The main elements of boilers are:

1.Upper and lower drums;

3.The left combustion screen is gas-tight;

5.Right combustion screen, the pipes of which are made in the form and overlap the ceiling and the lower part of the firebox (under);

5.Front screen;

6.Rear screen;

7.Two manifolds of the rear combustion screen, made 0 159 * 6 mm;

8. Convective tube bundle;

9. Brickwork;

10.Metal frame;

11.Metal casing;

12.Headset;

13.Fittings;

14.Control and measuring instruments;

15. Three lower pipes, 0 159 * 6 mm for boilers with a steam capacity of up to 16 t/h and 0 219 * 6 mm for DE-25-14 boilers;

16. Recirculation pipe of the rear screen;

17.The blowing device is located on the left side of the convective beam;

18. Boiler piping.

The boiler drums are made of high-quality steel grade 16 GS, internal diameter 1000 mm. The thickness of the drum walls is 13 mm. The convective beam is made along the entire length of the drums from pipes with a diameter of 51ˣ2.5 mm. The left combustion screen is made of pipes 0 51*4 mm. The right combustion screen, front and rear screens are made of pipes d = 51˟2.5 mm. Two rear screen collectors are made of pipes d = 159ˣ6 mm. The recirculation pipe is made of a pipe with a diameter of 76ˣ3.5 mm. Three down pipes with a diameter of 259ˣ6 mm (boilers DE-25-14).

The length of the cylindrical part of the drums increases from 2250 mm for DE-4-14 boilers to 7500 mm for DE-25-14 boilers. The center-to-center distance of the drums is 2750 mm. For access to the inside of the drums, there are manholes in the front and rear bottoms of the drums.

The width of the convective beam is 890 mm for boilers 4; 6.5 and 16 tons of steam and 1000 mm for boilers with a steam capacity of 10 and 25 tons of steam per hour.

The pitch of the convective bundle pipes along the drums is 90 mm, transverse - 110 mm. The middle row of convective bundle pipes along the axis of the drums has a pitch of -120 mm. The pipes of the outer row of the convective bundle have a longitudinal pitch of -55 mm. At the entrance to the drums, the pipes are separated into two rows.

In convective bundles of boilers with a steam capacity of 4; 6.5 and 10 tons of steam per hour, to ensure the required flue gas velocities, longitudinal steel partitions are installed

Boilers with a steam capacity of 16 and 25 tons of steam per hour do not have partitions in the convective beam, and the speed of movement of the flue gases is maintained by changing the width of the convective beam (1000 mm).

The convective beam is separated from the combustion chamber by a gas-tight left combustion screen. Gas tightness is ensured by registering metal plates between the pipes along their entire height from the lower drum to the upper drum.

In the rear part of the left combustion screen, metal plates (spacers) are not installed; the pipes of the rear part of the convective bundle are made in a corridor and form “windows” for the flow of flue gases from the furnace into the convective bundle.

The areas where the screen pipes are routed at the entrance to the drums are compacted with chamotte concrete.

The pipes of the right combustion screen form the bottom and ceiling of the firebox.

Front screen pipes in the amount of 4 or 2 (various modifications of boilers) border the burner embrasure on the right and left and are inserted into the upper and lower drums (see in the figure).

Boiler DE-25-14 GM (Rear view)

The cross-section of the combustion chamber is the same for all boilers. The average height of the combustion chamber is 2400 mm, width 1790 mm. The depth of the combustion chamber increases with increasing boiler steam production from 1930 mm for DE-4-14 boilers to 6960 mm for boilers with 25 tons of steam per hour.

The main part of the pipes of the convective bundle, the right combustion screen, as well as the pipes of the front screen are connected to the drums by flaring.

The pipes of the gas-tight partition, as well as part of the pipes of the right combustion screen and the outer row of the convective beam, are welded to the drums by electric welding.

The pipes of the rear furnace screen are welded to the lower and upper collectors 0 159 * 6 mm. The collectors, in turn, are welded to the upper and lower drums.

The ends of the collectors on the side opposite the drums are connected by an unheated recirculation pipe 0 76 * 3.5 mm.

On all boilers, to protect against overheating on the firebox side of the recirculation pipe and the collectors and back screen pipes, in combustion chamber two tubes 0 51 * 2.5 mm are installed, connected to the drums by flaring (see Fig. No. 2, page 6).

DE boilers with a steam capacity of up to 10 t/h have four circulation circuits:

Water circulation circuit of the convective beam and the left combustion screen;

Circulating water circuit of the right combustion screen;

Front screen water circulation circuit;

Water circulation circuit of the rear combustion screen.

In boilers DE-16-14 and DE-25-14, which have partitions inside the drums and 2-stage evaporation, water circulation is much more complicated.

Boilers with steam capacity 4; 6.5 and 10 tons of steam per hour work with single-stage evaporation. In boilers with a steam capacity of 16 and 25 tons of steam per hour, 2-stage evaporation is used. For these purposes, metal partitions are made in the drums dividing the drums into two compartments: a large compartment - finishing and a small compartment - salt. In the upper drum, the partition is not continuous, that is, it does not cover the entire diameter of the drum.

A solid partition is installed in the lower drum.

In the second stage of evaporation, using transverse partitions in the drums, the following are carried out:

Rear part of the left and right firebox screens;

Rear screen;

Part of a convective bundle of pipes located in an area with higher flue gas temperatures.

The second stage of the upper drum is supplied with water through an overflow pipe 0133 mm long, at least 2 meters long, passing through the dividing partition of the upper drum.

The second stage evaporation circuit has three lower unheated pipes 0159*6 mm, for DE boilers with a steam capacity of up to 16 tons of steam per hour and 0219*6 mm for DE-25-14 boilers.

The drainage system of the salt compartment circuit consists of unheated pipes. The downward system of the first stage of evaporation consists of the last rows of convective bundle pipes along the gas flow.

Separation devices are located in the steam volume of the upper drum: perforated a metal sheet and plate separators.

In the water volume of the upper drum there is a feed pipe and a pipe for introducing chemical reagents. Guide shields and visors for cleaning steam from hardness salts.

The upper drum of the boiler also contains calming speakers and impulse tubes from the finishing and salt compartments to the water level indicators.

Water level indicators are connected to pipes (impulse pipes) coming from the steam and water volumes from the finishing and salt compartments of the upper drum.

Technological solutions TM4
Total information
Equipment layout. Plan at elevation 0.000. View from above. Sections A-A, B-B
Gas ducts of the boiler DE-25-14GM. Plan
Gas ducts of the boiler DE-25-14GM. Sections A-A, B-B. Node I
Gas ducts of the boiler DE-25-14GM. Section B-B. Plan G-G
Air ducts of the boiler DE-25-14GM. Sections A-A, B-B. Node I. Plan at elevation. 2.700
Feedwater pipelines. Plan. Section A-A
Steam pipelines P = 1.37 MPa (14 kgf/sq. cm). Plan. Sections A-A, B-B, B-C
Steam and fuel oil pipelines within the DE-25-14GM boiler. Plan. Sections A-A, B-B
Exhaust, purge and drainage pipelines of the DE-25-14GM boiler. Plan. Section A-A
Exhaust, purge and drainage pipelines of the DE-25-14GM boiler. Sections B-B, V-V, G-G
Piping pipelines KTAN'a-0.8UG and heater KPZ-11-SK-0.1UZ. Plan. Sections A-A, B-B
Scheme of drainage and purge of steam pipeline P = 1.37 MPa (14 kgf/sq. cm)
Additional ladders for boiler DE-25-14GM. Plan. Section A-A
Blowing device DN32. Section A-A
General form thermal insulation for a section of a flat wall. Development task
Gas supply GSV2
Total information
Gas equipment for boiler DE-25-14GM. Boiler front. Plan
Specification for gas equipment of the boiler DE-25-14GM
Gas equipment for economizer EB1-808I. View A
Reinforced concrete structures KZh2
Pendant layout diagram. Total information
Layout of underground structures
Fragment 1. Section 7-7. FOM1. Formwork and reinforcement
FOM2. Formwork and reinforcement. Cuts 2-2…8-8; section a-a
Layout diagram metal structures
Metal frames MP1, MP2
Metal frame MP3. Site L1
Metal technical specification
Automation ATM2
Boiler DE-25-14GM. Total information
Boiler DE-25-14GM. Automation scheme
Boiler DE-25-14GM. Electrical power supply circuit diagram
Boiler DE-25-14GM. Electrical circuit diagram for controlling a valve on steam
Boiler DE-25-14GM. Electrical circuit diagram for controlling a valve on a fuel oil pipeline
Boiler DE-25-14GM. Electrical circuit diagram of the fuel regulator
Boiler DE-25-14GM. Electrical circuit diagram of the level regulator
Boiler DE-25-14GM. Electrical circuit diagram of the air regulator
Boiler DE-25-14GM. Electrical circuit diagram of the vacuum regulator
Boiler DE-25-14GM. External wiring diagram
Boiler DE-25-14GM. External wiring connection diagram
Gas pulse cleaning. Automation diagram for external wiring and connections
Boiler DE-25-14GM. Layout plan
Boiler DE-25-14GM. Installation of MEO-100/25-0.25U to valve 9s-4-2 on the fuel oil pipeline to the boiler
Boiler DE-25-14GM. Installation of MEO-100/25-0.25U to the KRP-50m valve on the feedwater pipeline to the boiler
Boiler DE-25-14GM. Installation of MEO-250/63-0.25U for smoke exhauster DN-12.5
Boiler DE-25-14GM. Installation of MEO-100/25-0.25U to the VDN-11.2 fan
Boiler DE-25-14GM. Installation of MEO-100/25-0.25U to the regulating disc valve 32TsO22BK Du150
Boiler DE-25-14GM. Installation of the MIS-4100 electromagnet on the safety shut-off valve type PKN Du200

Our company took an active part in the preparation of the project, delivery and commissioning of the DE-25 steam boiler with a "Weishaupt" WKG 80/3-A burner, isp. ZM-NR, installed in the Kaluga region. Due to the failure of the old DE-25 steam boiler, it was decided to completely replace it. The new boiler was supplied from the Biysk Boiler Plant by rail.
The modern DE 25-14 GMO steam boiler is a fully factory-ready product - it is supplied as a single transportable unit with lining and casing, unlike the old boiler with heavy lining.
The failed DE 25 boiler was dismantled.

In its place (by partially dismantling the ceilings) a new steam boiler was installed. This required modification of the foundations (the layout and geometric dimensions of the old and new boilers do not match) and a change in the gas pipeline layout. The use of an automated modulating burner "Weishaupt" necessitated a significant increase in pressure in the supply gas pipeline (up to 4 kgf/cm2), which entailed the design and installation of a new gas pipeline line. Since the boiler was initially adapted by the manufacturer for the installation of a Weishaupt burner, no project for connecting the burner to the boiler was required.

Based on the results of agreements with the customer, the following equipment was adopted: burner "Weishaupt" WKG 80/3-A, used. ZM-NR, DN 150 was supplied complete with a gas train and burner control cabinet, as well as a blower fan. The burner gas train includes a double magnetic valve, a regulator high pressure gas, filter, ball valve, as well as safety automation, valve leak testing unit, connecting and mounting elements. The existing smoke exhauster and economizer were left. In order to reduce the cost of the project, it was decided to abandon the modules frequency control fan and smoke exhauster motors, but provided for the possibility of installing them in the future. For this purpose, a W-FM 200 combustion manager was installed on the burner, including a frequency control module.
Thus, the approximate cost of supplying the specified burner configuration was 3,500,000 rubles (including the control cabinet and fan station, including VAT). Other costs related to gas pipeline design, foundation modifications and adjustments amounted to about 200,000 rubles, the cost of the actual installation and commissioning work amounted to about 800,000 rubles (incl. VAT). The cost of a new DE 25-14 GMO steam boiler with lining was approximately 3,000,000 rubles. (incl. VAT). Thus, the cost of purchasing equipment and all work to replace the DE 25 steam boiler with a new one using a Weishaupt automated modulating burner amounted to approximately 7,500,000 rubles. in view of VAT.

Installing the burner on the boiler did not pose any difficulties. According to the operating conditions of the boiler plant at the time of measurements, the steam output of the boiler was limited to 20 tons.

Name of the operating parameter of the steam boiler DE 25

Unit change

Meaning

Boiler steam production

T/h 19.61

3

Fuel consumption

4 5 107,0

oC

Flue gas temperature behind the economizer

Feedwater temperature before/after economizer

O C 80/120

Water pressure at the boiler inlet

Kgs/cm 2 8.0

Steam pressure in the boiler drum

Kgs/cm 2 7.5

12

Vacuum in the boiler furnace

14

Pa 0

ppm 23

Excess air coefficient behind the boiler

Heat loss with flue gases

18

The same from chemical underburning of fuel

№	a couple per hour. The measurement results are shown in the following table:
1
2
M 3 / h 1384.21	Air temperature in front of the burners	282,5
Flue gas temperature behind the boiler	Air temperature in front of the burners
6
7
8	9
10
11
13
15
16
17

Same for the environment
Boiler efficiency

Among the identified non-critical shortcomings in the operation of the boiler installation as a whole, it should be noted that the response of the outdated smoke exhauster damper drive lags behind the change in vacuum in the furnace caused by the operation of a higher-speed modern blower fan damper servo drive installed on the burner. In this case, fluctuations in vacuum/pressure are observed in the furnace of the steam boiler with sudden changes in steam consumption. The problem is not fundamental, and can be finally eliminated by installing frequency regulators on the electric motors of the fan and smoke exhauster.
At the moment, the steam boiler DE-25/14 GMO has been put into operation and is being operated as usual. The automation of the modulating burner clearly ensures the specified steam pressure, smoothly reducing or increasing the heat output of the burner. A significant increase in control accuracy has been achieved, the participation of boiler room personnel in the operation of the boiler plant has become minimal, the level of safety of the facility as a whole has increased, and gas consumption has decreased. There are no complaints about the operation of the boiler.

Name of the operating parameter of the steam boiler DE 25

Name of equipment and parameters

- DE-25/14GMO

2

Boiler steam output

T/h 25

3 4 saturated

Heating surface (full)

M 2 271

№	Application:
list of main equipment installed at the facility.
1
Design steam pressure	kgf/cm 2	13
Design steam temperature	Air temperature in front of the burners
5
6

Checkout

Order

PURPOSE OF THE PRODUCT

DE boilers are double-drum, vertical-water-tube boilers designed to produce saturated or slightly superheated steam used for the technological needs of industrial enterprises, heating, ventilation and hot water supply systems.

Basic specifications boiler DE-25-14GMO are given in the table.

Price
6,700,000 rub.

Model specifications Boiler DE-25-14GMO

Steam capacity, t/h	25
Working pressure (excess) of steam at the outlet, MPa (kg/cm?)	1,3 (13)
Temperature of superheated steam at the outlet, ? C	194
Feed water temperature, ? C	100
Estimated efficiency (gas), %	93
Estimated efficiency (fuel oil), %	91
Estimated fuel consumption (gas), m?/h	1762
Estimated fuel consumption (fuel oil), m?/h	1670
Total heating surface of the boiler, m?	262
Superheater heating surface	-
Boiler water volume, m?	16.4
Steam volume of the boiler, m?	2.6
The water reserve in the water indicator glass is max. level, min	3.1
Total number of convective bundle tubes, pcs.	703
Dimensions of transportable unit, LxWxH, mm	9390x3090x4032
Layout dimensions, LxWxH, mm	10095x5240x6072
Boiler length (with stairs and platforms), mm	11500
Boiler width, mm	5770
Boiler height, mm	4720
Weight of transportable boiler block, kg	23500
Weight of the boiler as supplied by the factory, kg	27850
Basic kit assembled	Boiler block with casing and insulation, stairs, platforms, burner GMP-16
Additional equipment:
Economizer	BVES-V-1
Economizer	EB1-808
Fan	VDN-11.2-1500
Smoke exhauster	DN-12.5-1500
Box No. 1	(Fittings for boiler DE-25-14GMO)
Box No. 2	(Safety devices for boiler DE-25-14GMO)

PRODUCT DESCRIPTION

The combustion chamber of the boilers is located on the side of the convective beam, equipped with vertical pipes flared in the upper and lower drums. The width of the combustion chamber along the axes of the side screen pipes is the same for all boilers - 1790 mm. Combustion chamber depth: 1930 - 6960 mm. The main components of the boilers are the upper and lower drums, the convective beam, the front, side and rear screens that form the combustion chamber.

The pipes of the gas-tight partition and the right side screen, which also forms the ceiling of the combustion chamber, are inserted directly into the upper and lower drums. The ends of the rear screen pipes are welded to the upper and lower collectors Ф 159х6 mm. The front screen pipes of the DE-25-14GMO boiler are flared in the upper and lower drums. In all standard sizes of DE boilers, the diameter of the upper and lower drums is 1000 mm. The distance between the axes of the drums is 2750 mm (the maximum possible according to the conditions for transporting the block along railway). The length of the cylindrical part of the boiler drums with a capacity of 10 t/h is 7500 mm. For access to the inside of the drums, there are manhole gates in the front and rear bottoms of each of them. Drums for boilers with operating absolute pressure of 1.4 and 2.4 MPa (14 and 24 kgf/cm2) are manufactured from steel sheet in accordance with GOST 5520-79 from steel grades 16GS and 09G2S GOST 19281-89 and have a wall thickness of 13 and 22 mm. In the water space of the upper drum there is a feed pipe and a pipe for introducing phosphates, and in the steam volume there are separation devices. The lower drum contains a device for steam heating of water in the drum during kindling and pipes for draining water; for boilers with a capacity of 25 t/h, there are perforated pipes for periodic purging.

Boilers with a steam capacity of 25 t/h use two-stage evaporation. The second stage of evaporation includes the rear part of the furnace screens and part of the convective beam, located in a zone with more high temperature gases The second stage evaporation circuits have an unheated downdraft system.

The convective beam is separated from the combustion chamber by a gas-tight partition, in the rear part of which there is a window for the entry of gases into the beam. The partition is made of pipes Ø 51x2.5 mm placed closely with a pitch of 5 = 55 mm and welded together. When inserted into drums and pipes, they are separated into two rows. The distribution points are sealed with metal spacers and chamotte concrete. The convective bundle is formed by vertical pipes Ø 51 x 2.5 mm arranged in a corridor, flared in the upper and lower drums. The pipe pitch along the drum is 90 mm, the transverse pitch is 110 mm (except for the average pitch, which is 120 mm).

DE-16-14GMO boilers do not have stepped partitions in the beam, and the required level of gas velocities is maintained by changing the beam width from 890 to 1000 mm. Flue gases pass across the entire cross-section of the convective beam and exit through the front wall into the gas box, which is located above the combustion chamber, and through it they pass to the economizer located at the rear of the boiler.

All standard sizes of boilers have the same circulation circuit. The contours of the side screens and the convective beam of all standard sizes of boilers, as well as the front screen of boilers with a steam capacity of 25 t/h, are closed directly to the drums; the contours of the rear screen of all boilers are connected to the drum through intermediate collectors: the lower one is distributing (horizontal) and the upper one is collecting (inclined). The ends of the intermediate collectors on the side opposite to the drums are united by an unheated recirculation pipe Ф 76 x 3.5 mm.

As the primary separation devices of the first stage of evaporation, guide shields and canopies installed in the upper drum are used, ensuring the delivery of the steam-water mixture to the water level. A horizontal louvered separator and a perforated sheet are used as secondary separation devices of the first stage of the DE-25-14GMO boiler. The separation devices of the second stage of evaporation are longitudinal shields that ensure the movement of the steam-water mixture, first to the end, and then along the drum to the transverse partition separating the compartments. The staged evaporation compartments communicate with each other via steam through a window above the transverse partition, and via water through a feed pipe Ø 89 - 108 mm, located in the water volume.

On boilers with a capacity of 25 t/h, the superheater is vertical, drained, made of two rows of pipes Ø 51x2.5 mm, the outer row pipes when entering the collectors Ø 159 mm are cased to Ø 38 mm.

Dense shielding of the side walls (relative pitch of the pipes a = 1.08), ceiling and bottom of the combustion chamber makes it possible to use light insulation on boilers in two to three layers of insulating boards with a total thickness of 100 mm, laid on a layer of fireclay concrete on a grid 15-20 mm thick. For DE-25-14GMO boilers, the front wall lining is made of fireclay bricks 125 mm thick and several layers of insulating boards 175 mm thick, the total thickness of the front wall lining is 300 mm. The lining of the rear wall consists of a layer of fireclay bricks 65 mm thick and several layers of insulating boards 200 mm thick; the total thickness of the lining is 265 mm. To reduce suction into the gas path of the boiler, the insulation is covered from the outside with metal sheet cladding 2 mm thick, which is welded to the frame. Cut sheathing sheets are supplied by the factory in packages. The use of pipe lining with a tight pipe pitch can improve the dynamic characteristics of boilers and significantly reduce heat losses to the environment, as well as losses during start-ups and shutdowns.

Standard cast iron economizers EB, proven by long-term operating experience, are used as tail heating surfaces of boilers.

The boilers are equipped with stationary blowers located on the left side of the boiler. For blowing boilers, saturated or superheated steam with a pressure of at least 0.7 MPa (7 kgf/cm2) is used.

All boilers have a support frame to which the mass of the boiler elements operating under pressure, the mass of boiler water, as well as the mass of the piping frame, pipe lining and lining are transferred. The fixed supports of the boilers are the front supports of the lower drum. The middle and rear supports of the lower drum are movable and have oval holes for bolts that are attached to the support frame during transportation.

Each boiler E (DE) is equipped with two spring safety valves, one of which is a control valve. On boilers without a superheater, both valves are installed on the upper drum of the boiler and any of them can be selected as a control valve; on boilers with a superheater, the control valve is the valve of the superheater outlet manifold.

Nominal steam production and steam parameters corresponding to GOST 3619-89 are provided at a feed water temperature of 100°C when burning fuels: natural gas with a specific heat of combustion of 29300 - 36000 kJ/kg (7000 - 8600 kcal/m3) and fuel oil grades 40 and 100 according to GOST 10588-75.

The control range is from 20 to 100% of the nominal steam output. Short-term operation with a load of 110% of the rated steam output is allowed. Maintaining the superheat temperature in boilers with steam superheaters is ensured in the load range of 70-100%

DE-25-14GMO boilers can operate in the pressure range of 0.7-1.4 MPa (7-14 kgf/cm2). With a decrease in operating pressure, the boiler efficiency does not decrease.

In boiler houses designed to produce saturated steam without imposing strict requirements on its quality, the steam production of DE type boilers at a pressure reduced to 0.7 MPa (7 kgf/cm2) can be taken the same as at a pressure of 1.4 MPa (14 kgf/cm2).

For boilers type E (DE) throughput safety valves corresponds to the nominal boiler performance at an absolute pressure of not less than 0.8 MPa (8 kgf/cm2). If the heat-using equipment connected to the boiler has a maximum operating pressure less than the above values, additional safety valves should be installed on it to protect this equipment. When operating at reduced pressure, safety valves on the boiler and additional safety valves installed on the equipment must be adjusted to the actual operating pressure.

With a decrease in pressure in boilers to 0.7 MPa (7 kgf/cm2), changes in the configuration of boilers with economizers are not required, since in this case the underheating of water in the feed economizers to the steam saturation temperature in the boiler is more than 20 ° C, which satisfies the requirements rules of Rostekhnadzor.

Boilers are supplied assembled as one transportable unit, including upper and lower drums with internal drum devices, a pipe system of screens and a convection beam (if necessary, a superheater), a support frame, a piping frame, casing, insulation, and a burner.

TECHNICAL DESCRIPTION, INSTRUCTIONS

INSTALLATION, OPERATION, MAINTENANCE AND REPAIR

00.0303.002 Ie

INTRODUCTION

TECHNICAL DESCRIPTION

FITTINGS, INSTRUMENTATION AND SAFETY DEVICES

INSTALLATION INSTRUCTIONS

Transportation

Reception and storage of the boiler

Requirements for the boiler installation location

Boiler installation

Installation of burners

Security measures

Drying of lining, alkalization

WATER CHEMICAL REGIME OF BOILERS

OPERATING INSTRUCTIONS

General provisions

Inspection and preparation for kindling

Kindling

Putting the boiler into operation

Stopping the boiler

Emergency stop

INTERNAL CLEANING OF THE BOILER

Mechanical boiler cleaning

Chemical boiler cleaning

BOILER REPAIR

a common part

Types of defects and damage to boiler elements

Checking the condition of the boiler elements

Carrying out repair work

Marking

BOILER INSPECTION PROGRAM

Drum inspection

Inspection of heating surface pipes

Inspection of screen collectors, superheater

Inspection of pipelines within the boiler, unheated pipes with an outer diameter of 100 mm or more

Standards for assessing the quality of examined elements

LIST OF REGULATIVE AND TECHNICAL DOCUMENTATION APPLIED IN EXPERT DEFECTOSCOPIC INSPECTION OF STEAM BOILERS DKVR AND DE

Appendix 1. Slider diagrams, sheets 1, 2, 3, 4 Appendices

Appendix 2. Figure safety valve

Appendix 3. Preparing pipes for welding. Types of plugs and their installation

INTRODUCTION

This manual provides a description, design and technical characteristics of the boilers.

The instructions were developed in accordance with GOST 2.601-68 “ESKD. Operational Documents" and contains information necessary for installation, start-up, commissioning, operation, maintenance and repair of gas-oil boilers of type DE, steam capacity 4; 6.5; 10; 16 and 25 t/h with an absolute pressure of 1.4 and 2.4 MPa (14 and 24 kgf/cm2) according to GOST 3619-89.

In addition to these instructions, when carrying out work, you must additionally be guided by the following documents:

“Rules for the design and safe operation of steam and hot water boilers” approved by the Gosgortekhnadzor of Russia (hereinafter referred to as “Rules for Boilers”);

“Rules for the design and safe operation of steam and hot water pipelines” approved by Gosgortekhnadzor;

SNiP 3.05.05 – 84 “ Technological equipment and technological pipelines";

SNiP 3.01.01 – 85 “Organization of construction production”;

SNiP 3.05.07 – 85 “Automation system”;

SNiP 111 – 4 – 80 “Safety in construction”;

VSN 217 – 87 “Preparation and organization of construction and installation work during the construction of boiler houses”;

SNiP 3.01.04 – 87 “Acceptance of completed construction projects. General provisions";

GOST 27303 – 87 “Steam boilers. Acceptance after installation."

TECHNICAL DESCRIPTION

Purpose, technical data and design of boilers

DE steam boilers are designed to produce saturated or superheated steam used for the technological needs of industrial enterprises, as well as heating, ventilation and hot water supply systems.

The main characteristics and parameters of the boilers are given in Table 1.

Double-drum vertical water-tube boilers are made according to the “D” design scheme, a characteristic feature of which is the lateral location of the combustion chamber relative to the convective part of the boiler.

The main components of the boilers are the upper and lower drums, the convection beam and the left combustion screen (gas-tight partition), the right and rear combustion screens that form the combustion chamber, as well as the screening pipes for the front wall of the firebox.

In all standard sizes of boilers, the internal diameter of the upper and lower drums is 1000 mm. The length of the cylindrical part of the drums increases with increasing boiler steam production from 2250 mm for 4 t/h boilers to 7500 mm for 25 t/h boilers. The distance between the drum axes is 2750 mm.

The drums are made of sheet steel grade 16GS GOST5520-79 with a thickness of 13 and 22 mm for boilers with an operating absolute pressure of 1.4 and 2.4 MPa, respectively (14 and 24 kgf/cm2).

For access to the inside of the drums, there are manholes in the front and rear bottoms.

The convective beam is formed by vertical pipes Ø51x2.5 mm located along the entire length of the cylindrical part of the drums, connected to the upper and lower drums.

The width of the convective beam is 1000 mm for boilers with a steam capacity of 10; 25 t/h and 890 mm - for other boilers.

The longitudinal pitch of the convective bundle pipes is 90 mm, the transverse pitch is 110 mm (except for the average pitch located along the axis of the drums, equal to 120 mm). The pipes of the outer row of the convective bundle are installed with a longitudinal pitch of 55 mm; When entering the drums, the pipes are separated into two rows of holes.

In convective bundles of boilers 4; 6.5 and 10 t/h, longitudinal cast iron or stepped steel partitions are installed. Boilers 16 and 25 t/h do not have partitions in the bundle.

The convective beam is separated from the combustion chamber by a gas-tight partition (left combustion screen), in the rear part of which there is a window for gases to enter the beam.

The pipes of the gas-tight partition, the right side screen, which also forms under the ceiling of the combustion chamber, and the pipes of the front wall screening are inserted directly into the upper and lower drums.

The cross-section of the combustion chamber is the same for all boilers. Its average height is 2400 mm, width - 1790 mm. The depth of the combustion chamber increases with increasing boiler steam production from 1930 mm for DE - 4 t/h to 6960 mm for DE - 25 t/h.

Factory designation of standard sizes

Steam productivity, t/h

Boiler operating pressure MPa (kgf/cm2)

State or temperature of steam, °C

Total heating surface, m 2

Boiler water volume, m 3

Steam volume of the boiler, m 3

Dimensions of the transportable unit

Boiler dimensions by boiler cell

Weight of transportable boiler block, kg

Boiler weight as supplied by the plant, kg

Type of gas and oil burner

Estimated fuel consumption for separate combustion

Accessories

economizer

fan

Fuel oil, kg/h

Gas, m 3 / h

DE-4-14GM-O/R/

saturated

EB2-94I (BVES-1-2)

DE-4-14-225GM-O

overheated 225(+25;-10)

DE-6.5-14GM-O/R/

saturated

EB2-142I (BVES-2-2)

VDN-11.2-1000

DE-6.5-14-225GM-O

overheated 225(+25;-10)

DE-10-14GM-O/R/

saturated

EB2-236I (BVES-3-2)

DE-10-14-225GM-O

overheated 225(+25;-10)

DE-10-24GM-O

saturated

DE-10-24-250GM-O

overheated 250(+25;-10)

DE-16-14GM-O/R/

saturated

EB2-330I (BVES-4-1)

VDN-11.2-1500

DE-16-14-225GM-O

overheated 225(+25;-10)

DE-16-24GM-O

saturated

DE-16-24-250GM-O

overheated 250(+25;-10)

DE-25-14GM-O/R/

saturated

EB2-808I (BVES-5-1)

VDN-11.2-1500

DE-25-14-225GM-O

overheated 225(+25;-10)

DE-25-15-270GM-O

overheated 270(+25;-10)

DE-25-15-285GM

overheated 285(+25;-10)

DE-25-24GM-O

saturated

DE-25-24-250GM-O

overheated 250(+25;-10)

DE-25-24-380GM-O

overheated 270(+25;-10)

VDN-12.5-1500

Table 1

To the table

The minimum steam load of boilers, depending on the state of the burner, is 20-30% of the calculated one.

The maximum steam load of boilers, taking into account sufficient blast and draft (short-term) for boilers DE-4-10GM-120% of the calculated one; for boilers DE16-25GM-110% of the calculated value.

Feed water temperature - 100°C (+10; -10).

The temperature of the blast air in front of the burner is not lower than 10°C.

The letter “O” in the factory designation of boilers means: a boiler with casing and insulation.

When equipping boilers operating on fuel oil with a steel economizer, in order to increase the service life of the latter, it is necessary to provide additional feedwater heaters that ensure heating of the water in front of the economizer to 130°C (to increase the temperature of the wall of the economizer coils). This is due to the low-temperature, sulfurous corrosion that occurs under these conditions, which occurs intensively when sulfurous acid condenses onto colder metal walls below the dew point.

The plant can equip boilers with a steam capacity of 4; 10 t/h compact steel economizers supplied as one unit with the boiler and feedwater heaters installed in the lower drum.

The pipes of the right combustion screen Ø51x2.5 mm are installed with a longitudinal pitch of 55 mm; When entering the drums, the pipes are separated into two rows of holes.

The shielding of the front wall is made of pipes Ø51x2.5 mm.

The gas-tight partition is made of pipes Ø51x2.5 mm or Ø51x4 mm, installed at 55 mm intervals. At the entrance to the drums, the pipes are also separated into two rows of holes. The vertical part of the partition is sealed with metal spacers welded between the pipes. The pipe distribution areas at the entrance to the drums are sealed with metal plates and chamotte concrete welded to the pipes.

The main part of the pipes of the convective bundle and the right furnace screen, as well as the shielding pipes of the front wall of the furnace, are connected to the drums by rolling.

To increase the strength of the rolling joints, one annular recess is rolled into the walls of the holes drilled for the pipes being rolled. When rolling, the metal of the pipe fills the recess, creating a labyrinth seal.

Pipes of the gas-tight partition are connected to the drums by electric welding or rolling: part of the pipes of the gas-tight partition, the right combustion screen and the outer layer of the convective beam, which are installed in holes located in the welds or heat-affected zone, are attached to the drum by electric welding or rolled.

The design of the rear firebox screen is possible in two versions:

Pipes of the rear furnace screen Ø51x2.5 mm, installed with a pitch of 75 mm, are welded to the upper and lower screen collectors Ø159x6 mm, which in turn are welded to the upper and lower drums. The ends of the rear screen collectors on the side opposite the drums are connected by an unheated recirculation pipe Ø76x3.5 mm; to protect the recirculation pipes and collectors from thermal radiation, two pipes Ø51x2.5 mm are installed at the end of the combustion chamber, connected to the drums by rolling.

C-shaped pipes Ø51x2.5 mm, forming the rear screen of the firebox, are installed in increments of 55 mm and connected to the drums by rolling.

Boiler superheaters 4; 6.5 and 10 t/h are made of coils from pipes Ø32x3 mm.

On boilers of 16 and 25 t/h at a pressure of 1.4 and 2.4 MPa with steam superheating of 225°C and 250°C, the superheaters are vertical, made of two rows of pipes Ø51x2.5 mm. The outer row of pipes when entering the Ø159x6 mm collectors are cased up to Ø38 mm. The two-stage superheater is located at the beginning of the convective beam (opposite the exit window from the furnace). The outer row of the superheater, made of cased pipes, simultaneously serves as part of the enclosing wall of the boiler block. Saturated steam from the upper drum is directed by bypass pipes Ø108x4.5 mm to the upper manifold of the first superheating stage, located second along the gas flow. Having passed the pipes of the first stage, the lower manifold Ø159x6 mm and the pipes of the second stage of superheating, the steam is supplied to the outlet of the manifold Ø159x6 mm.

The steam superheater of the DE-25-24-380 GM boiler is made of coil pipes Ø38x3 mm, two-stage and is located at the beginning of the convective beam across the entire width of the flue. To regulate superheat, a surface desuperheater located in the lower drum of the boiler and two control valves are used.

Saturated steam from the upper drum is directed by bypass pipes Ø108x4.5 mm to the upper manifold of the first superheating stage (second along the gas flow). Having passed through the coils and the first stage, steam from the lower outlet of the collector is directed either by two pipes Ø108x4.5 mm to the desuperheater, or by one pipe Ø108x4.5 mm to the lower collector of the second stage of superheating (the first in the flow of gases).

Having passed the second stage, the steam is supplied to the outlet through the upper manifold. The superheater collectors are made of pipes Ø159x6 mm.

Boilers with steam capacity 4; 6.5 and 10 t/h are made with a single-stage evaporation scheme. In boilers 16; 25 t/h – two-stage evaporation scheme. The second stage of evaporation, using transverse partitions in the drums, includes the rear part of the left and right furnace screens, the rear screen and part of the convective beam located in the zone with a higher gas temperature.

The second stage of evaporation is fed from the first stage through a Ø108 mm bypass pipe passing through the transverse partition of the upper drum. The circuit of the second stage of evaporation has unheated downpipes Ø159x4.5mm.

Lowering link of circulation circuits of boilers 4; 6.5 and 10 t/h, and the first stage of evaporation of boilers 16 and 25 t/h are the last least heated rows of convective bundle pipes along the gas flow.

In the water space of the upper drum there is a feed pipe and fenders, and in the steam volume there are separation devices.

The lower drum contains a device for steam heating of water during kindling, a perforated purge pipeline and pipes for draining water.

As primary separation devices, fender shields and guide visors installed in the upper drum are used, ensuring the supply of the steam-water mixture to the water level. A perforated sheet and a louvered separator are used as secondary separation devices.

The fender shields, guide visors, louvered separators and perforated sheets are made removable to allow complete inspection and repair of the rolling connections of the pipes with the drum and the drum itself. All separation devices are attached to half-clamps welded to the drum using studs and nuts. Disassembly and assembly of louvered separators and perforated sheets is carried out element by element. Dismantling of fender shields begins with the lower shield. Assembly of separation devices is carried out in the reverse order.

When assembling steam separation devices, you should pay attention to creating a tightness in the places where the fender panels are connected to each other and in the places where they are attached to the half-clamps, as well as in the places where the guide visors are connected to the strip with studs: install new paronite gaskets, lubricated with graphite.

If it is necessary to adjust the water chemistry of boilers, the introduction of phosphates should include a line between the economizer and the boiler.

On boilers with steam capacity 4; 6.5 and 10 t/h are provided continuous blowing from the lower manifold of the rear screen (in the case where the rear screen has a manifold). On boilers with steam capacity 4; 6.5 and 10 t/h in which the rear furnace screen is made of C-shaped Ø51 mm, periodic boiler blowing is combined with continuous blowing, carried out from the front bottom of the lower drum: it is recommended to insert the periodic blowing pipeline in the gap between the shut-off and regulating body on the line continuous blowing.

Boilers with a steam capacity of 16 and 25 t/h have continuous blowing from the second evaporation stage (salty compartment) of the upper drum and periodic blowing from the clean and salty compartments of the lower drum and the lower collector of the rear screen (in the case where the rear screen has a collector).

Flue gas output from boilers with steam capacity 4; 6.5 and 10 t/h are carried out through a window located on the rear wall of the boiler. On boilers with a steam capacity of 16 and 25 t/h, the exit of flue gases is through a window in the left side wall of the boiler at the end (along the gas flow) of the convective beam.

To clean the outer surface of the convective beam pipes from deposits, the boilers are equipped with stationary blowers or a wave generator (GUV).

The blower has a pipe with nozzles that must be rotated when blowing. The outer part of the apparatus is attached to the casing of the left convective wall of the boiler. The blower pipe is rotated manually using a flywheel and chain.

For blowing, saturated or superheated steam from operating boilers is used at a pressure of at least 0.7 MPa.

The shock wave generator, like gas-pulse cleaning (GCP), is a representative of the shock wave cleaning method, based on the interaction of contaminated heating surfaces with a shock wave and a high-speed flow of combustion products that are formed during the combustion of a powder charge.

The portable device, weighing 17 kg, consists of the shock wave generator itself with a remote trigger mechanism, a corresponding barrel and a powder charge.

To carry out activities using this cleaning method, boilers are equipped with special pipes and installation platforms (attachment points to the casing).

To remove soot deposits from the convective beam, hatches are installed on the left wall of the boiler.

All boilers have three peeper hatches - two on the right side and one on the rear walls of the combustion chamber.

The opening into the firebox can be the hole of the explosion valve or the burner lance.

Explosion valves on boilers 4; 6.5; 10 t/h are located at the front of the boiler. On boilers of 16 and 25 t/h there are three explosion valves - one on the front wall and two on the boiler flue.

Boilers are manufactured at the factory in the form of one transportable unit, mounted on a support frame and including: drums, pipe system, superheater (for boilers with superheated steam), frame, insulation and casing.

Boilers can also be manufactured as a block without insulation and cladding installed at the factory: in this case, the insulation and cladding of the boiler block is carried out during installation in the manner described below.

Dense shielding of the side walls (relative pitch of pipes S = 1.08), ceiling and bottom of the combustion chamber allows the use of light insulation 100 mm thick on boilers, laid on a layer of fireclay concrete 15-20 mm thick, applied over a grid. Asbestos-vermiculite slabs or those with thermophysical properties equivalent to them are used as insulation.

The lining of the front wall is made of refractory fireclay bricks of class A or B diatomaceous brick, insulating boards, the lining of the rear wall is made of refractory fireclay bricks and insulating boards.

To reduce air suction, the insulation on the outside is covered with metal sheeting 2 mm thick, which is welded to the frame.

The plant does not supply brickwork and insulation materials.

Technical documentation for insulation implementation for design organizations and customers.

Boiler blocks, in the marking of which the last letter is O, are manufactured and supplied by the plant in insulation and casing.

As insulation on these boilers, mullite-silica felt MKRV-200 GOST 23619-79 is used and mineral wool increased temperature resistance TU36.16.22-31-89, laid between dense enclosing heating surfaces and the boiler casing.

To seal inter-pipe gaps at the entrance to drums, in explosion valves, burner flanges, manhole covers and other components, asbestos cardboard KAON-1-5 GOST 2850-80 and asbestos cord SHAON 22 GOST 1779-83 are used.

Sheathing sheets for blocks supplied insulated have a thickness of 3 mm, 2 mm for boilers supplied without insulation, and are welded along the entire contour of the junction to the frame elements.

More information about the insulation (lining) of boilers is described in the sections devoted to the installation and repair of boilers.

The support frame takes the load from the boiler elements operating under boiler water pressure, as well as the frame, insulation and cladding.

The load from the boiler pressure elements and boiler water is transferred to the support frame through the lower drum.

To install the lower drum, the design of the support frame includes front and rear transverse beams with support pads, as well as supports - two to the right of the drum (from the firebox side) on the transverse beams and two to the left of the drum on the longitudinal beam.

The lower drum at the front of the boiler is fixed motionless by welding the drum to the transverse beam of the support frame through a ring and fixed supports. The frame and casing from the front of the boiler are also fixedly attached to the lower drum. Thermal expansion the drum is provided towards the rear bottom, for which the rear supports are made movable. A benchmark is installed on the rear bottom of the lower drum to control the thermal expansion of the drum (boiler). Installation of benchmarks to control the thermal expansion of boilers in the vertical and transverse directions is not required, since the design of the boilers ensures thermal movement in these directions.

To burn fuel oil and natural gas, gas and oil burners GMP and GM are installed on the boilers (Table 1).

The main components of the burners are the gas part, a blade apparatus for swirling air, a nozzle assembly with main and backup steam-mechanical nozzles and flaps that serve to close the holes of the removed nozzle.

At the front of the burner, installation of a peephole and an ignition-protective device is provided.

The combustion chamber for two-stage fuel combustion, installed on 25 t/h boilers, includes a housing, inner and outer shells and a tangential air swirler.

The fuel is supplied in full quantity to the GMP-16 burner, installed at the front of the combustion chamber for two-stage fuel combustion. There, through the annular slot formed by the outer casing and the inner shell of the combustion chamber, primary air is supplied (70% of the total amount of air required for complete combustion of the fuel), secondary air (30% of the total) enters through the annular gap and the tangential swirler cameras. The directions of rotation of primary and secondary air are the same.

The combustion chamber of two-stage fuel combustion is protected from torch radiation by fire-resistant fireclay masonry of class “A”.

The embrasure of the GMP-16 burner is of a conical type with an opening angle of 35° to one side, while that of the GM-10, GM-7, GM-4.5 and GM-2.5 burners is of a conical type with an opening angle of 25° to one side.

The GM-7, GM-4.5 and GM-2.5 air burners are vortex, the GM-10 burner is direct-flow vortex.

The boilers are earthquake-resistant under seismic impacts of up to 9 points (on the MSK-64 scale) inclusive.

The design of boilers is constantly being improved, so individual components and parts may differ slightly from those described in

instructions.

FITTINGS, CONTROL AND INSTRUMENTS AND

SAFETY DEVICES

Each boiler is equipped with two spring safety valves.

On boilers without a superheater, both valves are installed on the upper drum of the boiler.

On boilers with a superheater, one valve is installed on the drum, the second - on the outlet manifold of the superheater.

The valves are adjusted in accordance with the instructions in the corresponding section of the “Installation Instructions”.

The boilers are equipped with two direct-acting water level indicators, which are connected to pipes communicating with the steam volumes of the upper drum.

In boilers with a steam capacity of 16 and 2.5 t/h with a two-stage evaporation scheme, one of the water level indicators is connected to the clean compartment, the second to the salty one.

Installation of indicators and their maintenance are carried out in accordance with the accompanying technical documentation of the plant and the Boiler Rules (section 6.3).

The boilers are equipped with the required number of pressure gauges and fittings.

To connect safety devices and control systems on the boilers, installation locations for selected devices are provided, the location of which is shown in the general drawings.

The choice of the type of instruments of the instrumentation and automation system and the installation location of their boiler room is determined by the design organization when developing the boiler room project, taking into account the requirements of section 6.7. Rules on boilers and SNiP.

INSTALLATION INSTRUCTIONS

Transportation

Boilers are supplied to consumers in two options:

Assembled in one transportable block with lining and cladding. The cladding is supplied separately, the lining materials are not supplied by the factory;

Assembled in one transportable block with lining and cladding.

Technical documentation for installation insulation is sent to design organizations and customers.

Boilers can be transported by rail, road and water transport.

Transportation by rail is carried out in accordance with the “Rules for the transportation of goods” approved by the Ministry of Railways.

Boilers loaded onto a railway platform; together with all fastenings fit into the loading dimensions in accordance with the requirements technical specifications for loading.

There are special load brackets on the boiler block for slinging and rigging. Slinging to other parts of the boiler is not permitted.

To transport boilers on roads, trailers of appropriate load capacity are used, which have the necessary devices for reliable fastening of the blocks. The speed of transportation on a trailer on paved roads should be no more than 40 km/h, on unpaved roads - no more than 20 km/h.

Transportation by sea is carried out in accordance with the “Rules for the safe maritime transportation of general cargo”.

Reception and storage of the boiler

The consumer must accept the boiler from the railway or other transport organizations in accordance with the “Instructions on the procedure for accepting production products technical purpose and consumer goods”, approved by the State Arbitration, as well as in accordance with the technical and shipping documentation of the manufacturer.

Responsibility for organizing the acceptance and storage of equipment lies with the customer or the organization conducting the warehouse under the contract.

When accepting boiler blocks, their external surfaces are inspected, the condition of screen and convection pipes, drums and other elements is checked.

The surfaces of drums, collectors, and flanges must not have nicks, dents or other defects.

All fittings must be subjected to external and internal inspection, as well as hydraulic testing for density and strength in accordance with GOST 356-80.

Upon completion of the inspection, a technical acceptance certificate for the equipment is drawn up with a list of defects attached. Defects found must be corrected.

Boiler blocks, packages and boxes with parts must be stored indoors. In the absence of premises, it is allowed to store boilers delivered without lining and casing on open area with their installation on linings.

Pipe flanges must be closed with plugs or conical plugs with a diameter 10 mm larger than the hole diameter, drum manholes and manifold hatches are closed and battened down.

Boiler fittings, fasteners, flanges, blowers must be stored indoors.

When stored in an open area, boiler blocks and component assembly units must be periodically (at least once every 3 months) inspected and, if contamination, damage to paint, rust, or other defects are detected, undergo re-preservation.

Storage of boiler blocks in insulation and casing should only be carried out indoors or, in extreme cases, under a canopy. All hatches, manholes and openings through which, during storage or movement, moisture may enter under the boiler casing and the mullite-silica felt may become wet should be carefully closed.

Requirements for the boiler installation site

Before installing the boiler on the foundation, it is necessary to divide the installation axes of the boiler - the longitudinal axis and the front line of the boiler.

The axes are laid out according to the drawings, taking measurements from the columns or walls of the building. Due to possible inaccuracies in the construction of the building, after preliminary alignment of the boiler axes, it is necessary to check their mutual perpendicularity.

Having starting points, check the following geometric dimensions:

a) dimensions of foundation embedded parts;

b) correct location of embedded parts in the horizontal plane and in plan;

c) compliance with the drawings of the dimensions of the foundation as a whole and its rectangularity (by comparing the lengths of the diagonals).

Tolerances on the dimensions of the foundation are determined by the requirements under which the dimensions of the boiler support frame must fit within the dimensions of the embedded parts.

When checking the foundation, you should be guided by the requirements of SNiP 3.05.05-84.

Acceptance of the foundation is formalized by a tripartite act (customer, general contractor and installation organization) with the drawing up of an as-built diagram of the foundation.

Boiler installation

Installation of boilers and boiler auxiliary equipment must be carried out by a specialized organization that has permission from the Gosgortekhnadzor authorities in accordance with the “Instructions on the procedure for issuing permits for the right to install supervision facilities,” approved by Gosgortekhnadzor.

Installation of boilers and equipment can begin under the following conditions:

availability of complete design and estimate documentation, technical documentation manufacturers of equipment and design and installation documentation;

readiness of the construction part, confirmed by certificates of handover for installation to the customer and the installing organization;

equipping the facility with equipment, structures, materials, instruments and automation equipment.

Activities to prepare the facility for the start of construction and installation work, with solving the issues of acquiring equipment and materials, construction readiness and organizational and technical preparation of installation production, should be carried out in accordance with VSN 217-87 “Preparation and organization of construction and installation work during the construction of boiler houses.”

Specific requirements for the arrangement of assembly sites, access roads, sanitary and storage facilities, connecting electricity, water supply and sewerage, staffing the facility with labor, installation equipment, mechanisms, as well as the technology of work during installation of equipment are developed in the work execution project (WPP), submitted by the installation organization no later than 3 months before the start of work.

Installation of boilers and equipment can be carried out in the following conditions: during the new construction of a boiler room, during the expansion of the boiler room and during the reconstruction of the facility.

In new construction, boilers and equipment are installed, as a rule, or when combining installation and construction work, or in case of high construction readiness - in a closed building - through the left installation openings.

When combining installation and construction work, the installation of boiler blocks on the foundation is carried out using jib cranes in an open building during the construction process. United

the technological sequence of installation of boilers, boiler-auxiliary equipment and building elements is determined by the work project.

Installation of boilers in a closed building is carried out by sliding along special rolling tracks through installation openings provided in the building from the front of the boilers (axial sliding) or from the end of the building (lateral sliding).

Installation of the boiler using an axial slide (see Appendix 1, Fig. 1) is carried out in the following sequence:

After checking the completion of the boiler room subfloor, install rolling tracks, the length of which should ensure installation of the boiler block by crane on the outside of the tracks (outside the building) and subsequent movement of the block through the installation opening to the design installation site.

After installing and joining the track sections, align it according to elevation marks and in plan. The difference in marks of the knurling path in any cross section should not exceed 2 mm.

Secure the knurling path against transverse shear by tacking temporary stops to the embedded parts of the boiler (P1. Fig. 2).

Install and secure a traction winch at the ends of the track (in the building).

Weld the parts of the support tables for jacks to the boiler support frame (from the drum side) (P1. Fig. 3). Tie the bottom of the support posts (under the boiler firebox) with temporary beams.

Lubricate the surfaces of the tracks with grease and install a platform with transverse support beams under the boiler at their outer end (P1. Fig. 4).

To reduce friction and traction forces during sliding, it is possible to use special roller rollers (P1. Fig. 5) installed under the platform. In this case, the platform must have limiting stops to prevent lateral displacement from the slider axis (P1. Fig. 5).

Using jacks, place the block on temporary supports, remove the track sections and install (lower) the boiler on the foundation (P1. Fig. 6).

Jack the boiler using two jacks alternately on each side, changing the linings.

Carry out alignment of the boiler block, which consists of checking the compliance of the longitudinal axis and front line of the boiler, the mounting axes of the boiler laid out on the foundation, checking the coincidence of the axes of the upper and lower drums in the same vertical plane. The permissible deviation of the upper drum from the horizontal axis should not exceed 2 mm per meter of length, but not more than 10 mm over the entire length.

Axial sliding is also possible through openings in the building from the side of the tail surfaces of the boilers.

When installing a boiler using a side slide (P1, Fig. 7), the installation of the initial paths is carried out “in two threads” from the end of the boiler house building through the installation opening to the boiler foundation.

After aligning and securing the knurling paths, weld temporary beams to the bottom of the boiler support posts to rest on the knurling paths (P1. view D. Fig. 7).

Install transverse mounting braces along the ends of the boiler support frame. Weld tables for jacks and eyes for attaching the winch rope to the frame (from the lower drum side) (P1. Fig. 8).

The slide is carried out using a traction winch attached to the ends of the tracks behind the boiler foundation.

When installing equipment in a closed building with limited space, the installation of economizers and draft machines is carried out, as a rule, before installing the boilers.

Sliding of economizers is carried out using knurling tracks, traction winches and mounting equipment, similar to sliding of boilers.

When expanding a boiler room, installation of boilers is carried out, as in the case of new construction, in an open building when combined with the construction of a boiler room extension or in a closed extension through installation openings using a slider.

Boiler room reconstruction work often involves the installation of new boilers in an existing building at various building elevations. Preparation for installation of the boiler at the mark is carried out similarly to the preparation of the facility for new construction or expansion of the boiler house, including making a foundation for the boiler up to the design mark and constructing an installation opening. In addition, it is necessary to make a landing platform in front of the installation opening, level with the construction mark, and also, if the building is old, check the load-bearing capacity of the mark, other building structures

The take-off platform (P1. Fig. 9) must be equipped with a continuous boardwalk and fencing; the rolling tracks, the outer ends of which are brought out onto the take-off platform, must be aligned, fixed and lubricated with grease.

Weld temporary connections and beams, parts for jacking to the boiler support frame, as well as move the boiler in the same way as described above.

Rigging work when installing boilers in conditions of new construction, expansion and reconstruction of boiler houses should be carried out using mechanisms whose load capacity and traction force are given in Table 2.

Table 2.

Boiler factory designation	Boiler block weight, t	Minimum crane lifting capacity, t	Winch pulling force, t	Loading capacity of jacks, t
DE-4-14GM-O/R/
DE-4-14-225GM-O
DE-6.5-14GM-O/R/
DE-6.5-14-225GM-O
DE-10-14GM-O/R/
DE-10-14-225GM-O
DE-10-24GM-O
DE-10-24-250GM-O
DE-16-14GM-O/R/
DE-16-14-225GM-O
DE-16-14GM-O
DE-16-24GM-O
DE-16-24-250GM-O
DE-25-14GM-O/R/
DE-25-14-225GM-O
DE-25-15-270GM-O
DE-25-15-285GM
DE-25-24GM-O
DE-25-24-250GM-O
DE-25-24-380GM-O

The installation technology, as well as the characteristics of the installation equipment in each specific case are determined by the work project.

After installing the boiler on the foundation and checking its position, loosen the bolted connections of the supports on the support frame, tightened before transporting the block (on boiler blocks supplied with casing and lining, the bolted connections of the supports on the support frame are loosened at the factory), ensuring free expansion of the boiler elements according to the diagram thermal expansions. Remove elements that strengthen the block for the period of transportation and installation, if these elements are installed at the factory.

Install a benchmark to monitor thermal expansion of the boiler.

Install fittings and pipelines within the boiler.

Produce hydraulic test boiler in accordance with the Boiler Rules (section 5.14.).

Hydraulic testing may be carried out at a temperature environment not lower than +5 °C. The water temperature should be between 5-40°C. The pressure (excessive) for hydraulic testing and adjustment of safety valves is given in Table 3, as well as in the Boiler Certificate.

Table 3

Boilers with steam capacity 4-25 t/h

Working pressure in the drum, MPa (kgf/cm2)	Steam state or steam temperature, °C	Boiler hydraulic test pressure (test pressure), MPa (kgf/cm2)	Setting pressure of safety valves MPa (kgf/cm2)	Number and installation location of safety valves
				2-top drum
				2-top drum
				1-top drum
				1-superheater
				1-top drum
				1-superheater
				1-top drum
				1-superheater
				1-top drum
				1-superheater
				1-top drum
				1-superheater

The pressure rise time during hydrotesting must be at least 10 minutes, holding time under test pressure must also be at least 10 minutes. After holding under test pressure, reduce the pressure to working pressure and inspect the rolling and welded joints.

During testing, control the water pressure with two pressure gauges, one of which must have an accuracy class of at least 1.5.

Since boilers have small areas of welds and rolling joints that are difficult to inspect during a hydraulic test, it is recommended that after reducing the pressure to operating pressure, maintain it for the time required for inspection.

The tightness of the rolling joints may be compromised as a result of non-compliance with the conditions for loading and unloading the blocks during transportation by rail (other modes of transport) and at the installation site. If leaks are detected in the rolling joints, drain the water from the boiler and repair the leaks.

Repeated flaring is allowed no more than three times. If it is impossible to eliminate leaks by additional pipe flaring, the flaring joints should be replaced with welded ones.

After eliminating the leaks, the boiler must be presented in accordance with the Boiler Rules for technical examination.

The lining and insulation of boilers supplied from the factory without lining and casing must be carried out according to the factory drawings and boiler house design documentation.

A woven mesh is attached to the pipes of the side screens and stretched to the washers welded on the boiler block, which is pushed down to the pipes. In places with sparse pipe spacing, a layer of plywood or cardboard supporting concreting with chamotte concrete is laid. Then chamotte concrete is applied, which is spread evenly over the mesh and thoroughly compacted. The thickness of the chamotte concrete should be 15 mm from the outer generatrix of the pipe. 3-4 hours after laying the chamotte concrete, it should be moistened, moistened with water and the cracks that appear should be rubbed.

Hardening of concrete must occur at an ambient temperature of at least +5 °C. At ambient temperatures above +10 °C, chamotte concrete should be covered with plastic film or other material to prevent rapid evaporation of water and moistened with water every 3-4 hours. After the chamotte concrete has hardened (if the concrete is prepared with aluminous cement, then within a day), heat-insulating slabs are installed. Before this, the condition of the chamotte concrete is checked and all defects and imperfections are eliminated, since poor quality of the heat-resistant layer (cracks, leaks) can lead to a local increase in the wall temperature. Thermal insulation boards are installed close to the chamotte concrete layer.

When laying slabs, it is necessary to monitor the thickness of the seam and its complete filling with mortar.

The first layer of lining of the front and rear walls on the pipe side is laid with fireclay bricks, the second layer of lining of the firebox front is laid with diatomaceous brick, the third layer with asbestos-vermiculite or materials similar in thermophysical properties. The second layer of the side and rear walls of the boiler is also made of asbestos-vermiculite slabs or their substitutes.

The outer layer of the lining of all boiler walls is a gas-tight coating. The coating layer is about 5 mm. The coating should not have cracks or leaks that, during startup and operation of the boiler, would lead to leakage and leakage of flue gases between the insulation and the casing towards places where the vacuum in the flue increases. During subsequent installation, it is necessary to provide natural ventilation sufficient for drying the lining, which will avoid corrosion of the pipes from the side of the chamotte concrete application.

When performing lining Special attention You should pay attention to its density in the places where the boiler fittings are installed. The insulation of the upper drum on the firebox side is done with fireclay bricks suspended on studs welded to the drum.

The compositions of chamotte concrete and gas-tight coatings are given in the factory drawings sent to the customer with the Boiler Certificate.

After completing the insulation work, the boiler casing is installed. Welding the casing ensures the required density of the boiler walls to eliminate excess cold air suction. Welds clean off slag and burr. Check the density of the casing with a torch, creating a vacuum of about 100 mm of water in the firebox. Art. The oscillation of the torch will indicate the place of lack of penetration. You can also check the density of the casing by creating a pressure of about 100 mm of water in the firebox. Art. and coated the welds with soapy water. Soap bubbles will be blown out in places where there is a lack of penetration.

When storing the boiler for a long time after installing the lining and casing, before putting the boiler into operation, in order to avoid oxygen corrosion of the pipe metal on the lining side, measures should be taken to dry the lining and ventilate the boiler furnace (see section “Drying the lining, alkalization”).

Install platforms and stairs.

When the boiler block is supplied with insulation and cladding, the lining of the firebox and lower drum is carried out using straight fireclay bricks of class B GOST 8691-73. Shotcrete cracks brickwork on the lower drum from the side of the firebox, use shotcrete of the following composition: ground fireclay - 75%, refractory clay - 15%, aluminous cement - 10%. Seal the gaps of the protective masonry along the lower pipe with an asbozurite-sovelite solution based on: sovelite powder grade “400” asbozurite powder grade “700”.

The lining of the upper drum from the firebox side is carried out with shaped fireclay bricks, fixed on pins, using shotcrete and metal mesh KSHOP-25-1.3 GOST 13603-89. Tie the mesh with wire 1-0-4 GOST 3282-74.

Insulation of the upper drum from the outside is carried out with sovelite products with a thickness of 100-120 mm (half-cylinders, segments, slabs) using asbozurite-sovelite mastic, metal mesh and cotton fabric GOST 3357-72.

The gas duct is insulated with sovelite slabs 50 mm thick in two layers, fastened to metal rods made of Ø6 mm wire, 110 mm long. The rods are tacked to the flue duct elements using manual arc welding. After tensioning the mesh, bend the rods. Asbozurite-sovelite mastic and cotton fabric with a total thickness of 10 mm are applied to the mesh.

It is possible to insulate the gas ducts, upper and lower drums with a layer of asbestos-diatom concrete 120 mm thick, applied over a wire frame.

Installation of burners

Install the air box and burner device. On boilers with a steam capacity of 25 t/h, the combustion chamber is installed horizontally from the front so that its longitudinal axis coincides with the axis of the combustion chamber, and is rigidly fixed in the air box of the boiler. When performing refractory lining of the combustion chamber, it is necessary to carefully adjust the bricks to each other, both in each row and between rows. The lining must have a smooth surface without steps. To ensure reliable operation of the refractory lining, the thickness of the seams between bricks or refractory blocks should be no more than 2-3 mm. A GMP-16 gas and oil burner is installed at the front of the chamber and centered with it.

When installing the GMP-16 burner, a support (cast iron ring) is installed at the front of the inner shell of the combustion chamber, and a large burner flange with a gas part is attached to the outer casing, on which a small flange with a blade apparatus and a steam-mechanical nozzle assembly is mounted. A gas supply pipe is welded to the gas supply pipe. Fuel oil and steam for atomization are supplied to two nozzles - the main and reserve. In this case, the main nozzle should be located horizontally in the center of the burner, the backup nozzle should be located under the main vertical plane at an angle of 6° to the horizontal axis of the burner. When installing the GMP-16 burner, check that the chamber body is parallel to the boiler axis.

Installation of GM-2.5 burners; GM-4.5; GM-7; GM-10 is produced in the same order. Only in this case the support is fastened to the front wall of the air box.

An important condition for good burner operation is the concentricity of the cones and the cylindrical section of the tuyere relative to the burner axis. Reducing the opening angle of the conical part can lead to coking and intense burnout of the tuyere. For manual fuel adjustment, it is recommended to install needle valves in front of the burner. Pressure gauges for monitoring the pressure of gas, fuel oil and steam for atomization are installed in front of the burner, after the regulators.

Air pressure is measured in the air box at the point indicated in the shop drawing. It is recommended to select the vacuum impulse in the furnace in the upper right part of the boiler front. Install thermometers on the air, gas and fuel oil lines.

When installing the fan and smoke exhauster, the blades of the guide vanes must be well secured and have minimal play. The blades must open along the gas-air path.

The actuators of the guide vanes must have a full opening time of at least one minute.

Air and gas pipelines must have a sufficient cross-section and a minimum number of turns. Turns should be made smoothly without sharp edges. It is also necessary to exclude the possibility of water getting into the gas and air ducts. When starting draft machines in a cold state, there should not be significant fluctuations in pressure and vacuum along the gas-air path of the boiler throughout the entire range of load control, which can be checked during the commissioning of the boiler using draft and pressure meters.

Install gas boxes and explosion valves, blowers and steam supply pipelines to them. Install an economizer, fan and exhaust fan (can be installed earlier).

Installation and operation of the burner, fan, smoke exhauster and economizer are described in their instructions.

In the process of preparation, installation and delivery of the boiler, in accordance with the requirements of SNiP 3.05.05-84 and other regulatory documents, the following production documentation is subject to execution and transfer to the working commission:

certificate of serviceability of the boiler;

act of handing over equipment for installation;

certificate of readiness of the foundation for installation work;

act of checking the installation of equipment on the foundation;

certificate for completing installation and checking the intra-drum device;

certificate for hydraulic testing of the boiler;

act of acceptance of the installation lining of the boiler;

test report for the density of the gas-air path with the boiler furnace;

certificate of quality of boiler installation;

certificate for checking the drying of the boiler lining;

boiler alkalization report;

certificate of acceptance of equipment after individual testing (three-party: customer, installer, adjuster).

Security measures

When carrying out installation and repair work on boilers, you should be guided by the “Rules for the design and safe operation of load-lifting cranes”. Gosgortekhnadzor, SNiP 111-4-80 “Safety in construction”, a system of labor safety standards.

An order for the installation organization must appoint a person responsible for the safe performance of work on moving cargo by cranes at the site and certified in accordance with the “Rules for the design and safe operation of load-lifting cranes.”

All boiler installation work should be carried out in accordance with the work execution plan (WPP), which contains a complete list of technological issues of occupational safety.

Before starting work, persons entrusted with their implementation must be thoroughly familiarized with the work project or technological note and instructed in safety precautions in accordance with the entry in the briefing log.

Slings used during installation and repair of boilers must be tested and provided with a tag indicating the last test; slingers must have certificates authorizing them to carry out the work.

Fastening points for mounting blocks, winches, and places where safety belts are attached must be checked before starting work.

Places where welding work is carried out must be fenced with fireproof screens: shields made of sheet steel, asbestos ceiling or tarpaulin with a height of at least 1.8 m. It is prohibited to carry out welding work from ladders.

Work in the boiler drum must be carried out with an observer located outside the drum constantly monitoring the work performer.

When welding in a boiler drum, it is necessary to use dielectric mats, helmets, armrests, and galoshes. In this case, a switch must be installed outside for the welder observing him to turn off the current when changing electrodes and breaks in work.

IN work area and at the installation site, fire protection panels must be installed, fully equipped with equipment.

Work must be carried out in a helmet; when using an abrasive tool, work with glasses. When working at height, be sure to use a safety belt.

In the dark, carry out work with the installation site illuminated at least 30 lux. When installing floodlights, the glare of light should be avoided.

During the period of installation and repair, the work area is dangerous and the presence of unauthorized persons in it is prohibited.

Scaffolding, scaffolding, and other devices for performing work at height must be inventory and manufactured according to standard designs.

Only persons who know its structure, have been trained, instructed and have a certificate are allowed to operate the electric winch.

When sliding boiler blocks using an electric winch (especially using rollers), the speed of movement should ensure full control over the correct movement of the block and timely correction in the event of its possible displacement from the axis of the slider.

For work on major repairs of boilers carried out in an existing boiler room, an area must be allocated with a permit issued. The approval certificate is issued by the customer and the repair organization. The allocated area must be fenced. In addition, when carrying out high-risk work, a work permit must be issued for each team and the work of installation mechanisms.

Simultaneous installation and dismantling work on different heights along one vertical is prohibited.

Dismantling of individual elements of boilers and pipelines within the boilers must be carried out with the condition that the remaining parts are in a stable position. Before cutting out the element to be removed, it must be securely strapped.

Before starting work inside the furnace and boiler drums, the responsible work manager must be issued a permit; approved by the chief engineer of the installation organization.

Work inside the boiler furnace may only be carried out at a temperature not exceeding 50-60°C with written permission (permit) from the head of the boiler room. The stay of the same person inside the boiler or flue at these temperatures should not exceed 20 minutes.

Before starting work, the firebox and flues must be ventilated for at least 10 minutes. illuminated, reliably protected from the penetration of gases and dust from the flues of operating boilers. A sample should be taken from the top of the firebox to check for the absence of gases.

The boiler gas pipelines and drains must be purged with compressed air and disconnected with plugs. The purge plugs must be fully open.

When working in a boiler, a voltage of 12 V should be used for electric lighting.

Working in a boiler with power tools is permitted at a voltage of no more than 36 V with the mandatory use of protective equipment (dielectric gloves, mats, etc.).

Hydraulic testing of the installed boiler is carried out after installation of all standard fittings. Safety valve springs are tight.

The boiler is filled with water via the supply line or by pouring from the water supply network with the vents open. The pressure is raised by a manual or electric piston pump connected to one of the intermittent purge lines.

Tightening of fasteners is allowed at a pressure of up to 0.3 MPa.

IT IS PROHIBITED TO INCREASE THE PRESSURE ABOVE THOSE INDICATED IN THE TABLE.

Detected defects are eliminated after reducing the pressure to zero and draining the water if necessary.

If there are signs of the release of poisonous or asphyxiating gases, poisonous, caustic liquids, etc. workers are obliged to immediately stop work and leave the danger zone without waiting for instructions from the customer’s personnel. The responsible engineer is obliged to immediately notify the customer about this.

Adjustment of safety valves

Safety valves are adjusted:

When starting the boiler, after installation.

When starting up the boiler after it has been in reserve.

When carrying out a technical inspection of the boiler.

Based on the results of checking the serviceability of the safety valves.

When the operating pressure in the boiler changes.

Adjustment of safety valves can be carried out on a bench, during hydraulic tests or during the alkalization process when discharging steam through the auxiliary line and installed steam removal pipelines.

Before installing safety valves, they should be inspected. Lubricate the thread of the pressure sleeve (silver graphite - 20%, glycerin - 70%, copper powder - 10%), check the condition of the sealing surfaces, the presence of rod seals.

In normal operation, the valve is closed, the plate is pressed against the seat by spring force. The force of the spring on the plate is regulated by the amount of its compression, produced using a threaded pressure bushing.

The pressure slowly rises and the safety valves are adjusted to the opening pressure indicated in Table 3.

If it is necessary to operate the boiler at a reduced pressure (but not lower than the values ​​​​specified in paragraph 1 of the “Boiler Maintenance” section), the valves are adjusted according to this operating pressure, in accordance with section 6.2. Boiler rules.

The safety valves are adjusted one by one in the following sequence (see P. II for the safety valve drawing):

set the required pressure in the boiler;

remove the manual detonation lever (4) and the protective cap (11);

by unscrewing the pressure sleeve (8) the valve begins to explode;

reduce the pressure in the boiler before seating the valve, and the difference between the pressure of explosion and seating of the valve should be no more than 0.3 MPa. By rotating the damper bushing (9) clockwise, the difference is increased, and counterclockwise, it is decreased. To rotate the damper bushing, it is necessary to loosen the locking screw (7); upon completion of the adjustment, lock the said screw;

measure the tension height of the spring with an accuracy of 1 mm and write it down in the journal;

upon completion of the adjustment, replace the protective cap and the manual detonation lever;

seal the protective cap of the hood.

To check the correct adjustment of safety valves, increase the pressure until the valve operates, then reduce the pressure until the valve closes.

If the valve response pressure does not correspond to the opening pressure indicated in the table, and the difference between the pressure of explosion and landing of the valve is more than 0.3 (3) MPa (kgf/cm2), repeat the adjustment.

Drying of lining, alkalization

1. After completing the installation of the boiler, it is recommended to dry the lining for 2-3 days using electric heaters, using wood, or using steam from operating boilers, which is supplied to the boiler filled with water to the lower level through the heating line of the lower drum. The process of heating water in the boiler must be carried out gradually and continuously; At the same time, it is necessary to monitor the water level in the boiler using direct-acting level indicators. During the drying period, the water temperature in the boiler is maintained at 80-90°C.

2. Alkalinization of the boiler is carried out to clean the internal surfaces of oily deposits and corrosion products.

To fill the boiler during alkalization and make up during the alkalization period, it is advisable to use chemically purified water. It is allowed to fill the boiler with raw clarified water at a temperature not lower than + 5°C.

The superheater is not subject to alkalization and is not filled with an alkaline solution.

It is cleaned of oily contaminants and rust by a stream of steam, for which the purge valve of the superheater is opened before alkalization.

Before alkalizing the boiler, the boiler is prepared for lighting (see section “Inspection and preparation for lighting”).

In order to save time and fuel, the introduction of reagents and the start of alkalization of the boiler should be done 1 day before the end of drying of the lining.

Reagents can be introduced using a metering pump with a container or through a tank with a capacity of 0.3-0.5 m3, installed above the platform of the upper drum. From the tank, introduce the reagent solution through a flexible hose through the valve of the “steam to own needs».

The following reagents are used for alkalization: caustic (caustic soda) or soda ash and trisodium phosphate (Table 4).

Before injection, the reagents are dissolved to a concentration of about 20%. Solutions of soda and trisodium phosphate must be introduced separately to avoid crystallization of trisodium phosphate in the boiler pipes. It is possible to introduce a solution of reagents from the tank into the boiler only in the complete absence of pressure in the latter. Personnel working on the operations of preparing the solution and introducing it into the boiler must be provided with special clothing (rubber aprons, boots, rubber gloves and masks with goggles).

Before the first firing of the boiler after installation, the springs of the safety valves are weakened if the valves have not been adjusted on the bench. With each increase in pressure during alkalization (0.3; 1.0; 1.3 MPa), by tightening the pressure bushings, the spring pressure on the valve corresponds to the steam pressure.

When alkalizing, after introducing reagents, fire up the boiler, in accordance with the requirements of the “Firing up” section, increase the pressure in the boiler to 0.3-0.4 MPa (3-4 kgf/cm2) and tighten the bolted connections of hatches and flanges. Alkalinization at this pressure should be carried out for 8 hours with a boiler load of no more than 25% of the nominal one.

Blow through the boiler at all points for 20-30 seconds. each and feed to the upper level.

Reduce pressure to atmospheric.

Raise the pressure to 1.0 MPa (10 kgf/cm2) and alkali at a load of no more than 25% - 6 hours.

The boiler is purged and recharged at a pressure reduced to 0.3-0.4 MPa (3-4 kgf/cm2).

New pressure rise to 1.3 MPa (13 kgf/cm2), and for boilers with excess pressure of 2.3 MPa (23 kgf/cm2) to a pressure of 2.3 MPa (23 kgf/cm2) and alkalization at load no more than 25% within 6 hours.

Boiler water is changed by repeatedly purging and filling the boiler.

During the alkalization process, do not allow water to enter the superheater. The superheater purge valve is always open. The total alkalinity of boiler water during alkalization must be at least 50 mg.eq/l. When falling below this limit, an additional part of the reagent solution is introduced into the boiler, and the pressure in the boiler should not exceed atmospheric pressure.

The end of alkalization is determined by analyzing the stability of the P 2 O 5 content in water.

Reagent consumption is given in Table 4. ¦

Table 4.

Boiler size	Name of reagents
	(caustic soda), kg	Na 3 PO 4 x12H 2 O (trisodium phosphate), kg
DE-10-14(24)GM
DE-16-14(24)GM
DE-25-14(24)GM

Note. The weight is indicated for 100% reagent. Lower reagent value for clean boilers, higher for boilers with a large layer of rust.

After alkalization, reduce the pressure to zero and, after reducing the water temperature to 70-80°C, drain the water from the boiler.

Open the drum hatches and manifold hatches, thoroughly wash the drums, intra-drum devices, and pipes using a hose with a fitting at a water pressure of 0.4-0.5 MPa (4-5 kgf/cm2), preferably at a temperature of 50-60 °C.

The condition of the heating surfaces is recorded in the chemical treatment log.

After alkalization, it is necessary to perform an inspection of the blow-off and drain fittings and direct-acting water level indicators.

If the period between alkalization and startup of the boiler exceeds 10 days, then the boiler must be put into conservation.

3. After alkalization, warm up and purge the steam pipeline from the boiler to the connection points to operating sections of steam pipelines or to steam consumers.

When warming up and purging, the following operations are performed:

the pressure in the boiler rises to operating pressure;

the water level rises above average by 30 mm;

the vent and drain valves are opened on the steam line;

gradually open the steam shut-off valve, reaching the highest steam flow within 5-10 minutes, while it is necessary to monitor the water level in the boiler.

Note: The procedure for purging the steam line may be different. It is regulated by the requirements of the production instructions depending on the diagrams of steam pipelines, purge pipelines and automation of valve control.

Comprehensive testing of boiler units and adjustment during complex testing

Comprehensive testing is the final stage of installation work.

The general and subcontracting organizations that carried out the installation of the boiler, instrumentation and automation, auxiliary equipment, electrical installation and other work, during the period of comprehensive testing of the boiler unit, ensure that their personnel are on duty to promptly eliminate identified defects in construction and installation work in accordance with the requirements of SNiP-3.05.05-84.

Before performing a comprehensive testing, the customer, together with the commissioning organization, draws up a testing program. Comprehensive testing is carried out by the customer’s personnel with the involvement of specialist adjusters.

The procedure for comprehensive boiler testing and commissioning must be brought into compliance with the requirements of SNiP 3.01.04-87 and GOST 27303-87.

Loads for complex testing are determined in the program (as a rule: nominal, minimum possible and intermediate).

Testing of the boiler operation in combination with the economizer, draft mechanisms, piping system, boiler room auxiliary equipment, and instrumentation system is carried out within 72 hours. During this period, the commissioning organization carries out adjustments of the combustion and water-chemical regimes, the instrumentation and control systems with the issuance of temporary regime cards. After the completion of comprehensive testing, defects and malfunctions identified during its implementation are eliminated (if necessary, the boiler is stopped); An act of comprehensive testing and commissioning of the boiler is drawn up.

WATER CHEMICAL REGIME OF BOILERS

The choice of method for processing source water for feeding boilers is made by a specialized (design, commissioning) organization, taking into account the quality of source water and the requirements of these Instructions.

Feed water quality standards are given in Table 5.

Table 5

The name of indicators	Units	Feed water quality standards depending on absolute pressure and type of fuel
		1.4 MPa (14 kgf/cm 2)		2.4 MPa (24 kgf/cm 2)
Font transparency, no less
Overall hardness	mcg-eq/kg
		not standardized
Free carbon dioxide		absent
pH value at 25°C

The quality of boiler (blowdown) water and the necessary regime for its corrective treatment are established by a specialized commissioning organization, taking into account the requirements set out in Table 6.

Table 6

	Single-stage evaporation boilers		Boilers with two-stage evaporation
	Without superheater	With superheater	1st stage of evaporation		2nd stage evaporation
			Without superheater	With superheater	Without superheater	With superheater
Phosphates, mg/kg
Relative alkalinity, %, no more

Administration of the enterprise with the involvement of a specialized commissioning organization based on the results commissioning work, as well as the requirements of technical guidelines for

organization of the water chemistry regime and chemical control and the requirements of Section 8 of the Boiler Rules develops and approves instructions for maintaining the water chemistry regime, which should

be at the staff workplace.

The boiler room must have a water treatment log to record the results of water and steam analysis, the implementation of the boiler purging regime and water treatment maintenance operations.

Whenever the boiler is stopped to clean the internal heating surfaces, the type and thickness of scale and sludge, the presence and type of corrosion, as well as signs of leaks (steaming, external salt build-ups) in the rolling joints must be recorded in the water treatment log.

user manual

General provisions

1. The instructions contain general instructions for the operation of steam boilers of the DE type, on the basis of which, in relation to specific conditions, taking into account instrumentation and control equipment, each boiler house develops its own production instructions, approved by the chief engineer of the enterprise.

The production instructions and operational diagram of the boiler room pipelines must be posted at the boiler room operator’s workplace.

2. Installation, maintenance and operation of DE type steam boilers should be carried out in accordance with the Boiler Rules.

3. Instructions for operating the burner, economizer, automation system and boiler auxiliary equipment are contained in the relevant instructions of the manufacturers of this equipment.

4. Installation, maintenance and operation of boiler room pipelines should be carried out in accordance with the Rules for the construction and safe operation of steam and hot water pipelines.

5. The owner of the boiler receives from the manufacturer a Boiler Passport, which is issued to the latter when the boiler is transferred to the new owner.

In the passport, in the appropriate section, the number and date of the appointment order, position, surname, name, patronymic of the person responsible for the good condition and safe operation boiler, the date of testing his knowledge of the Boiler Rules.

The specified person enters into the Passport information about the replacement and repair of boiler elements operating under pressure, and also signs the results of the inspection.

6. Acceptance into operation of a newly installed boiler must be carried out after its registration with the Gosgortekhnadzor authorities and technical examination on the basis of an act of the State or working commission on acceptance of the boiler for operation.

The boiler is put into operation by written order of the enterprise administration after checking the readiness of the boiler installation equipment for operation and organizing its maintenance.

7. In addition to the boiler passport, it is necessary in the boiler room to have a repair log, a water treatment log, a pressure gauge control log, a replacement log of the operation of boilers and auxiliary equipment.

8. Boiler maintenance can be entrusted to persons at least 18 years of age who have undergone medical training. examination, training and having a certificate for the right to service boilers in accordance with the requirements of subsection 9.2. Boiler rules.

Inspection and preparation for kindling

1. Check the water supply in the deaerator, the serviceability of the feed pumps and the presence of the required pressure in the feed line, power supply to the automation panels and actuators;

2. Make sure that the boiler elements and fittings are in normal condition and that there are no foreign objects in the firebox and flues;

3. Check the condition and density of the screen between the firebox and the convective beam;

4. Check the integrity of the protective lining of the drum, the presence and thickness of the asbestos membrane of explosive safety devices;

5. Check the readiness for start-up and operation of the blower fan and smoke exhauster. From the switchboard, test the remote control of the guide vanes, check that they are adjusted correctly for full opening and closing;

6. If the boiler is started after repairs during which the boiler drums were opened, then before closing them, make sure that there is no dirt, rust, scale and foreign objects; check the cleanliness of the pipe connecting the compartments of boilers with a steam capacity of 16 and 25 t/h; check for damage to the steam separation elements and inside the drum devices and for looseness of the joints of the fender panels, guide canopies, and the tightness of their connection to the drum and partition; Before installing new gaskets, thoroughly clean the abutment planes from remnants of old gaskets; When assembling, lubricate the gaskets and bolts with a mixture of graphite powder and oil to prevent burning;

7. Check the correct installation and ease of rotation of the blower pipes. The axes of the nozzles of the blowing pipes should be located in the center of the spaces between the boiling pipes;

8. Make sure: the normal condition of the burner parts, burner lance, front wall lining, drums;

9. Check the correct assembly of the burner nozzles.

In the nozzle of the GMP-16 burner, the steam pressure supplied to atomize the fuel affects the angle of the open fuel torch. When the steam pressure for spraying increases during kindling from 0.1 MPa (1 kgf/cm 2) to 0.25-0.3 MPa (2.5-3.0 kgf/cm 2), a reduction in the spray angle from 65° to 30°, at which coking of the walls of the two-stage fuel combustion chamber does not occur.

Visual control of the initial ignition zone and the exit edge of the embrasure or combustion chamber is carried out through the front hatch of the right side wall.

The temperature of the fuel oil in front of the nozzle should be within 110 -130°C, the viscosity should not exceed 3°VU;

10. After inspecting the firebox and gas ducts, close the manholes and hatches tightly;

11. After checking the serviceability of the fittings, make sure that:

the boiler purge valves are tightly closed, and if there is a superheater, the purge valve on the superheated steam chamber is open;

the economizer and boiler drain valves are closed;

boiler and economizer pressure gauges in operating position, i.e. pressure gauge tubes are connected by three-way valves to the medium in the drum and economizer;

direct mode level indicators are included, i.e.

steam and water valves (taps) are open and purge valves are closed;

the main steam shut-off valve and the “steam for auxiliary needs” valve are closed;

The economizer vents are open.

12. Fill the boiler with water at a temperature not lower than +5°C in the following sequence:

After turning on the feed pump (which is done according to the relevant instructions) and supplying water to the economizer, the valve of one of the supply lines opens slightly.

After the appearance of clarified water, the economizer vent closes. The boiler is filled to the lower level in the water indicator glass of the direct-acting level indicator. If the boiler is filled for the first time after repair, it is necessary to flush it, filling it twice with water to the upper level and discharging it through the blowdown and drainage.

The time for filling the boiler with water and its temperature must be indicated in the instructions for kindling.

While filling the boiler, check the tightness of the manhole and hatch valves, flange connections, and the tightness of the fittings (the omission of the latter can be judged by the heating of the pipes after the valves if the boiler is filled with warm water).

If leaks appear in manhole and hatch valves and flange connections, tighten them; if the leak is not eliminated, stop powering the boiler, drain the water and change the gaskets.

After the water in the boiler rises to the lower mark of the level indicator, stop feeding the boiler.

After this, you should check whether the water level in the glass is maintained. If it drops, you need to find out the reason, eliminate it, and then refill the boiler to the lowest level.

If the water level in the boiler rises while the feed valve is closed, which indicates that it is leaking, it is necessary to close the valve upstream.

13. Check the serviceability of the main and emergency lighting by turning it on;

14. Make sure that the boiler instrumentation and control system is working properly, check the fuel cut-off using simulated parameters;

15. Check the serviceability of the gas equipment of the boiler and the ignition protection device. If the boiler is preparing to be fired with fuel oil, run the fuel through the circulation circuit;

16. Supply steam from neighboring boilers to the heating line of the lower drum and heat the water in the boiler to 95-100°C.

Preheating the water will reduce thermal stresses in the metal of the lower drum of the boiler that arise during kindling due to temperature differences between the walls of the upper part, washed by hot combustion products, and the lower part, in contact with relatively cold water.

Kindling

1. The boiler should be fired up only if there is an order written in the shift log of the person responsible for the good condition and safe operation of the boiler or the person replacing him, determined by the order of the enterprise.

2. Turn on the smoke exhauster and blower fan with the guide vanes closed. Open the guide vanes slightly, maintaining a vacuum in the furnace of about 50 Pa (5 kgf/cm2). Ventilate the firebox for 3-5 minutes. Until ventilation is completed, it is prohibited to bring open fire into the firebox and flues.

3. After finishing ventilation, close the blower fan guide apparatus, set the air pressure in the burner to no more than 100 Pa (10 kgf/cm2) with a vacuum in the furnace of 30-40 Pa (3-4 kgf/cm2).

The possibility of turning on automatic vacuum control before ignition is determined by service technicians depending on local conditions (speed of the actuator of the smoke exhauster guide vane, nature of ignition, etc.).

4. When lighting the boiler on natural gas The procedure for personnel action will be determined by instructions drawn up in accordance with the “Safety Rules in the Gas Industry”, depending on the configuration of the boiler with gas equipment and an automation system. In all cases, it is necessary that the torch of the gas igniter beats steadily, covers at least 3/4 of the circle (observation is carried out through the rear hatch), and the main burner ignites when the gas pressure in it is no more than 500 Pa (50 kgf/cm2). If the pilot flame goes out or fails before the burner flame ignites, it is necessary to shut off the gas supply to the boiler and re-ventilate the firebox.

After igniting the burner, add air, maintaining the vacuum in the firebox within the same limits. Switch the automation from the “ignition” mode to the main mode. Visually, by the color of the flame or by the device, establish the fuel-air ratio corresponding to the completeness of combustion.

5. When lighting a boiler using fuel oil, warm up the nozzle well, passing steam through it, and circulate the fuel oil within the boiler. If there is no circulation pipeline, drain cold fuel oil from the pipeline from the valve at the insertion into the supply line to the nozzle valve through the purge fitting into the tank.

Reduce the steam supply to the nozzle, release gas to the gas igniter, and after the igniter ignites, slightly open the valve on the fuel oil line at the nozzle.

After igniting the fuel oil, by changing the pressure of the atomizing steam and air, set the optimal combustion mode.

Using steam pressure on the GMP-16 burner, adjust the angle of the torch so that it does not touch the edges of the embrasure.

6. When starting the first boiler in a boiler room running on fuel oil, it is recommended to use heating oil as kindling fuel.

In this case, air from a mobile compressor is supplied to the steam spray line. Heating oil is supplied to the fuel oil line with a pressure of 0.2-0.3 MPa (2-3 kgf/cm2).

The procedure for firing a boiler is the same as for fuel oil.

It is convenient to use a liquid additive station as a starting fuel facility if the latter is designed and built as part of a fuel storage facility.

A diagram of the use of equipment and pipelines of the additive station for this purpose is provided by adjusters.

If there is no gas igniter that consumes gas from a gas cylinder installation or gas pipeline, the nozzle is ignited from a homemade torch inserted into the firebox to the mouth of the burner through the hole for

The torch is removed (the igniter is extinguished) only after stable ignition of the main torch.

Before removing the main nozzle installed along the burner axis for cleaning and rinsing, you must:

insert the reserve nozzle into the provided hole;

connect it to steam and fuel oil pipelines;

ignite it from the torch of the main burner.

The reserve injector should be in operation for a short time, only during the period of replacement of the main one. The switched-off injector is immediately removed, this will prevent coking of the parts

sawing head.

7. During the kindling process it is necessary:

When steam appears through the open valve at the sample cooler, after displacing air from the upper boiler drum, close the valve of the sampling steam line on the boiler drum. From this moment on, it is necessary to carefully monitor the readings of the pressure gauge and the water level in the glasses of direct-acting water level indicators;

at a steam pressure of 0.05-0.1 MPa (0.5-1 kgf/cm2), use a pressure gauge to purge direct-acting water level indicators.

and a pressure gauge siphon tube.

When purging direct acting water level indicators:

a) open the purge valve - the glass is purged with steam and water;

b) close the water tap - steam is blown through the glass;

c) open the water tap, close the steam tap - the water pipe is blown out;

d) open the steam valve and close the purge valve. The water in the glass should rise quickly and fluctuate slightly at the water level mark in the boiler. If the level rises slowly, the water tap must be reopened.

Blowing the boiler and subsequent make-up will also replace the water in the economizer. It is necessary to monitor the temperature of the water, preventing it from boiling in the economizer. For boilers with steam superheaters, from the beginning of firing, open the superheater purge valve, which closes after connecting the boiler to the boiler room steam line.

Monitor the increase in pressure in the boiler, adjusting the amount of fuel and air supplied in accordance with the boiler operating chart.

If hatches and flange connections were opened during a shutdown, then when the pressure in the boiler increases to 0.3 MPa (3 kgf/cm2), the nuts of the bolts of the corresponding connections should be tightened.

It is recommended to increase the pressure in boilers filled with water at a temperature of 80 -100°C according to the following schedule:

for boilers with pressure (absolute) 1.4 MPa (14 kgf/cm2):

20 minutes after the start of kindling - 0.1 MPa (1 kgf/cm2):

35 minutes after the start of kindling - 0.4-0.5 MPa

(4-5 kgf/cm 2);

45 minutes after the start of crushing 1.3 MPa (13 kgf/cm 2);

for boilers with a pressure (absolute) of 2.4 MPa (24 kgf/cm 2) up to 45 minutes the schedule is the same, and then:

50 minutes after the start of kindling - 1.8 MPa (18 kgf/cm2);

60 minutes after the start of kindling - 2.3 MPa (23 kgf/cm2).

When starting boilers filled with water with a temperature below 80°C, the time for pressure to rise to 0.1 MPa (1 kgf/cm2) increases by 15-20 minutes.

During the kindling process, it is necessary to monitor the movement of the rear bottom of the lower drum along the benchmark. The values ​​of the calculated maximum thermal displacements of the boiler blocks (lower drums) are given in Table 7. If the thermal displacements are significantly less than the calculated ones, check whether the movable supports of the boiler are pinched.

Table 7

Factory designation of boilers	Amount of thermal displacement, mm
DE-10-14GM;
DE-10-14-225GM
DE-10-24GM;
DE-10-24-250GM
DE-16-14GM;
DE-16-14-225GM
DE-16-24GM;

Putting the boiler into operation

DE-16-24-250GM

DE-25-14GM;

DE-25-14-225GM DE-25-24GM;, means of operational communication, remote control of monitoring devices;

checking and turning on security automation and equipment automatic control(in accordance with production instructions turning on the automation can be done immediately after igniting the boiler), purging the boiler at all points.

If the automatic safety system malfunctions, starting the boiler is prohibited.

3. When the boiler is connected to a steam line that is under pressure, the pressure in the boiler should be equal to or slightly lower, but not more than 0.05 MPa (0.5 kgf/cm2), than the pressure in the steam line.

4. For boilers with steam superheaters, as the load increases, the boiler blowdown of the superheater decreases and completely stops when approximately half of the load specified for operation is reached.

Boiler maintenance

1. When operating boilers without superheaters, it is allowed to maintain the excess pressure in the boiler not lower than 0.7 MPa (7 kgf/cm 2) for boilers with an absolute pressure of 1.4 MPa (14 kgf/cm 2) and not lower than 1.8 MPa (18 kgf/cm2) for boilers with an absolute pressure of 2.4 MPa (24 kgf/cm2), at these pressures the throughput of the safety valves corresponds to the nominal performance of the boilers.

2. During operation it is necessary:

check the proper operation of pressure gauges, safety valves, direct-acting water level indicators and backup feed pumps within the following periods:

for boilers with a working pressure of 1.4 MPa (14 kgf/cm2) - at least once per shift;

for boilers with a working pressure of 2.4 MPa (24 kgf/cm2) - at least once a day;

check monthly the integrity of the asbestos membranes of the explosion valves;

clean and rinse the nozzle (when operating on fuel oil);

eliminate, if possible, leaks in oil seals, fittings gaskets and water indicator glasses;

monitor the serviceability of instrumentation;

Checking the serviceability of alarms and automatic protections must be carried out in accordance with the schedule and instructions approved by the chief engineer of the enterprise.

During boiler operation, maintain the specified operating steam pressure. The pressure gauge needle should not go beyond the red line (arrow on the body), corresponding to the maximum permitted pressure.

3. For boilers with superheaters, maintain the nominal temperature of the superheated steam, preventing it from changing beyond the deviations indicated in Table 1.

In DE-25-24-380GM boilers, monitor the change in the temperature of the superheated steam along the stages of the superheater.

Possible reasons for the increase in the temperature of superheated steam:

increase in load;

increasing excess air in the firebox;

contamination of screen pipes and boiler bundle up to the superheater;

decrease in feedwater temperature.

Possible reasons for a decrease in the temperature of superheated steam:

when the superheater pipes are contaminated;

at high level water in the drum;

with high alkalinity and boiler water foaming;

if the separation device malfunctions;

when the feed water temperature increases;

in case of leaks in the desuperheater.

For proper operation of the superheater it is necessary:

turn on the blowing of the superheater when the boiler is fired up and stopped, or when it is in hot reserve;

strictly observe the standards for salt content in boiler water and saturated steam;

Maintain the water level in the boiler near the middle level of the upper drum.

Quality control of saturated and superheated steam, carried out according to a schedule and control methods developed by a specialized commissioning organization, allows for timely detection of faults in the separation devices of boilers and the desuperheater of the DE-25-24-380GM boiler.

4. As the pipes of the convective beam become contaminated, which is manifested by an increase in the temperature of the flue gases, an increase in the resistance of the convective part along the gas path and a decrease in productivity, blow off the heating surfaces of the boiler, superheater and tail surfaces with steam or air according to the relevant instructions of the manufacturers; During repairs, washing with alkaline water is allowed.

Blowing with stationary blowing devices or gas-pulse cleaning should be carried out at a steady load and maximum pressure in the boiler.

The maximum and minimum load values ​​at which it is possible to blow or gas-pulse clean the heating surfaces of the boiler and economizer are determined by the commissioning organization based on the conditions for ensuring the removal of increasing volumes of flue gases by the smoke exhauster and maintaining stable combustion in the furnace.

Before blowing, warm up and blow through the drain the section of the steam line to the blower. After blowing, check the tightness of shutting off and opening the drainage of the blowing steam lines, since the passage of condensed steam into the gas ducts causes sulfuric acid corrosion of the heating surfaces.

When burning sulfurous, high-ash fuel oils, deposits on the heating surface become looser and can be blown off by adding special additives to the fuel oil, the use of which reduces the intensity of corrosion of heating surfaces with a wall temperature of less than 140-150°C.

5. Monitoring of the state of the combustion chamber during boiler operation is carried out through three hatches, two of which are installed on the side wall at the beginning and end of the combustion chamber, and the third on the rear wall at the right side screen. The exit edge of the burner embrasure is visible through the front hatch.

The side hatch, located at the end of the firebox, serves to monitor the combustion mode.

Through the rear hatch, one observes the igniter torch during debugging of the 33U, the filling of the combustion volume with the torch, and the condition of the embrasure and insulation of the upper drum.

The presence of fallen bricks on the underside indicates destruction of the insulation of the upper drum. In case of massive loss of bricks, as well as significant destruction or coking of the burner embrasure, the boiler must be stopped and repaired and cleaned.

6. Before the initial start-up of the boiler, it is necessary to carry out cold blowing.

For this:

turn on the smoke exhauster and fan;

set the nominal air pressure in the burner;

maintain a vacuum in the furnace of 20-30 Pa (2-3 kgf/cm2).

In this case, the vacuum pulsation in the furnace should not exceed 10 Pa (1 kgf/cm2), the air pulsation in front of the burner should not exceed 20 Pa (2 kgf/cm2).

Observation is carried out using panel devices.

If the pulsation exceeds the specified parameters, then you need to look for the reasons for the increased pulsation and eliminate them.

The causes of increased pulsation may be:

insufficient rigidity of steel gas ducts;

non-compliance of the aerodynamic characteristics of gas and air ducts with the recommendations of the “Standard method for aerodynamic calculation of boiler installations” of the TsKTI im.

Polzunova I.I.;

presence of water in gas ducts;

non-compliance of the burner installation, embrasure configuration or 2-stage combustion chamber with factory drawings.

The combustion mode must correspond to the regime map drawn up on the basis of boiler tests by the commissioning organization.

When adjusting the load, you should smoothly change the supply of air and gas. To increase the load manually, you must first increase the gas supply, then the air supply in accordance with the gas-air ratio graph. To reduce the load, the supply of air is first reduced, then gas. The vacuum is constantly maintained at 20-30 Pa (2-3 kgf/m2).

At least once a year, balance tests of the boiler should be done and the regime map should be adjusted if necessary.

7. Personnel must strictly adhere to the instructions for maintaining the water-chemical regime of the boiler and the chemical control schedule, the number and duration of periodic blowdowns, as well as the amount of continuous blowdown established based on the results of adjustment.

Due to the fact that alkalization does not ensure complete removal of corrosion products from the heating surfaces of the boiler, it is necessary to carry out increased blowing of the boiler during the first month of operation, periodically - 2 times per shift, continuous - at least 15% in the first five days, in subsequent days at least 5% to remove contaminants.

A month after starting the boiler, inspect the drums.

If an accident occurs in the boiler room during purging, stop purging immediately. An exception is the case when the boiler is overfilled with water, when the purging needs to be intensified.

Boiler room personnel and persons working on repairs of neighboring boilers must be notified of the upcoming boiler purging.

Periodic purging is carried out in the following order:

continuously monitoring the water level using direct-acting water level indicators, if the power regulator is not turned on (during lighting or after stopping the boiler), bring the water level in the boiler to the upper level; if the regulator is turned on, the level is maintained at the center of the glass;

open the second valve from the purge point: then slowly and carefully open the first valve and purge;

when hydraulic shocks appear in the purge pipelines, close the valves until the shocks disappear, then slowly open them again;

stop blowing if the water level approaches the lower level, to do this, first close the first valve from the blowing point, then the second. After purging, check the tightness of the purge valves (after the valves are not tightly closed, the purge pipeline does not cool down); If it is not possible to close the purge valves tightly and the water leakage is significant, it is necessary to stop the boiler.

It is prohibited to purge simultaneously from several points.

The time for purging the rear screen manifold should not exceed 15 seconds, other points - 30 seconds;

After each blowdown, make an entry in the log.

8. The design documentation of the plant accepts the location of the upper and lower permissible levels of ±80 mm relative to the axis of the upper drum in boilers with single-stage evaporation and in the clean compartment of boilers with two-stage evaporation.

In boilers with staged evaporation (capacity 16 and 25 t/h), the salt compartment is fed with water from the clean compartment, therefore, at loads close to the nominal, the water level in the salt compartment will be 20-50 mm lower than the water level in the clean compartment.

Significant “differences” in the water levels of the clean and salty compartments (in some cases exceeding 100 mm) observed during the operation of boilers with staged evaporation can be caused by the following reasons:

loose connection of the elements of steam separation devices to each other, to the drum and to the partition between the compartments;

drawing the flame into the convective part;

the bypass pipe was not installed according to the design;

violation of the thermal insulation of the lower pipes;

the presence of leaks in the partition between the compartments;

the steam pipe from the salt compartment to the water level indicator has sagging and leaky seams;

the partition between the compartments in the upper drum has protrusions at the horizontal cut point.

If the difference in levels in the clean and salty compartments is more than 80 mm, operation of the boiler is not allowed.

It is necessary to find out and eliminate the reasons for this “dispersion” of levels.

The automatic control system must be configured in such a way that fluctuations in the level in the drum at a steady load do not exceed ±20 mm from the average level. In boilers with staged evaporation, the automation is adjusted according to the readings of the clean compartment water level indicator.

9. Personnel must:

monitor the good condition of all connecting parts of pipelines, valves, valves, control valves within the boiler;

Open gate valves on all pipelines slowly and carefully, close tightly, make the last revolutions of the flywheel quickly;

all switching on and off of pipelines should be carried out with the knowledge of the shift supervisor, recording the operations performed in the shift log;

work on purging water level indicators, pressure gauges, and observing through peepers should be carried out wearing safety glasses;

All valve switching should be done with gloves on;

prevent fuel leaks;

strictly maintain the ratio of fuel and air pressures in accordance with the data of the regime map;

produce periodically gas analysis flue gases.

An increase in the oxygen content in the flue gases against the data of the regime map determined for the same load and the same conditions indicates an increase in suction in the furnace, flues or economizer;

monitor the temperature of the steel casing of the boiler.

Local heating of it to a temperature above 55°C indicates a violation of the lining in this zone (subsidence due to vibration of the boiler of mullite-silica felt with the formation of voids, cracking of the chamotte concrete layer and asbestos-vermiculite slabs);

Do not allow the boiler to be operated if there are leaks in the rolling joints (steaming, salt build-up).

When stopping the boiler for repairs and cleaning, carefully inspect the rolling connections of the pipes with the drums from the furnace side and if salts are detected in the form of fungi, growths, as well as if

ring cracks in the flared part of the pipes, carry out ultrasonic flaw detection or powder magnetoscopy of the flared areas.

Particular attention should be paid to timely detection of damage to heating surfaces.

Stopping the boiler

Stop the boiler in accordance with the production instructions.

After turning off the burner, blow out the direct-acting water level indicators, stop continuous blowing, close the shut-off valve at the boiler outlet, open the superheater purge, feed the boiler to the highest level on the glass of the direct-acting water level indicator, and then stop feeding. When working on fuel oil, after turning off the fuel, blow out the nozzle with steam.

In the future, as the level drops, it is necessary to periodically recharge the boiler. Monitor the water level in the boiler until the pressure drops completely.

Keep the TDM guide devices, peepholes, and manholes closed.

If it is necessary to quickly “cool down” the boiler for repairs, 1.5-2 hours after turning off the fuel supply, turn on the smoke exhauster with the fan and exhaust fan guide vanes closed, and after 4 hours slightly open the guide vanes. After cooling down, stop the smoke exhauster and close the devices.

It is prohibited to release water from the boiler without receiving an order from the person in charge of the boiler room. Upon receipt of permission, water should be released only after the water temperature has dropped to 70-80°C.

Drain the water slowly with the vent open.

Before placing the boiler for dry preservation, thoroughly clean all internal surfaces from deposits.

The boiler is securely disconnected from all pipelines using plugs.

After drying the boiler, to protect against corrosion, install baking trays filled with quicklime or calcined calcium chloride into the lower and upper drums through the open manholes; after installing the pans, close the manholes of the drums with lids. Do not allow chemicals to come into contact with the boiler surface.

The consumption of quicklime or calcium chloride during boiler preservation is given in Table 8.

Table 8

Boiler size	Name of reagents
	calcium chloride (CaCl 2), kg	quicklime (CaО), kg

Note. Place the amount of reagents indicated in the table in both drums. For boilers with a steam capacity of 16 and 25 t/h, place the reagents in both sections of the drums.

If you stop for a long time, it becomes necessary to replace the desiccant with a fresh one.

Preservation by the wet method consists of filling the boiler with feed water while maintaining excess pressure in the boiler.

When putting a working boiler into reserve, disconnect it from all water and steam lines after stopping, and blow through the lowest points to remove sludge. Then, without allowing the pressure in the boiler to drop below 0.15 MPa (1.5 kgf/cm2), connect it to the deaerator, fill it with deaerated water and leave it under pressure in the deaerator.

When putting the boiler into reserve after repair, before conservation, fill it with deaerated water to the normal level, melt it and at a pressure of 0.2-0.4 MPa (2-4 kgf/cm2) keep the vent open for 30-40 minutes to completely remove oxygen and carbon dioxide. After that, turn off the boiler and add feed water according to the described scheme.

Emergency stop

The boiler safety automation system must provide alarm and protection (fuel cut-off) according to the parameters given in Table 9

Table 9

	Parameter name	Signaling	Protection and alarm	Pulse collection location
	Gas pressure minimum/maximum (at Q n p = 8500 kcal/m 3)		(1750 kgf/cm 2)	At the inlet to the gas block
			(3000 kgf/cm 2)
	Fuel oil pressure, minimum		(15 kgf/cm 2)	At the inlet to the fuel oil block
	Vacuum in the furnace		Fuel: gas (+1; -8 kgf/m 2) within 10 s.	Specified in the factory drawing
			Fuel: fuel oil (-0.5; -1 kgf/m 2) within 10 s.
	Torch in the firebox		When extinguished within 2 s.	Branch pipe for self-propelled gun
	Air pressure, minimum		(10 kgf/m 2) within 10 s	Specified in the factory drawing
	Working pressure in the drum (excessive) Р р =1.3 MPa (13 kgf/cm 2) Р р =2.3 MPa (23 kgf/cm 2) Р р =1.4 MPa (14 kgf/cm 2) Р р =2.4 MPa (24 kgf/cm2) Р р =1.3 MPa (13 kgf/cm 2) Р р =2.54 MPa (25.4 kgf/cm 2)		MPa (kgf/cm 2)	Upper drum
	Drum water level			Upper drum

Note: 1. At pulse sampling points not according to the factory drawings, the automation must provide the specified parameters at the specified points.

Note: 2. A specialized commissioning organization can make adjustments to the parameters according to paragraphs. 1, 2 and 5 in justified cases, - for example: - significant deviationQ n R from the specified value, combustion of watered fuel oil.

The boiler must be stopped immediately in case of other violations listed in the operating instructions, in particular:

if a malfunction of the safety valve is detected, in which it is inoperative;

if all feed pumps stop operating or the feed line malfunctions, in which feed water does not flow into the boiler;

upon termination of all direct action water level indicators;

if the “dispersion” of levels in the water indicator glasses of the salt and clean compartments for boilers DE-16-14GM and DE-25-14GM exceeds 80 mm;

when screen or boiler pipes rupture;

when soot ignites in flues or economizer;

if during operation of the boiler strong hydraulic shocks or large vibrations of the boiler occur;

when the voltage disappears on all control and measuring instruments, remote and automatic control devices;

if a fire occurs in the boiler room, threatening the operating personnel or the boiler;

in case of an explosion in the combustion chamber or gas ducts;

when a malfunction of the safety automation or alarm system is detected.

2. Stop the boiler quickly: stop supplying fuel and air to the furnace.

After stopping the boiler, open the superheater purge a little and disconnect the boiler from the steam line. Close the boiler continuous blowdown valve.

A rupture of screen or boiler pipes manifests itself as follows:

the noise of a steam-water mixture flowing out in the firebox or flue is heard;

there is an emission of flame, combustion products and steam through the combustion openings, leakage of hatches, peepholes;

the level in the direct-acting water level indicator decreases and the pressure in the boiler drops.

In this case it is necessary:

stop the fuel supply, stop the blower fan, disconnect the boiler from the steam line;

if the level in the water level indicators remains visible, increase the water supply to the boiler (use a backup feed pump, turn off the power supply and switch to manual control), close the continuous purge valve;

if the water level in the direct action indicator is not established and continues to fall, stop feeding; Stop the smoke exhauster after steaming in the firebox or flue stops.

In case of slight damage to the boiler, screen or superheating pipe (fistula), provided that the normal water level is maintained, short-term operation of the boiler at reduced loads and pressure in the boiler is allowed with the permission of the boiler room manager.

4. When the water level in the boiler slowly decreases to the lower level mark and normal pressure in the boiler and feed line, it is necessary:

check the tightness of closing of all boiler purge valves, close the continuous purge valve;

Check through the peepholes and bottom hatches for leaks in the boiler.

If the level further decreases to the lower limit level, stop the boiler emergencyly.

Do not stop feeding the boiler. The boiler can be lit only after the water level has risen to average, identifying and eliminating the reasons for the drop in level.

If the water in the direct-acting level indicator disappeared behind the lower edge, and this was not noticed by the personnel, it is necessary to immediately turn off the fuel, stop supplying the boiler with water, close the main steam shut-off valve, and stop continuous purging. Stop the draft machines.

Open the superheater vent slightly.

When the water level in the boiler increases and it approaches the upper level mark and normal pressure in the boiler and feed line, it is necessary:

check the serviceability of the power regulator (it must be in the closed position);

open the purge valves of the lower drum, monitor the water level and, after it has dropped to medium, close the valves;

find out the reason for the increase in level and eliminate it.

6. When soot ignites in the flue ducts or the tail part of the boiler (economizer, air heater), the temperature of the flue gases increases sharply, smoke and flames may appear through leaks in hatches, manholes and flue duct connections.

In this case, it is necessary:

stop the fuel supply, increase the steam supply through the nozzle as much as possible, stop the smoke exhauster and blower fan, close their guide devices to stop air access to the source of fire, fill the flues with steam from the blower.

If there is no steam blowing (boilers and economizers are equipped with gas-pulse cleaning), it is necessary to provide a steam hose in the boiler room connected to the steam line fitting with a shut-off valve to allow steam to be supplied through a peephole or hatch. In this case, steam is supplied through the nozzle as well.

INTERNAL CLEANING OF THE BOILER

Clean the internal heating surfaces from scale by mechanical or chemical means.

Mechanical boiler cleaning

Before mechanical cleaning of the boiler, it is alkalized in accordance with these instructions (clause 2 of the section “Drying the lining, alkalization”).

After cooling, rinse the boiler (the temperature of the drum wall should not exceed 40-50°C).

Clean the boiler from scale mechanically using cutters and flexible shafts. Before cleaning the pipes, it is necessary to remove the fender shields of the steam separation devices, which block access to the pipes of the screens and the boiler bundle. Set the descaling time depending on the mode and duration of operation of the boiler and the quality of the water.

Any shutdown of the boiler must be used for a thorough inspection and, if necessary, for cleaning.

Chemical boiler cleaning

Based on laboratory analysis of the composition of deposits on the internal heating surfaces, a specialized organization determines the type of reagents and the chemical cleaning regime of the boiler:

a) Cleaning with mineral acids

The most effective cleaning is with a five percent solution of hydrochloric acid (HCl), which is carried out at 50-60°C with circulation of the solution in the circuit elements at a speed of at least 1 m/s to eliminate the precipitation of suspended particles. Dissolve the reagents in a solvent tank and heat with steam. The duration of treatment with the specified heating is 6-8 hours. Without heating, 12-14 hours.

To speed up the process of dissolving scale or deposits, NaF can be added to the hydrochloric acid solution in the ratio NaF: HCl = 1: 6.

For hydrochloric acid, inhibitors are used: PB-5, methenamine, catapine, BA-6, I-1-A, etc. The best effect is achieved by a mixture of PB-5 (0.5%) with methenamine (0.5%), catapine (0.3%) with methenamine (0.5%), I-1-A (0.3%) with methenamine (0.6%), BA-6 (0.5%) with methenamine (0.5 %).

For hydrazine acid cleaning, very diluted acid solutions are used (pH = 3-3.5). The concentration of hydrazine is maintained at 40-60 mg/l N 2 H 4: purification is carried out at a temperature of 100 ° C.

b) Cleaning with organic acids

You can use acids: citric, adipic, formic. Citric acid is more widely used, the use of which requires ensuring reliable circulation of the solution at a speed of at least 0.5 m/s, but not more than 1.8 m/s in order to avoid increased corrosion of the boiler metal. :

The acid concentration should be in the range of 1.0-3.0% (a three percent acid solution can bind 0.75% iron by weight).

Cleaning is carried out at a temperature of 95-105°C. The permissible concentration of iron in the solution is no more than 0.5%, and the pH of the solution should not exceed 4.5; The residence time of the solution in the boiler is 3-4 hours.

Citric acid effectively removes mill scale, but has no effect on silicates and copper, calcium compounds are removed in limited quantities. Do not allow interruptions in the circulation of solutions and add fresh acid to the solution. Spent solution citric acid should be forced out of the boiler with hot water rather than drained. The ability of citric acid to dissolve scale increases sharply when it is partially neutralized with ammonia until the formation of ammonium monocitrate (pH = 4).

Depending on the degree of surface contamination, the following are used: 1, 2 and 3% solutions of ammonium monocitrates. Catapine (0.1%) with Captax (0.02%) and OP-10 (0.1%) with Captax (0.1%) can be used as inhibitors for ammonium monocitrate. Ammonium monocitrate is not effective enough to remove thick deposits. Therefore, cleaning a heavily contaminated boiler is carried out in two stages: first with a 3-4% solution, and then with a 0.8-1.2% solution of monocitrate.

The boiler is cleaned with adipic acid at a temperature of 100°C. If surfaces are highly contaminated (150-200 g/m2), clean them in two stages: first with a 2% solution, then with a 1% solution. After washing with acids, especially without adding inhibitors, it is necessary to alkalize the boiler.

c) Purification with complexing reagents

Cleaning with complexones is rational in all cases where the use of mineral acids is unacceptable or undesirable. Complexons are especially convenient for operational cleaning. The following have been used in practice: ethylenediaminetetraacetic acid (EDTA) and its sodium salts, in particular the disodium salt - Trilon B; nitrilotriacetic acid (NTA, Trilon A).

For chemical cleaning of the boiler, specially formulated compositions of complexones should be used:

to remove predominantly alkaline earth deposits, the following composition, g/l:

trilon B 2-5;

OP-10 (or OP-7) 0.1;

Triethanolamine 0.2-0.5;

To remove predominantly iron acid deposits - compositions A, B, C, given in Table 10.

Table 10

Boilers are cleaned with complexing reagents at a temperature of 100°C. The speed of movement of the solution is 0.5-1.0 m/s, the duration of exposure is 4-8 hours, depending on the composition, thickness and density of deposits. The recommended concentration of EDTA solution is 0.3-0.5%, Trilon B 0.5-1.0%. If there is a large amount of deposits, these reagents can be added to the washing solution without limiting their total concentration in the solution, optimal value The pH is around 4 (3-5).

EDTA and Trilon B are suitable for removing predominantly calcium deposits. In this case, the pH of the medium should be increased with ammonia to 10, this will eliminate the need to add corrosion inhibitors.

d) Calculation of reagent consumption

The consumption of reagents is determined from the conditions for obtaining the required concentration of the reagent in the volume of the flushing circuit, according to the formula:

where: Q 1 - consumption of reagents, t;

C is the required concentration of reagents, %;

V is the volume of the flushing circuit, m 3 ;

a - safety factor equal to 1.2-1.4;

P is the density of the solution, t/m3.

When cleaning with complexones, the calculation is carried out taking into account two factors:

the required concentration of the solution and the required amount of reagent to completely dissolve deposits according to the formula:

, t (2)

where: Q 2 - the amount of reagent required to completely dissolve deposits, t;

C is the required concentration of the working solution, %;

d - specific contamination of the equipment surface, g/m2;

β - reagent consumption, g per 1 g of iron oxides (for iron oxide deposits); for ammonium monocitrate β=2.5-3 g/g;

S - surface to be cleaned, m2.

The obtained Q2 value is checked for the absence of supersaturation of the solution with iron in the volume of the flushed circuit, m3, using the formula:

, t/m 3 (3)

where: p - iron concentration, t/m3;

1.44 - conversion factor Fe 2 O 3 xFe.

Substituting the value d x S found from formula (2) into formula (3) we obtain:

, g/m 3

The ratio p must be observed< пр, где пр – предельно-допустимая концентрация железа в растворе комплексона. Значение пр составляет 9, 6 и 3 г/л соответственно для трех, двух, однопроцентного растворов моноцитрата аммония.

Ammonia consumption for the preparation of ammonium monocitrate is determined by the formula:

Q NH 3 =0.35 x Q lux, (4)

where: Q lx - consumption of citric acid, i.e.

For hydrazine-acid cleaning, the following reagent consumption is accepted, kg per 1 m 3 of water volume of the flushed circuit:

H 2 SO 4 (75%) - 20-22, HCl (25%) - 50-55, hydrazine hydrate (64%) - 0.6-0.7.

The amount of bleach Q chi consumed to neutralize hydrazine in the discharge solution is determined by the formula:

Q lux = 25ChS gd x V r, (5)

where: C gd is the concentration of hydrazine in the discharged solution, mg/kg;

V r - volume of solution, m 3.

Consumption of hydrochloric and adipic acids when washing with 2-5% solutions of caustic soda and ammonia. OP-7 for alkalization and neutralization of sodium nitrate and hydrazine during passivation, as well as inhibitors, is determined by formula (1).

TECHNICAL INSPECTION

1. Each boiler must undergo a technical inspection before being put into operation, periodically during operation and, if necessary, an extraordinary inspection.

Technical inspection of the boiler consists of external, internal inspections and hydraulic testing.

Technical inspection of the boiler must be carried out by the administration in accordance with the schedule of scheduled preventive maintenance (PPR), drawn up taking into account the requirements of the Rules for Boilers and the section “Boiler Repair” of this Instruction.

2. Since DE - GM boilers have small areas of welds and rolling joints, pipes in dense bundles that are inaccessible for internal and external inspections during technical inspections and repairs of boilers, internal and external inspections are carried out only in accessible places.

Assessment of the technical condition of boiler elements that are not available for internal and external inspections is carried out based on the results of internal and external inspections of boiler elements available for control, similar in purpose to the boiler elements subject to control, as well as based on the results of a hydraulic test.

For a more reliable check of the strength and density of rolling joints, the duration of holding boilers under test pressure can be increased to 20 minutes.

If massive corrosion phenomena and other defects are detected during a technical inspection, the volume of work carried out before the expiration of the design life of the boiler elements must correspond to those set out in the Expert Inspection Program (see section “Expert Inspection Program of Boilers”).