2006/42/CE
- Gas Directive 2009/73/EC according to PED
- Low Voltage Directive (LVD) 2006/95/EC
- Electromagnetic Directive 89/336/EEC.
Figure 1
Thermal Fluid Heaters series OILMATIC, type OMV, with ladder and
platform.
Figure 2
Thermal Fluid Heater OIL-MATIC OMV
AIR
FUEL
OIL OUTLET
BURNER FLAME
OIL INLET
EXHAUST GAS
1
2
3
4
OIL-MATIC coil
Heaters body
Upper cover
Burner
5
6
7
8
Thermal Oil Inlet

Thermal Oil Outlet
Thermal Oil Drain
Thermal Oil inner coil/furnace
5
2. TECHNICAL HIGHLIGHTS
At first glance, thermal fluid heaters of different equipment producers may appear the same. Deeply analyzing their characteristics it is clear that OIL-MATIC OMV has outstanding technical features. OIL-MATIC OMV heaters can be used with a
wide range of thermal fluids (both minerals and synthetics) and are available in a wide range of sizes, from 0,2 MW up to
5.8 MW.
Thanks to its easy design OIL-MATIC OMV series has found a large and successful application in many heating processes.
OMV Design
OMV design consists in a well proportioned heating surfaces dimensioning, where both the sections, radiant and
convective, are designed according to recent up-to-date
design formulas, taking into consideration of several
critical process data such as heat flow density, specific
thermal load per unit, max. recommended bulk and max.
film temperature.
Depending on the thermal output, OMV heaters employ up
to 4 concentric coils, containing up to 7 pipes in parallel
(see Figure 3); the extended convective section ensures
a higher exploiting of the hot gases, a gradual heat exchange rate
and reduced thermal stresses in the whole structure.
Figure 3.
OIL-MATIC OMV seamless spiral heating coils
Thanks to our innovative design, the OMV range also ensures :
Longer fluid life cycle
High safety margin during operation with thermal fluid temperature close to the maximum recommended bulk temperature.
Reduced carbon coating and carbon sooty formation at the film layer.
Uniform thermal fluid circulation velocity in each coil.
An innovative and reliable design of tube suspension ensures a free thermal expansion.
Thanks to the correct combination between wide surfaces (radiant and convective) and different fluid speed and flows,
OMV ensures lower heat flow if compared with other design, with evident benefits in terms of lower tube wall and fluid
film temperatures.
Multi Coil Design Properties

OMV heater employs several coils pipe seamless type, having a reduced section in order to ensure higher fluid velocity and,
consequently, a reduced Delta T between mass and wall fluid temperature.
Thanks to the particular restricted section of the coil the fluid in OMV heater circulates in turbulent flow and the fluid speed
at any point is in a status of continuous undergoing changes both in magnitude and direction; this implies a more balanced
heat flow and increased heat transfer properties.
Moderate Delta Temperature between bulk and film

In our OMV the fluid flow is in turbulent condition, which is enough to ensure flat temperature profile and a reduced difference between film and bulk temperature along the entire circuit.
Figure 4 Right side

partially turbulent condition
The fluid film, in this thermal flow condition, has a temperature of
3035C higher than the bulk one and this situation leads to a fast flow
degradation.
Although only a part of the whole fluid volume is present in the film layer,
if the fluid temperature exceeds the max. recommended value (as very
often happens in the inner coil, called the radiant section), the whole
volume of fluid is quickly involved in a larger degradation rate.
The rate of degradation generally doubles with an increase of temperature of 10C.
The film temperature is not the only one to be controlled in this process,
also the bulk temperature must be under control.
A cracking event occurs in a coil heater when the fluid velocity (and consequently the turbulence) decreases and the thermal fluid remains in
prolonged contact with the heated surfaces. Even though the bulk temperature may not change so evidently the film temperature can rise very
quickly leading to cracking.
Figure 4 Left side
turbulent condition
This is the best operating condition peculiar of our OMV Coil Heater Design, characterized by a reduced difference of temperature between the
film and the bulk.
Design of Heaters
The fundamental principles.
Figure 4
Heat exchange in the oil pipes depending on oil speed
In order to minimize the degradation rates when using mineral oils

above 600 F (316C), users should take extra care with a proper heater selection in terms of combustion chamber dimension choice.
A larger volume combustion chamber allows more space around the
burner, which minimizes the radiant energy reaching the

coil surface. The same thing could be said regarding the
space between the coils.
The radiant section is the area of the tubing that actually faces the flame; depending on geometry and design,
up to 70% of the total heat is transferred in the radiant
section.
The resulting localized heat flow can be three times the
average in the entire heater, with film temperatures exceeding the average fluid temperature by 150 F (83C)
or even more. In some heaters, the maximum recommended film temperature of a fluid can be exceeded
even if the average temperature is largely within limits.
OIL-MATIC employs a new coil design, which, if combined
with the fluids turbulent flow, guarantees excellent heat
transfer conditions and the best fluid temperature profile, as per recommendation of all the fluid suppliers.
The fluids high turbulence and velocity rates in the radiant section prevent the formation of fluid stagnation areas that might lead to boiling and hot spot phenomena
and, consequently, rapid fluid degradation.
Figure 5
Thermal fluid velocity in a OIL-MATIC heater
2. TECHNICAL HIGHLIGHTS
Moreover higher flow velocity in the coils enables to
control the fluid itself with simpler control devices,
which are not recommended on heaters with lower
flow circulation speed, for the same thermal degradation prevention reasons.
Reduced Fluid Degradation Rate
The reduced fluid degradation rate is achieved
thanks to the homogeneous heat flow. On the contrary, single or dual coil heater design (or fluid flow
connected in parallel arrangements) are characterised by a wide unbalanced condition between
the inner and outer coil where the difference in
temperature both film and bulk can be over 35C
from the set point with a consequent reduced safety
margin.
In OMV Heaters circulates only thermal fluids in
liquid phase
This condition allows a balanced heat transfer rate
between the sections in order to ensure:
High fluid velocity in radiation section.
Figure 6
Reduced fluid degradation rate.
Degradation rate vs Operating temperature
Maximum exploiting of the flue gases and high
heat transfer rate also in the convection section.
Gradual fluid temperature increases in radiation section and in countercurrent to the gases in order to avoid any thermal
shock.
Figure 7
Thermal oil heater series OIL-MATIC, type OMV, horizontal version
3. COMPETITIVE ADVANTAGES
Two versions: vertical and horizontal.
Wide choice of sizes. Our wide range

allows our customers to define the proper
capacity in accordance to their usage
needs.
Maximum efficiency and high reliability,

with air preheater OMV can reach thermal
efficiency up to 92%
Multi coil design.

Lower thermal stresses of the pressure
vessel and higher prevention against fluid
overheating.
Easy maintenance.
The upper cover facilitates inspection and
cleaning of the combustion chamber and
the internal parts of the steam generator.
Easy-to-use and reliable automatic

combustion regulation.
Two-stages version: the regulation of
air/fuel ratio is progressive and realized
through on/off valves fitted on the fuel
feeding lines; modulating version: realized
through an electronic control system
acting on the burner output by means of a
modulating air/fuel servomotor.
Figure 8
Thermal Fluid Heater OIL-MATIC OMV, with
operators control panel
Compact design and high performance

Thanks to its concentric multi-coil
construction, OIL-MATIC has a large
heating surface, nonetheless the compact
design of the heater guarantees a better
heat exchange.
Figure 9
Thermal Fluid Heater OIL-MATIC OMV coils
4. TECHNICAL CHARACTERISTICS AND OVERALL DIMENSIONS: OIL-MATIC OMV

Table 1. Technical characteristics of thermal oil heater series OIL-MATIC type OMV. Characteristics of this table are generalized to the entire
range of models OIL-MATIC. Additional data and deviations from standard are available on request.
THERMAL FLUID HEATER SERIES OIL-MATIC, TYPE OMV MODELS
OMV OMV OMV OMV OMV OMV OMV OMV
Unit
200
300
400
600
800 1000 1250 1500
Thermal capacity
OMV
2000
OMV
2500
OMV
3000
OMV
4000
OMV
5000
Mcal/h
200
300
400
600
800
1000
1250
1500
2000
2500
3000
4000
5000
5,8
MW
0,2
0,3
0,5
0,7
0,9
1,2
1,5
1,7
2,3
2,9
3,5
4,7
Efficiency at 100 % of the load*
87
87
87
87
88
88
88
88
88
88
88
88
88
87,5
87,5
87,5
87,5
88,5
88,5
88,5
88,5
88,5
88,5
88,5
88,5
88,5
Max. thermal fluid temperature
350
350
350
350
350
350
350
350
350
350
350
350
350
Pressure drop fluid side P
bar
1,0
1,0
0,6
1,3
1,1
1,4
0,7
1,1
0,8
1,5
1,5
2,0
2,0
Max T between outlet and inlet temp.
30
30
30
30
30
33
40
40
40
40
40
50
50
OVERALL DIMENSIONS AND CONNECTIONS

L
Lenght
mm
1250
1400
1620
1620
1880
1880
2020
2020
2120
2420
2470
2635
2800
Width
mm
1200
1300
1380
1380
1600
1600
1790
1790
1950
2140
2330
2665
3000
Height
mm
2050
2050
2450
2710
3350
3350
3420
3420
4000
4350
4600
5360
6120
N1
Thermal oil inlet flange
DN
50
65
80
80
100
100
125
125
125
150
150
150
200
N2
Thermal oil outlet flange
DN
50
65
80
80
100
100
125
125
125
150
150
150
200
N3
Thermal oil drain flange
DN
20
20
20
20
25
25
25
25
25
25
25
25
25
N4
Natural gas inlet
DN/PN
3/4"
1"
1"
1"1/2
1"1/2
2"
2"
2"
50/16
50/16
50/16
80/16
100/16
N6
Liquid fuel inlet
DN/PN
1/2
1/2
1/2
1/2
3/4
3/4
11/2
11/2
11/2
2 1/2
2 1/2
N5
Stack diameter
mm
164
220
314
314
400
400
400
400
400
470
470
535
600
Thermal oil volume in the boiler
75
96
165
165
418
418
670
670
1070
1083
1530
2250
2970
Boiler empty weight
1,1
1,4
1,6
1,7
2,7
2,7
3,3
3,3
4,4
5,7
7,2
10,6
14
TYPE OF BURNER (REGULATION STAGES)**

Heavy fuel oil burner
stages
1 stage
2 stages
2 stages or modulating
modulating
Natural gas fuel
stages
1 stage
2 stages
modulating
Diesel oil burner
stages
1 stage
2 stages
Min. gas pressure
50
50
50
50
100
100
100
100
100
150
150
300
300
Nat. gas (100% of the load)
mbar
Nm3/h
27,0
40,6
54,1
81,1
107,0
133,7
167,1
200,5
267,4
334,2
401,1
534,8
668,4
Nm3/h
20,2
30,3
40,3
60,5
79,8
99,7
124,6
149,6
199,4
249,3
299,1
398,8
498,5
Diesel oil (100% of the load)
l/h
22,5
33,8
45,1
67,6
89,1
111,4
139,3
167,1
222,8
278,5
334,2
445,6
557,0
l/h
16,8
25,2
33,6
50,4
66,5
83,1
103,9
124,6
166,2
207,7
249,3
332,3
415,4
Heavy fuel oil (100% of the load)
kg/h
23,7
35,5
47,4
71,1
93,7
117,2
146,4
175,7
234,3
292,9
351,5
468,6
585,8
kg/h
17,7
26,5
35,3
53,0
69,9
87,4
109,2
131,1
174,7
218,4
262,1
349,5
436,8
modulating
FUEL CONSUMPTION***
FUEL CALORIFIC POWER

Heavy fuel oil***
Natural gas
Diesel oil
kcal/kg
9700
kca l/Nm3
8500
kcal/kg
10200
INSTALLED TOTAL ELECTRIC POWER (400V 3Ph+N)

Heavy fuel oil
Nat. gas or diesel oil
KW
4,2
6,0
6,0
9,6
19,4
20,9
20,9
31,6
31,6
35,7
35,7
47,6
59,5
KW
0,4
0,5
0,7
1,5
1,5
2,2
4,6
4,6
10,2
15,3
15,3
20,4
25,5
THERMAL OIL CIRCULATION PUMP CHARACTERISTICS*****

Flow rate
m3/h
20
20
25
40
60
60
65
75
105
125
150
165
205
40
40
40
40
40
40
40
40
40
45
45
50
50
Installed total electric power
KW
5,5
5,5
5,5
7,5
11
11
11
15
15
22
22
22
30
Power consumption
KW
2,3
2,3
2,8
4,5
6,8
6,8
7,4
8,5
11,9
16,0
19,2
20,5
25,5
Pump head
10
Figure 10
OIL-MATIC OMV overall dimensions, vertical version
* Efficiency calculated at thermal oil temperature 250 C

** Indicated data of models burner regulation system are standard.
Modulating regulation system for other models on request
*** Fuel consumption calculated at thermal oil temperature 250 C
**** heavy fuel oil max viscosity considered is 7E at 50C, please ask for higher
viscosities.
***** Typical application thermal oil circulation pump data; Bono Energia technical office will propose the most suitable solution according to customers needs
and plants characteristics (lenght of the thermal circuit, oil pressure drop in the
system)
L
11
4. TECHNICAL CHARACTERISTICS AND OVERALL DIMENSIONS:

OIL-MATIC OMV HORIZONTAL VERSION
Table 2. Overall dimensions and connections of thermal oil heater series OIL-MATIC type OMV, HORIZONTAL VERSION. Characteristics are generalized to the
entire range of models OIL-MATIC. Additional data and deviations from standard are available on-demand.
THERMAL FLUID HEATER SERIES OIL-MATIC, TYPE OMV HORIZONTAL VERSION MODELS
OMV OMV OMV OMV OMV OMV OMV OMV OMV OMV
Unit
200
300
400
600
800 1000 1250 1500 2000 2500
Thermal capacity
OMV
3000
OMV
4000
OMV
5000
Mcal/h
200
300
400
600
800
1000
1250
1500
2000
2500
3000
4000
5000
MW
0,2
0,3
0,5
0,7
0,9
1,2
1,5
1,7
2,3
2,9
3,5
4,7
5,8
87
87
87
87
88
88
88
88
88
88
88
88
88
87,5
87,5
87,5
87,5
88,5
88,5
88,5
88,5
88,5
88,5
88,5
88,5
88,5
350
350
350
350
350
350
350
350
350
350
350
350
350
bar
1,0
1,0
0,6
1,3
1,1
1,4
0,7
1,1
0,8
1,5
1,5
2,0
2,0
30
30
30
30
30
33
40
40
40
40
40
50
50

L
Lenght
mm
2050
2050
2450
2710
3350
3350
3420
3420
4000
4350
4600
5360
6120
Width
mm
1450
1450
1740
1740
1900
1900
2150
2150
2350
2490
2750
2875
3000
Height
mm
1390
1390
1390
1390
1680
1680
1810
1810
1960
2330
2380
2590
2800
N1
DN
50
65
80
80
100
100
125
125
125
150
150
150
200
N2
DN
50
65
80
80
100
100
125
125
125
150
150
150
200
N3
DN
20
20
20
20
25
25
25
25
25
25
25
25
25
N4
Natural gas inlet
DN/PN
3/4"
1"
1"
1"1/2
1"1/2
2"
2"
2"
50/16
50/16
50/16
80/16
100/16
N6
Liquid fuel inlet
DN/PN
1/2
1/2
1/2
1/2
3/4
3/4
11/2
11/2
11/2
2 1/2
2 1/2
N5
Stack diameter
mm
164
220
314
314
400
400
400
400
400
470
470
535
600
75
96
165
165
418
418
670
670
1070
1083
1530
2250
2970
Boiler empty weight
1,2
1,5
1,7
1,8
2,8
2,8
3,4
3,4
4,5
5,8
7,3
10,7
14
stages
1 stage
2 stages
modulating
Natural gas fuel
stages
1 stage
2 stages
modulating
Diesel oil burner
stages
1 stage
2 stages
TYPE OF BURNER (REGULATION STAGES)**
modulating
FUEL CONSUMPTION***
Min. gas pressure
mbar
50
50
50
50
100
100
100
100
100
150
150
300
300
Nm3/h
Nm3/h
27,0
40,6
54,1
81,1
107,0
133,7
167,1
200,5
267,4
334,2
401,1
534,8
668,4
20,2
30,3
40,3
60,5
79,8
99,7
124,6
149,6
199,4
249,3
299,1
398,8
498,5
l/h
22,5
33,8
45,1
67,6
89,1
111,4
139,3
167,1
222,8
278,5
334,2
445,6
557,0
l/h
16,8
25,2
33,6
50,4
66,5
83,1
103,9
124,6
166,2
207,7
249,3
332,3
415,4
kg/h
23,7
35,5
47,4
71,1
93,7
117,2
146,4
175,7
234,3
292,9
351,5
468,6
585,8
kg/h
17,7
26,5
35,3
53,0
69,9
87,4
109,2
131,1
174,7
218,4
262,1
349,5
436,8


Heavy fuel oil***
Natural gas
Diesel oil
kcal/kg
kca
9700
l
Nm3
8500
kcal/kg
10200

Heavy fuel oil
KW
4,2
6,0
6,0
9,6
19,4
20,9
20,9
31,6
31,6
35,7
35,7
47,6
59,5
KW
0,4
0,5
0,7
1,5
1,5
2,2
4,6
4,6
10,2
15,3
15,3
20,4
25,5
THERMAL OIL CIRCULATION PUMP CHARACTERISTICS*****

m3/h
20
20
25
40
60
60
65
75
105
125
150
165
205
40
40
40
40
40
40
40
40
40
45
45
50
50
KW
5,5
5,5
5,5
7,5
11
11
11
15
15
22
22
22
30
12consumption
Power
KW
2,3
2,3
2,8
4,5
6,8
6,8
7,4
8,5
11,9
16,0
19,2
20,5
25,5
Flow rate
Pump head
Figure 11
OIL-MATIC OMV overall dimensions, horizontal version.

** Indicated data of models burner regulation system are standard.
Modulating regulation system for other models on request
*** Fuel consumption calculated at thermal oil temperature 250 C
**** heavy fuel oil max viscosity considered is 7E at 50C, please ask
for higher viscosities.
***** Typical application thermal oil circulation pump data; Bono Energia technical office will propose the most suitable solution according
to customers needs and plants characteristics (lenght of the thermal
circuit, oil pressure drop in the system)
W
13
4. TECHNICAL CHARACTERISTICS AND OVERALL DIMENSIONS:

OIL-MATIC OMV PA
Table 3. Technical characteristics of thermal oil heater series OIL-MATIC type OMV PA. OMV PA version is available only from model OMV 800. Characteristics
of this table are generalized to the entire range of models OIL-MATIC with air preheater. Additional data and deviations from standard are available on-demand.
THERMAL FLUID HEATER SERIES OIL-MATIC, TYPE OMV PA MODELS

Unit
OMV PA
800
OMV PA
1000
Mcal/h
800
1000
1250
1500
2000
2500
3000
4000
5000
MW
0,9
1,2
1,5
1,7
2,3
2,9
3,5
4,7
5,8
Thermal capacity
OMV PA OMV PA OMV PA OMV PA OMV PA OMV PA OMV PA

1250
1500
2000
2500
3000
4000
5000
92
92
92
92
92
92
92
92
92
92,5
92,5
92,5
92,5
92,5
92,5
92,5
92,5
92,5
350
350
350
350
350
350
350
350
350
bar
1,1
1,4
0,7
1,1
0,8
1,5
1,5
2,0
2,0
30
33
40
40
40
40
40
50
50

L
Lenght
mm
3250
3250
3600
3600
3800
4500
4600
5400
5400
Width
mm
1600
1600
1750
1750
1950
2150
2550
2950
2950
Height
mm
3250
3450
3500
3500
3600
4000
4200
5300
6100
N1
DN
100
100
125
125
125
150
150
150
200
N2
DN
100
100
125
125
125
150
150
150
200
N3
DN
25
25
25
25
25
25
25
25
25
N4
Natural gas inlet
DN/PN
1"1/2
2"
2"
2"
50/16
50/16
50/16
80/16
100/16
N6
Liquid fuel inlet
DN/PN
3/4
3/4
11/2
11/2
11/2
2 1/2
2 1/2
N5
Stack diameter
mm
400
400
400
400
400
470
470
535
600
418
418
670
670
1070
1083
1530
2250
2970
Boiler empty weight
3,7
3,7
4,8
4,8
5,9
7,8
9,4
15
20
stages
Natural gas fuel
stages
Diesel oil burner
stages
TYPE OF BURNER (REGULATION STAGES)***

***
modulating
***
FUEL CONSUMPTION****
Min. gas pressure
mbar
100
100
100
100
100
150
150
300
300
Nm3/h
Nm3/h
102,3
127,9
159,8
191,8
255,8
319,7
383,6
511,5
639,4
76,3
95,4
119,2
143,1
190,8
238,5
286,2
381,6
476,9
l/h
85,3
106,6
133,2
159,8
213,1
266,4
319,7
426,3
532,8
l/h
63,6
79,5
99,4
119,2
159,0
198,7
238,5
318,0
397,5
kg/h
89,6
112,1
140,1
168,1
224,1
280,1
336,2
448,2
560,3
kg/h
66,9
83,6
104,5
125,4
167,2
209,0
250,8
334,4
417,9


Heavy fuel oil*****
Natural gas
Diesel oil
kcal/kg
9700
kca l/Nm3
8500
kcal/kg
10200

Heavy fuel oil
KW
19,4
20,9
20,9
31,6
31,6
35,7
35,7
47,6
59,5
KW
1,5
2,2
4,6
4,6
10,2
15,3
15,3
20,4
25,5
THERMAL OIL CIRCULATION PUMP CHARACTERISTICS******

m3/h
60
60
65
75
105
125
150
165
205
40
40
40
40
40
45
45
50
50
KW
11
11
11
15
15
22
22
22
30
Power consumption
KW
6,8
6,8
7,4
8,5
11,9
16,0
19,2
20,5
25,5
Flow rate
Pump head
14
Figure 12
OIL-MATIC OMV PA with air preheater overall dimensions.
L
*** For technical reason we recommend natural gas burner. For other fuel please refer to technical office.
**** Fuel consumption calculated at thermal oil temperature 250 C
***** heavy fuel oil max viscosity considered is 7E at 50C, please ask for higher viscosities.
****** Typical application thermal oil circulation pump data; Bono Energia technical office will propose the
most suitable solution according to customers needs and plants characteristics (lenght of the thermal
circuit, oil pressure drop in the system)
15
4. TECHNICAL CHARACTERISTICS: THERMAL EFFICIENCY
91
90
Efficiency %
89
88
87
86
85
84
Figure 13 The coefficient of performance (COP) of the thermal fluid heater OIL-MATIC (from model OMV 800), crossed with
the load. The maximum efficiency with the three reference temperatures is reached at 75% of the load.
95
94
Efficiency %
93
92
91
90
89
88
Figure 14 The coefficient of performance (COP) of the thermal fluid heater OIL-MATIC (from model OMV 800)equipped with
an air preheater (PA), crossed with the load. The maximum efficiency with the three reference temperatures is reached at
75% of the load.
16
Figure 15
Thermal oil heater

OIL-MATIC type OMV,
with operators panel
Figure 16
Thermal oil heaters OIL-MATIC

type OMV PA with air preheater
installed, to achieve high
efficiency
17
5. P&ID - BOILER ROOM (WITH ATMOSPHERIC EXPANSION TANK)
18
OMV P&ID Elements Description

OMV
Thermal Oil Heater OMV
P1
Loading Pump
P2
Oil Circulation Pump
P3
Oil Circulation Pump (spare)
T1
Oil Storage Tank
U1
Utilities
V1
Atomspheric Expansion Tank
Figure 17
A P&ID sample for an oil circuit containing an
OIL-MATIC heater, a single wall oil storage tank,
an atmospheric expansion tank, a circuit loading
pump and two oil circulation pumps.
Modifications or other deviations from standard
are available upon demand.
SUPPLY LIMIT
CANNON BONO
CUSTOMER
OMV P&ID Symbols Meaning

LI
Level Indicator
LSLL
Level Switch Belove Low
INSTRUMENTATION SYMBOLS
Motor
AND IDENTIFICATION ISA S-5.1
PDSL
Pressure Differential Switch Low
PDAL
Pressure Differential Alarm Low
PI
Pressure Indicator
QE
Electrical Panel
TAH
Temperature Alarm High
TAHH
Temperature Alarm High Above TAH
TE
Temperature Element
TI
Temperature Indicator
TIC
Temperature Indicator Controller
TISL
Temperature Indicator Switch Low
TLH
Temperature Level High
TSH
Temperature Switch High
TSHH
Temperature Switch High Above TSH
TV
Temperature Valve
19
5. P&ID - BOILER ROOM (WITH PRESSURIZED EXPANSION TANK)
20

B1
P1
Loading Pump
P2
P3
Oil Circulation Pump (spare)
T1
Oil Storage Tank
U1
Utilities
V1
Pressurized Expansion Tank

Figure 18
A P&ID sample for an oil circuit containing
an OIL-MATIC heater, a double wall oil
storage tank, a pressurized expansion
tank, a circuit loading pump and an oil
circulation pump.
Modifications or other deviations from
standard are available upon demand.
SUPPLY LIMIT
LAL
Level Alarm Low
LI
Level Indicator
LSLL
Level Switch Below Low
Motor
PAL
Pressure Alarm Low
PDSL
PDAL
PI
Pressure Indicator
PSHH
Pressure Switch Above High
PSL
Pressure Switch Low
PSV
Pressure Safety Valve
QE
Electrical Panel
TAH
TAHH
TE
Temperature Element
TI
Temperature Indicator
TIC
TISL
TLH
TSH
TSHH
TV
Temperature Valve
CANNON BONO
CUSTOMER
21
5. P&ID - MODULATING BURNING SYSTEM (NATURAL GAS)

U10
Combustion air fan
U11
Strainer
Figure 19
Natural gas combustion modulating system P&ID.
The data processing schemes are standardized to the
entire OIL-MATIC OMV range; further measurements
and modifications are available on-demand.
OMV P&ID Ancillaries Symbols Meaning

BAL
Flame alarm low level
BE
Flame scanner
BSL
Flame switch low level
BV
On/off actuated valve
BZ
Electrical igniter
FV
Flow valve
Motor
PAL/H Pressure alarm high

PCV
Pressure control valve
PDSL
Pressure differential switch low
PDAL
Pressure differential alarm low
PI
Pressure indicator
PSH
Pressure switch high
PSL
Pressure switch low
VSP
Gas leakage test (from OMV 800)
VSPAL Gas leakage test alarm high (from OMV 800)
Burner management system
Interlock - burner shutdown
SUPPLY LIMIT
Burner
CANNON BONO
Flexible Joint
Autocleaner Strainer
22
CUSTOMER
*$6/($.$*(
7(67
23
5. P&ID - MODULATING BURNING SYSTEM,

LIQUID FUEL (HEAVY FUEL OIL OR DIESEL OIL)

E10
Fuel oil preheater
P10
Fuel oil feed pump*
U10
Combustion air fan
Figure 20
Fuel oil combustion modulating system P&ID
(may be heavy fuel oil or diesel oil).
The data processing schemes are standardized
to the entire OIL-MATIC OMV range; further
measurements and modifications are available
on-demand.

BAL
Flame alarm low level
BE
Flame scanner
BSL
BV
BZ
Electrical igniter
FC
Frequency controller
FV
Flow valve
Motor
PI
Pressure indicator
TAL
Temperature alarm low
TSL
Temperature switch low
TIC
Temperature indicator controller
TE
Thermoelement
Burner
Autocleaner strainer
* Spare fuel oil feed pump on request
24
SUPPLY LIMIT
CANNON BONO
CUSTOMER
25
5. P&ID - MODULATING BURNING SYSTEM, DUAL FUEL (NATURAL GAS + LIQUID FUEL)

E10
Fuel oil preheater
P10
Fuel oil feed pump*
U10
Combustion air fan
U11
Strainer
Figure 21
Natural gas + liquid fuel oil dual fuel modulating
combustion system P&ID.
The data processing schemes are standardized
to the entire OIL-MATIC OMV range; further
measurements and modifications are available
on-demand.

BAL
Flame alarm low levef
BE
Flame scanner
BSL
BV
BZ
Electrical igniter
FC
Frequency controller
FV
Flow valve
Motor
PAL/H Pressure alarm high

PCV

Burner
Autocleaner strainer
Flexible Joint
Pressure control valve
PDSL
Pressure differential switch low
PDAL
Pressure differential alarm low
PI
Pressure indicator
PSH
Pressure switch high
PSL
Pressure switch low
TAL
Temperature alarm low
TSL
Temperature switch low
TIC
Temperature indicator controller
TE
Thermoelement
VSP
Gas leakage test (from OMV 800)
VSPAL Gas leakage test alarm high (from OMV 800)
* Spare fuel oil feed pumpon request
26
SUPPLY LIMIT
CANNON BONO
CUSTOMER
27
6. THERMAL OIL CIRCUIT LAYOUT

Figure 22
Typical thermal oil circuit layout, with thermal
oil heater OMV, skid with two pumps, thermal oil
expansion tank and thermal oil storage tank
5
2
4
1
28
7
5
Chimney
Reserve Oil Circulation Pump
Thermal Oil Expansion Tank
Thermal Oil Storage Tank
Gear Pump
29
7. THERMAL OIL SYSTEM ELEMENTS
This section is dedicated to the equipment that is part of the thermal oil circuit. Having a high-profile knowhow in the technology of the thermal fluid heaters, Bono Energia technical office can easily recommend
and offer the best solution according to the customers needs.
A thermal oil system, besides one or more thermal oil heater, usually comprise:
A thermal oil storage tank; it can be installed above ground with a storage basin or underground (a
double-wall construction is required with the second option). The design volume is usually 1.5 times
the total volume of oil in the plant. The tank must be assembled as required by the applicable standards, being especially careful to prevent fire outbreaks. If possible, it is preferable that the point of
installation be below the minimum level of the plant, so that the thermal oil is drained spontaneously.
Its possible to drain the thermal oil when its temperature is lower than the one projected for the tank
(usually room temperature);
An expansion vessel to absorb fluid dilation: its capacity is usually about 1/3 of the total fluid contained
in the plant. The expansion vessel can be either atmospheric or pressurized. The expansion vessel
must be positioned so that the minimum pressure required by the suction pump inlet is guaranteed
(NPSHr). The connecting line between the expansion vessel and the oil circuit must not be stoppable.
The expansion vessel (and the connecting line) usually do not need to be insulated, because the temperature of the oil must be contained as much as possible in order to prevent oxidization of the thermal
fluid when it comes into contact with the air. The atmosphere in contact with the oil can for this purpose be made inert with nitrogen, for this reason the vessel should be located in a safe area;
A thermal fluid transfer pump (reversible) that can load and unload the plant;
One or more user machines equipped with their own regulator and valve to adjust user heat capacity,
to ensure oil circulation within the heater even if a heat request is missing; user heat capacity should
be regulated in order to have the same thermal oil flow rate through the heater. A three-way valve can
be used for this purpose. The valve can be a diverter or mixer-diverter valve.
One or more circulation pumps which must be sized so as to ensure the flow of thermal oil required by
the heater. The prevalence must overcome all frictions of the heater, valves, line, and connected utilities. Oil flow rate to the heater must in all operating conditions not be less than the one decided in the
order, so as to ensure the oil lasts and that the heater is preserved intact and cracking is prevented.
The electric circuit of the circulation pump is usually connected to the burners circuit so that if the
motor trips, the burner is automatically disabled. Heaters control panel is capable of managing the
motor trip signal, even if circulation pumps are not supplied by Bono Energia.
30
7. THERMAL OIL SYSTEM ELEMENTS: GEAR PUMP OVERALL DIMENSIONS

Figure 23
OIL-MATIC OMV thermal oil gear pump overall dimensions and connections. Thermal oil gear pump selection depends
on the total amount of oil in the circuit; Bono Energia technical office will propose the most suitable solution according to
customers needs and plants characteristics (lenght of the thermal circuit, oil pressure drop in the system)
THERMAL OIL CIRCULATION GEAR PUMP

Unit
PO 60
PO 100
PO 150
PO 250
PO 300
Lenght
mm
324
334
369
385
426
Width
mm
136
136
153
153
171
Height
mm
177
177
195
195
216
Thermal oil inlet
DN/PN
3/4
3/4
3/4
Thermal oil outlet
DN/PN
3/4
3/4
3/4
Capacity
l/h
600
1000
1500
2000
3000
Pump thrust
Motor power
kW
1,1
1,5
25
0,37
0,55
0,75
31
7. THERMAL OIL SYSTEM ELEMENTS:

CIRCULATION PUMP SKID OVERALL DIMENSIONS - SINGLE PUMP
Typical application thermal oil circulation skid overall dimensions and connections; Bono Energia technical office will propose the most suitable solution according to customers needs and plants characteristics (lenght of the thermal circuit, oil pressure drop in the system)
Figure 24
OIL-MATIC OMV thermal oil circulation pump
skid overall dimensions and connections.
THERMAL OIL CIRCULATION PUMP SKID DIMENSIONS AND CONNECTIONS (ONE PUMP SKID)
Unit
OMV 200OMV 300OMV 400OMV 600
OMV
2000
OMV
2500
OMV
3000
OMV
4000
OMV
5000
2000
2000
2450
2450
2550
2700
2700
3100
3100
Width
mm
400
400
400
500
500
500
600
600
600
600
600
600
600
Height
mm
1400
1400
1600
1600
1800
1800
1900
1900
2200
2550
2550
3000
3000
Base
Thermal oil circulation pumps
Thermal oil inlet connections
200
Thermal oil drain connection
Antivibration Joints
Strainers
32
1500
OMV
1500
mm
1500
OMV
1250
Lenght
Thermal oil outlet connection
1400
OMV
1000
1400
OMV
800
DN
65
65
80
80
100
100
125
125
125
150
150
200
PN
16
16
16
16
16
16
16
16
16
16
16
16
16
DN
65
65
80
80
100
100
125
125
125
150
150
200
200
16
PN
16
16
16
16
16
16
16
16
16
16
16
16
DN
20
20
20
20
25
25
25
25
25
25
25
25
25
PN
16
16
16
16
16
16
16
16
16
16
16
16
16

CIRCULATION PUMP SKID OVERALL DIMENSIONS - TWO PUMPS
Figure 25
OIL-MATIC OMV thermal oil circulation pump
skid overall dimensions and connections.
THERMAL OIL CIRCULATION PUMP SKID DIMENSIONS AND CONNECTIONS (TWO PUMPS)
Unit
OMV 200OMV 300OMV 400OMV 600
OMV
800
OMV
1000
OMV
1250
OMV
1500
OMV
2000
OMV
2500
OMV
3000
OMV
4000
OMV
5000
Lenght
mm
1400
1400
1500
1500
2000
2000
2450
2450
2550
2700
2700
3100
3100
Width
mm
1050
1050
1050
1300
1300
1300
1600
1600
1600
1600
1600
1600
1600
Height
mm
1650
1650
1850
1900
2100
2100
2300
2300
2600
2950
2950
3400
3400
Base
Thermal oil circulation pumps
Thermal oil inlet connections
200
Thermal oil outlet connection
Expansion line connection
Vent connection
Thermal oil drain connection
Antivibration Joints
Strainers
DN
65
65
80
80
100
100
125
125
125
150
150
200
PN
16
16
16
16
16
16
16
16
16
16
16
16
16
DN
65
65
80
80
100
100
125
125
125
150
150
200
200
16
PN
16
16
16
16
16
16
16
16
16
16
16
16
DN
65
65
65
65
65
65
65
65
65
65
65
65
65
PN
16
16
16
16
16
16
16
16
16
16
16
16
16
DN
15
15
15
15
15
15
15
15
15
15
15
15
15
PN
16
16
16
16
16
16
16
16
16
16
16
16
16
DN
20
20
20
20
25
25
25
25
25
25
25
25
25
PN
16
16
16
16
16
16
16
16
16
16
16
16
16
33

ATMOSPHERIC EXPANSION TANKS
Table 4
Atmospheric expansion tank dimensions, vertical version*. Usually the volume of the expansion tank should be approximately 35% of the total amout of thermal oil in the circuit.
Oil Expansion Tank Atmospheric Type - ATM (Vertical version*)
Model
VEO
ATM 300
VEO
ATM 600
VEO
ATM 1000
VEO
ATM 1500
VEO
ATM 2000
VEO
ATM 3000
VEO
ATM 4000
VEO
ATM 5000
VEO
ATM 6000
Nominal capacity
liters
300
600
1000
1500
2000
3000
4000
5000
6000
Diameter
mm
600
800
900
1100
1270
1500
1500
1600
1800
Shell height
mm
1000
1050
1500
1500
1500
1500
2000
2260
3020
Total height
mm
1660
1800
2200
2200
2200
2310
2810
3030
3800
A) Inspection hole diameter
mm
400
400
400
400
400
400
400
450
450
B) Overflow
DN
32
50
50
50
50
50
65
65
65
F) Tank vent
DN
15
25
25
25
25
25
25
25
25
G) Expansion
DN
32
50
50
50
50
50
65
65
65
H) Total drain connection
DN
25
40
40
40
40
40
40
40
40
I) Local Drain
DN
15
15
15
15
15
15
15
15
15
L) Connection to vent header
DN
25
25
25
25
25
25
25
25
25
Figure 26
Atmospheric expansion
tank, vertical version
* horizontal version is also available on request
34

PRESSURIZED EXPANSION TANKS
Table 5. Pressurized expansion tanks dimensions - Vertical version*. Usually the volume of the expansion tank should be
approximately 30% of the total amout of thermal oil in the circuit.
Oil Expansion Tank Pressurized Type - (Vertical version*)
Model
VEO
P 300
VEO
P 600
VEO
P 1000
VEO
P 1500
VEO
P 2000
VEO
P 3000
VEO
P 4000
VEO
P 5000
VEO
P 6000
Nominal capacity
liters
300
600
1000
1500
2000
3000
4000
5000
6000
Diameter
mm
550
800
800
950
1100
1250
1400
1600
1700
Shell height
mm
1050
1050
1500
1700
1700
2000
2000
2000
2500
Total height
mm
1600
1900
2100
2700
2700
3200
3700
4200
4700
A) Inspection hole diameter
mm
400
400
400
400
400
400
400
400
400
F) Tank vent
DN
15
25
25
25
25
25
25
25
25
G) Expansion
DN
32
50
50
50
50
50
65
65
65
H) Total Drain
DN
25
40
40
40
40
40
40
40
40
I) Local Drain
DN
15
15
15
15
15
15
15
15
15
L) Connection to vent header
DN
25
25
25
25
25
25
25
25
25
P1) Nitrogen pressurization
DN
15
15
15
15
15
15
15
15
15
inches
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
PSV) Safety valve
Figure 27
Pressurized expansion
tank, vertical version
* horizontal version is also available on request
35

THERMAL FLUID DUAL WALL STORAGE TANKS
Table 6
Dual wall storage tank dimensions
Thermal Fluid Storage Tank dual wall - VEO
Model
VEO
VEO
VEO
VEO
VEO
VEO
VEO
VEO
VEO
VEO
1000
2000
4000
5000
6000
8000
10000
12000
15000
20000
liters
1000
2000
4000
5000
6000
8000
10000
12000
15000
20000
L) Length
mm
1500
1800
2050
2500
3500
4050
4000
4200
5000
5000
Tank diameter ()
mm
1100
1300
1600
1600
1600
1600
1900
1900
2200
2350
A) Overflow
DN
32
40
40
50
50
50
50
65
65
65
B) Vent ()
inch
C) Inlet ()
inch
D) Pump suction ()
inch
F) Drain ()
inch
Wall thickness
mm
Empty weight
Kg
450
770
960
1090
1230
1640
2290
2430
3390
3850
DIAMETER
Dual wall storage tank capacity
Figure 28
Dual wall storage tank
36

THERMAL FLUID STORAGE TANKS
Table 7
Single wall storage tank dimensions
Thermal Fluid Storage Tank single wall
Model
VEO
VEO
VEO
VEO
VEO
VEO
VEO
VEO
VEO
VEO
1000
2000
4000
5000
6000
8000
10000
12000
15000
20000
Single wall storage tank capacity
liters
1000
2000
4000
5000
6000
8000
10000
12000
15000
20000
L) Length
mm
1500
1800
2050
2500
3500
4050
4000
4200
5000
5000
Tank diameter ()
mm
1100
1500
1600
1600
1600
1600
1900
1900
2200
2350
A) Overflow
DN
32
40
40
40
50
50
50
65
65
65
B) Vent ()
inch
C) Inlet ()
inch
D) Pump suction
DN
25
32
32
32
40
40
40
50
50
50
F) Drain
DN
15
15
15
15
20
20
20
20
20
20
Wall thickness
mm
Empty weight
Kg
220
410
550
580
650
810
1250
1350
1630
1790
SL) Saddle length
mm
650
900
1100
1100
1100
1100
1300
1300
1400
1500
SD) Saddle distance
mm
800
950
1100
1300
1800
2100
2100
2150
2600
2600
SW) Saddle width
mm
100
160
160
200
200
200
200
200
200
200
DIAMETER
Saddle dimensions
Figure 29
Single wall storage tank
37
8. INSTALLATION
GENERAL COMMENTS
To operate at its best, the Generator must be installed correctly and must be operated and checked in accordance with the instructions provided in the manual
The Generator is supplied as a completely operational monoblock unit.
The Generator must be installed upon a rigid level base, preferably on a concrete slab, in a place that gives
personnel adequate access to the equipment.
Good ventilation is essential to supply a quantity of air sufficient for combustion and a suitable temperature
for the normal functioning of the electrical devices (the temperature must not exceed 35-40C).
The premises housing the boiler must have at least two entrances for air that are always open. One entrance
must be as close as possible to the fan.
The height of the boiler room must be sufficient to allow personnel to gain access to the burner.
THE GENERATOR MUST NOT BE INSTALLED IN THE OPEN UNDER A ROOF

UNLESS IT HAS BEEN CONSTRUCTED FOR THIS PURPOSE.
CONNECTIONS TO BE CARRIED OUT
Chimney pipe for smoke

Oil pipes
Pipes to discharge oil from the generator
Connection pipes to the expansion chamber
Feeding pipes for combustible material
Electric power to the board
DURING INSTALLATION FIRST MAKE THE HYDRAULIC CONNECTIONS AND

THEN THE ELECTRIC CONNECTIONS
CHIMNEY
The chimney pipe must not have a diameter that is smaller than that of the boiler exit connection and its height
must conform to the provisions in force.
In every case throttling or localized flow resistance must be avoided as this may inhibit the proper functioning
of the Generator.
OIL PIPING
Make the connections between the generator outlet, the installation delivery and the return pipes to the intake
connection of the circulation pump. Install a filter in front of the circulation pump to hold back any impurities.
The diameter of the pipes must not be less than that of the boiler connection; to limit flow resistance there
must not be any narrowing of the pipes nor must there be any corners.
In order to limit heat loss along the pipes we recommend covering them with an insulating material.
The oil pipe connection is supplied with a flange. In the designing stage the manufacturer did not
provide for any load on these connections.
Accordingly, any type of mechanical strain due to the weight of the pipes or expansion stress must
be avoided. If this is not possible an expansion joint and/or suitably sized supports must be provided.
PIPING AND CONNECTIONS TO THE EXPANSION CHAMBER

Run a pipe from the pump intake pipes (return from the installation) and connect it to the expansion chamber. This
pipe must be as straight as possible and counter-slopes and traps must be avoided.
Moreover, all the breather pipes of the installations must be channelled into the expansion chamber.
38
ELECTRICAL CONNECTIONS
Always refer to the enclosed wiring diagram.
Check that the tension and the frequency correspond to that indicated in the enclosed wiring diagram.
The customer is responsible for the connection and installation of the power cable. The electrical installation must be carried out in a workmanlike manner in accordance with EN 60204.
Always install a differential magnetothermic switch of adequate amperage upstream of the power line.
OPERATIONS TO FILL AND EMPTY THE INSTALLATION

Fill the generator and the installation as follows:
Ensure that all the following valves are open:
Service on-off valves
Oil circulation pump on-off valves (if a reserve circulation pump is installed the on-off valves of this pump
must also be open)
Boiler and installation relief valves and the expansion chamber atmospheric relief valves (VEO).
Storage tank relief valve
Check that the expansion chamber draining valves are closed.
At this point, check that the direction of rotation of the transfer pump is that for intake and not vice-versa.
Start the transfer pump and commence filling the plant, from the bottom to the top to facilitate the expulsion of air.
As soon as the level of oil in the expansion chamber has reached the minimum level on the visual indicator,
stop the pump and close the following valves:
Generator exhaust valves
Service outlet valves
Expansion chamber exhaust valves
Oil transfer and reserve circulation pump on-off valves
The air valves must remain open

Proceed to bleed the oil circulation pump using the plug located on the shaft support.
If required, grease the bearings of the pump and the motor and check the alignment of the connection joint by
turning the pump by hand.
Start the pump and check the direction of rotation. Check the absorption of the motor. The oil pump must be
made to operate for a certain amount of time before lighting the burner - in any event until no further variations in pressure are noted on the oil inlet and outlet gauges of the generator.
After the burner has been lit at the minimum setting, maintain an oil temperature gradient that does not exceed 60-70C for each hour of operation.
When a temperature of 120-130C has been reached carry out the following operations:
Stop the oil circulation pump and close all the breathers of the generator (the breathers of the expansion
chamber and the storage tank must always remain open).
Drain any condensate in the expansion chamber
Re-start the pump and the burner at the minimum setting and thereafter bring the oil temperature to the
maximum working value.
If drops in pressure due to cavitations of the pump occur, it is necessary to stop the burner and to bleed the
installation by opening the vent located at the highest point of the installation, whilst the pump is operating, until the inlet and outlet pressure from the generator stabilizes.
N.B. To restore the oil level in the expansion chamber it is necessary to:
open the transfer pump isolating valve
open the expansion chamber exhaust valve
start the oil transfer pump and load the chamber to the cold working level
stop the pump
close the expansion chamber exhaust valve
close the oil transfer pump isolating valve.
39
9. THERMAL FLUID BRANDS & TYPES - MINERAL FLUIDS

This section is dedicated to the thermal fluid selection. The type of thermal oil should be chosen according to
the maximum working temperature, considering that under normal working conditions film temperature is
approximately 20 C higher than bulk temperature
For example:
Max working temperature = 260 C;
T Film - Bulk = 20 C
T Film = 280 C
Table 8
Typical characteristics of a suitable mineral fluid to be used in our OMV series.
Characteristic
Unit
Value of suggested mineral oil
Max. working temperature
300
Pour point temperature
-10
Viscosity at 40C
cSt
20
Flash point temperature COC (VA)
220
Specific weight at 15C
Kg/dm3
0,86
Kg/dm3
0,68
Specific heat at 15C
KJ/Kg K
2,0
KJ/Kg K
2,8
mbar
80
Vapor pressure
Table 9
Mineral fluids brands and types.
Supplier Brand
Oil type
PETRO-CANADA
CALFLO
ESSO
ESSOTHERM 500
AGIP
ALARIA 3
BP
TRANSCAL LT-N
MOBIL
MOBILTHERM 605
SHELL
THERMIA B
40
9. THERMAL FLUID BRANDS & TYPES - SYNTHETHIC FLUIDS
Table 10
Typical characteristics of a suitable synthetic fluid to be used in our OMV series.
Unit
Value of suggested
synthetic oil (liquid phase)
Value of suggested synthetic

oil (vapor phase)
Max. working temperature
345
400
Pour point temperature
-32
+12
Viscosity at 40C
cSt
29,64
2,48
Flash point temperature COC (VA)
170
110
Kg/dm3
1,008
1,064
Kg/dm3
0,808
0,818
KJ/Kg K
1,560
1,540
KJ/Kg K
2,570
2,314
Vapor pressure at 200C
kPa
2,23
24,00
Vapor pressure at 300C
kPa
30
239
Characteristic
Table 11
Synthetic fluids brands and types.
Supplier Brand
Oil type
SOLUTIA
THERMINOL 55 / THERMINOL 66 / THERMINOL VP1
DOW
DOWTHERM Q
DOW
SYLTHERM 800
DOW
DOWTHERM A
41
10. SCOPE OF SUPPLY - STANDARD EQUIPMENT

STANDARD EQUIPMENT - OIL-MATIC OMV
Set of concentric tangent coils made of carbon steel tubes
THERMAL OIL HEATER

PRESSURE VESSEL
Spiral coil tubular screen on the upper furnace (from OMV 800)
Carbon steel heater shell containing the coils
Removable cover for inspection
Flanged connection for stack with counterflange included
REFRACTORIES
INSULATION AND
EXTERNAL LAGGING
BASE
Refractory material
Insulation of the external casing in mineral wool panels
Stainless steel external lagging
Base frame made with iron bars
VALVES AND
ACCESSORIES
Set of thermal fluid inlet and outlet pressure gauges

Set of thermal fluid inlet and outlet thermocouples
Burner box
Flame scanner
Burning ignition device
Observation port for flame control
Air swirler
TYPE OF FUEL AVAILABLE*
Combustion air fan
BURNING SYSTEM
- Monoblock (with
integrated air fan)
- Dual block (with
separated air fan)
Natural gas pressure gauge

Internal gas header with multi-nozzle system
NATURAL GAS
FUEL (NG)
N.2 Feeding gas train electrically actuated shut-off valves

Feeding gas electrically actuated regulating valve
HEAVY FUEL OIL

(HFO)
DIESEL OIL (DO)
Fuel pump station, complete with on/off valve

Preheating station electrical thermoregulation system
Fuel pump station, complete with on/off gate valve
Cycle programming panel for burner ignition and flame control (safety automatic device)
BURNING CONTROL
AND SAFETY
EQUIPMENT
Safety pressure switch for minimum air combustion pressure

Gas leakage test - VPS (only for natural gas fuel, from model OMV 800)
Temperature switches for fuel temperature regulation (only for heavy fuel oil)
N.2 Max/min gas pressure switches (for gas fuel only)
Steel cabinet, oven painting, front door, IP54 protection
Power section, main switch and door locking device, magneto-thermal switches to protect each power user, tropicalized
power contactors
ELECTRIC PANEL
Control auxiliary section, ignition and flame control panel, alarms and shut-down logic, alarm horn contacts, auxiliaries
protection fuses
Burner START/STOP switch/indicator, alarms acknowledgement with lamps
Alarm panel (from model OMV 800)
N.2 Thermoelements for inlet/outlet thermal fluid temperature detection
Heater inlet thermal fluid indicator (digital electronic type)
THERMAL OIL HEATER

SAFETY EQUIPMENT
Heater outlet thermal fluid regulator, digital electronic type

Safety differential pressure switch for inadequate thermal fluid circulation
Automatic thermal oil pump switch off system (from model OMV 800)
Burner interlock for thermal fluid circulation for pump motor trip
ELECTRIC WIRING
42
With flexible conduits and tight terminal fittings for high mechanical resistance and water proof sealing
* dual fuel burning systems are available (NG + HFO, NG + DO) and include the burning system equipment above listed for each fuel type.
10. SCOPE OF SUPPLY - OPTIONAL

OPTIONAL EQUIPMENT - OIL-MATIC OMV
Tube bank with flue gases running inside and air running outside the tubes
AIR PRE-HEATER (FOR EFFICIENCY UP TO 92%)

FROM MODEL OMV 800
Rectangular section shape casing

Mineral wool insulation, external covering made of stainless steel
Inspection and maintenance bottom door
COMBUSTION AIR FAN SPEED CONTR. SYSTEM
Electrical inverter
SPARE FUEL PUMP (FOR LIQUID FUEL BURNER)
Spare fuel pump
THERMAL OIL CIRCULATION PUMP
Single stage centrifugal pump

N.2 On-off valves
Strainer
COMMON SKID FOR

OIL CIRCULATION
PUMP (FOR ONE PUMP)
N.2 Pressure indicators

N.2 Antivibration connection (for antivibration joints and for press. indicators)
Magneto-thermal swich for motor pump control (star-triangle connection from 18,5 kW)
Piping and fittings
N. 4 On-off valves
N. 2 Strainers
COMMON SKID FOR

TWO OIL CIRCULATION
PUMPS
N. 4 Pressure indicators
N. 4 Antivibration connection (for antivibration joints and for press. indicators)
N. 2 Magneto-thermal swiches for motor pump control (star-triangle connection from 18,5 kW)
Piping and fittings
Body of the tank
OIL STORAGE TANK

(SINGLE WALL)
Set of saddles
Set of flange connections
Body of the tank
OIL STORAGE TANK

(DOUBLE WALL)
Manometer
Pump suction check valve
Set of flanged connections
Body of the tank
Level indicator
OIL EXPANSION TANK

(ATMOSPHERIC TYPE)
Inspection hole
Low level switch
Temperature indicator
Set of flanged connections
Body of the tank
Level indicator
Inspection hole
OIL EXPANSION TANK

(PRESSURIZED TYPE)
Low level switch

Thermometer
Safety valve
Pressure switch
OIL LOADING PUMP
Thermal fluid loading pump

Pump electrical starter (integrated in the electrical panel)
BONOOptispark industrial boilers management and control automatic system
AUTOMATIC BOILER CONTROL SYSTEM

OPTISPARK (FROM MODEL OMV 1000)
Burner management system (BCU)

Flue gas oxygen control system with separated probe
Control of the air/fuel ratio (GARC) and of the supply of oxygen (electric cam)
THERMAL OIL DEAERATOR
Thermal oil deaerator
LADDER AND PLATFORM
Ladder and platform
43
11. APPENDIX 1. OIL-MATIC OMV SPECIAL EXECUTIONS
This section is dedicated to special executions of OIL-MATIC OMV thermal fluid heaters, showing few examples of the great
variety of solutions that BONO can provide
to the customer. These are clear examples of the attention paid to the customers needs and the high level of quality
standards and customization of the design
and production of industrial steam boilers
by BONO ENERGIA.
Figure 30
Thermal oil heater OIL-MATIC OMV
equipped with two circulation pumps,
installed in the same skid. This heater is equipped with air preheater to
achieve thermal efficiency up to 92%.
Figure 31
View of an OIL-MATIC OMV customized electrical panel. This boiler was highly customized, with an
explosion-proof construction, according to ATEX Directive. Another
peculiar aspect of the boiler is the
fuel burnt, which is hydrogen sulphide ( H2S )
44
Figure 32
In this special execution, three circulation pumps are installed on a single
skid. This is a special execution available for special projects, in this case
two pumps plus are installed with a reserve one, whose use can be splitted for
two boilers
Figure 33
Three OIL-MATIC OMV thermal oil
heaters. These heaters field of application is Oil & Gas; the fuel burnt
is a combination of diesel oil and hydrogen sulphite, another example of
our expertise and know-how in combustion technologies, which ensures
highly customized solutions.
45
11. APPENDIX 1. OIL-MATIC OMV SPECIAL EXECUTIONS
Figure 34
A P&ID sample for two OIL-MATIC heaters, an oil storage tank, an expansion tank, a
circuit loading pump and three circulation pumps. In this application A P&ID sample
for two OIL-MATIC heaters, an oil storage tank, an expansion tank, a circuit loading
pump and three circulation pumps. In this application In this application there are
two independent thermal oil circuits, with different T. Moreover in this customized
solution the circuits have two different flow rates, thus guarateeing each consumers
request.This P&ID was designed for a highly customized project and represents an
indicative solution, please ask for available modifications.
SUPPLY LIMIT
OPTION
CANNON BONO
46
CUSTOMER

B1-B2
LI
Level Indicator
TE
Temperature Element
H1
Thermal Oil Header (from plant)
Motor
TIC
H2
Thermal Oil Header (to plant)
PDSL
TISL
L1
Chimney
PDAL
TLH
P1-P2-P3
Oil Circulation Pumps
P4
Second Circuit Pump
PI
Pressure Indicator
TSH
P5
Oil Loading Pump
QE
Electric
TSHH
TV
Temperature Valve
T1
Oil Storage Tank
TAH
U1
Utilities
TAHH
V1
Atmospheric Expansion Tank
47
12. APPENDIX 2. BONO ENERGIA PRODUCT RANGE
STEAM BOILERS
UNI-MATIC UM
FLASH COIL STEAM GENERATORS
Applications: food & beverage, textile industry,
plastics and rubber industry, woodworking,
laundries
Steam production: from 0.3 to 3 t/h
Pressure: up to 12 bar
STEAM-MATIC SM and SG
FIRE TUBE STEAM BOILERS
Applications: pulp and paper industry, food &
beverage, district heating, plastics and rubber
industry, chemicals and petrochemical industry,
textile
Steam production: from 1 to 25 t/h
Pressure: from 12 to 30 bar
CLAJTUB CTD
WATER TUBE STEAM BOILERS
Applications: chemical processes, refinery,
petrochemical industry, power generation
utilities, sugar refineries
Steam production: up to 180 t/h
Pressure: up to 80 bar
Temperature: up to 480 C
UNI-MATIC UM
STEAM-MATIC SG
HRSG
HEAT RECOVERY STEAM GENERATORS
Applications: paper mill, chemical and
pharmaceutical, district heating, cogeneration,
textile
Steam production: up to 40 MW
From gas turbine: from 3 to 15 MW (el.),
from engine: from 3 to 20 MW (el.)
CLAJTUB CTD
CLAJTUB CT
48
THERMAL FLUID HEATERS

OIL-MATIC OMV
THERMAL FLUID HEATERS, MULTI-COIL
TECHNOLOGY
Applications: typography, cosmetics
industry, wood & paper, chemical industry,
petrochemical
Thermal capacity: 0.2 to 6 MW
Fluid temperature: up to 350 C
OIL-MATIC OMP
THERMAL FLUID HEATERS, MULTITUBULAR
Applications: pharmaceutical, petrochemical
Thermal capacity: from 1.7 to 17 MW
OIL-MATIC OMV
OIL-MATIC HTH
HIGH TEMPERATURE THERMAL FLUID
HEATERS
Applications: district heating, oil & gas, others
Thermal capacity: from 2 to 35 MW
SUPERHEATED WATER BOILERS

CTH
MULTITUBULAR SUPER HEATED WATER
GENERATORS
Applications: district heating and others
Thermal capacity: up to 40 MW
package: up to 80 MW - field erected
Temperature: over 100 C, up to 260 C
OIL-MATIC OMP
SM-ASA, SG-ASA
FIRE TUBE SUPERHEATED WATER BOILERS
Applications: district heating and others
Thermal capacity: from 0.7 to 17 MW
Temperature: over 100 C
CTH
49
DISCLAIMER: All the data presented in this technical book are indicative and subject of changing due to
product customization and innovation processes.
They must be considered by the user only at the first stage of product selection; CANNON BONO declines
any responsibility for wrong usage of mentioned data and invites the user to contact our commercial
department for further details.
Bono Energia S.p.A

Via Resistenza 12 - 20068 Peschiera Borromeo (Mi) - Italy
Phone +39 0255302848 - Fax +39 025471955
www.bono.it
Ed. N1

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OIL-MATIC

THERMAL FLUID HEATERS

Technical Book Thermail Fluid Heaters OMV

THERMAL FLUID HEATERS SERIES

1. General Information about Thermal Fluid Heaters

Thermal fluid heathers of the series OIL-MATIC,

OIL-MATIC OMV fields of application are typically:

Models of the series OIL-MATIC include:

OMV 200: up to 0,2 MW, 200.000 Kcal/h.

OIL-MATIC heaters are supplied as packaged

Thermal Oil Inlet

Multi Coil Design Properties

Moderate Delta Temperature between bulk and film

Figure 4 Right side

In order to minimize the degradation rates when using mineral oils

burner, which minimizes the radiant energy reaching the

Two versions: vertical and horizontal.

Wide choice of sizes. Our wide range

Maximum efficiency and high reliability,

Multi coil design.

Easy-to-use and reliable automatic

Compact design and high performance

4. TECHNICAL CHARACTERISTICS AND OVERALL DIMENSIONS: OIL-MATIC OMV

Efficiency at 100 % of the load*

Efficiency at 75 % of the load*

Max. thermal fluid temperature

Pressure drop fluid side P

Max T between outlet and inlet temp.

OVERALL DIMENSIONS AND CONNECTIONS

Thermal oil inlet flange

Thermal oil outlet flange

Thermal oil drain flange

Natural gas inlet

Liquid fuel inlet

Thermal oil volume in the boiler

Boiler empty weight

TYPE OF BURNER (REGULATION STAGES)**

Natural gas fuel

Diesel oil burner

Min. gas pressure

Nat. gas (100% of the load)

Nat. gas (75% of the load)

Diesel oil (100% of the load)

Diesel oil (75% of the load)

Heavy fuel oil (100% of the load)

Heavy fuel oil (75% of the load)

FUEL CALORIFIC POWER

INSTALLED TOTAL ELECTRIC POWER (400V 3Ph+N)

THERMAL OIL CIRCULATION PUMP CHARACTERISTICS*****

Installed total electric power

* Efficiency calculated at thermal oil temperature 250 C

4. TECHNICAL CHARACTERISTICS AND OVERALL DIMENSIONS:

Efficiency at 100 % of the load*

Efficiency at 75 % of the load*

Max. thermal fluid temperature

Pressure drop fluid side P

Max T between outlet and inlet temp.

OVERALL DIMENSIONS AND CONNECTIONS

Thermal oil inlet flange

Thermal oil outlet flange

Thermal oil drain flange

Natural gas inlet

Liquid fuel inlet