1 MW process boiler house

Contents

1.1 General information

1.2 Fire Fighting Equipment

1.3 Thermal mechanical solutions

1.3.1 Design Solutions

1.3.2 Thermal diagram

1.3.3 Water treatment and blowdown

1.3.4 Pipelines

1.3.5 Safety valves

1.3.6 Flue and chimney

1.3.7 Corrosion protection and thermal insulation

1.3.8 Installation Instructions

1.4 Heating and ventilation

1.4.1 Initial data and main solutions for heating and ventilation

1.4.2 Heat supply

1.4.3 Heating

1.4.4 Ventilation

1.4.5 Corrosion protection and thermal insulation

1.4.6 Installation Instructions

1.5 Gas supply

1.5.1 Accounting of gas quantity expenditures

1.5.2 Gas Supply Solutions

1.5.3 Installation Instructions

1.6 Occupational safety

1.6.1 List of main regulatory documents

1.6.2 Occupational safety measures

1.7 Information on fuel, water, thermal and electrical energy requirements, energy saving measures

1.7.1 Fuel Requirements Information

1.7.2 Thermal Energy Requirements Information

1.7.3 Energy conservation measures

1 MW Process Boiler House

General Information

The project provides for the construction of a production boiler house. The boiler room is designed to ensure the operation of the production line for baking bakery products using MIWE technology (Germany).

Design parameters of outdoor air:

for maximum winter mode - minus 25 ° С;

for the coldest month mode - minus 6.6 ° С;

for summer mode - plus 24.7 ° С.

The heating capacity of the boiler house is 1.027 MW

The boiler room is provided for round-the-clock and year-round.

According to the reliability of heat supply to consumers, the boiler room belongs to the second category.

Fire fighting equipment

The boiler room is equipped with primary fire extinguishing equipment in accordance with the requirements of the "Fire Safety Rules in Ukraine" NAPB A.01.0012004: powder extinguishers of the OP9B type in the amount of 6 pcs.

Thermal mechanical solutions

Design solutions

The project provides for installation of boiler room equipment and pipelines in the designed building .

Two boilers of the HKZ 400 type are installed in the boiler house, operating on a high-temperature organic coolant (hereinafter referred to as VK) with a heating capacity of 400 kW each manufactured by MIWE and one steam boiler UND 350 with a steam capacity of 350 kg/h manufactured by LOOS International (Germany ).

The boilers to be installed are products of full factory readiness and are equipped with safety and regulation automation in the scope of supply.

Requirements of Rules for arrangement and safe operation of steam and water heating boilers DNAOP 0.001.08 do not apply to boilers HKZ 400.

The project provides for:

- typical arrangement of boilers and auxiliary equipment, adopted on the recommendation of the manufacturer of the bakery baking line - MIWE;

- boilers and other equipment in block transportable version of high factory readiness;

- enlarged groups of technologically connected auxiliary equipment;

- enlarged piping installation units.

Boiler room operation is accepted in automatic mode without permanent maintenance personnel .

The HKZ 400 boilers are supplied with the following assembly units (for each boiler):

circulation pump module with flow rate of 26 m3/h, head of 40 m of water. article;

expansion tank of type AD1100l;

receiving tank of KV140l type;

collector of SG1100l type;

Instrumentation, automation, piping.

The UND 350 boiler is equipped with the following assembly units:

water softening module of WTM 60 type;

service module of WSM 800 type;

PM type feed pump module;

Instrumentation, automation, piping.

The supplier of the enlarged groups of technologically connected auxiliary equipment and piping assembly units is MIWE.

Fuel for boilers - natural gas according to GOST 5542. Each boiler is equipped with a WG type fan burner manufactured by Weishaupt GmbH (Germany).

For gas supply to the boiler house, see the section "Gas supply" of this explanatory note.

Thermal diagram

Control of heat release is provided for high-quality - according to the technology of the main production.

MARLOTHERM SH product with 300 ° C boiler outlet temperature is used as IC. The design temperature difference between the IC in the supply and return pipelines is 40 ° С.

The second heat carrier for bakery products baking process is saturated with pressure of 0.3 kgf/cm2. Condensate return is not provided according to the requirements of the main production technology.

VIC circulation is provided by closed loop. The available pressure in the IC system is created only by circulating IC pumps equipped with HKZ 400 boilers. The IC is maintained for many years of operation (subject to its operating temperature).

Expansion of the IC during its heating is compensated in the expansion tanks AD1100l installed at el. + 6.850. Collectors SG1100l are designed for initial filling of the system.

Degasser and intake tanks KV140l structurally connected with expansion tanks are provided for air removal from the IC system.

The addition and discharge of VOC is provided according to the readings of the service organization serving the main production process line. VIC discharge is provided by a mobile pump for vehicles and is exported for regeneration or disposal.

Water treatment and blowdown

The steam boiler is powered by softened and deaerated water.

To soften the feed water, a factory-made water softening module of the WTM 60 type is provided. Water softening is carried out using the two-stage Nacation method.

For deaeration of softened water, a service module WSM 800 is provided. The module also heats feedwater, samples of water and steam. Chemical-thermal deaeration method. The WSM 800 includes the following main assemblies:

deaerated feedwater capacity;

reagent injection unit;

sampler with sample cooler;

Instrumentation, automation and piping.

Blowdown of steam boiler UND 350 is automated according to the boiler water analysis readings. Purge water separation is performed in WSM 800 module.

Pipelines

Fibre-optic pipelines are accepted from steel seamless pipes of group A as per GOST 55075. Material of steel of grade 20 pipes as per GOST 1050.

The steam pipeline is accepted from steel electric welded pipes as per GOST 10704-91.

Safety valves

Each boiler is provided with a safety valve.

Discharge from relief valves of boilers HKZ 400 is provided in headers SG1100l.

The release from the safety valve of the boiler UND 350 is provided outside the boiler building to the atmosphere. Condensate and liquid drain from the safety valve exhaust pipe is drained to the sewer.

Flue and chimney

Flue gases are removed from boilers by gas ducts collected from finished double-walled elements (such as a sandwich) made of corrosion-resistant steel with thermal insulation between the walls of production of ALTALIT LLC in Zaporozhye.

An individual chimney is provided for each boiler. For HKZ 400 boilers, chimneys are made of elements manufactured by ALTALIT LLC and are located outside the building with a wall mount. Inner wall thickness of elements is 1.0 mm.

For the boiler UND 350, the chimney is metal and installed inside the boiler room with an exit through the ceiling outside the boiler building. The design of the chimney for the boiler UND 350 is being developed in the architectural and construction part of the project.

Corrosion protection and thermal insulation

Thermal insulation of pipelines is accepted by mineral wool cylinders on a synthetic binder manufactured by ROCKWOOL (Poland). Thickness of thermal isolation is accepted for the HERE pipelines - 120 mm (the giving pipeline) and 90 mm (return pipeline), for a steam line - 50 mm.

Insulation of fibre-optic pipes is accepted in 2 layers:

for supply: 1 layer - cylinders 40 mm thick and 114 mm inner diameter, 2 layer - cylinders 80 mm thick and 159 mm inner diameter;

for reverse: 1 layer - cylinders 40 mm thick and 114 mm inner diameter; 2 layer - cylinders with a thickness of 50 mm and an internal diameter of 159 mm.

The chimney for the boiler UND 350 is covered with heat insulation plates from mineral wool on a synthetic binder according to DSTU B B.2.7972000 (GOST 957396), grade 75. The design thickness of the thermal insulation of the chimney is taken to be 80 mm, the custom thickness of the insulation (taking into account the sealing coefficient of 1.5) is 90 mm.

Protective coating of thermal insulation is accepted from aluminum sheet AD1.N as per GOST 21631 - 76. The thickness of the protective coating is accepted for the supply pipelines of the IC and the chimney of the boiler UND 350 - 0.5 mm, for the return pipelines of the IC and the steam line - 0.3 mm.

Perform identification painting of pipelines in accordance with the requirements of GOST 14202 - 69.

Installation Instructions

Installation and testing of boilers, pipelines, and other equipment shall be carried out in accordance with the requirements of the following regulatory documents:

DNAOP 0.001.26-96 "Rules for arrangement and safe operation of steam boilers with steam pressure not more than 0.07 MPa (0.7 kgf/cm2), water heating boilers and water heaters with water heating temperature not more than 115 ° С";

SNiP 3.05.05 - 84 "Process equipment and process pipelines";

SNiP 3.05.01 - 85 "Internal sanitary and technical systems";

SNiP III4 - 80 "Safety in construction,"

and in accordance with the installation instructions of manufacturers' plants (firms).

Installation, testing and adjustment of equipment and pipelines shall be carried out by an organization with a state license to perform the specified works.

Installation of the enlarged groups of technologically connected auxiliary equipment and piping installation units, as well as testing and adjustment of all boiler room equipment is carried out by the supplier - MIWE.

Heating and ventilation

Initial data and main solutions for heating and ventilation

Outside air design parameters:

for heating design - minus 25 ° С;

average temperature of heating period - minus 1.6 ° С;

the average temperature of the coldest month is minus 6.6 ° C.

The heating period is 180 days.

The internal air temperature in the cold period of the year is accepted as plus 5 ° С (standby heating).

Heat supply

Heat supply of the reconstructed building is taken as centralized. The source of heat supply of the building is the existing boiler house of the Luganskmlyn enterprise. The heat supply system of the designed building is connected to the existing heat network of the enterprise. Coolant - water with parameters 70-55 ° С.

Control of heat release - high-quality at the heat source, depending on the temperature of the outside air.

Heating

Heating of the building was accepted by air heating units of the VOLCANO VR1 type manufactured by EUROHEAT HQ Sp. z o.o. (Poland). 2 units are accepted for installation.

Operation of air-heating units is automated.

Pipelines of the heat supply system of air-heating units are accepted from steel water and gas pipes as per GOST 3262-75. Pipeline laying is accepted as open.

Ventilation

Ventilation of the building is accepted with a natural urge of air. Air inflows through external grates located at the bottom of the gate and the walls of the building. Air exhaust - through deflectors located on the roof of the building.

For additional ventilation of the boiler room during the summer period, it is possible to open windows.

Corrosion protection and thermal insulation

Thermal insulation of pipelines is accepted by thermal insulation cylinders manufactured by ROCKWOOL (Poland). Coating layer over insulation is accepted by aluminium sheet of type AD1.N 0.3 GOST 2163176.

Anti-corrosion coating of pipelines is accepted with paint BT177 OST 610426 - 79 in 2 layers according to the 1st layer of primer GF021 GOST 25129 - 82.

All metal fasteners of pipelines and equipment are covered with oil paint in 2 times.

Installation Instructions

Installation and testing of the systems shall be carried out in accordance with the requirements of SNiP 3.05.01 - 85 "Internal Sanitary and Technical Systems," SNiP III4 - 80 "Safety in Construction," as well as according to the installation instructions of the manufacturers' plants (firms).

Installation, testing and adjustment of equipment and pipelines shall be carried out by an organization with a state license to perform the specified works.

Gas supply

The adopted decisions on gas supply comply with the requirements of DBN B.2.5202001 "Gas supply" and DNAOP 0.001.20-98 "Safety Rules for Gas Supply Systems of Ukraine."

Two HKZ 400 boilers manufactured by MIWE (Germany) and one UND 350 boiler manufactured by LOOS International (Germany) are installed in the designed boiler house

Boilers accepted in the project are automated equipment of full factory readiness and are equipped with safety and regulation automation in the scope of supply.

Flue gas removal from boilers is carried out through individual chimneys (see section "Thermal mechanical solutions").

The boiler room operation mode is accepted as automated, without permanent maintenance personnel.

For boiler room automation, see "Automation"

Low pressure gas is used for gas supply of boilers. A low-pressure gas pipeline (up to 5 kPa) is introduced into the boiler room. The gas pipeline inlet is connected to the external gas pipeline designed by a separate project.

Disconnecting device at gas inlet to boiler house is located outside boiler house building.

The gas supply was calculated according to DBN B.2.520-2001 .

Accounting of gas quantity expenditures

The commercial gas consumption accounting unit is common to the enterprise, located on the territory of the enterprise .

In-house (process) accounting of gas quantity is provided for each boiler.

Internal accounting of gas consumption is carried out by GMSG type gas meters produced by the domestic enterprise GP plant Arsenal (Kiev).

Installation of gas flow metering units for each boiler is provided at the front of the boilers at the gas pipeline supply to the burner.

For boiler room ventilation, refer to "Heating and Ventilation."

The estimated gas flow rate per HKZ 400 boiler is 45.5 m3/h, per UND 350 boiler - 28.0 m3/h. The estimated gas flow rate for the boiler house as a whole is 119.0 m3/h.

Gas Supply Solutions

Designed gas pipelines are accepted from steel water and gas pipes according to GOST 3262-75 and electric welded pipes according to GOST 10704-91. Pipe material according to GOST 3262 - 75 - common-quality carbon steel according to GOST 380 or high-quality steel according to GOST 1050 - 88 of the first grade. Pipe material as per GOST 10704 - 91 - steel of grade St3ps as per GOST 380 - 94, delivery according to group B of GOST 10705 - 80.

Gasket of gas pipelines is accepted as open. Laying of gas pipelines through the wall is provided in cases according to the series 5.905 - 15. Fill the space between the gas pipeline and the case with a ground pack, rubber bushings or other elastic materials .

The gas pipelines are fixed according to the series 5.905-8.

The project provides for the control of carbon monoxide microconcentrations (0.005 volume percent CO) and the control of pre-explosion gas concentrations of 20% of the lower concentration limit of flammability (NCCP) in the gasified room by installing an annunciator. When 20% of the FFL is reached, the valve switch installed at the gas inlet to the boiler room operates.

Installation Instructions

Install and test the gas supply system in accordance with the requirements of DBN B.2.520-2001, SNiP III4 - 80 "Safety in construction" and DNAOP 0.001.20-98, as well as according to the manufacturer's instructions for the installation of equipment.

Installation, testing and adjustment of the gas supply system should be carried out by an organization that has a state license to perform these works.

Installation of gas metering units shall be carried out in strict accordance with the drawing. When installing each meter, it is necessary to set it strictly vertically to the level in order to avoid jamming of the rotors.

After installation, cover all gas pipelines laid indoors with oil paint in 2 times. The gas pipeline laid outside the building is covered with two layers of PP115 aerial, GOST 15907 - 70, on two layers of GF021 primer, GOST 25129 - 82.

Colour as per GOST 14202.

Information on fuel, water, thermal and electrical energy requirements, energy saving measures

Fuel Requirements Information

The annual consumption of conventional fuel is:

for heating the boiler house 3.01 tons;

for technology 373.55 tons.

The annual consumption of natural gas with a calorific value of 34 MJ/m3 is:

for boiler house heating 2594 m3;

for 321997 m3 technology.

About Thermal Energy Requirements

The estimated heat consumption is:

for heating the boiler room 67780 W;

for 695000 watts technology.

The annual thermal energy demand is 10948 GJ.

Energy conservation measures

For the heat and mechanical part of the boiler room and for the heating system, the following energy saving measures are provided:

effective thermal insulation of pipelines with WC, hot water and steam pipelines;

automatic maintenance of the specified air temperature inside the boiler room

automated heat release to the main technology.