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Boiler Operation
and
Maintenance Manual
-1-
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II. Boiling
Warning: If the boiling does not meet the requirements, the quality of the
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steam will be deteriorated, and corrode pipes and headers by produced soda,
which will endanger the safe and economic operation of the boiler and affect the
service life of the boiler.
1. The boiling is chemically treated with NaOH and Na3PO4·12H2O in the
boiler. The purpose is to remove oil and rust in the boiler to ensure that the
boiler is heated evenly and operates normally.
2. The amount of dosing should meet the requirements of the equipment's
technical documentation. If there is no regulation, it should comply with the
following table:
Note: (1) Drugs are calculated at 100% purity.
(2) In the absence of trisodium phosphate, sodium bicarbonate may be used
instead, and the weight is 1.5 times that of trisodium phosphate.
(3) The sodium bicarbonate boiling can be used alone and its weight is
calculated as the pot water volume of 6Kg/m3.
3.When dosing, furnace water should be at low water level.
4.The end of the boiling should keep the boiler pressure at about 75% of the
working pressure, the cooking time is generally 2-3 days.
5.During the boiling, regular furnace water analysis, furnace water
alkalinity is not less than 45mmol / L, otherwise it should be added dosing.
6. After the boiling is completed, the sediment in the drum and the
collection box should be cleaned, and the valves inside the boiler that contacted
with the liquid medicine should be flushed to check whether there is any
blockage of the sewage.
7.After the boiling,it should meet the following requirements:
(1) The inner wall of the drum and header should be free of oil.
(2) The metal surface should be free of rust spots after wiping away
attachments.
8.Boilering work can be carried out at the same time in the late stage of the
oven.
III.Adjust the safety valve
Warning: Failure to adjust the safety valve as required may cause the boiler
to explode! !
1. Drying furnace and boiling are qualified, a tightness test should be
conducted.
2. Continue to step up to working pressure to perform the following checks:
(1) The tightness of each hole, hand hole, valve, flange, and gasket.
(2) Expansion of drums, headers, pipes, and brackets.
3. The safety valve shall be adjusted and verified by the statutory
calibration department. Afterwards, a comprehensive verification shall be
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conducted by the statutory department every year. Adjustments should meet the
following requirements:
Safety valve setting pressure
Note: (1) There must be a safety valve on the boiler to adjust according to
the lower setting pressure in the table.
(2) The working pressure in the table refers to the working pressure at
the location of the safety valve device.
(3) The safety valve should be free from leakage and impact.
4. After completion of the above work, the boiler shall be tested for 48
hours at full load. During the test run, attention shall be paid to checking that all
parts and accessories are operating properly.
IV.Firing
Warning: The temperature rise during overheating should not be too fast, to
avoid uneven heating of various components, resulting in excessive stress,
affecting the service life of the boiler. The
1. Boiler before fire: Inspection of the inside and outside of the boiler, no
tools and other debris left in the drum and collection box, no welding or debris
in the furnace tube, main steam pipe, water supply pipe, sewage pipe, etc.
Temporary partitions and plugs of upper facilities shall be completely removed;
cover plates such as manholes and hand holes shall be installed, and bolts shall
be tightly tightened so that furnace walls and furnace arches shall be free of
cracks, deformation or collapse, furnace walls and drums, and sets. There are
enough expansion gaps at the contact parts of the box, etc., and the fillers are
filled inside as required. The furnace door, the gray door, and the inspection
door switch are flexible and have been closed tightly. Blower, induced draft fan
damper, good wind adjustment performance.
2. Check the main safety accessories. The water level gauge, pressure
gauge, safety valve, drain valve, etc. shall meet the requirements; whether there
is leakage in the joints of pipelines, valves, manholes, hand holes, flanges, etc. If
there is leakage Should be eliminated.
3. Put ignition material such as wood, oil cotton yarn on the grate during
ignition, open the large draft fan to adjust the door, increase the natural
ventilation, and adjust the small flue gas regulating door after the ignition of the
pilot, and intermittently open the induced draft fan After the ignition of the
igniting material, the manual coal addition is started and the blower can be
turned on. Observe the fire situation from the furnace door, properly perform the
fire, and adjust the drum draft volume. The furnace negative pressure is
maintained at 20~30Pa.
4. After the fire has risen, the boiler water level will gradually increase and
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should be observed at any time. The sewage discharge method can be used to
maintain the normal water level.
5.Steam boiler when the pressure rose to 0.05 ~ 0.2MPa, the water level
meter should be flushed, when the pressure rose to 0.15 ~ 0.2MPa should be
cleaned pressure gauge elbow, and pay attention to the situation of the pressure
gauge.
6. When the pressure of the boiler rises to 0.2~0.3MPa, check whether the
manhole and hand hole are leaking.
7. When the boiler is put into normal operation, it will be checked again on
all parts of the boiler to find out whether the conditions of each part are normal.
V. Steam supply
When the gas pressure in the boiler is close to the working pressure, it is
prepared to supply steam to the outside, and the water level in the boiler before
steam is not to exceed the normal water level. Steam combustion in the furnace
is stable during steam supply.
When supplying steam, the main steam valve should be opened slightly to
allow trace steam to be warmed. At the same time, the drain valve on the
pipeline should be opened to release condensate. The warm-up time is
determined by the length of the pipe, the diameter, the steam temperature, etc. It
is usually no less than ten minutes. When warming the pipe, attention should be
paid to the expansion of the pipe and the condition of the pipe support. If any
abnormality is found, the warm pipe should be stopped and the faults and
defects should be eliminated. After the pipeline is hot, the condensate on the
pipeline is gradually reduced. Before the main steam valve can be fully opened,
it should be started slowly. At the same time, pay attention to whether the
components of the boiler have special sounds. If any, check immediately.
If necessary, stop the furnace inspection. After the main steam valve is fully
opened, the main steam valve handwheel should be returned half a turn to
prevent it from rotating after thermal expansion. After the steam is supplied to
the boiler, it is necessary to check whether the accessory parts, valves, and
meters are leaky or not, and whether the work is normal. In order to prevent full
water (steam water), in any case, do not make the water level not visible part of
the glass tube, while the main steam valve should not be opened too large,
generally controlled between 1 to 2 laps, in the normal combustion conditions
At that time, the rated output can be achieved.
VI.Steam integration
If several steam boilers operate in parallel, they send steam to the same
steam pipe called steam integration(also boiler integration). And before the
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furnace should reduce the furnace firepower, open the steam valve on the drain
valve, and flush the water level gauge again, check the water level is normal.
The furnace should be carried out when the boiler steam pressure and steam
steam pressure difference (0.05 ~ 0.1MPa). Slowly open the main steam valve
and wait until the sound of steam is not heard in the steam pipe before you can
open the main steam valve. After the main steam valve is fully opened, it should
be closed once and then the bypass valve should be closed. When the furnace is
in operation, attention should be paid to observe the changes of the water level
and steam pressure. If there is a water hammer phenomenon in the pipeline, the
water discharge should be strengthened and the furnace should be strengthened.
After the furnace, the water on each steam boiler must match the evaporation of
the boiler to maintain it at the normal water level.
VII.Steam boiler operation management
Warning: The pressure gauge, water level gauge, and safety valve are
improperly managed and operated during operation, which can cause the boiler
to explode! ! ! The furnace is operated for a long period of time under positive
pressure. It is easy to burn personnel, burn furnace doors and other parts until
forced shutdown.
(一)Safe operation of boilers
(1) When the boiler is operating, it must maintain the specified normal
water level, and the water level must not be lower than the minimum safe water
level or higher than the highest safe water level.
(2) Attention should always be paid to working pressure to maintain normal
air pressure. The working pressure specified by the boiler shall be marked with a
red line on the pressure dial of the boiler. The water level meter shall have clear
signs indicating the highest and lowest safe water levels and normal water
levels.
(3) Necessary procedure
(a) Flush the glass water level gauge once.
(b) Check whether the direct reading water level gauge and the glass water
level gauge equipped with a direct reading water level meter are consistent.
(c) Check the tightness of the drum and header drain valve.
(d) According to the water quality of the boiler, all sewage discharge valves
discharge one or two times.
(e) All pumps shall be tested during their succession, and the condition of
each feed pump shall be checked with a short-term start-up method.
(4) The pressure gauge shall comply with the relevant technical standards,
and its calibration and maintenance shall comply with the requirements of the
national measurement department. Before the pressure gauge is installed, it shall
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be checked and the date of the next calibration shall be indicated. The pressure
gauge shall be sealed after verification. .
(5) The safety valve shall be equipped with an exhaust pipe, and the
exhaust pipe shall pass through to a safe place and have enough flow cross-
sectional area to ensure the exhaust gas is unblocked. At the same time the
exhaust pipe should be fixed.
The bottom of the safety valve exhaust pipe should be equipped with a
hydrophobic pipe to a safe location. It is not allowed to install valves on the
exhaust pipe and the drain pipe.
Economizer safety valve should be equipped with a drain pipe and lead to a
safe place. No valve is allowed on the drain.
(6)Always pay attention to the relationship between the air pressure and the
combustion, and must control the negative pressure at the outlet of the
combustion chamber to be 20~30Pa so that the boiler does not exhibit positive
pressure combustion.
(7) Visit the boiler regularly. If there is a leak in the furnace wall or door,
repair it immediately and listen for any special sounds. These sounds may be
leaks or steam leaks in the boiler. eliminate.
(8) The inspection of the boiler body, electrical equipment, feed pumps,
various valves, meters, and ancillary equipment is often conducted.
(9) When opening the valve or the cock, disable the sledgehammer or other
objects to knock, and prohibit the lengthened valve handle from opening
forcefully.
(10) In order to prevent the valve and valve seat of the safety valve from
sticking, the manual and automatic opening test of the safety valve should be
performed periodically. The boiler safety valve should be checked at least once
a year.
(二) Economic Operation of Boilers
In the process of operation of the boiler, the use unit shall do the
following:
1. Boiler users should use boilers and auxiliary equipment products that
meet safety, environmental protection, energy conservation, and other related
regulatory requirements.
2. The installation of industrial boilers shall meet the requirements of
GB50273-2009 "Construction and Acceptance Specifications for Boiler
Installation Projects".
3. To do a good job of boiler water treatment, the quality of feed water and
boiler water should meet the requirements of GB/T1576-2008 Industrial Boiler
Water Quality.
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4. The insulation of industrial boilers, their auxiliary equipment and heat
pipes shall comply with the requirements of TSG G0002-2010 "Boiler Energy-
saving Technical Supervision Regulations".
5. Newly installed auxiliary boilers for industrial boilers should use
energy-efficient products that meet the latest national standards or industry
standards.
6. Industrial boilers should be operated with fuels that are similar in design
or design to fuel.
7. When the industrial boiler is in operation, the combustion conditions
should be adjusted. The pressure, temperature, and water level should all remain
relatively stable.
8. When the industrial boiler is operating, the load changes, it is necessary
to monitor the operation of the boiler and make adjustments in time. The boiler
operating load should not be less than 80% of the rated load often or for a long
time.
9. In addition to the provisions of GB 13271-2001 "Emission Standard of
Air Pollutants for Boilers", the emission of air pollutants during the operation of
industrial boilers shall also comply with the requirements for the relevant
environmental protection standards for the use of units of boilers.
10. During the operation of the industrial boiler, the flue gas side of the
heating surface should be periodically cleaned and kept clean. The side of
steamed water on the heating surface should be regularly checked for corrosion
and scaling and anti-corrosion and descaling.
11. During the operation of industrial boilers, boiler fuel supply systems,
smoke systems, soda systems, instruments, valves, and thermal insulation
structures should be inspected frequently to ensure that they are tight and intact.
12. Industrial boilers should be equipped with water flow meters, pressure
gauges, thermometers and other instruments and meters that can indicate the
economic operation of the boiler. The instruments and meters used should be
regularly calibrated or certified as required.
13. The unit using industrial boilers shall implement the "Measures for the
Administration of Special Equipment Operators." Operational operators shall
carry out safety and economic operation training assessments and hold
certificates.
14. The industrial boiler use unit shall establish and improve the technical
file of the boiler safety in use to ensure that the equipment is in good condition.
The content of the safety technology file shall comply with the relevant
provisions of the “Regulations for the Supervision and Management of Special
Equipment”, and shall also include the installation and acceptance records,
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technical renovation files, and energy-saving and environmental protection
inspection files.
15. In the use of industrial boiler operation should be done to record the
original operation of the boiler.
16. The industrial boiler thermal efficiency index should not be less than
78%.
17. Industrial boiler operation exhaust temperature index does not exceed
170 °C.
18. The index of excess air ratio at the smoke exhaust location of industrial
boilers shall not exceed 1.65.
VIII.Blow-down
1.The release of water so that the alkalinity of the furnace water does not
exceed a certain concentration, in line with the furnace water alkalinity
requirements. Sewage discharge and discharge should be controlled according to
the results of chemical analysis and adjusting the opening of the drain valve or
drain valve.
2. Regular discharge or discharge of water is to exclude deposits in the
drum and to adjust the salt content of the boiler water in order to achieve the salt
content of the boiler water.
3.Regular discharge should be carried out at high water level and low load,
the time is as short as possible so as not to affect the water cycle. In general, at
least one discharge of sewage shall be carried out in each shift.
4. The boiler water should be drained when the boiler in high water
level.When the sewage is drained, close attention should be paid to the change
of the water level in the drum. The sewage discharge rate should be less than 3%
(Each sewage should be used to reduce the water in the drum to be 25~30mm. ).
Failure to discharge according to regulations will also lead to boiler
accidents!
5.The sewage operation procedure is as follows: first completely open the
second valve (one away from the drum or the container), and then slightly open
the first valve to preheat the sewage pipeline, and then open the first valve (this
When there is no impact sound in the sewage pipe, if there is impact, the first
valve should be closed until the impact sound disappears, and then slowly open.)
Pay attention to the control of the discharge volume.
6. If two or more boilers use the same sewage mains, and there is no check
valve on the sewage pipe, it is forbidden that two or more groups of sewage
valves work simultaneously.
7. It is forbidden to use the extension bar to extend the handle to open the
drain valve.
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8. After the sewage is drained, the first valve should be closed and the
second valve closed. The leaked valve can be repaired or replaced when the
furnace is shut down.
IX.Dust collector precaution
1. There should be no steam leakage at the flange joints of the dust collector
and the smoke wind pipe.
2. The dust in the lower part of the dust collector should be cleaned in each
shift.
X.Stop the boiler
1. Boiler shutdown is generally divided into three situations:
(1) Temporary failure requires temporary shutdown.
(2) For inspection or repair, the boiler should be completely shut down
when the boiler water is discharged.
(3) Stop the furnace immediately in special circumstances.
2. The above three shutdown furnaces are different due to different
conditions. The specific steps are as follows:
(1) Temporary shutdown
In case of temporary shutdown, the blower shall be turned off, the fan shall
be slightly opened, the coal shall be stopped, and relevant faults shall be
promptly dealt with. If the failure cannot be resolved within 1 to 2 hours, it shall
be transferred to a temporary shutdown to continue to resolve the failure.
Attention shall be paid to changes in the water level.
(2) Complete shutdown:
It is planned that there should be a complete shutdown. Generally, the
furnace should be stopped once for 1~3 months. When shutting down the
furnace, pay attention to safety and maintenance equipment. Stop the furnace
according to the steps of temporarily stopping the furnace.
(3) Immediately stop the boiler: In case of one of the following conditions
during the boiler operation, the furnace shall be immediately stopped: a. The
boiler water level is lower than the lowest visible edge of the water level table;
b. The water supply is continuously increased and other measures are taken, but
the water level continues to decline; c The boiler water level exceeds the highest
visible water level (full of water), and the water level cannot be seen even after
the water is discharged. d The water pump fails completely or the water supply
system is faulty. The water can not be fed into the boiler. The e water level
gauge or the safety valve is all ineffective; f is set in the steam space. The
pressure gauges have all failed; g boiler elements are damaged and endanger the
safety of the operating personnel; h burning equipment is damaged, the furnace
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wall collapses or the boiler frame is burned red and other serious threats to the
safe operation of the boiler; i other abnormal conditions endanger the safe
operation of the boiler. When the furnace is immediately shut down, the furnace
door should be opened to quickly clean the fuel on the grate, turn off the drum,
draw the fan, and open the main steam valve and safety valve.
3.Immediately stop the furnace steps:
(1) Stop the forced fan firstly,then stop the induced draft fan.
(2) Remove fuel cinder from the furnace at the fastest speed.
(3) When the boiler is immediately shut down due to a water shortage
accident, water supply to the boiler is strictly forbidden, and the steam venting
of the safety valve may not be increased to prevent the boiler from being
exposed to sudden temperature or pressure changes to expand the accident. If
there are no water shortages, alternative measures for reducing blood pressure
may be adopted.
XI.Care and maintenance
1. It is not allowed to inflate the furnace with positive pressure to prevent
burning of the door or front panel.
2. If the furnace wall is found to be damaged, the furnace should be shut
down for repair within 24 hours.
3, each class should check the blower, induced draft fan, feed pump
lubricants, oil shortage should be timely refueling.
4. All fans have severe vibration and should be stopped for inspection.
Generally, the internal impeller wears and should be replaced.
5, the bottom of the boiler on the ground level can not be water, to prevent
wet corrosion base.
6. The new boiler shall be inspected once after 2 to 3 weeks of operation.
The boiler shall be shut down once every 2 to 3 months.
7.Check the content:
(1) Remove dirt from the surface of the heated surface of the tube.
(2) Open the smoke box to clear the dust in the smoke tube and check the
wear of the smoke tube. Whether the insulation layer of the cigarette box falls
off, and if it is damaged, it shall be promptly repaired.
(3) whether the furnace wall has cracks or damage.
(4) Open the manhole, hand hole, remove dirt and other deposits in the
drum and header. If the scale thickness is found to be more than 2mm, it should
be cleaned.
(5) Auxiliary machine transmission cleaning and refueling.
8. Maintenance methods for boilers that are not used for a long time: There
are two methods, dry method and wet method. Shut down the furnace for more
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than one month.
Law, the following months can be used to stop the furnace wet maintenance
method.
(1) Dry care method
After the boiler is shut down, the boiler water is discharged, the internal dirt
is completely removed, rinsed cleanly, and dried by micro-fire, then the 10 to 30
mm block of quicklime is placed in the drum so as not to contact the quicklime
with the metal. The weight is calculated with a boiler capacity of 6 kg/m3, and
then all the holes, hand holes, and pipe valves are closed. Every three months
inspection, such as lime broken into powder, should be replaced in time, the
boiler re-run lime and the disk removed.
(2) Wet maintenance method
After the boiler is turned off, the boiler water is discharged, the internal dirt
is completely removed, rinsed, the treated water is refilled, the water is heated to
100° C., the vapor in the water is discharged from the furnace, and then all the
valves are closed. Wet maintenance must not be used in places where the
climate is cold so as to avoid freezing the boiler and damaging the boiler.
XII.Water treatment
Warning: The water quality does not meet the requirements. It will cause
scale sedimentation in the silt drum and the lower part of the collection box,
destroy the water circulation, make the tube overheat, deform, burst the tube,
and even cause the drum to overheat and lead to cracking and explosion of the
drum! ! !
In order to save fuel and extend the service life of boilers, boiler feed water
and boiler water should meet the requirements of GB/T1576-2008 Industrial
Boiler Water Quality.
Boiler feed water and boiler water quality should meet the following
requirements
Boiler steam quality indicators: steam humidity should not exceed 3%.
XIII. Regular inspection
The regular inspection of boilers in use shall be conducted in accordance
with the "Regulations for Periodic Boiler Inspection" issued by the State Bureau
of Quality and Technical Supervision.
XIV. Use Management
In the process of using the boiler, the using unit shall do the following:
1. Responsible for energy-saving management of boilers and their
systems. The technical personnel engaged in energy-saving management should
have relevant expertise in boilers and be familiar with relevant national laws,
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regulations, safety technical specifications and corresponding standards.
2. Establish and implement relevant systems for energy-saving
management of boilers and their systems. The relevant systems for energy
conservation management include at least the following:
(1) Energy-saving target responsibility system and management post
responsibility system;
(2) Daily energy-saving inspection system for boilers and their systems,
and make corresponding inspection records and archive;
(3) Boiler fuel admission inspection analysis and management system, and
the correct choice of fuel according to design requirements;
(4) Meter calibration and management system;
(5) Boiler and system maintenance system;
(6) Boiler water quality management system;
(7) The training and assessment system for boiler operators and water
treatment workers, the education and training of the boiler operators' economic
operation knowledge, the assessment work plan, and the training and assessment
records.
3. The user unit shall establish a mechanism for energy efficiency
assessment, rewards and punishments, actively implement contract energy
management in light of the actual conditions of the unit, arrange regular energy
efficiency tests, and conduct timely rectification for those that do not meet the
energy conservation requirements.
4. The user unit shall regularly maintain and maintain the equipment,
instruments, devices, pipelines and valves included in the boiler and its systems.
When abnormal conditions are found, it shall be handled and recorded in a
timely manner.
5. Conduct routine inspections and monitoring of the energy efficiency of
boilers and their systems. Key inspection and monitoring items, including boiler
fuel use and design fuel compliance, fuel consumption, medium outlet
temperature and pressure, boiler feedwater and make-up water temperature,
exhaust temperature, furnace wall surface temperature, and system availability ,
take, drip, leak, etc.
6.To strengthen energy testing, measurement and statistics work. The
qualified unit of industrial boilers shall regularly evaluate the energy efficiency
of boilers and their systems. The evaluation method shall refer to the “Industrial
Energy Efficiency Test and Evaluation Rules” (TSG G003).
7. The user unit shall conduct a regular energy efficiency test for the boiler
in use every two years. The test work shall be combined with the external
inspection of the boiler and conducted by the energy efficiency testing agency
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determined by the AQSIQ.
8. The boiler operator shall timely adjust and adjust the boiler operation
quantity and boiler output according to the change of the end user's steam
quantity and heat load, and the conditional boiler house may install the boiler
load automatic adjustment device.
9. The normal rate of boiler discharge should meet the following
requirements:
(1) No more than 10% of the industrial boilers are treated with
demineralized water as a make-up water or simply treated with pots and dosing;
(2) The industrial boiler with demineralized water is not more than 2%.
10. The unit using boilers shall establish energy efficiency technical files
for special equipment with high energy consumption in accordance with the
provisions of the "Administrative Measures on Energy-saving Supervision and
Administration of Special Equipment with High Energy Consumption". The
qualified users shall centralize the management of boiler product energy
efficiency technology files with product quality files and equipment usage files.
The boiler energy efficiency technology archive includes at least the following:
(1) Randomized delivery data of boiler products (including product energy
efficiency test report);
(2) Quality certification data such as auxiliary boilers and auxiliary
equipment;
(3) Boiler installation and commissioning report, energy conservation and
transformation data;
(4) Energy efficiency evaluation or energy efficiency test report of boiler
installation, transformation and maintenance;
(5) Periodical test reports and annual operating energy efficiency
evaluation reports for boiler energy efficiency;
(6) Routine energy conservation inspection records for boilers and their
systems;
(7) Measurement and inspection instrument calibration certificate;
(8) Boiler water treatment report;
(9) Fuel Analysis Report.
XV.Special tips
1. The installation of the boiler should be completed by a qualified
installation company and the local boiler pressure vessel supervision department
should go through the construction procedures.
2. Before installation, safety valves and pressure gauges must be checked
and certified by the statutory calibration department, and they must be checked
and approved once a year after use.
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3.Boiler users must go to the local boiler pressure vessel monitoring agency
for the use of registration procedures
4. The boiler is strictly prohibited from running in water shortage. The
water should meet the requirements of the manual and be drained regularly.
5.The boiler operating worker should obtain the operation certificate issued
by the statutory department.