OPERATING MANUAL Biomass Boiler

HENAN YUANDA BOILER CORPORATION LTD
Boiler Operation
and
Maintenance Manual
HENAN YUANDA BOILER CORPORATION, LTD.

Tel:0086-371-60137716 Fax:0086-371-60137715
www.yuanda-boiler.com
-1-
Chapter I、 Introduction to the boiler

structure
I. Structure Introduction

The DZH1-1.0-T boiler is a longitudinal, horizontal, three-pass, single-
drum, water-fired tube shell boiler. The boiler body consists of the boiler shell,
spirally thread smoke pipes, container and water-wall tubes. The left and right
sides of the furnace are water-cooled walls,they are the radiation heating
surface, the two wings of the furnace are convection heating surfaces, and the
convection heating surface of the spirally thread smoke pipes is arranged in the
drum. The design fuel is the biomass, which ensures the boiler's safety, stable
and efficient combustion. An economizer is arranged at the rear of the boiler,
and the outer side of the boiler main body is a three-dimensional guard plate
shell. The combustion equipment is an active hand grate. The high-temperature
flue gas generated after the fuel is burned on the grate,flows from the front to the
back in the furnace, enters the convection tube bundles on the two wings
through the partition outlet smoke window, and enters the threaded tobacco
pipe, the rear smoke box and the economizer through the front smoke box. The
dust collector is led to the chimney by the induced draft fan to the atmosphere.
The boiler is equipped with a furnace door and a ash removal door to facilitate
cleaning, cleaning, cleaning and maintenance of the heated surface. The boiler
adopts new technologies such as arched tube plates and spirally thread smoke
pipes, and cover with a fire-resistant layer at the bottom of the boiler shell to
solve the cracks in the tube plates of the boiler shells, the drum bulges at the
bottom of the drum, the water-cooled wall burst tubes, and low thermal
efficiency,insufficient output, poor fuel quality and other issues. The boiler is
equipped with furnace pressure teat points, furnace outlet temperature and
exhaust temperature measurement points to ensure safe and economical
operation of the boiler.
II. The boiler system overview
When the boiler room system is designed, under the premise of ensuring
safety performance, the energy utilization rate can be fully increased, water,
electricity, self-use heat and other consumption can be reduced, and heat energy
recovery and cascade utilization can be promoted. When the boiler room
equipment is arranged, the length of pipes and smoke ducts and the number of
elbows should be minimized to reduce the flow resistance so that the boiler can
operate under the best energy efficiency conditions.
When the user's thermal load fluctuates frequently and frequently,
measures should be taken to balance the load and achieve effective regulation.
The system of multiple boilers should be equipped with centralized
control devices to ensure that the boilers are allowed to be balanced and that
they are in economic operation.
The boiler medium parameters should be selected to meet the
requirements, and the rated outlet pressure and temperature of the boiler should
not be too different from the pressure and temperature used.
The auxiliary boiler configuration should be matched with the boiler to
meet the requirements for the efficient operation of the boiler and its system.
1. Coal feeding system
The fuel is manually added to the grate through the furnace door for
combustion.
2. Dust removal
In order to meet the increasingly stringent environmental requirements,
ceramic multi-pipe dust collectors are preferred to minimize the smoke
generated by the boiler. During operation, the fault of the dust collector is
monitored at any time, and problems are adjusted and repaired so that the dust
removal efficiency is not reduced.
3. Drum, induced wind system
There is a close relationship between the selection of the drum and the
draft system and the system layout. The selection of the fan parameters should
be based on the rated output of the boiler, the fuel type, the combustion method,
and the resistance of the smoke system, based on the oxygen content of the air
and the temperature of the flue gas. The density and the local air pressure are
corrected, and a wind adjustment device is provided on the drum and the
induced draft fan to facilitate adjustment of the air volume.
4. Water supply system
Feedwater pump should be geared.
5. Boilers and their systems should eliminate running, running, dripping
and leaking, make full use of condensate and secondary steam, and take
measures to maximize the recovery of recycled condensate.
III. Technical characteristics
1. The lower part of the drum is equipped with a rising tube row and
covered with a refractory layer at the bottom to eliminate the dead water area at
the bottom of the drum, so that the slime is not easy to deposit, the high
temperature area of the drum can be well cooled, and the drum can be prevented
from bulging under the drum.
2. The use of water and fire pipe layout has achieved enhanced heat transfer
performance, which has achieved the characteristics of increased temperature
and fast pressure rise, and improved the thermal efficiency of the boiler.
3.Compact structure, small size, saving boiler room infrastructure
investment.
4.Stable operation, easy adjustment, sufficient output, high thermal
efficiency.
5.Quick installation type, after the boiler arrived, only need to install water
system， electricity system and pipeline。
6.The boiler has a certain role in dust reduction. The boiler dust
concentration is controlled below the standard to ensure that the boiler dust
emissions meet the national environmental protection regulations.
Chapter II、 Installation Instructions

Note: The boiler installation must meet the following criteria:
1. Supervision Regulations for Steam Boiler Safety Technology (1996);
2.GB50273-2009 boiler installation engineering construction and
acceptance specifications.
3.TSG G0002-2010 "Boiler Energy Conservation Technical Supervision
Management Regulations"
I.installation preparation
Warning: The construction unit of the boiler installation must have a boiler
installation permit issued by the provincial boiler pressure vessel safety
supervision agency in accordance with the boiler level and installation type.
Before the construction, the construction unit must go to the safety supervision
institution where the unit is located to handle the installation notice. The
notification content is as follows: construction type, main construction item,
equipment type, equipment level, equipment name, equipment type, equipment
location, equipment manufacturing unit, equipment manufacturing Date, user,
address of the user, owner and telephone of the using unit, legal representative
of the construction unit, construction unit, person in charge of the construction
site and telephone, technical person in charge of the construction site, address of
the construction organization, project plan, construction date and general
acceptance Dates, total project budgets, subcontracted units (when
subcontracted), submitted documents, site management, specialties, and
operating personnel can be constructed only after review and approval.
Otherwise, no construction is allowed. During the construction process, it must
accept the supervision and inspection of the local supervision and inspection
agency.
1. Before installing the boiler, the installation unit shall send the boiler floor
plan and the drawings indicating the distance to the relevant building, boiler
technical data related to boiler safety and energy saving to the supervision and
inspection agency of the place where the boiler is used for installation
notification, and fill in the installation instructions. The book can only be
constructed after the approval of the review; otherwise, no construction is
allowed.
2. For the registration procedures, according to the “Regulations for
Supervision of Steam Boiler Safety Technology”, the unit that uses the boiler
shall go through the registration formalities according to the “Boiler Usage
Registration Regulations” of the safety supervision department.
3. Organize staff to learn to install technical measures, safety technical
specifications, and be familiar with boiler design and related technical
documents.
4. Before the boiler is installed, the boiler body, combustion equipment,
auxiliary equipment, and accessories shall be checked, checked and checked
according to technical documents, and records shall be made. If it is found that it
does not meet the relevant standards, it should be promptly submitted to the
factory.
II. Boiler and auxiliary machine lifting
1. Boiler body, combustion equipment, auxiliary equipment, accessory
packing box and instrument packing box should be hoisted according to the
hoisting position specified by the factory. It is the user's responsibility to place
the hook in any position and damage it.
2. Load-carrying vehicles, lifting equipment, wire ropes and winches
required for banding shall have sufficient load capacity and shall comply with
technical specifications.
3. Before lifting, please select lifting equipment according to the large size
and large weight marked in the boiler code, and formulate corresponding safety
precautions.
III. Boiler installation
Before and during the boiler installation, it must be supervised by the local
supervision and inspection agency. If the installation unit finds that there are
quality problems affecting the safe use of the pressure parts, it shall stop
installing and report the local safety supervision agency. The safety supervision
agency shall promptly put forward opinions on the quality issues raised.
Installation work must be in accordance with the requirements of the relevant
regulations to ensure the quality of construction. The sectional acceptance and
hydraulic pressure test of the boiler installation quality shall be carried out
jointly by the boiler installation unit and the use unit. In general acceptance, in
addition to the boiler installation unit and the use unit, safety supervision
agencies should also be sent to participate.
1. The foundation of the boiler should be determined according to the local
soil quality and the basic drawings provided by the manufacturer should be used
to design basic construction drawings from the civil engineering department.
2. After the boiler foundation reaches its strength, inspection and
acceptance shall be made according to the boiler design, and the three overall
baselines of the boiler shall be drawn:
(1) Longitudinal reference line - the center of the burning equipment or the
center of the drum.
(2) Horizontal reference line - front panel position line
(3) Elevation baseline - Marks can be selected around the base for the
relevant locations. The relative offset between the markers should not exceed 2
mm.
3, according to the positioning center line of the boiler to place large pieces
of boiler, requiring the boiler front end higher than the back end so that the
boiler has a certain degree of inclination, the water level connection pipe check
the left and right water level table to make it horizontal, allowing the tilt is not
Greater than 2mm. Otherwise, the lower side should be leveled with a horn.
After the boilers are in place, the muddy pressure plate and the two corners of
the boiler are inlaid with cement, and according to the basic pattern, the wind
hoe and the slag door are installed, and strict airtightness is required.
4. When the chimney is installed, it can not be directly seated on the dust
collector. It should be supported by the bracket. The chimney connection should
be filled with asbestos rope for sealing, and the wire rope should be tightened
and fixed in time. After the chimney is installed, the vertical state should be
maintained and the wire rope should be evenly distributed.
5. Installation of boilers shall be conducted in accordance with the relevant
provisions of GB50273-2009 "Boiler Installation Engineering Construction and
Acceptance Specifications".
IV. Auxiliary machine installation
1. The installation of dust collector, induced draft fan and blower should be
installed after the inspection of damper,the dust-locking and transmission parts
of dust collector is qualified. Check for any defects such as stuck or leaked air
after installation. Finally, turn on the power supply and test to see if the motor
steering is correct, whether there is frictional vibration or if the motor
temperature is normal. In order to make the fan of the induced draft fan well
lubricated at high temperature, the bearing seat should take effective cooling
measures and be lubricated regularly. When the induced draft fan runs cold, the
flue gas regulating door should be closed to prevent the motor starting current
from being too large and burning the motor. The cold running time should not
exceed 5 minutes.
2. Boiler auxiliary equipment with a motor power exceeding 15KW should
be equipped with a step-down starter.
3, the installation of economizer, check carefully before the installation of
the shell panel is smooth, with or without collision damage; whether the ribbed
tube damage; the connection of the elbow bolt loose. First, install the
economizer bracket so that the horizontal error is in the range of ±3mm and the
elevation error is in the range of ±5mm. Then put the economizer on the bracket.
Check whether the height, distance and bolt hole of the inlet flange of the
economizer flue gas and the outlet flange of the flue gas of the boiler are in
agreement. Then adjust the economizer bracket to ensure the installation
accuracy. After the economizer is calibrated, weld it according to the pattern
requirements and water concrete.
V. The installation of pipeline instruments
The configuration of metering, detection, and control instruments in the
boiler system should meet the requirements of TSG G0002-2010, Appendix B of
the Boiler Energy Conservation Technical Supervision Regulations. That is, the
water supply flow meter, pressure gauge, and smoke outlet temperature should
be configured to measure the outlet temperature of the furnace. Thermocouples
and display instruments, furnace outlet pressure gauges, heat pipes and valves
shall have good sealing and thermal insulation properties, and the surface
temperature of the heat pipes and valves shall not exceed 50°C.
The boiler is equipped with a water level automatic alarm controller. The
function and features of the product are as follows:
(1) High and low water level automatic alarm function (acousto-optical
alarm): When the boiler water level is higher than normal water level by more
than 50mm and below the normal water level by 35mm, it will give an audible
and visual alarm.
(2).There is a water shortage interlock protection function, that is, when
the boiler water level is lower than the normal water level of 45mm or less, the
induced wind and blast will automatically stop and be locked. Once water is
scarce, the induced wind, the blast, and the water pump are all interlocked and
can only be restarted after the reset is turned on with a dedicated key.
(3) Automatic boiler water level control function: When the boiler water
level is lower than the normal water level 20mm below, the water pump will
automatically open. When the water level rises above the normal water level
20mm, the water pump will stop automatically, and the water pump can also be
manually controlled on the instrument panel. And stop.
(4). With on-line and off-line functions: On the back panel of the
instrument, there are two switches, namely fan interlock switch and pump online
off-line switch. When the switch is in the interlocked or offline state, the wind
and drum are The wind and the pump are controlled by the machine, and online
and offline functions must be converted using a special key.
(5) The pressure gauge should be installed in a position where it can be
easily observed and purged, and protected from high temperatures and
vibrations.
(6) The pressure gauge shall have a trap pipe, and a cock shall be installed
between the pressure gauge and the trap pipe so that the pipe can be purged and
the pressure gauge can be replaced.
(7) The red line shall be marked on the scale to indicate the working
pressure of the boiler.
(8) The safety valve must be calibrated by the statutory authority before
installation. Generally, the exhaust pipe should be installed. The exhaust pipe
should pass through to a safe place and have sufficient cross-sectional area to
ensure the smooth flow of the exhaust gas. The bottom of the safety valve
exhaust pipe is equipped with a hydrophobic pipe that is connected to a safety
place. No valve is allowed on the exhaust pipe and the drain pipe.
(9) Each boiler should be equipped with an independent sewage pipe. The
sewage pipe should be reduced as much as possible to ensure that the pollution
is unimpeded and it is connected to an outdoor safety place or a sewage
expansion tank. Periodical discharge of several boilers, such as a total discharge
pipe, must have Proper security measures.
(10) Boiler drain valves and drain pipes are banned to connect by screw
thread.
VI.Hydrostatic test
After the boiler is installed and the pressure components of the boiler are
overhauled, hydraulic pressure test should be done.
1. The following work should be done before the hydrostatic test:
(1) Internal cleaning and surface inspection of the tested part.
(2) Check the tube for clogging.
(3) Install pressure gauges that are qualified by the statutory authority (not
less than 2), and then perform a verification every year by the statutory
authority.
2. The following requirements shall be met during the hydrostatic test:
After the boiler is installed, the interior of the boiler should be inspected
and cleaned, manholes and valves closed, and then the hydrostatic test should be
performed as specified.
(1) Remove the debris and dirt from the boiler and check the tightness of
each joint.
(2) Close the valves on the boiler. The safety valve seat can be sealed with
a cover plate. Fill clean water (water temperature is generally 20~70°C) from
the water inlet and open the vent valve to empty. Close the vent valve when the
clean water is full. . The ambient temperature should be higher than 5 °C,
otherwise there must be antifreeze measures. And prevent boiler surface
condensation.
(3) The pressure test pressure of the boiler is 1.4 MPa.
(4) After connecting the pressure test pump to the water inlet, the pump
can be turned on.
(5) The water pressure should rise slowly. When the pressure rises to the
working pressure, the pressure rise should be suspended, check for leaks or
abnormal phenomena, and then rise to the test pressure, hold it at this pressure
for 20 minutes, and then fall again. The work pressure is checked and the
pressure should remain unchanged during the inspection.
(6) The hydrostatic test is qualified when it meets the following conditions:
a. There are no water droplets and water mist on the metal walls and welds
of the pressure elements;
b. No residual deformation was found after the hydrostatic test.
Chapter III、Operating Instructions

Note: The use of the boiler must meet the following criteria:
1. Supervision Regulations for Steam Boiler Safety Technology (1996);
2.JB/T10094-2002 general technical conditions for industrial boilers;
3.GB13271-2001 boiler air pollutant emission standards;
4. GB/T1576-2008 industrial boiler water quality.
5.TSG G0002-2010 Technical Regulations for Boiler Energy
Conservation Technology Supervision
I. Dry furnace
1.The following conditions should be prepared before drying furnace
(1) All boilers and complete accessories have been assembled and tested for
hydrostatic pressure.
(2) Antisepsis and insulation are completed, and the debris in the flue is
cleared.
(3) The boiler valve instrument should be qualified.
(4) After the auxiliary machine required for the boiler has been
commissioned, all parts have the conditions for safe start-up.
2.Dry furnace method and precautions
(1) Before the dry furnace, the boiler must be filled with water accord water
level line.
(2) The flame should be in the hearth of the furnace and be evenly burned.
It should not be interrupted.
(3) The heating temperature of the oven is controlled according to the
temperature of the flue gas at the outlet of the furnace. The daily temperature
rise does not exceed 80°C, and the temperature of the flue gas should not exceed
160°C.
(4) The oven time is generally about 5 days,intermittently starts the drum
and draws the fan to perform mechanical ventilation.
3.The dry furnace's qualified criteria:
After drying furnace ,there should be no deformation or cracks on the
surface of boiler furnace, and the concrete must not be collapsed. Meet the
following requirements when qualified.
Temperature measurement method: The wall on the right side of the
combustion chamber is 1.5~2m. The temperature of the outer surface of the side
wall 100mm inward shall be measured at 50°C, and it shall continue for 48h.
4.Drying furnace curve as shown below:
II. Boiling
Warning: If the boiling does not meet the requirements, the quality of the
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
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
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
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
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.
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,
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.
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
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
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,
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
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.
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.
　　

OPERATING MANUAL Biomass Boiler

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HENAN YUANDA BOILER CORPORATION LTD

HENAN YUANDA BOILER CORPORATION, LTD.

Chapter I、 Introduction to the boiler

Chapter II、 Installation Instructions

Chapter III、Operating Instructions

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