Boiler DE-25-14GM

Contents

INTRODUCTION

TECHNICAL DESCRIPTION

Purpose, technical data and boiler arrangement

VALVES, INSTRUMENTATION AND SAFETY INSTRUMENTS

INSTALLATION INSTUCTION

Transportation

Boiler acceptance and storage

Boiler Installation Site Requirement

Installation of boilers

Burner installation

Security measures

Control of safety valves

Drying of coating, alkaline

Complex testing of boilers and adjustment during complex testing

WATER-CHEMICAL MODE OF BOILERS

OPERATING INSTRUCTION

General provisions

Inspection and preparation for flushing

Kindling

Actuation of the boiler

Boiler Maintenance

Boiler stop

Emergency stop

INTERNAL BOILER CLEANING

Mechanical cleaning of boiler

Boiler Chemical Cleaning

TECHNICAL EXAMINATION

BOILER REPAIR

1. General part

2. Types of defects and damages of boiler elements

3. Check of boiler elements status

4. Repair works

5. Marking

BOILER EXPERT SURVEY PROGRAMME

1. Inspection of drums

2. Inspection of heating surface pipes

3. Inspection of screen headers, superheater

4. Inspection of pipelines within the boiler, non-heated pipes with external diameter of 100mm and more

5. Standards for assessing the quality of the surveyed elements

LIST OF REGULATORY AND TECHNICAL DOCUMENTATION USED IN EXPERT INSPECTION OF DKVR AND DE STEAM BOILERS

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

Appendix 2. Figure of safety valve

Appendix 3. Preparation of pipes for welding. Types of blankings and their installation

Introduction

This manual describes the equipment and specifications of the boilers.

The instruction is developed in accordance with GOST 2.60168 "ESKD. Operational Documents "and contains the information necessary for installation, start-up, adjustment, operation, maintenance and repair of gas-oil boilers of DE type, steam capacity 4; 6,5; 10; 16 and 25 t/h with absolute pressure 1.4 and 2.4MPa (14 and 24 kgf/cm2) as per GOST 3619 -89.

In addition to this instruction, the following documents shall be used in the performance of works:

- "Rules for arrangement and safe operation of steam and hot water boilers" approved by the Gosgortekhnadzor of Russia (hereinafter referred to as "Boiler Rules");

- "Rules for arrangement and safe operation of steam and hot water pipelines" approved by Gosgortekhnadzor;

- SNiP 3.05.05 - 84 "Process equipment and process 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 works during the construction of boiler houses";

- SNiP 3.01.04 - 87 "Acceptance of completed construction facilities. General provisions ";

- GOST 27303 - 87 "Steam boilers. Acceptance after installation. "

Technical description

Purpose, technical data and boiler arrangement

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

Main characteristics and parameters of boilers are given in Table 1.

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

The main components of the boilers are the upper and lower drums, the convective bundle and the left furnace screen (gas-flooded partition) forming the firebox-measure, the right and rear furnace screens, as well as the screening pipes of the front wall of the furnace.

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

Drums are made of sheet steel of grade 16GS GOST552079 13 and 22 mm thick for boilers with working absolute pressure of 1.4 and 2.4 MPa (14 and 24 kgf/cm2), respectively.

For access inside drums in front and rear bottoms there are blades.

The convective bunch is formed by the vertical pipes Ø51x of 2.5 mm, koridornoraspolozhenny on all length of a cylindrical part of drums, attached to the top and lower drums.

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

The longitudinal pitch of the pipes of the convective bundle 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). Pipes of the outer row of the convective bundle are installed with a longitudinal pitch of 55 mm; at the input to the drums, the tru-bos are divided 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 have no partitions in the bundle.

The convective bundle is separated from the furnace chamber by a getter partition (left furnace screen), in the rear part of which there is a window for entry of gases into the bundle.

Pipes of gas-flooded partition, right side screen forming also under and ceiling of furnace chamber, and pipes of front wall shielding are introduced directly into upper and lower drums.

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

FITTINGS, INSTRUMENTATION AND

SAFETY INSTRUMENTS

Each boiler is equipped with two spring safety valves.

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

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

Valves are controlled according to the instructions of the relevant section "Installation Instructions."

Two direct water level indicators are provided on the boilers, which are connected to pipes communicating with the steam volumes of the upper drum.

In boilers with 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 compartment.

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

Boilers are equipped with the required number of pressure gauges and valves.

For connection of safety devices and control systems on boilers, places of installation of sampling devices are provided, the location of which is given in general drawings.

The type of instruments of the instrument system and the place of installation of their boiler house shall be selected by the design organization when designing the boiler house taking into account the requirements of section 6.7. Boiler and SNiP Regulations.

Installation Instructions

Transportation

The boilers are delivered to the consumer in two versions:

1. In assembled form by one transportable unit in cloth and skin. The cladding is supplied by a separate place, the cladding materials are not supplied by the plant;

2. Assembled by one transportable unit in cloth and skin.

Technical documentation for installation insulation shall be sent to the design organizations and customers.

Boilers can be transported by rail, road and water.

Transportation by rail is carried out in accordance with the "Rules for the carriage of goods" approved by the IPU.

Boilers submerged on the railway platform; together with all attachments fit into the loading dimension in accordance with the requirements of the loading specification.

For slinging and rigging on the boiler unit there are special load brackets. Slinging for other parts of the boiler is not allowed.

For the transportation of boilers on the roads, trailers of appropriate lifting capacity are used, having the necessary devices for reliable attachment of units. Transportation speed on the trailer on paved roads shall be not more than 40 km/h, on unpaved roads - not more than 20 km/h.

Transportation by sea is carried out in accordance with the "Rules for the safe maritime transportation of general goods."

Boiler acceptance and storage

The consumer must accept the boiler from the railway or other transport organizations in accordance with the "Instructions on the Procedure for the Acceptance of Industrial and Technical Products and Consumer Goods," approved by the State Arbitration Service, as well as in accordance with the technical and shipping documentation of the manufacturer.

The customer or the organization leading the warehouse and the farm under the contract shall be responsible for organizing the acceptance and preservation of the equipment.

During acceptance of boiler units, their external surfaces are inspected, condition of screen and convective pipes, drums and other elements is checked.

The surfaces of drums, manifolds, flanges shall have no nicks, dents and other defects.

All reinforcement shall be subjected to external and internal inspection, as well as hydraulic test for density and strength in accordance with GOST 35680.

Upon completion of the inspection, an act of technical acceptance of the equipment is drawn up, with a list of defects attached. Detected defects shall be rectified.

Boiler units, packages and boxes with parts shall be stored in enclosed rooms. In the absence of premises, it is allowed to store boilers delivered without coating and cladding on a covered platform with their installation on liners.

Pipe flanges shall be closed with plugs or conical plugs with a diameter 10 mm greater than the diameter of the hole, the drums and manifold panels shall be closed and retracted.

Boiler fittings, fasteners, flanges, blowing devices shall be stored in a closed room.

When stored on an open site, boiler blocks and components of the assembly units must be inspected periodically (at least 1 times per 3 month) and subject to re-preservation if contamination, paint damage, rust, and other defects are detected.

Boiler units shall be stored in insulation and lining only in a closed room or, as a last resort, under a canopy. All manholes, blades and holes through which moisture can fall under the boiler skin during storage or movement and wet mullite silica felt should be carefully closed.

Boiler Installation Requirements

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

The axes are divided according to drawings, making measurements from columns or walls of the building. Due to possible inaccuracies in the construction of the building after preliminary breakdown of the boiler axes, it is necessary to check their mutual perpendicular.

With starting points, check the following geometric dimensions:

a) dimensions of embedded parts of the foundation;

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

c) compliance with the drawings of the overall dimensions of the foundation and its rectangle (by comparing the lengths of the diagonals).

The tolerances on the size of the foundation are determined by the requirements under which the dimensions of the boiler support frame must fit into the dimensions of the embedded parts.

When checking the foundation, follow the requirements of SNiP 3.05.0584.

The foundation acceptance shall be executed by a tripartite act (customer, general contractor and installation organization) with preparation of the as-built foundation diagram.

Control of safety valves

Control of safety valves is performed:

1. During boiler start-up, after installation.

2. When starting the boiler after it is in reserve.

3. During technical inspection of the boiler.

4. Based on the results of serviceability check of safety valves.

5. When the operating pressure in the boiler changes .

Control of safety valves can be carried out on the bench, during hydraulic tests or during alkalization during steam discharge through the auxiliary line and installed steam removal pipelines.

Safety valves shall be reviewed prior to installation. Lubricate the threads of the pressure bushing (silver graphite - 20%, glycerin - 70%, copper powder - 10%), check the condition of sealing surfaces, presence of rod seals.

In normal operation the valve is closed, the disc is pressed to the seat by spring force. The spring force on the disc is controlled by the amount of its compression by means of a threaded pressure bushing.

Pressure rises slowly and safety valves are adjusted for the opening start pressure specified in Table 3.

If it is necessary to operate the boiler at reduced pressure (but not lower than the values specified in item 1 of the section "Boiler Maintenance"), the valves are adjusted according to this operating pressure, according to section 6.2. Boiler rules.

Control of safety valves is performed alternately in the following sequence (for the safety valve figure, refer to Item II):

- set the required pressure in the boiler;

- remove manual blasting lever (4) and protective cap (11);

- unscrewing the pressure bushing (8) to achieve start-explosion of the valve;

- reduce the pressure in the boiler before the valve fit, at that the difference between the pressure of explosion and the valve fit must be not more than 0.3 MPa. By turning the damper bushing (9) clockwise, the difference is increased and the difference is reduced. To rotate the damper bushing, loosen the locking screw (7), upon completion of adjustment, lock the specified screw by-lock;

- measure the spring tightening height with accuracy of 1 mm and record it in the replaceable log book;

- upon completion of adjustment install the protective cap and manual blasting lever in place;

- seal the protective cap of the valve.

To verify that the safety valves are properly adjusted, raise the pressure until the valve is activated, thereby reducing the pressure until the valve is closed.

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