Instructions for use dkvr. Operation of hot water boilers Production instructions for service personnel of hot water boilers
RUSSIAN JOINT STOCK SOCIETY OF ENERGY AND ELECTRIFICATION "UES OF RUSSIA"
DEPARTMENT OF SCIENCE AND TECHNOLOGY TYPICAL INSTRUCTIONS FOR THE OPERATION OF WATER BOILERS WITH EXTERNAL HEAT EXCHANGERS
RD 34.26.515-96 ORGRES BEST EXPERIENCE SERVICE
Moscow 1997 Content
| 1. GENERAL PROVISIONS 2. BOILER UNIT 2.1. Preparatory operations 2.2. Fuel oil boiler firing 2.3. Heating up the boiler using gas 3. TRANSFERRING THE BOILER FROM ONE KIND OF FUEL TO ANOTHER FUEL 3.1. Converting the boiler from fuel oil to gas 3.2. Conversion of the boiler from gas to fuel oil 4. MAINTENANCE OF THE BOILER DURING OPERATION UNDER LOAD 5. STANDARDS OF A WATER-CHEMICAL MODE OF A CLOSED CIRCUIT 6. STOPPING THE BOILER 7. EMERGENCY PROCEDURES 8. INSTRUCTIONS FOR SAFETY AND EXPLOSION HAZARD , AUTO REGULATION, TECHNOLOGICAL PROTECTION, INTERLOCKING AND SIGNALING 9.1. Recommended scope of instrumentation equipment 9.2. Boiler automatic regulation system 9.3. Technological protection 9.4. Local defenses 9.5. Locks 9.6. Process signaling Annex 1 BRIEF DESCRIPTION OF WATER BOILER KVGM-180-150 Appendix 2 EXAMPLE FORM OF A MODE CARD OF A WATER BOILER |
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TYPICAL INSTRUCTIONS FOR THE OPERATION OF WATER BOILERS WITH EXTERNAL HEAT EXCHANGERS |
RD 34.26.515-96 |
Entered into force on 01.01.97.
1. GENERAL PROVISIONS
1.1. Hot water boilers are installed at many CHPPs, however, with a low quality of network water (especially in large cities of the country) and the presence in it a large number iron is intensively skidded by deposits of their internal heating surfaces. The greatest number of damage to heating surfaces of hot water boilers relates to heating surfaces of convective packages. This is explained. mainly by their increased heat perception due to the location in the zone of high temperatures of gases, which leads to an increase in the sweep of water temperatures and, as a consequence, to the appearance of significant deposits of iron in individual coils. To increase the reliability of the heating surfaces, hot water boilers are included in heating network through water-to-water heat exchangers. In this case, the boiler (closed circuit) is powered by high quality water, continuous and periodic blowdowns of the closed circuit are performed, which eliminates the appearance of a large amount of iron in the circuit water. 1.2. All the basic provisions of operation of boilers with external heat exchangers 1 given in this Model Instruction are valid for boilers of any heating capacity, depending on which only the number and connection diagram of external heat exchangers, as well as the number and type of pumps, change. Short description hot water boiler KVGM-180-150 is given in Appendix 1. 1.3. The temperature of the loop water at the outlet of the boiler (at the inlet to the water-to-water heat exchangers) when operating at its rated heating capacity to ensure the design temperature of the heating water at the outlet of the heat exchangers equal to 150 ° C must be at least 180 ° C. In this case, switching on the boiler according to the peak (two-pass) scheme is excluded, since at a circuit water temperature at the outlet of the boiler equal to 180 ° C, its heating capacity will increase in comparison with the calculated one by about 1.8 times, which is unacceptable. 1.4. The installation of external water-to-water heat exchangers should be considered expedient if the quality indicators of the feed water of the closed loop of the boiler do not exceed the values given in Sec. 5 of this Model Instruction. The expediency of switching on a hot water boiler according to a two-circuit scheme in cases where the quality of the make-up water does not meet the conditions given in section. 5, should be assessed by the design organization with the implementation of the necessary feasibility study, justifying the costs of installing additional water treatment devices to obtain the appropriate quality of the closed loop make-up water. 1.5. This Model Instruction sets out general order, the sequence and conditions for the implementation of the main technological operations, ensuring reliable and economical operation of gas-oil water-heating boilers with external water-to-water heat exchangers. 1.6. On the basis of this Model Instruction, local instructions are developed taking into account the peculiarities of the connection diagram for water-to-water heat exchangers and equipment. 1.7. During the operation of boilers, in addition to this Typical instruction, it is necessary to be guided by the following guidance documents, as: "Rules for the design and safe operation of steam and hot water boilers." - M .: NPO OGT, 1994; "Safety regulations for the operation of equipment for power plants and heating networks." - M .: Energoatomizdag, 1995; "Safety rules in the gas industry." - M .: Nedra, 1991; "Typical operating instructions for the gas facilities of thermal power plants: RD 34.20.514-92". M: S PO ORGRES, 1994; "Explosion safety rules when using fuel oil in boiler plants: RD 34.03.351-93" .- M .: SPO ORGRES, 1994; "Rules technical exploitation power plants and networks Russian Federation: RD 34.20.501-95 ".- M .: SPO ORGRES, 1996;" Guidelines for monitoring the condition of the main equipment of thermal power plants, determining the quality and chemical composition sediments: RD 34.74.306-87 ".- M .: VTI, 1987;" Typical instructions for operational chemical cleaning of hot water boilers ".- Moscow: SPO Soyuztekhenergo, 1980;" Instructions for alkalization of steam and hot water boilers. " .: STSNTI ORGRES, 1970; "Guidelines for the scope of technological measurements, signaling, automatic control at thermal power plants: RD 34.35.101-88" .- M .: SPO Soyuztekhenergo, 1988; "Guidelines for calculating the maximum permissible temperature of heated water ensuring the absence of surface boiling in hot water boilers: RD 34.26.101-94 ".- M .: Rotaprint VTI, 1994;" Scope and technical conditions for the implementation of technological protection of power equipment of power plants with cross-links and hot water boilers. - M .: SPO Soyuztekhenergo, 1987. You should also follow the instructions of the manufacturers.2. UNITING THE BOILER
2.1. Preparatory operations
2.1.1. Firing up the boiler after installation and overhaul must be preceded by: acceptance of the main and auxiliary equipment , flushing and alkalization in accordance with the Instructions for alkalization of steam and hot water boilers (see paragraph 1.7 of this Model instruction). All gas pipelines, before starting gas in them, must undergo control pressure testing with air at a pressure of 0.01 MPa (1000 kgf / m 2). The rate of pressure reduction in this case should not exceed 600 Pa / h (60 kgf / m 2 / h). Fuel should be supplied to the introduced or repaired boiler pipeline only after checking the tightness of the shut-off elements on the fuel supply to the burners and ignition devices. 2.1.2. The boiler must be fired up by order of the shift supervisor of the power plant (duty dispatcher of the heating network). 2.1.3. The boiler is fired up under the guidance of the shift supervisor of the boiler and turbine shop or a senior machinist, and after exiting the overhaul or installation - under the supervision of the head (deputy head) of the boiler and turbine shop or his substitute (head of the boiler room). 2.1.4. All operations to prepare the boiler for firing up must be performed by the boiler operator under the supervision of the senior operator. 2.1.5. Make sure that all repair work is stopped, that there are no repair personnel in the field of work and that there are no foreign objects near the equipment being prepared for work. 2.1.6. Inspect the boiler and auxiliary equipment and make sure that: the boiler lining is in good working order, the insulation of pipelines that drain and supply water to the boiler and water-to-water heat exchangers; the serviceability of the fittings, at the same time, pay attention to the presence of all fastening bolts in the covers and flange connections, the condition of the rods, the sufficiency of the stuffing box packing, the presence of a reserve for tightening the stuffing boxes and all fastening bolts in the heat exchanger covers; the serviceability of the drives to the gates and valves, at the same time, check the serviceability of the mechanical rods-rods (no run-outs, cracks, the presence of washers and cotter pins in the hinge joints), ease of control of the gates, manually in place; the absence of local indicators of the position of dampers and valves "Open" and "Closed" to risks on their axes; check the working range of movement of the gates, set the KDU and MEO handwheels of the gates and valves drives to the operating position, which ensures their remote control from the electric drive; serviceability of boiler benchmarks, condition of pipeline supports; the readiness of the shot unit, the presence of shot in the bunkers; availability and serviceability of fire extinguishing equipment; serviceability and sufficiency of the main and emergency lighting of the boiler and auxiliary equipment; serviceability of all means of communication and signaling; serviceability and readiness for operation of the boiler nozzles. Only nozzles checked and calibrated on a water bench should be installed on the boiler, for this: when assembling, carefully inspect the nozzles in order to check the cleanliness of the surfaces, the absence of burrs, nicks, coke and dirt (do not allow nozzle parts even with minor defects to be assembled); check the nozzles operating with a fuel oil pressure of up to 2 MPa (20 kgf / cm 2) on a water bench at a water pressure equal to the nominal fuel pressure; check nozzles designed to work with high pressure at a water pressure of at least 2 MPa; make sure that the air pressure when checking the steam mechanical nozzles corresponds to the pressure of the steam going to atomization; the quality of spraying when checking the nozzles on the stand is determined visually - the cone of sprayed water should have a finely dispersed structure without individual drops, continuous jets and easily distinguishable places of thickening (stripes) visible to the eye; check the opening angle of the cone for the set of nozzles installed on the boiler (should not deviate more than ± 5 ° from the factory standard); when checking at the stand, pay attention to the tightness of the individual elements of the nozzle and its barrel (nozzles with loose connections of individual elements are not allowed to be installed on the boiler); check the difference in the nominal performance of individual nozzles in the set, which should not exceed 1.5%; each boiler must be provided with a spare set of nozzles. 2.1.7. All boiler burners must be equipped with remotely and locally controlled ignition protection devices. Provision shall be made for the use of a manual igniter. 2.1.8. Inspect the firebox, boiler convection heating surfaces and heat exchangers. Make sure through the Lazes and hatches that the burners and pipes of the boiler heating surfaces are in a normal external condition. Make sure there are no foreign objects or debris on staircases... 2.1.9. Check that the valves on the boiler steam supply lines are closed, including for blowing out the nozzles. 2.1.10. Make sure to: close the shut-off and control valves on the fuel oil supply lines to the boiler, recirculation, to the drain collector and shut-off valves before each oil nozzle; disconnecting the boiler fuel oil pipeline with plugs; closing the shut-off and control valves on the gas pipeline to the boiler and shut-off valves on the gas supply to the burners, disconnecting the gas pipeline with plugs, closing the valves to the igniters. 2.1.11. Submit an application for the assembly of the electrical circuit of the electric motors of mechanisms and remote control fittings and gates. 2.1.12. Apply for voltage supply for instrumentation, protection, interlock and alarm. 2.1.13. Check the serviceability of measuring instruments, interlocks, protections and valve remote control. 2.1.14. If plugs are not installed on fuel lines, check the actions of protection, interlocks and valve control without opening the valve in front of the handfuls (injectors). 2.1.15. Ventilate the furnace and boiler gas-air ducts by turning on the smoke exhauster, gas recirculation smoke exhauster (DRG) and the fan; ventilation should last at least 10 minutes with a total air flow to the boiler of at least 25% of the nominal. 2.1.16. Before starting the boiler firing up, all fittings along the water path of the boiler and heat exchangers, both in the circuit and in the network water, must be closed. To fill the boiler with loop water, open: valves K-9 and K-10 on the water supply pipeline from the deaerators of the boiler tanks, or from the water treatment of hot water boilers (Fig. 1), valves K-19 and K-21 on the suction side of the pumps, flooding the closed loop (Refinery); valve K-12 on the bypass of closed loop pumps (NZK); valve-K-1 on the boiler loop water inlet pipeline: all air vents on the boiler. Rice. 1. Thermal diagram of a boiler with an external heat exchanger:1 - water heat exchanger; 2 - closed loop pump; 3 - closed loop make-up pump: 4 - pump for pumping out from the drain tank; 5 - tank for drainage from the boiler and periodic blowdown; 6 - drainage and periodic blowdown expander;
| - | boiler circuit water; | |
| - | heating network circuit; | |
| - | periodic blowdown; | |
| - | continuous blowdown of the circuit; | |
| - | air vent; | |
| - | valve; | |
| - | gate valve with electric drive; | |
| - | flange connection; | |
| - | control valve; | |
| - | flow washer; | |
| - | transition |
Rice. 2. Scheme of steam and oil pipelines of the KVGM-180 boiler: 
Rice. 3. Diagram of gas pipelines of the KVGM-180 boiler: 2.2. Fuel oil boiler firing
2.2.1. Control the western device from the panel or locally near the burners. 2.2.2. Set the total air pressure to 200-300 Pa (20-30 kgf / m 2), maintain the vacuum at the top of the furnace at 20-30 Pa (2-3 kgf / m 2). 2.2.3. Set the "Protection" key to the "Ignition" position, in this case the protections against: a decrease in the water pressure behind the boiler; increasing the water pressure behind the boiler; increasing the temperature of the water behind the boiler; turning off the blower fan, smoke exhauster; loss of voltage on devices of remote and automatic control and all measuring instruments ... 2.2.4. Open a manually operated valve (when firing locally) or with an electric drive (when firing from the panel) on the fuel oil pipeline in front of the ignited nozzle. 2.2.5. Supply steam to spray fuel oil, set the pressure in front of the nozzles to 0.2-0.25 MPa (2-2.5 kgf / cm 2). 2.2.6. Turn on the ignition device of one of the burners of the lower tier, visually make sure that its torch ignites and stably burns. 2.2.7. Open the valve with an electric (when firing from the panel) or manual (when firing in place) actuator in front of the firing nozzle. The fuel oil should immediately ignite. 2.2.8. Control the vacuum in the furnace, maintaining it at a level of 30-50 Pa (3-5 kgf / m 2). 2.2.9. Watch the combustion process: the torch should be straw-colored, smokeless, stable, without dark stripes and luminous "stars"; pull it up to the mouth of the embrasure by reducing the air supply. 2.2.10. Acting on the fuel oil and air supply, adjust the combustion mode. 2.2.11. The subsequent burners, first the lower ones, then the upper ones, ignite in the same order using Western devices. 2.2.12. Switch off the ignition devices of the operating burners after the combustion in the furnace becomes stable. 2.2.13. Close the MP motorized gate valve. 2.2.14. Set the control valve to the appropriate fuel oil pressure in front of the nozzles. 2.2.15. If during the ignition process in the first kindled burner fuel oil does not light up, immediately close its supply to the boiler, turn off the ignition device and ventilate the burners, furnace and flue gas ducts for at least 10 minutes at an air flow rate of at least 25% of the nominal. After eliminating the cause of non-ignition, proceed with re-ignition. 2.2.16. If in the process of firing up the boiler one burner does not light up or goes out (with the others running), close the fuel oil supply to this burner, turn off its ignition device, eliminate the cause of the burner extinguishing and, blowing it out with air, proceed to reigniting. 2.2.17. In case of complete extinguishment of the flame in the furnace, immediately stop the fuel oil supply to the boiler and turn off all ignition devices. Only after eliminating the causes of extinction and performing the operations of clause 2.1.15 can one start kindling. 2.2.18. At the end of the boiler firing up operations, set the "Protection" key to the "On" position, in this case the protections against: extinguishing the flame in the furnace; lowering the fuel oil pressure downstream of the control valve. 2.2.19. After the end of the boiler firing up and when the iron content in the closed loop decreases to the values specified in section. 5, close the boiler intermittent blowdown.2.3. Gas boiler firing up
2.3.1. After completing the operations according to item 2.1.26, proceed to the boiler firing up. 2.3.2. Control the ignition devices from the panel or directly on site. 2.3.3. Set the "Protection" key to the "Ignition" position, in this case the protections listed in clause 2.2.3 are activated. 2.3.4. Set the air pressure at 200-300 Pa (20-30 kgf / m2). 2.3.5. Open the first valve on the gas line in front of the ignited burner, as well as the valve on the gas line to the ignition device. Close the valve on the burner safety plug. 2.3.6. Turn on the ignition device of one of the burners of the lower tier, visually make sure the ignition and stable combustion of the igniter. 2.3.7. Open the second valve upstream of the burner to be ignited. The gas should immediately ignite. Adjust the combustion process by acting on the gas and air supply. 2.3.8. Fire the subsequent burners (first the lower ones, then the upper ones) like the first one. 2.3.9. After achieving stable combustion in the furnace, extinguish the ignition devices of the operating burners. Close the valves on the safety plug (SB). 2.3.10. Set the required gas pressure in front of the injectors with the control valve and turn it on to the machine. 2.3.11. If, during the ignition process, gas does not ignite in any burner from the ignited group, immediately close its supply to the boiler, turn off the ignition device and ventilate the burners, furnace, boiler flue gas ducts for at least 10 minutes at an air flow rate of at least 25% of the nominal. After eliminating the causes of non-ignition, proceed with re-ignition. 2.3.12. If during firing up the burner does not light up or goes out (with the ignition group burners running), close the gas supply to this burner, turn off the ignition device, eliminate the cause of non-ignition or extinguishing and, after blowing the burner with air, proceed to re-ignition. 2.3.13. In the event of a complete extinguishing of the flame in the furnace, immediately stop the gas supply to the boiler, disconnect all ZZZU. Only after eliminating the causes of extinction and performing the operations of clause 2.1.15, proceed to re-firing. 2.3.14. At the end of the boiler firing up operations, set the "Protection" key to the "On" position, in this case, the protections against the extinction of the common flame in the furnace are additionally activated; lowering the gas pressure downstream of the control valve. 2.3.15. After the end of the boiler firing up and when the iron content in the closed loop decreases to the values specified in section. 5, close the boiler intermittent blowdown.3. TRANSFER OF A BOILER FROM ONE KIND OF FUEL TO ANOTHER
3.1. Converting the boiler from fuel oil to gas
3.1.1. When converting the boiler from fuel oil to gas, perform the following operations: check the shut-off valve actuation and the operability of technological protections and gas interlocks by affecting the actuators or a signal in a volume that does not interfere with the operation of the boiler; prepare and fill the boiler gas pipeline with gas (see p. 2.1.26); supply gas and light one of the lower burners (see paragraphs 2.3.2; 2.3.4; 2.3.5 and 2.3.7); after the gas has ignited, close the valves on the oil pipeline to the nozzle of this burner; make sure that the torch is burning steadily; blow through the nozzle with a feather, slide it out of the burner and remove it. 3.1.2. Change the remaining burners from fuel oil to gas in the same way. 3.1.3. Put the steam and oil pipelines of the boiler into reserve. 3.1.4. After converting all operating burners from fuel oil to gas, put the fuel selection key in the "Gas" position.3.2. Converting the boiler from gas to fuel oil
3.2.1. When converting the boiler from gas to fuel oil, perform the following operations: prepare and fill the boiler fuel oil pipelines with fuel oil (see paragraph 2.1.25); supply fuel oil to the nozzles (one of the lower ones) and light it up (see paragraphs 2.2.1; 2.2.3; 2.2.5-2.2.8); close the valves on the gas pipeline in front of the burner; make sure that the torch is burning steadily; open the burner safety plug valve. 3.2.2. Change the rest of the burners from gas to fuel oil in the same way. 3.2.3. Put the boiler gas pipelines into reserve. 3.2.4. After converting all operating burners from gas to fuel oil, set the fuel selection key to the “Fuel oil” position.4. MAINTENANCE OF THE BOILER DURING LOAD OPERATION
4.1. Do not allow the boiler to operate without activated technological protections, interlocks, alarms and automatic regulators. 4.2. Operate the boiler in accordance with the regime chart (Appendix 2) according to the indications of instrumentation (instrumentation). Demand from the personnel on duty of CTAI to ensure constant operability and correct readings of the instrumentation. 4.3. Timely identify deviations from the normal operating conditions of the boiler and take prompt measures to eliminate violations of the operating modes of the boiler and auxiliary equipment, acting in accordance with the instructions of section. 6 of this Model Instruction. 4.4. While the boiler is in operation, observe: the combustion mode, the operation of the burners and nozzles; the absence of fistulas in the pipes of the heating surfaces, headers of heat exchangers, bypass pipes and loop network pipelines, periodically listening and inspecting them; fuel parameters before the control valve and before the burners; operability of control systems, remote control and autoregulation, protection, interlocks and signaling; the density of the gas-air path; water flow in the manhole cooling system; the condition of the fittings of the water and fuel lines of the boiler; the state of lining and insulation; operation of auxiliary equipment; serviceability of working and emergency lighting; serviceability of communication systems. 4.5. According to the job description, perform a routine inspection of the boiler, heat exchangers and auxiliary equipment. Record the detected equipment defects in the defect log. 4.6. When making rounds, inspect all gas pipelines within the boiler, detect gas leaks by sound, touch, smell, or the coating of possible leaks with soapy water (bubbles indicate the location of the leak). In the event of a gas leak, immediately inform the chief driver or shift supervisor and additionally the person responsible for the safe operation of the gas facility, or the shop manager. 4.7. Basic parameters of the boiler with the rated heating capacity: Circuit water temperature at the boiler inlet ................................... ..... 110 ° С Circuit water temperature at the boiler outlet ................................... 180 ° С Circuit water pressure at the boiler outlet ........................................ .2.2 MPa (22 kgf / cm 2) Underheating of circuit water to boiling ................................. ..................... Not less than 30 ° С The temperature of the supply water at the outlet of the heat exchangers depends on the temperature of the return supply water and its flow through the heat exchangers, but should not exceed 150 ° C. 4.8. Due to the operation of the control valve B-1 of the refinery bypass on the machine, maintain the pressure on the suction side of the NZK, depending on their type, at the level of 1.7-2.0 MPa (17-20 kgf / cm 2). 4.9. Open the continuous blowdown of the closed boiler circuit, for which: open the manual valves on the continuous blowdown pipeline and gate valves P-2 and P-3; in the absence of an installation for cleaning industrial condensates, direct the continuous blowdown of the circuit to the waste water discharge tanks, for this, close the P-3 valve and open the corresponding manual valves; Supply the purge water of the boiler closed loop cooled in tanks with a temperature not exceeding 30 ° C to the VPU. 4.10. Put on the machine a control valve B-2, installed on the bypass line of the heat exchangers loop water, to maintain the loop water temperature at the boiler inlet at 110 VC. 4.11. Do not allow the temperature difference between the circulating water at the inlet to the heat exchangers and the network at the outlet from them to exceed more than 40 ° C. If this is exceeded, reduce the flow of heating water through the heat exchangers or the heating capacity of the boiler. The value of the specified temperature difference above 40 ° C is allowed only if there is a calculation justification reflected in the factory operating instructions for heat exchangers. The rate of increase or decrease in the temperature of the loop water in heat exchangers with changes in the boiler heating capacity should not exceed 60 ° C per hour for heat exchangers installed in a heated room, and 30 ° C per hour when installed outdoors and should be specified according to the technical documentation for each type heat exchangers. 4.12. Regulation of the boiler heating capacity in the range of loads of 30-100% for gas and 45-100% for fuel oil is carried out by changing the fuel pressure in the conditions of the boiler operation with all burners on. 4.13. To increase the heating capacity of the boiler, first increase the draft, then the air flow and finally the fuel consumption. When decreasing heating capacity, first reduce fuel consumption, then air consumption and draft. 4.14. Observe the combustion process visually. 4.15. When burning fuel oil or gas, to limit local heat fluxes in the furnace and reduce harmful emissions of nitrogen oxides in the range of boiler heat output of 60-100%, work with the included DRGs. The permissible degree of opening of the DRG guide vanes is determined in the course of operating tests, depending on the application of specific gas recirculation schemes. 4.16. Maintain excess air in flue gases from the boiler at a rated heat load of at least 1.05-1.1 for gas and 1.1-1.15 for fuel oil. 4.17. When turning on the DRG while the boiler is running, first raise the air pressure to 30 Pa (300 kgf / m2) at the nominal heating capacity of the boiler, then gradually open the DRG guide vanes to the recommended value. 4.18. In case of a noticeable increase in the iron content in the closed loop of the boiler during its operation, as instructed by the duty personnel of the chemical department, open the periodic boiler blowdown. 4.19. After reducing the iron content in the boiler to the standards provided in section. 5, close the periodic boiler blowdown. 4.20. To assess the condition of the inner surface of the pipes, cut out control samples from undamaged areas in the area: furnace walls at the marks between the burners and above the upper tier; lower bending coils of upper convective packages. 4.21. In the case of an increase in the hydraulic resistance of the heat exchanger tubes through the network water at an estimated flow rate of about 1.5 times, it is necessary to carry out their individual flushing with the help of a mobile high-pressure unit, which is performed by a specialized organization.5. STANDARDS OF WATER-CHEMICAL REGIME OF A CLOSED CIRCUIT
5.1. In a closed loop, two different water regimes : alkaline mode with feeding the circuit with turbine condensate at CHPPs of any pressure, feed or make-up water of high-pressure drum boilers; alkaline mode with feeding the circuit with Na-catnonated water (if the industrial circuit is located in the boiler room). 5.2. Alkaline mode with feeding a closed loop with turbine condensate at a CHPP of any pressure, feed or make-up water of high-pressure drum boilers. 5.2.1. The quality of the make-up water of the closed loop must meet the following standards: Total hardness, μg eq / kg ............................ Not more than 3 Content dissolved oxygen, μg / kg, no more: when fed with feed water ................ 10 when fed with condensate or demineralized water ............. .................. 50 (set by power supply systems) Content of iron compound, μg / kg ........... Not more than 50 Content of oil products, mg / kg ................. Not more than 0.3 Hydrazine content, μg / kg ...................... ... Lack 5.2.2. The water quality of the closed circuit must meet the following standards: Total hardness ....................................... ......... Not more than 10 μg eq / kg Dissolved oxygen content ............. Not more than 50 μg / kg Iron compounds ......... ..................................... Not more than 100-150 μg / kg pH value (at a temperature 25 ° C) ............... 9.5-10 5.3. Alkaline mode with feeding a closed loop with Na-cationized water (if the industrial loop is located in the boiler room). 5.3.1. The quality of the closed loop make-up water must meet the following standards: Total hardness ...................................... .......... Not more than 50 μg eq / kg Total alkalinity .............................. ............... Not more than 5 μg-eq / kg Content of dissolved oxygen ............. Not more than 50 μg / kg Content of free carbon dioxide .. .............. 0 Amount of suspended solids ...................... Not more than 5 mg / kg Content of oil products .. ........................... Not more than 0.5 mg / kg Content of iron compound ............ ............. Not more than 100 μg / kg 5.3.2. The water quality of the closed circuit must meet the following standards: Total hardness ....................................... .......... Not more than 60 μg eq / kg Dissolved oxygen content ............. Not more than 50 μg / kg Iron content ........ ..................................... No more than 200-250 μg / kg pH value (at a temperature 25 ° C) ............. .. 9,5-10 Content of oil products ............................. Not more than 1 mg / kg 5.4. The blowdown of the circuit in all water modes must ensure the maintenance of the closed loop water norms for iron compounds. The total consumption of continuous and periodic blowdown based on the conditions for maintaining the Veda pressure in a closed loop should not exceed 30 t / h per one boiler. 5.5. The direct addition of hydrazine and other toxic substances to the circuit water and make-up water is prohibited. 5.6. Maintaining the required pH values of the closed loop water should be carried out by injecting ammonia or caustic soda. The introduction of solutions of alkaline reagents is carried out into the make-up water supply pipeline to the suction side of the refinery. 5.7. When commissioning a closed loop after its installation, hot water boilers with operational deposits on the inner surface in an amount of 500 g / m 2 or more must be chemically cleaned. Newly commissioned hot water boilers must be alkalized after installation before commissioning. 5.8. Operational chemical cleaning of heating surfaces should be carried out with a specific contamination of them with deposits of more than 600 g / m 2. 5.9. Heat exchanger tubes are made of corrosion-resistant steels.6. STOPPING THE BOILER
6.1. Stopping the boiler in reserve for a period not exceeding 3 days. 6.1.1. When stopping the boiler operating on fuel oil, perform the following operations: thoroughly clean the convective heating surfaces of the boiler; sequentially, starting with the upper ones, turn off the burners by closing the valves on the fuel oil supply to the nozzles; cover the air supply to the switched off burners; blow the nozzles with steam by opening the valves (1Pr-6Pr); close the steam supply for spraying fuel oil (1P-6P); remove the disconnected nozzles from the firebox; close the shut-off valve, RK and shut-off valves on the supply and recirculation fuel oil pipelines of the boiler; visually make sure that the torch is completely extinguished in the firebox. 6.1.2. When stopping a gas-fired boiler, perform the following operations: one by one, starting from the upper ones, turn off the burners by closing the fittings on the gas supply to the burners, open the safety plugs; close the air supply to the burners to be switched off; close the shut-off valve, RKG and shut-off valves on the gas supply line to the boiler; open the purge plugs on the disconnected gas pipeline; ventilate the furnace, gas ducts and air ducts for at least 10 minutes (see item 2.1.15). 6.1.3. Stop the DRG, the smoke exhauster and the fan, close their guide vanes. 6.1.4. Disable process protections by placing the Protection switch in the Disabled position. 6.1.5. After the boiler and heat exchangers have cooled down to a temperature 10-20 ° C higher than the temperature of the supply water at the inlet to the heat exchangers: turn off the NZK and close the valves K-13 - K-16 on their suction and discharge side; to ensure the circulation of water in a closed loop, leave one refinery in operation; open valve K-12 on the NZK bypass; close the continuous closed loop blowdown. 6.2. Boiler shutdown for more than 3 days. Disconnect all gas pipelines to the boiler and perform the following operations: clean the fuel oil pipelines of the boiler and outlets to the burners from fuel oil by blowing them with steam into the drainage pipeline; disconnect the boiler fuel oil lines from all boiler room fuel oil lines and purge lines with plugs; gas pipelines of the boiler, all outlets to the burners free from gas by blowing compressed air and disconnect from all lines with plugs; the end of the purge is determined by analysis (the residual gas content in the purge air should not exceed 1/5 of the lower ignition limit of natural gas); disconnect the ignition devices with plugs from the gas supply pipelines to them; when installing heat exchangers outdoors or in unheated room at a negative outside temperature, to prevent a drop in the temperature of the heat exchangers and their accompanying pipelines when the boiler is shut down, flow the make-up water through the heat exchangers due to the operation of the refinery through the bypass pipe of the heat exchangers circulating water, for which open the bypass of the B-2 control valve; close the control valve B-2 and manual valves on the bypass pipe of the heat exchangers, close the shut-off valve K-2 at the outlet of the loop water from the boiler and turn off the NZK, turn on the continuous blowdown of the circuit; at positive ambient temperatures in the places where heat exchangers are installed, stop the refinery, close valves K-19 and K-20 on its suction and discharge side; close the manual fittings and the B-1 control valve at the refinery bypass; close the manual fittings and the B-2 control valve on the bypass piping of the heat exchangers; turn off the NZK and close the valves K-13 - K-16 on their suction and pressure sides; open the valves of all air vents and boiler drains; after fulfilling the requirements of clause 6.1.5, drain the water from the boiler, for which close the valves K-1 and K-2 at the inlet and outlet of the boiler; drain the supply water from the heat exchangers, for which close the valves C-2 - C-7 at the supply water inlet to and out of the heat exchangers; open the valves of all drains and air vents of the heat exchanger tube system; drain the loop water from the heat exchanger housings, for which close the valves K-3 - K-8 at the loop water inlet and outlet of the heat exchanger housings and open the valves of all air vents and drains from them; drainage into the drainage and periodic blowdown expander (see p. 2.1.18); submit an application for disassembly of electrical circuits of electric motors of mechanisms and remote control of valves and gates; internal inspection, cleaning and repairs of the boiler should only be carried out with written permission (as well as) in compliance with the relevant safety regulations; perform gas hazardous work in accordance with the Safety Regulations in the Gas Industry. 6.3. If the boiler is taken out for a period of more than 30 days (summer period), prior to the conservation of the boiler and the heat exchangers, make an external examination of the heat exchanger tubes in order to assess their density, for which: turn off the heat exchangers using the mains water with plugs, drain them; remove the covers from the casings of all heat exchangers; create a loop water pressure equal to 1.0-1.2 MPa (10-12 kgf / cm 2) by activating the NZK and, if necessary, the refinery, adjusting the loop water pressure with the B-1 control valve; inspect the tubes, in case of damage, restore their tightness, and if this is not possible, muffle them; carry out all operations to inspect the heat exchanger tubes at a circuit water temperature not higher than 45 ° С. 6.4. After installing the covers on the heat exchanger housings, carry out the internal preservation of the boiler and heat exchangers by pumping make-up water from the deaerator tanks through the boiler and a closed circuit; turn off the refinery and NZK and open valves K-11 and K-12 on their bypasses; discharge the make-up water through the continuous blowdown pipeline into the drain expander and the periodic blowdown pipeline with its subsequent supply to the unit for purification of industrial condensates or to the TLU; pump water during the entire stopping time of the boiler. 6.5. Internal preservation of the boiler and heat exchangers installed in heating boiler rooms, carry out sodium silicate solution in accordance with the current Methodical instructions for the conservation of heat and power equipment.7. EMERGENCY PROVISIONS
7.1. In the event of equipment malfunction: carefully check the performance and based on the readings of the instruments and external signs get an idea of the violation of the regime; inform the shift supervisor of the CTC or power plant about the incident; establish the nature and location of the damage; enable the backup and disconnect the damaged equipment; make sure that the backup equipment is working properly; take steps to recover the damaged equipment. 7.2. In case of accidents, immediately provide medical assistance to the injured person in accordance with current regulations... Arrange a call medical staff and notify the shift supervisor of the CTC and power plant about the incident. 7.3. Register in the operational log the available data on the accident, indicating the beginning, the nature of the course and the actions of the personnel to eliminate it, as well as the time of individual events (switching on and off equipment, actuation of interlocks, protection and signaling). 7.4. The boiler must be stopped immediately by the protections (see clause 9.3 of this Standard Instruction) or directly by the personnel in the event of: failure of the circulating water flow meter, if at the same time there are mode violations that require readjustment of the power supply; shutdown of the NZK and non-activation of the standby pump by ATS; shutdown of the refinery and non-inclusion of the standby pump for the automatic transfer switch; increasing the pressure of loop water at the outlet of the boiler to 2.6 MPa (26 kgf / cm 2) or lowering it at the indicated temperatures to values lower than those given in the table. Note . Circuit water pressure must be higher than supply water pressure. Circuit water pressure values in the table are given taking into account its underheating to saturation temperature at 30 ° C. rupture of pipes of the heating surfaces of the boiler, collectors and pipelines at an appropriate pressure; detecting cracks, swelling, gaps or sweating in welds, leaks in the main elements of heat exchangers; extinction of the torch in the firebox; unacceptable decrease in gas or fuel oil pressure downstream of the control valve; turning off the smoke exhauster or blower fan; explosion in the furnace, gas duct, destruction of the lining, other damage that threatens personnel and equipment; fires posing a danger to personnel, equipment and remote control circuits of the disconnecting valve, fittings included in the protection scheme; increasing the temperature of the loop water at the outlet of the boiler up to 190 ° С; loss of voltage on remote and automatic control devices or all instrumentation; rupture of the fuel oil pipeline or gas pipeline within the boiler. 7.5. In case of emergency shutdown of the boiler: close the valves С-1 and С-8 on the return and direct pipelines of the heating system and open their bypasses; close valves K-3, K-5 and K-7 at the loop water supply to the heat exchangers and open their bypasses; remove from AVR NZK; stop the NZK and close the valves on the suction and discharge side, close the P-2 valve on the continuous blowdown pipeline of the circuit; open valve K-12 on the NZK bypass; in the event of an emergency shutdown of the refinery, additionally open the valve K-11 on their bypass. 7.6. The boiler must also be shut down by order of the management in the event of: detection of holes in the heating surfaces, collectors, pipelines, leaks and vapors in the fittings and flange connections of the boiler, as well as in the flanges of the heat exchanger casings; malfunctions of individual protections or devices for remote and automatic control, as well as instrumentation. The stopping time of the boiler in these cases is determined by the chief engineer of the power plant or the chief of the boiler house.8. INSTRUCTIONS FOR SAFETY, EXPLOSION AND FIRE SAFETY
8.1. Basic instructions on safety, explosion and fire safety should be reflected in local instructions drawn up in accordance with the guidelines listed in clause 1.7 of this Model instruction. 8.2. The safety requirements for servicing heat exchangers are given in the installation and operating instructions issued by the manufacturer of the heat exchangers, on the basis of which, depending on the type of heat exchangers, local instructions are developed.9. SCOPE OF EQUIPMENT OF THE BOILER WITH MEASURING EQUIPMENT, AUTOMATIC CONTROL, TECHNOLOGICAL PROTECTION, INTERLOCKING AND SIGNALING
To control the operation of the boiler, the following instrumentation must be installed: recording and indicating flow meter for measuring the flow rate of loop water through the boiler; registering flow meter for measuring the flow of heating water through heat exchangers; recording flow meter for measuring the flow rate of continuous closed-loop blowdown; showing a flow meter for measuring the flow rate of periodic boiler blowdown; registering flow meter for measuring the flow rate of the make-up water of the circuit; showing pressure gauge for measuring water pressure in front of the boiler (behind the NZK); registering and indicating pressure gauge for measuring the water pressure behind the boiler; showing pressure gauge for measuring water pressure in front of the NZK; indicating pressure gauge for measuring water pressure in front of the make-up pump; showing pressure gauge for measuring the pressure of the return water supply; showing pressure gauge for measuring the pressure of circulating water in the heat exchanger housings; indicating devices for measuring pressure drops in the network water at the inlet and outlet of each heat exchanger; recording and indicating device for measuring the temperature of the loop water in front of the boiler; registering and indicating device for measuring the temperature of the loop water behind the boiler; showing device for measuring the temperature of the return supply water; a registering device for measuring the temperature of direct network water; a recording device for measuring the temperature of the loop water at the inlet to each heat exchanger; a recording device for measuring the temperature of the loop water at the outlet of each heat exchanger; a recording device for measuring the temperature of the network water at the outlet of the outlet heat exchangers; registering and showing device for measuring gas flow rate; indicating pressure gauge for measuring gas pressure downstream of the control valve; registering and indicating pressure gauge for measuring gas pressure in the gas pipeline to the boiler; registering and showing flow meter for measuring fuel oil consumption to the boiler; indicating pressure gauge for measuring fuel oil pressure downstream of the control valve; registering and indicating pressure gauge for measuring the pressure of fuel oil in the fuel oil pipeline to the boiler; showing steam pressure gauge for fuel oil spray; registering flow meter for measuring fuel oil consumption for recirculation; indicating device for measuring the temperature of fuel oil in front of the burners; a recording device for measuring the temperature of flue gases; indicating devices for measuring the temperature of flue gases along the width of convective packages (via a switch); showing device for measuring air pressure behind the blower fan; a recording device for measuring the temperature of the bearings of draft machines; oxygen meters (left and right); instruments for measuring the transparency of flue gases (right to left); showing a device for measuring the vacuum at the top of the furnace. The following should be installed on site: pressure gauges on the gas supply lines to each burner; pressure gauges on the fuel oil supply lines for each burner; sawing steam pressure gauges for each burner; draft pressure gauges on the central and peripheral air ducts for each burner; pressure gauge for measuring gas pressure behind the control valve; pressure gauge to measure the fuel oil pressure downstream of the control valve.9.2. Boiler automatic regulation system
The system includes the following regulators: main; fuel; general air; vacuum at the top of the firebox; loop water pressure on the NZK suction side; the temperature of the circuit water in front of the boiler.9.3. Technological protections
Values of protection response time delays are determined by the manufacturer of boiler equipment and applicable instructions. The equipment disconnected by the protections, after elimination of the triggering causes, is included in the work by the duty personnel. On boilers using two types of fuel, a switch is installed for the input and output of protections, which has separate provisions for each type of fuel. The boiler shutdown is protected by: extinguishing the flame in the furnace; lowering the gas pressure downstream of the control valve; lowering the fuel oil pressure downstream of the control valve with a time delay of up to 20 s; turning off the smoke exhauster; turning off the fan; failure of the circulating water flow meter, if at the same time there is a violation of the mode, requiring readjustment of the power supply; shutdown of the NZK and failure to turn on the standby pump by ATS; shutdown of the refinery and failure to turn on the standby pump for the automatic transfer switch; increasing the pressure of the loop water at the outlet of the boiler to 2.6 MPa (26 kgf / cm 2); increasing the temperature of the loop water at the outlet of the boiler to 190 ° C. Protection for reducing the underheating of the circuit water less than 30 ° C is introduced if there is a device for forming a setpoint based on the difference between the actual temperature of the circuit water and the saturation temperature of the corresponding pressure of the circuit water at the outlet of the boiler (see table clause 7.4) and is performed instead of protection for decreasing pressure ... For previously designed boilers, where such protection is not installed, protection is installed to reduce the pressure of the loop water at the outlet from the boiler with a setting of 1.9 MPa (19 kgf / cm 2) and a time delay of 10 s. The tolerances for the values of the protection settings depend on the class of devices, the delivery of which is determined by the design organization.9.4. Local defenses
9.4.1. In the event of non-ignition or failure of the burner flame, the oil nozzle or gas burner is switched off, as well as the ignition device by closing the electrified fittings in front of the burner. 9.4.2. If after 10 s the torch of the switched on igniter does not appear or goes out, then it is switched off by gas and electric spark.9.5. Locks
9.5.1. When the smoke exhauster is turned off, the boiler is stopped, the valve on the gas supply to the igniter is closed, the electric spark, the blower fan and the DRG are turned off. 9.5.2. When the smoke exhauster (fan) guide vane is fully opened and its electric motor operates at the first speed, by blocking it, the electric motor switches to the second speed with a time delay of up to 3 s. 9.5.3. The electric motor of the smoke exhauster or fan does not turn on if the diffuser is not completely closed. 9.5.4. The fan does not turn on if the exhauster is not turned on. 9.5.5. When the fan is turned off, its guide vanes are closed. 9.5.6. The valve on the gas pipeline to the boiler does not open if at least one of the motorized valves for each burner is not closed.9.6. Process signaling
Signals of deviation of the main parameters from the set values should be sent to the boiler control panel, causing the light panels and sound signal to turn on: boiler shutdown; extinction of the torch in the firebox; decrease or increase in fuel pressure downstream of the control valve; change in vacuum at the top of the furnace; increasing the temperature of the water leaving the boiler; increasing the permissible temperature difference between the loop and network water in heat exchangers; decrease or increase in water pressure at the outlet of the boiler; reducing the flow rate of loop water through the boiler; turning off the smoke exhauster; turning off the blower fan; turning off the recirculation smoke exhauster; shutdown of burners; the disappearance of voltage in the protection circuits.Annex 1
BRIEF DESCRIPTION OF WATER BOILER KVGM-180-150
Gas-oil hot water boiler KVGM-180-150 is installed at the TPP. Boiler - direct-flow, T-shaped configuration, designed for combustion of gas and fuel oil. screen tubes 6480x5740 mm. Front and rear screens are made of 60x4 pipes with a pitch of 64 mm. Intermediate screens separating the firebox and convective gas ducts are made of gas-tight pipes of the same diameter, pitch - 80 mm. In the lower part of the firebox, the front and rear screens form the hearth slopes. The top of the combustion chamber is covered with ceiling panels that turn into the side screens of the downpipe flues. The ceiling and side screens of the convection shafts are composed of 38x4 pipes with a pitch of 42 mm. The collectors inside the boiler are taken with a diameter of 273x14 mm; the material of the heated pipes of the heating surfaces, collectors and bypass pipelines is steel 20. In the latest modifications of the boiler, all firewalls have a gas-tight design. The design of the ceiling and side screens in convective gas ducts has also been changed, which are now made of 60x4 mm pipes. The strength of the combustion chamber is provided by stiffening belts. The casing consists of carbon steel sheet. The firebox is suspended from the ceiling frame of the frame with the help of special rods. In the first boiler samples, the combustion chamber is equipped with six vortex gas burners, which are located on the side screens of the furnace in two tiers oppositely, with triangles pointing upwards. They are equipped with steam-mechanical nozzles equipped with a movement mechanism. Each burner must be equipped with an ignition-protective device. Subsequently, the manufacturer produced boilers KVGM-180-150 with twelve direct-flow burners located in the furnace according to the MEI scheme, as well as six and eight vortex burners on the side screens of the furnace, respectively, in three and two tiers in height. In subsequent modifications of the boiler (model KVGM-180-150-2M), for the organization of the combustion process on the front and rear walls in the corners of the furnace, eight direct-flow gas-oil burners are installed, placed in two tiers with a tangent direction to an imaginary circle in the center. The lower deck burners are ignition type. Each burner is equipped with an ignition-protective device (ZZU). Convective heating surfaces are located in two drop shafts with fully shielded walls. The enclosing surfaces of the gas ducts are: side screens of the furnace; side panels of gas ducts; front and back walls of gas ducts. The front and rear walls of the convection shaft are made of pipes with a diameter of 95x5 (steel 20) with a pitch of 136 mm. To ensure tightness, a 40 mm wide fin is welded between the pipes. The pipes of the front and rear walls of the convection shaft serve as collectors U-shaped coils made of pipes 32x3 mm (steel 20). The arrangement of pipes in the downpipe is staggered with a step S 1 = 68 and S 2 = 60 mm Circulation circuit In the main operating mode of the boiler (Fig. A1.1), loop water is supplied by closed-loop pumps to the common inlet chamber of the boiler, from which it is directed through the bypass pipes to the right half of the lower collectors of the front and rear screens of the furnace, as well as to lower collectors of the right side screen of the furnace, the right side screen of the convection shaft and the ceiling screen, from which water enters the front and rear panels (risers), into the upper, middle and lower convective half-sections of the right downstream flue. From their lower collectors, water flows into the left half of the lower collectors of the front and rear screens of the furnace, into the lower collectors of the left side screen of the furnace, as well as the left side screen of the convection shaft and the ceiling screen. From the indicated heating surfaces and from the left half of the front and rear screens of the furnace through the bypass pipes, water is supplied to the front and rear panels (risers), to the upper, middle and lower convective half-sections of the left downstream flue, from which it enters the common outlet chamber.
Rice. A1.1. Hydraulic diagram of a hot water boiler KVGM-180-150 (basic mode): 1 - front screen of the furnace; 2 - rear screen of the furnace; 3 - right side firebox screen; 4 - right side screen of the convection shaft and ceiling screen; 5 - front panel (risers); upper, middle and lower convective half-sections of the right downward gas duct; 6 - rear panel (risers); upper, middle and lower convective half-sections of the right downward gas duct; 7 - left side screen of the furnace; 8 - left side screen of the convection shaft and ceiling screen; 9 - front panel (risers); upper, middle and lower convective half-sections of the left downstream duct; 10 - rear panel (risers); upper, middle and lower convective half-sections of the left downstream duct; 11 - boiler inlet chamber; 12 - boiler outlet chamber; Cleaning of heating surfaces When the boiler is running on fuel oil, a shot blasting is provided to clean the convective heating surfaces from external deposits. The transport of 3-5 mm shot is carried out using an air injector. In the installation scheme, an avalanche discharge of shot is adopted, which provides a more efficient cleaning of pipes. In order to prevent the throwing of shot into the furnace, the height of the "threshold" from the upper row of the convective package is about 1500 mm. To eliminate the drift of shot, a protective grid is installed in the exhaust gas duct. It is recommended to use gas-impulse cleaning instead of a shot-blasting machine. Boiler lining Boiler lining consists of insulating and reinforcing materials, asbestos sprayed part, reinforced mesh, sealing plaster and polymer-coated glass cloth. Lining thickness 110-130 mm. The collectors on the side of the gas ducts are protected with fire-resistant concrete: the outer part is covered with asbestos insulation. Chimney-blowing unit The boiler is equipped with one VDN-25-11 y fan. Air intake can be carried out both from the premises and from the street. For heating the air to positive temperatures after the blowing fan, the installation of water heaters KVV-12P is provided. The thrust is organized by the DN-24x2-0.62 GM smoke exhauster. Recirculation of flue gases taken in front of the last convective package and supplied to the air duct behind the blower fan is created by the VDN-21 recirculation smoke exhauster. In subsequent modifications of the boiler, it is equipped with a VDN-26 fan, water heaters KVB-12B-PU-3 and a gas recirculation fan VGDN-17. Design data and design characteristics of the KVGM-180-150 water heating boiler Nominal heating capacity, MW (Gcal / h). ............................. 209 (180) Water pressure, MPa (kgf / cm 2), design .................................. ................... 2,5 (25) Water temperature, ° С: at the inlet ................. .................................................. ........................................... 110 at the exit .... .................................................. .................................................. ... 180 Water consumption, t / h ........................................ .................................................. ...... 2500 Minimum hydraulic resistance of the path, MPa (kgf / cm 2) ........ 0.3 (3) Range of regulation of heating capacity,% of the nominal ....... 30-100 Overall dimensions, mm: width ............................................. .................................................. ............ 14400 depth .................................... .................................................. ..................... 7300 height ........................... .................................................. ... ............................. 29880 Note . Indicators of the basic boiler variant are given. The design characteristics of water-to-water heat exchangers are not given in this section, since heat exchangers are ordered by the design organization at various manufacturers. Their data is reflected in the factory operating instructions for each type of heat exchanger.
Appendix 2
EXAMPLE FORM OF A MODE CARD OF A WATER BOILER
Operating mode: main Fuel: gas, fuel oil|
Indicator |
Heating capacity,% of nominal |
Water pressure at the outlet of the boiler, MPa (kgf / cm 2) | Boiler inlet water temperature, ° С | Circuit water temperature at the outlet of the boiler (at the inlet to the heat exchangers), ° С | Return water temperature, ° С | Direct supply water temperature. ° C | The temperature difference between the loop water at the inlet to the heat exchangers and the network water at their outlet, ° С | Circuit water consumption, t / h | Supply water consumption, t / h | Hydraulic resistance of heat exchangers for network water, MPa (kgf / cm 2) | Number of operating burners, pcs. | Fuel consumption: | m 3 / h | kg / h | Fuel pressure behind the control valve, MPa (kgf / cm 2) | Fuel pressure in front of burners, MPa (kgf / cm 2) | Air pressure behind the fan, kPa (kgf / cm 2) | Air pressure in front of burners, kPa (kgf / cm 2) | Steam pressure for fuel oil spray, MPa (kgf / cm 2) | Fuel oil temperature. ° C | Vacuum at the top of the furnace, Pa (kgf / m 2) | Oxygen content in the operating section,% | Exhaust gas temperature, ° С | Efficiency d. boiler gross,% | Specific emissions of nitrogen oxides, g / m 3 | DRG guide vane opening degree,% | Note . Regime card issued as of ______ |
RUSSIAN JOINT STOCK SOCIETY OF ENERGY AND ELECTRIFICATION "UES OF RUSSIA"
DEPARTMENT OF SCIENCE AND TECHNOLOGY TYPICAL INSTRUCTIONS FOR THE OPERATION OF WATER BOILERS WITH EXTERNAL HEAT EXCHANGERS
RD 34.26.515-96 ORGRES BEST EXPERIENCE SERVICE
Moscow 1997 Content
| 1. GENERAL PROVISIONS 2. BOILER UNIT 2.1. Preparatory operations 2.2. Fuel oil boiler firing 2.3. Heating up the boiler using gas 3. TRANSFERRING THE BOILER FROM ONE KIND OF FUEL TO ANOTHER FUEL 3.1. Converting the boiler from fuel oil to gas 3.2. Conversion of the boiler from gas to fuel oil 4. MAINTENANCE OF THE BOILER DURING OPERATION UNDER LOAD 5. STANDARDS OF A WATER-CHEMICAL MODE OF A CLOSED CIRCUIT 6. STOPPING THE BOILER 7. EMERGENCY PROCEDURES 8. INSTRUCTIONS FOR SAFETY AND EXPLOSION HAZARD , AUTO REGULATION, TECHNOLOGICAL PROTECTION, INTERLOCKING AND SIGNALING 9.1. Recommended scope of instrumentation equipment 9.2. Boiler automatic regulation system 9.3. Technological protection 9.4. Local defenses 9.5. Locks 9.6. Process signaling Annex 1 BRIEF DESCRIPTION OF WATER BOILER KVGM-180-150 Appendix 2 EXAMPLE FORM OF A MODE CARD OF A WATER BOILER |
|
TYPICAL INSTRUCTIONS FOR THE OPERATION OF WATER BOILERS WITH EXTERNAL HEAT EXCHANGERS |
RD 34.26.515-96 |
Entered into force on 01.01.97.
1. GENERAL PROVISIONS
1.1. Hot water boilers are installed at many CHPPs, however, with the low quality of network water (especially in large cities of the country) and the presence of a large amount of iron in it, an intensive drift of deposits of their internal heating surfaces occurs. The greatest number of damage to heating surfaces of hot water boilers relates to heating surfaces of convective packages. This is explained. mainly by their increased heat perception due to the location in the zone of high temperatures of gases, which leads to an increase in the sweep of water temperatures and, as a consequence, to the appearance of significant deposits of iron in individual coils. To increase the reliability of the heating surfaces, hot water boilers are connected to the heating network through water-to-water heat exchangers. In this case, the boiler (closed circuit) is powered by high quality water, continuous and periodic blowdowns of the closed circuit are performed, which eliminates the appearance of a large amount of iron in the circuit water. 1.2. All the basic provisions of operation of boilers with external heat exchangers 1 given in this Model Instruction are valid for boilers of any heating capacity, depending on which only the number and connection diagram of external heat exchangers, as well as the number and type of pumps, change. A brief description of the KVGM-180-150 hot water boiler is given in Appendix 1. 1.3. The temperature of the loop water at the outlet of the boiler (at the inlet to the water-to-water heat exchangers) when operating at its rated heating capacity to ensure the design temperature of the heating water at the outlet of the heat exchangers equal to 150 ° C must be at least 180 ° C. In this case, switching on the boiler according to the peak (two-pass) scheme is excluded, since at a circuit water temperature at the outlet of the boiler equal to 180 ° C, its heating capacity will increase in comparison with the calculated one by about 1.8 times, which is unacceptable. 1.4. The installation of external water-to-water heat exchangers should be considered expedient if the quality indicators of the feed water of the closed loop of the boiler do not exceed the values given in Sec. 5 of this Model Instruction. The expediency of switching on a hot water boiler according to a two-circuit scheme in cases where the quality of the make-up water does not meet the conditions given in section. 5, should be assessed by the design organization with the implementation of the necessary feasibility study, justifying the costs of installing additional water treatment devices to obtain the appropriate quality of the closed loop make-up water. 1.5. This Standard Instruction establishes a general procedure, sequence and conditions for the implementation of the main technological operations that ensure reliable and economical operation of gas-oil hot water boilers with external water-to-water heat exchangers. 1.6. On the basis of this Model Instruction, local instructions are developed taking into account the peculiarities of the connection diagram for water-to-water heat exchangers and equipment. 1.7. During the operation of boilers, in addition to this Model Instruction, it is necessary to be guided by such guidelines as: "Rules for the construction and safe operation of steam and hot water boilers." - M .: NPO OGT, 1994; "Safety regulations for the operation of equipment for power plants and heating networks." - M .: Energoatomizdag, 1995; "Safety rules in the gas industry." - M .: Nedra, 1991; "Typical operating instructions for the gas facilities of thermal power plants: RD 34.20.514-92". M: S PO ORGRES, 1994; "Explosion safety rules when using fuel oil in boiler plants: RD 34.03.351-93" .- M .: SPO ORGRES, 1994; "Rules for the technical operation of power plants and networks of the Russian Federation: RD 34.20.501-95" .- M .: SPO ORGRES, 1996; "Guidelines for monitoring the condition of the main equipment of thermal power plants, determining the quality and chemical composition of deposits: RD 34.74.306-87" .- M .: VTI, 1987; "Typical instructions for operational chemical cleaning of hot water boilers." - M .: SPO Soyuztekhenergo, 1980; "Instructions for alkalization of steam and hot water boilers." - M .: SCSTI ORGRES, 1970; "Guidelines for the scope of technological measurements, signaling, automatic control at thermal power plants: RD 34.35.101-88" .- M .: SPO Soyuztekhenergo, 1988; "Guidelines for calculating the maximum permissible temperature of heated water, ensuring the absence of surface boiling in hot water boilers: RD 34.26.101-94" .- M .: Rotaprint VTI, 1994; "Scope and technical conditions for the implementation of technological protection of power equipment of power plants with cross-links and hot water boilers." - M .: SPO Soyuztekhenergo, 1987. You should also follow the instructions of the manufacturers.2. UNITING THE BOILER
2.1. Preparatory operations
2.1.1. Boiler firing up after installation and overhaul must be preceded by: acceptance of the main and auxiliary equipment, flushing and alkalization in accordance with the Instruction on alkalization of steam and hot water boilers (see clause 1.7 of this Standard Instruction). All gas pipelines, before starting gas in them, must undergo control pressure testing with air at a pressure of 0.01 MPa (1000 kgf / m 2). The rate of pressure reduction in this case should not exceed 600 Pa / h (60 kgf / m 2 / h). Fuel should be supplied to the introduced or repaired boiler pipeline only after checking the tightness of the shut-off elements on the fuel supply to the burners and ignition devices. 2.1.2. The boiler must be fired up by order of the shift supervisor of the power plant (duty dispatcher of the heating network). 2.1.3. The boiler is fired up under the guidance of the shift supervisor of the boiler and turbine shop or a senior machinist, and after exiting the overhaul or installation - under the supervision of the head (deputy head) of the boiler and turbine shop or his substitute (head of the boiler room). 2.1.4. All operations to prepare the boiler for firing up must be performed by the boiler operator under the supervision of the senior operator. 2.1.5. Make sure that all repair work is stopped, that there are no repair personnel in the field of work and that there are no foreign objects near the equipment being prepared for work. 2.1.6. Inspect the boiler and auxiliary equipment and make sure that: the boiler lining is in good working order, the insulation of pipelines that drain and supply water to the boiler and water-to-water heat exchangers; the serviceability of the fittings, at the same time, pay attention to the presence of all fastening bolts in the covers and flange connections, the condition of the rods, the sufficiency of the stuffing box packing, the presence of a reserve for tightening the stuffing boxes and all fastening bolts in the heat exchanger covers; the serviceability of the drives to the gates and valves, at the same time, check the serviceability of the mechanical rods-rods (no run-outs, cracks, the presence of washers and cotter pins in the hinge joints), ease of control of the gates, manually in place; the absence of local indicators of the position of dampers and valves "Open" and "Closed" to risks on their axes; check the working range of movement of the gates, set the KDU and MEO handwheels of the gates and valves drives to the operating position, which ensures their remote control from the electric drive; serviceability of boiler benchmarks, condition of pipeline supports; the readiness of the shot unit, the presence of shot in the bunkers; availability and serviceability of fire extinguishing equipment; serviceability and sufficiency of the main and emergency lighting of the boiler and auxiliary equipment; serviceability of all means of communication and signaling; serviceability and readiness for operation of the boiler nozzles. Only nozzles checked and calibrated on a water bench should be installed on the boiler, for this: when assembling, carefully inspect the nozzles in order to check the cleanliness of the surfaces, the absence of burrs, nicks, coke and dirt (do not allow nozzle parts even with minor defects to be assembled); check the nozzles operating with a fuel oil pressure of up to 2 MPa (20 kgf / cm 2) on a water bench at a water pressure equal to the nominal fuel pressure; check nozzles designed to work with high pressure at a water pressure of at least 2 MPa; make sure that the air pressure when checking the steam mechanical nozzles corresponds to the pressure of the steam going to atomization; the quality of spraying when checking the nozzles on the stand is determined visually - the cone of sprayed water should have a finely dispersed structure without individual drops, continuous jets and easily distinguishable places of thickening (stripes) visible to the eye; check the opening angle of the cone for the set of nozzles installed on the boiler (should not deviate more than ± 5 ° from the factory standard); when checking at the stand, pay attention to the tightness of the individual elements of the nozzle and its barrel (nozzles with loose connections of individual elements are not allowed to be installed on the boiler); check the difference in the nominal performance of individual nozzles in the set, which should not exceed 1.5%; each boiler must be provided with a spare set of nozzles. 2.1.7. All boiler burners must be equipped with remotely and locally controlled ignition protection devices. Provision shall be made for the use of a manual igniter. 2.1.8. Inspect the firebox, boiler convection heating surfaces and heat exchangers. Make sure through the Lazes and hatches that the burners and pipes of the boiler heating surfaces are in a normal external condition. Make sure there are no foreign objects or debris in the stairwells. 2.1.9. Check that the valves on the boiler steam supply lines are closed, including for blowing out the nozzles. 2.1.10. Make sure to: close the shut-off and control valves on the fuel oil supply lines to the boiler, recirculation, to the drain collector and shut-off valves before each oil nozzle; disconnecting the boiler fuel oil pipeline with plugs; closing the shut-off and control valves on the gas pipeline to the boiler and shut-off valves on the gas supply to the burners, disconnecting the gas pipeline with plugs, closing the valves to the igniters. 2.1.11. Submit an application for the assembly of an electrical circuit of electric motors of mechanisms and remote control of valves and gates. 2.1.12. Apply for voltage supply for instrumentation, protection, interlock and alarm. 2.1.13. Check the serviceability of measuring instruments, interlocks, protections and valve remote control. 2.1.14. If plugs are not installed on fuel lines, check the actions of protection, interlocks and valve control without opening the valve in front of the handfuls (injectors). 2.1.15. Ventilate the furnace and boiler gas-air ducts by turning on the smoke exhauster, gas recirculation smoke exhauster (DRG) and the fan; ventilation should last at least 10 minutes with a total air flow to the boiler of at least 25% of the nominal. 2.1.16. Before starting the boiler firing up, all fittings along the water path of the boiler and heat exchangers, both in the circuit and in the network water, must be closed. To fill the boiler with loop water, open: valves K-9 and K-10 on the water supply pipeline from the deaerators of the boiler tanks, or from the water treatment of hot water boilers (Fig. 1), valves K-19 and K-21 on the suction side of the pumps, flooding the closed loop (Refinery); valve K-12 on the bypass of closed loop pumps (NZK); valve-K-1 on the boiler loop water inlet pipeline: all air vents on the boiler. Rice. 1. Thermal diagram of a boiler with an external heat exchanger:1 - water heat exchanger; 2 - closed loop pump; 3 - closed loop make-up pump: 4 - pump for pumping out from the drain tank; 5 - tank for drainage from the boiler and periodic blowdown; 6 - drainage and periodic blowdown expander;
| - | boiler circuit water; | |
| - | heating network circuit; | |
| - | periodic blowdown; | |
| - | continuous blowdown of the circuit; | |
| - | air vent; | |
| - | valve; | |
| - | gate valve with electric drive; | |
| - | flange connection; | |
| - | control valve; | |
| - | flow washer; | |
| - | transition |
Rice. 2. Scheme of steam and oil pipelines of the KVGM-180 boiler: Rice. 3. Diagram of gas pipelines of the KVGM-180 boiler: 2.2. Fuel oil boiler firing
2.2.1. Control the western device from the panel or locally near the burners. 2.2.2. Set the total air pressure to 200-300 Pa (20-30 kgf / m 2), maintain the vacuum at the top of the furnace at 20-30 Pa (2-3 kgf / m 2). 2.2.3. Set the "Protection" key to the "Ignition" position, in this case the protections against: a decrease in the water pressure behind the boiler; increasing the water pressure behind the boiler; increasing the temperature of the water behind the boiler; turning off the blower fan, smoke exhauster; loss of voltage on remote and automatic control devices and all measuring devices. 2.2.4. Open a manually operated valve (when firing locally) or with an electric drive (when firing from the panel) on the fuel oil pipeline in front of the ignited nozzle. 2.2.5. Supply steam to spray fuel oil, set the pressure in front of the nozzles to 0.2-0.25 MPa (2-2.5 kgf / cm 2). 2.2.6. Turn on the ignition device of one of the burners of the lower tier, visually make sure that its torch ignites and stably burns. 2.2.7. Open the valve with an electric (when firing from the panel) or manual (when firing in place) actuator in front of the firing nozzle. The fuel oil should immediately ignite. 2.2.8. Control the vacuum in the furnace, maintaining it at a level of 30-50 Pa (3-5 kgf / m 2). 2.2.9. Watch the combustion process: the torch should be straw-colored, smokeless, stable, without dark stripes and luminous "stars"; pull it up to the mouth of the embrasure by reducing the air supply. 2.2.10. Acting on the fuel oil and air supply, adjust the combustion mode. 2.2.11. The subsequent burners, first the lower ones, then the upper ones, ignite in the same order using Western devices. 2.2.12. Switch off the ignition devices of the operating burners after the combustion in the furnace becomes stable. 2.2.13. Close the MP motorized gate valve. 2.2.14. Set the control valve to the appropriate fuel oil pressure in front of the nozzles. 2.2.15. If during the ignition process in the first kindled burner fuel oil does not light up, immediately close its supply to the boiler, turn off the ignition device and ventilate the burners, furnace and flue gas ducts for at least 10 minutes at an air flow rate of at least 25% of the nominal. After eliminating the cause of non-ignition, proceed with re-ignition. 2.2.16. If in the process of firing up the boiler one burner does not light up or goes out (with the others running), close the fuel oil supply to this burner, turn off its ignition device, eliminate the cause of the burner extinguishing and, blowing it out with air, proceed to reigniting. 2.2.17. In case of complete extinguishment of the flame in the furnace, immediately stop the fuel oil supply to the boiler and turn off all ignition devices. Only after eliminating the causes of extinction and performing the operations of clause 2.1.15 can one start kindling. 2.2.18. At the end of the boiler firing up operations, set the "Protection" key to the "On" position, in this case the protections against: extinguishing the flame in the furnace; lowering the fuel oil pressure downstream of the control valve. 2.2.19. After the end of the boiler firing up and when the iron content in the closed loop decreases to the values specified in section. 5, close the boiler intermittent blowdown.2.3. Gas boiler firing up
2.3.1. After completing the operations according to item 2.1.26, proceed to the boiler firing up. 2.3.2. Control the ignition devices from the panel or directly on site. 2.3.3. Set the "Protection" key to the "Ignition" position, in this case the protections listed in clause 2.2.3 are activated. 2.3.4. Set the air pressure at 200-300 Pa (20-30 kgf / m2). 2.3.5. Open the first valve on the gas line in front of the ignited burner, as well as the valve on the gas line to the ignition device. Close the valve on the burner safety plug. 2.3.6. Turn on the ignition device of one of the burners of the lower tier, visually make sure the ignition and stable combustion of the igniter. 2.3.7. Open the second valve upstream of the burner to be ignited. The gas should immediately ignite. Adjust the combustion process by acting on the gas and air supply. 2.3.8. Fire the subsequent burners (first the lower ones, then the upper ones) like the first one. 2.3.9. After achieving stable combustion in the furnace, extinguish the ignition devices of the operating burners. Close the valves on the safety plug (SB). 2.3.10. Set the required gas pressure in front of the injectors with the control valve and turn it on to the machine. 2.3.11. If, during the ignition process, gas does not ignite in any burner from the ignited group, immediately close its supply to the boiler, turn off the ignition device and ventilate the burners, furnace, boiler flue gas ducts for at least 10 minutes at an air flow rate of at least 25% of the nominal. After eliminating the causes of non-ignition, proceed with re-ignition. 2.3.12. If during firing up the burner does not light up or goes out (with the ignition group burners running), close the gas supply to this burner, turn off the ignition device, eliminate the cause of non-ignition or extinguishing and, after blowing the burner with air, proceed to re-ignition. 2.3.13. In the event of a complete extinguishing of the flame in the furnace, immediately stop the gas supply to the boiler, disconnect all ZZZU. Only after eliminating the causes of extinction and performing the operations of clause 2.1.15, proceed to re-firing. 2.3.14. At the end of the boiler firing up operations, set the "Protection" key to the "On" position, in this case, the protections against the extinction of the common flame in the furnace are additionally activated; lowering the gas pressure downstream of the control valve. 2.3.15. After the end of the boiler firing up and when the iron content in the closed loop decreases to the values specified in section. 5, close the boiler intermittent blowdown.3. TRANSFER OF A BOILER FROM ONE KIND OF FUEL TO ANOTHER
3.1. Converting the boiler from fuel oil to gas
3.1.1. When converting the boiler from fuel oil to gas, perform the following operations: check the shut-off valve actuation and the operability of technological protections and gas interlocks by affecting the actuators or a signal in a volume that does not interfere with the operation of the boiler; prepare and fill the boiler gas pipeline with gas (see p. 2.1.26); supply gas and light one of the lower burners (see paragraphs 2.3.2; 2.3.4; 2.3.5 and 2.3.7); after the gas has ignited, close the valves on the oil pipeline to the nozzle of this burner; make sure that the torch is burning steadily; blow through the nozzle with a feather, slide it out of the burner and remove it. 3.1.2. Change the remaining burners from fuel oil to gas in the same way. 3.1.3. Put the steam and oil pipelines of the boiler into reserve. 3.1.4. After converting all operating burners from fuel oil to gas, put the fuel selection key in the "Gas" position.3.2. Converting the boiler from gas to fuel oil
3.2.1. When converting the boiler from gas to fuel oil, perform the following operations: prepare and fill the boiler fuel oil pipelines with fuel oil (see paragraph 2.1.25); supply fuel oil to the nozzles (one of the lower ones) and light it up (see paragraphs 2.2.1; 2.2.3; 2.2.5-2.2.8); close the valves on the gas pipeline in front of the burner; make sure that the torch is burning steadily; open the burner safety plug valve. 3.2.2. Change the rest of the burners from gas to fuel oil in the same way. 3.2.3. Put the boiler gas pipelines into reserve. 3.2.4. After converting all operating burners from gas to fuel oil, set the fuel selection key to the “Fuel oil” position.4. MAINTENANCE OF THE BOILER DURING LOAD OPERATION
4.1. Do not allow the boiler to operate without activated technological protections, interlocks, alarms and automatic regulators. 4.2. Operate the boiler in accordance with the regime chart (Appendix 2) according to the indications of instrumentation (instrumentation). Demand from the personnel on duty of CTAI to ensure constant operability and correct readings of the instrumentation. 4.3. Timely identify deviations from the normal operating conditions of the boiler and take prompt measures to eliminate violations of the operating modes of the boiler and auxiliary equipment, acting in accordance with the instructions of section. 6 of this Model Instruction. 4.4. While the boiler is in operation, observe: the combustion mode, the operation of the burners and nozzles; the absence of fistulas in the pipes of the heating surfaces, headers of heat exchangers, bypass pipes and loop network pipelines, periodically listening and inspecting them; fuel parameters before the control valve and before the burners; operability of control systems, remote control and autoregulation, protection, interlocks and signaling; the density of the gas-air path; water flow in the manhole cooling system; the condition of the fittings of the water and fuel lines of the boiler; the state of lining and insulation; operation of auxiliary equipment; serviceability of working and emergency lighting; serviceability of communication systems. 4.5. According to the job description, perform a routine inspection of the boiler, heat exchangers and auxiliary equipment. Record the detected equipment defects in the defect log. 4.6. When making rounds, inspect all gas pipelines within the boiler, detect gas leaks by sound, touch, smell, or the coating of possible leaks with soapy water (bubbles indicate the location of the leak). In the event of a gas leak, immediately inform the chief driver or shift supervisor and additionally the person responsible for the safe operation of the gas facility, or the shop manager. 4.7. Basic parameters of the boiler with the rated heating capacity: Circuit water temperature at the boiler inlet ................................... ..... 110 ° С Circuit water temperature at the boiler outlet ................................... 180 ° С Circuit water pressure at the boiler outlet ........................................ .2.2 MPa (22 kgf / cm 2) Underheating of circuit water to boiling ................................. ..................... Not less than 30 ° С The temperature of the supply water at the outlet of the heat exchangers depends on the temperature of the return supply water and its flow through the heat exchangers, but should not exceed 150 ° C. 4.8. Due to the operation of the control valve B-1 of the refinery bypass on the machine, maintain the pressure on the suction side of the NZK, depending on their type, at the level of 1.7-2.0 MPa (17-20 kgf / cm 2). 4.9. Open the continuous blowdown of the closed boiler circuit, for which: open the manual valves on the continuous blowdown pipeline and gate valves P-2 and P-3; in the absence of an installation for cleaning industrial condensates, direct the continuous blowdown of the circuit to the waste water discharge tanks, for this, close the P-3 valve and open the corresponding manual valves; Supply the purge water of the boiler closed loop cooled in tanks with a temperature not exceeding 30 ° C to the VPU. 4.10. Put on the machine a control valve B-2, installed on the bypass line of the heat exchangers loop water, to maintain the loop water temperature at the boiler inlet at 110 VC. 4.11. Do not allow the temperature difference between the circulating water at the inlet to the heat exchangers and the network at the outlet from them to exceed more than 40 ° C. If this is exceeded, reduce the flow of heating water through the heat exchangers or the heating capacity of the boiler. The value of the specified temperature difference above 40 ° C is allowed only if there is a calculation justification reflected in the factory operating instructions for heat exchangers. The rate of increase or decrease in the temperature of the loop water in heat exchangers with changes in the boiler heating capacity should not exceed 60 ° C per hour for heat exchangers installed in a heated room, and 30 ° C per hour when installed outdoors and should be specified according to the technical documentation for each type heat exchangers. 4.12. Regulation of the boiler heating capacity in the range of loads of 30-100% for gas and 45-100% for fuel oil is carried out by changing the fuel pressure in the conditions of the boiler operation with all burners on. 4.13. To increase the heating capacity of the boiler, first increase the draft, then the air flow and finally the fuel consumption. When decreasing heating capacity, first reduce fuel consumption, then air consumption and draft. 4.14. Observe the combustion process visually. 4.15. When burning fuel oil or gas, to limit local heat fluxes in the furnace and reduce harmful emissions of nitrogen oxides in the range of boiler heat output of 60-100%, work with the included DRGs. The permissible degree of opening of the DRG guide vanes is determined in the course of operating tests, depending on the application of specific gas recirculation schemes. 4.16. Maintain excess air in flue gases from the boiler at a rated heat load of at least 1.05-1.1 for gas and 1.1-1.15 for fuel oil. 4.17. When turning on the DRG while the boiler is running, first raise the air pressure to 30 Pa (300 kgf / m2) at the nominal heating capacity of the boiler, then gradually open the DRG guide vanes to the recommended value. 4.18. In case of a noticeable increase in the iron content in the closed loop of the boiler during its operation, as instructed by the duty personnel of the chemical department, open the periodic boiler blowdown. 4.19. After reducing the iron content in the boiler to the standards provided in section. 5, close the periodic boiler blowdown. 4.20. To assess the condition of the inner surface of the pipes, cut out control samples from undamaged areas in the area: furnace walls at the marks between the burners and above the upper tier; lower bending coils of upper convective packages. 4.21. In the case of an increase in the hydraulic resistance of the heat exchanger tubes through the network water at an estimated flow rate of about 1.5 times, it is necessary to carry out their individual flushing with the help of a mobile high-pressure unit, which is performed by a specialized organization.5. STANDARDS OF WATER-CHEMICAL REGIME OF A CLOSED CIRCUIT
5.1. In a closed loop, two different water modes can be used: alkaline mode with feeding the loop with turbine condensate at a CHPP of any pressure, feed or make-up water of high pressure drum boilers; alkaline mode with feeding the circuit with Na-catnonated water (if the industrial circuit is located in the boiler room). 5.2. Alkaline mode with feeding a closed loop with turbine condensate at a CHPP of any pressure, feed or make-up water of high-pressure drum boilers. 5.2.1. The quality of the make-up water of the closed loop must meet the following standards: Total hardness, μg eq / kg ............................ Not more than 3 Content dissolved oxygen, μg / kg, no more: when fed with feed water ................ 10 when fed with condensate or demineralized water ............. .................. 50 (set by power supply systems) Content of iron compound, μg / kg ........... Not more than 50 Content of oil products, mg / kg ................. Not more than 0.3 Hydrazine content, μg / kg ...................... ... Lack 5.2.2. The water quality of the closed circuit must meet the following standards: Total hardness ....................................... ......... Not more than 10 μg eq / kg Dissolved oxygen content ............. Not more than 50 μg / kg Iron compounds ......... ..................................... Not more than 100-150 μg / kg pH value (at a temperature 25 ° C) ............... 9.5-10 5.3. Alkaline mode with feeding a closed loop with Na-cationized water (if the industrial loop is located in the boiler room). 5.3.1. The quality of the closed loop make-up water must meet the following standards: Total hardness ...................................... .......... Not more than 50 μg eq / kg Total alkalinity .............................. ............... Not more than 5 μg-eq / kg Content of dissolved oxygen ............. Not more than 50 μg / kg Content of free carbon dioxide .. .............. 0 Amount of suspended solids ...................... Not more than 5 mg / kg Content of oil products .. ........................... Not more than 0.5 mg / kg Content of iron compound ............ ............. Not more than 100 μg / kg 5.3.2. The water quality of the closed circuit must meet the following standards: Total hardness ....................................... .......... Not more than 60 μg eq / kg Dissolved oxygen content ............. Not more than 50 μg / kg Iron content ........ ................................... .. Not more than 200-250 μg / kg pH value (at a temperature of 25 ° C) ............... 9.5-10 Content of oil products ......... .................... Not more than 1 mg / kg 5.4. The blowdown of the circuit in all water modes must ensure the maintenance of the closed loop water norms for iron compounds. The total consumption of continuous and periodic blowdown based on the conditions for maintaining the Veda pressure in a closed loop should not exceed 30 t / h per one boiler. 5.5. The direct addition of hydrazine and other toxic substances to the circuit water and make-up water is prohibited. 5.6. Maintaining the required pH values of the closed loop water should be carried out by injecting ammonia or caustic soda. The introduction of solutions of alkaline reagents is carried out into the make-up water supply pipeline to the suction side of the refinery. 5.7. When commissioning a closed loop after its installation, hot water boilers with operational deposits on the inner surface in an amount of 500 g / m 2 or more must be chemically cleaned. Newly commissioned hot water boilers must be alkalized after installation before commissioning. 5.8. Operational chemical cleaning of heating surfaces should be carried out with a specific contamination of them with deposits of more than 600 g / m 2. 5.9. Heat exchanger tubes are made of corrosion-resistant steels.6. STOPPING THE BOILER
6.1. Stopping the boiler in reserve for a period not exceeding 3 days. 6.1.1. When stopping the boiler operating on fuel oil, perform the following operations: thoroughly clean the convective heating surfaces of the boiler; sequentially, starting with the upper ones, turn off the burners by closing the valves on the fuel oil supply to the nozzles; cover the air supply to the switched off burners; blow the nozzles with steam by opening the valves (1Pr-6Pr); close the steam supply for spraying fuel oil (1P-6P); remove the disconnected nozzles from the firebox; close the shut-off valve, RK and shut-off valves on the supply and recirculation fuel oil pipelines of the boiler; visually make sure that the torch is completely extinguished in the firebox. 6.1.2. When stopping a gas-fired boiler, perform the following operations: one by one, starting from the upper ones, turn off the burners by closing the fittings on the gas supply to the burners, open the safety plugs; close the air supply to the burners to be switched off; close the shut-off valve, RKG and shut-off valves on the gas supply line to the boiler; open the purge plugs on the disconnected gas pipeline; ventilate the furnace, gas ducts and air ducts for at least 10 minutes (see item 2.1.15). 6.1.3. Stop the DRG, the smoke exhauster and the fan, close their guide vanes. 6.1.4. Disable process protections by placing the Protection switch in the Disabled position. 6.1.5. After the boiler and heat exchangers have cooled down to a temperature 10-20 ° C higher than the temperature of the supply water at the inlet to the heat exchangers: turn off the NZK and close the valves K-13 - K-16 on their suction and discharge side; to ensure the circulation of water in a closed loop, leave one refinery in operation; open valve K-12 on the NZK bypass; close the continuous closed loop blowdown. 6.2. Boiler shutdown for more than 3 days. Disconnect all gas pipelines to the boiler and perform the following operations: clean the fuel oil pipelines of the boiler and outlets to the burners from fuel oil by blowing them with steam into the drainage pipeline; disconnect the boiler fuel oil lines from all boiler room fuel oil lines and purge lines with plugs; gas pipelines of the boiler, all outlets to the burners free from gas by blowing compressed air and disconnect from all lines with plugs; the end of the purge is determined by analysis (the residual gas content in the purge air should not exceed 1/5 of the lower ignition limit of natural gas); disconnect the ignition devices with plugs from the gas supply pipelines to them; when installing heat exchangers outdoors or in an unheated room at a negative outside temperature, to prevent a drop in the temperature of heat exchangers and their associated pipelines when the boiler is shut down, flow make-up water through the heat exchangers due to the operation of the refinery through the bypass pipe of the heat exchangers loop water, for which open the bypass of the control valve B -2; close the control valve B-2 and manual valves on the bypass pipe of the heat exchangers, close the shut-off valve K-2 at the outlet of the loop water from the boiler and turn off the NZK, turn on the continuous blowdown of the circuit; at positive ambient temperatures in the places where heat exchangers are installed, stop the refinery, close valves K-19 and K-20 on its suction and discharge side; close the manual fittings and the B-1 control valve at the refinery bypass; close the manual fittings and the B-2 control valve on the bypass piping of the heat exchangers; turn off the NZK and close the valves K-13 - K-16 on their suction and pressure sides; open the valves of all air vents and boiler drains; after fulfilling the requirements of p. 6.1.5 drain the water from the boiler, for which close the valves K-1 and K-2 at the inlet and outlet of the boiler; drain the supply water from the heat exchangers, for which close the valves C-2 - C-7 at the supply water inlet to and out of the heat exchangers; open the valves of all drains and air vents of the heat exchanger tube system; drain the loop water from the heat exchanger housings, for which close the valves K-3 - K-8 at the loop water inlet and outlet of the heat exchanger housings and open the valves of all air vents and drains from them; drainage into the drainage and periodic blowdown expander (see p. 2.1.18); submit an application for disassembly of electrical circuits of electric motors of mechanisms and remote control of valves and gates; internal inspection, cleaning and repairs of the boiler should only be carried out with written permission (as well as) in compliance with the relevant safety regulations; perform gas hazardous work in accordance with the Safety Regulations in the Gas Industry. 6.3. If the boiler is taken out for a period of more than 30 days (summer period), prior to the conservation of the boiler and the heat exchangers, make an external examination of the heat exchanger tubes in order to assess their density, for which: turn off the heat exchangers using the mains water with plugs, drain them; remove the covers from the casings of all heat exchangers; create a loop water pressure equal to 1.0-1.2 MPa (10-12 kgf / cm 2) by activating the NZK and, if necessary, the refinery, adjusting the loop water pressure with the B-1 control valve; inspect the tubes, in case of damage, restore their tightness, and if this is not possible, muffle them; carry out all operations to inspect the heat exchanger tubes at a circuit water temperature not higher than 45 ° С. 6.4. After installing the covers on the heat exchanger housings, carry out the internal preservation of the boiler and heat exchangers by pumping make-up water from the deaerator tanks through the boiler and a closed circuit; turn off the refinery and NZK and open valves K-11 and K-12 on their bypasses; discharge the make-up water through the continuous blowdown pipeline into the drain expander and the periodic blowdown pipeline with its subsequent supply to the unit for purification of industrial condensates or to the TLU; pump water during the entire stopping time of the boiler. 6.5. Carry out the internal preservation of the boiler and heat exchangers installed in heating boiler rooms with a sodium silicate solution in accordance with the current Methodological Guidelines for the preservation of heat and power equipment.7. EMERGENCY PROVISIONS
7.1. In case of equipment malfunctions: carefully check the performance indicators and, based on the readings of the instruments and external signs, form an idea of the violation of the regime; inform the shift supervisor of the CTC or power plant about the incident; establish the nature and location of the damage; enable the backup and disconnect the damaged equipment; make sure that the backup equipment is working properly; take steps to recover the damaged equipment. 7.2. In the event of an accident, immediately treat the injured person in accordance with the regulations in force. Arrange a call for medical personnel and notify the shift supervisor of the CTC and power plant about the incident. 7.3. Register in the operational log the available data on the accident, indicating the beginning, the nature of the course and the actions of the personnel to eliminate it, as well as the time of individual events (switching on and off equipment, actuation of interlocks, protection and signaling). 7.4. The boiler must be stopped immediately by the protections (see clause 9.3 of this Standard Instruction) or directly by the personnel in the event of: failure of the circulating water flow meter, if at the same time there are mode violations that require readjustment of the power supply; shutdown of the NZK and non-activation of the standby pump by ATS; shutdown of the refinery and non-inclusion of the standby pump for the automatic transfer switch; increasing the pressure of loop water at the outlet of the boiler to 2.6 MPa (26 kgf / cm 2) or lowering it at the indicated temperatures to values lower than those given in the table. Note . Circuit water pressure must be higher than supply water pressure. Circuit water pressure values in the table are given taking into account its underheating to saturation temperature at 30 ° C. rupture of pipes of the heating surfaces of the boiler, collectors and pipelines at an appropriate pressure; detecting cracks, swelling, gaps or sweating in welds, leaks in the main elements of heat exchangers; extinction of the torch in the firebox; unacceptable decrease in gas or fuel oil pressure downstream of the control valve; turning off the smoke exhauster or blower fan; explosion in the furnace, gas duct, destruction of the lining, other damage that threatens personnel and equipment; fires posing a danger to personnel, equipment and remote control circuits of the disconnecting valve, fittings included in the protection scheme; increasing the temperature of the loop water at the outlet of the boiler up to 190 ° С; loss of voltage on remote and automatic control devices or all instrumentation; rupture of the fuel oil pipeline or gas pipeline within the boiler. 7.5. In case of emergency shutdown of the boiler: close the valves С-1 and С-8 on the return and direct pipelines of the heating system and open their bypasses; close valves K-3, K-5 and K-7 at the loop water supply to the heat exchangers and open their bypasses; remove from AVR NZK; stop the NZK and close the valves on the suction and discharge side, close the P-2 valve on the continuous blowdown pipeline of the circuit; open valve K-12 on the NZK bypass; in the event of an emergency shutdown of the refinery, additionally open the valve K-11 on their bypass. 7.6. The boiler must also be shut down by order of the management in the event of: detection of holes in the heating surfaces, collectors, pipelines, leaks and vapors in the fittings and flange connections of the boiler, as well as in the flanges of the heat exchanger casings; malfunctions of individual protections or devices for remote and automatic control, as well as instrumentation. The stopping time of the boiler in these cases is determined by the chief engineer of the power plant or the chief of the boiler house.8. INSTRUCTIONS FOR SAFETY, EXPLOSION AND FIRE SAFETY
8.1. Basic instructions on safety, explosion and fire safety should be reflected in local instructions drawn up in accordance with the guidelines listed in clause 1.7 of this Model instruction. 8.2. The safety requirements for servicing heat exchangers are given in the installation and operating instructions issued by the manufacturer of the heat exchangers, on the basis of which, depending on the type of heat exchangers, local instructions are developed.9. SCOPE OF EQUIPMENT OF THE BOILER WITH MEASURING EQUIPMENT, AUTOMATIC CONTROL, TECHNOLOGICAL PROTECTION, INTERLOCKING AND SIGNALING
To control the operation of the boiler, the following instrumentation must be installed: recording and indicating flow meter for measuring the flow rate of loop water through the boiler; registering flow meter for measuring the flow of heating water through heat exchangers; recording flow meter for measuring the flow rate of continuous closed-loop blowdown; showing a flow meter for measuring the flow rate of periodic boiler blowdown; registering flow meter for measuring the flow rate of the make-up water of the circuit; showing pressure gauge for measuring water pressure in front of the boiler (behind the NZK); registering and indicating pressure gauge for measuring the water pressure behind the boiler; showing pressure gauge for measuring water pressure in front of the NZK; indicating pressure gauge for measuring water pressure in front of the make-up pump; showing pressure gauge for measuring the pressure of the return water supply; showing pressure gauge for measuring the pressure of circulating water in the heat exchanger housings; indicating devices for measuring pressure drops in the network water at the inlet and outlet of each heat exchanger; recording and indicating device for measuring the temperature of the loop water in front of the boiler; registering and indicating device for measuring the temperature of the loop water behind the boiler; showing device for measuring the temperature of the return supply water; a registering device for measuring the temperature of direct network water; a recording device for measuring the temperature of the loop water at the inlet to each heat exchanger; a recording device for measuring the temperature of the loop water at the outlet of each heat exchanger; a recording device for measuring the temperature of the network water at the outlet of the outlet heat exchangers; registering and showing device for measuring gas flow rate; indicating pressure gauge for measuring gas pressure downstream of the control valve; registering and indicating pressure gauge for measuring gas pressure in the gas pipeline to the boiler; registering and showing flow meter for measuring fuel oil consumption to the boiler; indicating pressure gauge for measuring fuel oil pressure downstream of the control valve; registering and indicating pressure gauge for measuring the pressure of fuel oil in the fuel oil pipeline to the boiler; showing steam pressure gauge for fuel oil spray; registering flow meter for measuring fuel oil consumption for recirculation; indicating device for measuring the temperature of fuel oil in front of the burners; a recording device for measuring the temperature of flue gases; indicating devices for measuring the temperature of flue gases along the width of convective packages (via a switch); showing device for measuring air pressure behind the blower fan; a recording device for measuring the temperature of the bearings of draft machines; oxygen meters (left and right); instruments for measuring the transparency of flue gases (right to left); showing a device for measuring the vacuum at the top of the furnace. The following should be installed on site: pressure gauges on the gas supply lines to each burner; pressure gauges on the fuel oil supply lines for each burner; sawing steam pressure gauges for each burner; draft pressure gauges on the central and peripheral air ducts for each burner; pressure gauge for measuring gas pressure behind the control valve; pressure gauge to measure the fuel oil pressure downstream of the control valve.9.2. Boiler automatic regulation system
The system includes the following regulators: main; fuel; general air; vacuum at the top of the firebox; loop water pressure on the NZK suction side; the temperature of the circuit water in front of the boiler.9.3. Technological protections
Values of protection response time delays are determined by the manufacturer of boiler equipment and applicable instructions. The equipment disconnected by the protections, after elimination of the triggering causes, is included in the work by the duty personnel. On boilers using two types of fuel, a switch is installed for input and output of protections, which has separate positions for each type of fuel. The boiler shutdown is protected by: extinguishing the flame in the furnace; lowering the gas pressure downstream of the control valve; lowering the fuel oil pressure downstream of the control valve with a time delay of up to 20 s; turning off the smoke exhauster; turning off the fan; failure of the circulating water flow meter, if at the same time there is a violation of the mode, requiring readjustment of the power supply; shutdown of the NZK and failure to turn on the standby pump by ATS; shutdown of the refinery and failure to turn on the standby pump for the automatic transfer switch; increasing the pressure of the loop water at the outlet of the boiler to 2.6 MPa (26 kgf / cm 2); increasing the temperature of the loop water at the outlet of the boiler to 190 ° C. Protection for reducing the underheating of the circuit water less than 30 ° C is introduced if there is a device for forming a setpoint based on the difference between the actual temperature of the circuit water and the saturation temperature of the corresponding pressure of the circuit water at the outlet of the boiler (see table clause 7.4) and is performed instead of protection for decreasing pressure ... For previously designed boilers, where such protection is not installed, protection is installed to reduce the pressure of the loop water at the outlet from the boiler with a setting of 1.9 MPa (19 kgf / cm 2) and a time delay of 10 s. The tolerances for the values of the protection settings depend on the class of devices, the delivery of which is determined by the design organization.9.4. Local defenses
9.4.1. In the event of non-ignition or failure of the burner flame, the oil nozzle or gas burner is switched off, as well as the ignition device by closing the electrified fittings in front of the burner. 9.4.2. If after 10 s the torch of the switched on igniter does not appear or goes out, then it is switched off by gas and electric spark.9.5. Locks
9.5.1. When the smoke exhauster is turned off, the boiler is stopped, the valve on the gas supply to the igniter is closed, the electric spark, the blower fan and the DRG are turned off. 9.5.2. When the smoke exhauster (fan) guide vane is fully opened and its electric motor operates at the first speed, by blocking it, the electric motor switches to the second speed with a time delay of up to 3 s. 9.5.3. The electric motor of the smoke exhauster or fan does not turn on if the diffuser is not completely closed. 9.5.4. The fan does not turn on if the exhauster is not turned on. 9.5.5. When the fan is turned off, its guide vanes are closed. 9.5.6. The valve on the gas pipeline to the boiler does not open if at least one of the motorized valves for each burner is not closed.9.6. Process signaling
Signals of deviation of the main parameters from the set values should be sent to the boiler control panel, causing the light panels and sound signal to turn on: boiler shutdown; extinction of the torch in the firebox; decrease or increase in fuel pressure downstream of the control valve; change in vacuum at the top of the furnace; increasing the temperature of the water leaving the boiler; increasing the permissible temperature difference between the loop and network water in heat exchangers; decrease or increase in water pressure at the outlet of the boiler; reducing the flow rate of loop water through the boiler; turning off the smoke exhauster; turning off the blower fan; turning off the recirculation smoke exhauster; shutdown of burners; the disappearance of voltage in the protection circuits.Annex 1
BRIEF DESCRIPTION OF WATER BOILER KVGM-180-150
Gas-oil hot water boiler KVGM-180-150 is installed at the TPP. Boiler - direct-flow, T-shaped configuration, designed for combustion of gas and fuel oil. Combustion chamber The combustion chamber of a prismatic boiler has dimensions along the axes of wall tubes 6480x5740 mm. Front and rear screens are made of 60x4 pipes with a pitch of 64 mm. Intermediate screens separating the firebox and convective gas ducts are made of gas-tight pipes of the same diameter, pitch - 80 mm. In the lower part of the firebox, the front and rear screens form the hearth slopes. The top of the combustion chamber is covered with ceiling panels that turn into the side screens of the downpipe flues. The ceiling and side screens of the convection shafts are composed of 38x4 pipes with a pitch of 42 mm. The collectors inside the boiler are taken with a diameter of 273x14 mm; the material of the heated pipes of the heating surfaces, collectors and bypass pipelines is steel 20. In the latest modifications of the boiler, all firewalls have a gas-tight design. The design of the ceiling and side screens in convective gas ducts has also been changed, which are now made of 60x4 mm pipes. The strength of the combustion chamber is provided by stiffening belts. The casing consists of carbon steel sheet. The firebox is suspended from the ceiling frame of the frame with the help of special rods. In the first boiler samples, the combustion chamber is equipped with six vortex gas burners, which are located on the side screens of the furnace in two tiers oppositely, with triangles pointing upwards. They are equipped with steam-mechanical nozzles equipped with a movement mechanism. Each burner must be equipped with an ignition-protective device. Subsequently, the manufacturer produced boilers KVGM-180-150 with twelve direct-flow burners located in the furnace according to the MEI scheme, as well as six and eight vortex burners on the side screens of the furnace, respectively, in three and two tiers in height. In subsequent modifications of the boiler (model KVGM-180-150-2M), for the organization of the combustion process on the front and rear walls in the corners of the furnace, eight direct-flow gas-oil burners are installed, placed in two tiers with a tangent direction to an imaginary circle in the center. The lower deck burners are ignition type. Each burner is equipped with an ignition-protective device (ZZU). Convective heating surfaces are located in two drop shafts with fully shielded walls. The enclosing surfaces of the gas ducts are: side screens of the furnace; side panels of gas ducts; front and back walls of gas ducts. The front and rear walls of the convection shaft are made of pipes with a diameter of 95x5 (steel 20) with a pitch of 136 mm. To ensure tightness, a 40 mm wide fin is welded between the pipes. The pipes of the front and rear walls of the convection shaft serve as collectors U-shaped coils made of pipes 32x3 mm (steel 20). The arrangement of pipes in the downpipe is staggered with a step S 1 = 68 and S 2 = 60 mm Circulation circuit In the main operating mode of the boiler (Fig. A1.1), loop water is supplied by closed-loop pumps to the common inlet chamber of the boiler, from which it is directed through the bypass pipes to the right half of the lower collectors of the front and rear screens of the furnace, as well as to lower collectors of the right side screen of the furnace, the right side screen of the convection shaft and the ceiling screen, from which water enters the front and rear panels (risers), into the upper, middle and lower convective half-sections of the right downstream flue. From their lower collectors, water flows into the left half of the lower collectors of the front and rear screens of the furnace, into the lower collectors of the left side screen of the furnace, as well as the left side screen of the convection shaft and the ceiling screen. From the indicated heating surfaces and from the left half of the front and rear screens of the furnace through the bypass pipes, water is supplied to the front and rear panels (risers), to the upper, middle and lower convective half-sections of the left downstream flue, from which it enters the common outlet chamber.Rice. A1.1. Hydraulic diagram of a hot water boiler KVGM-180-150 (basic mode): 1 - front screen of the furnace; 2 - rear screen of the furnace; 3 - right side firebox screen; 4 - right side screen of the convection shaft and ceiling screen; 5 - front panel (risers); upper, middle and lower convective half-sections of the right downward gas duct; 6 - rear panel (risers); upper, middle and lower convective half-sections of the right downward gas duct; 7 - left side screen of the furnace; 8 - left side screen of the convection shaft and ceiling screen; 9 - front panel (risers); upper, middle and lower convective half-sections of the left downstream duct; 10 - rear panel (risers); upper, middle and lower convective half-sections of the left downstream duct; 11 - boiler inlet chamber; 12 - boiler outlet chamber; Cleaning of heating surfaces When the boiler is running on fuel oil, a shot blasting is provided to clean the convective heating surfaces from external deposits. The transport of 3-5 mm shot is carried out using an air injector. In the installation scheme, an avalanche discharge of shot is adopted, which provides a more efficient cleaning of pipes. In order to prevent the throwing of shot into the furnace, the height of the "threshold" from the upper row of the convective package is about 1500 mm. To eliminate the drift of shot, a protective grid is installed in the exhaust gas duct. It is recommended to use gas-impulse cleaning instead of a shot-blasting machine. Boiler lining Boiler lining consists of insulating and reinforcing materials, asbestos sprayed part, reinforced mesh, sealing plaster and polymer-coated glass cloth. Lining thickness 110-130 mm. The collectors on the side of the gas ducts are protected with fire-resistant concrete: the outer part is covered with asbestos insulation. Chimney-blowing unit The boiler is equipped with one VDN-25-11 y fan. Air intake can be carried out both from the premises and from the street. For heating the air to positive temperatures after the blowing fan, the installation of water heaters KVV-12P is provided. The thrust is organized by the DN-24x2-0.62 GM smoke exhauster. Recirculation of flue gases taken in front of the last convective package and supplied to the air duct behind the blower fan is created by the VDN-21 recirculation smoke exhauster. In subsequent modifications of the boiler, it is equipped with a VDN-26 fan, water heaters KVB-12B-PU-3 and a gas recirculation fan VGDN-17. Design data and design characteristics of the KVGM-180-150 water heating boiler Nominal heating capacity, MW (Gcal / h). ............................. 209 (180) Water pressure, MPa (kgf / cm 2), design .................................. ................... 2,5 (25) Water temperature, ° С: at the inlet ................. .................................................. ........................................... 110 at the exit .... .................................................. .................................................. ... 180 Water consumption, t / h ........................................ .................................................. ...... 2500 Minimum hydraulic resistance of the path, MPa (kgf / cm 2) ........ 0.3 (3) Range of regulation of heating capacity,% of the nominal ....... 30-100 Overall dimensions, mm: width ............................................. .................................................. ............ 14400 depth .................................... .................................................. ..................... 7300 height ........................... .................................................. ... ............................. 29880 Note . Indicators of the basic boiler variant are given. The design characteristics of water-to-water heat exchangers are not given in this section, since heat exchangers are ordered by the design organization at various manufacturers. Their data is reflected in the factory operating instructions for each type of heat exchanger.
Appendix 2
EXAMPLE FORM OF A MODE CARD OF A WATER BOILER
Operating mode: main Fuel: gas, fuel oil|
Indicator |
Heating capacity,% of nominal |
Water pressure at the outlet of the boiler, MPa (kgf / cm 2) | Boiler inlet water temperature, ° С | Circuit water temperature at the outlet of the boiler (at the inlet to the heat exchangers), ° С | Return water temperature, ° С | Direct supply water temperature. ° C | The temperature difference between the loop water at the inlet to the heat exchangers and the network water at their outlet, ° С | Circuit water consumption, t / h | Supply water consumption, t / h | Hydraulic resistance of heat exchangers for network water, MPa (kgf / cm 2) | Number of operating burners, pcs. | Fuel consumption: | m 3 / h | kg / h | Fuel pressure behind the control valve, MPa (kgf / cm 2) | Fuel pressure in front of burners, MPa (kgf / cm 2) | Air pressure behind the fan, kPa (kgf / cm 2) | Air pressure in front of burners, kPa (kgf / cm 2) | Steam pressure for fuel oil spray, MPa (kgf / cm 2) | Fuel oil temperature. ° C | Vacuum at the top of the furnace, Pa (kgf / m 2) | Oxygen content in the operating section,% | Exhaust gas temperature, ° С | Efficiency d. boiler gross,% | Specific emissions of nitrogen oxides, g / m 3 | DRG guide vane opening degree,% | Note . Regime card issued as of ______ |
Manufacturing instruction - the main document according to which the boiler room personnel must act. It stipulates general rules and specific actions of personnel in a given situation.
The instruction given is an example model instructions boiler room operators. The instruction is given to each operator personally in hands, against signature.
The main points of the production instructions for the operator of the gasified boiler house:
I. General Provisions.
The procedure for the operator's admission to work
The rights and obligations of the boiler operator
· The admission of unauthorized persons to the boiler room is allowed only if accompanied by the head of the boiler room with the permission of the administration.
· It is forbidden to engage in extraneous activities on duty.
II. Preparation for firing up (kindling) the boiler.
· The boiler is fired up only with a written order from the head of the boiler room.
Preparing to ignite the steam boiler
· Make sure that there are no people and foreign objects in the boiler furnace and gas ducts.
· Check the working order of the boiler and chimney lining.
· Check the condition of the explosion safety valves.
· Check the serviceability of the safety valves (by detonating).
· Test drives of air dampers of smoke exhausters and fans.
· Check the presence of natural draft in the firebox.
· Check the serviceability of the smoke exhauster and fans.
· Check the condition of the boiler headset.
Check serviceability shut-off valves on the boiler pipelines (feed, blowdown).
· Check the serviceability and activation of the water-indicating glasses.
· Check the operability of the automatic regulation.
· Make sure that the backup feed pump is working.
· Open the air vents on the upper drum of the steam boiler.
· Close the valve on the continuous blowdown line.
· Make sure there is water in the deaerator.
· Fill the economizer with water.
· Open the valve on the supply line.
· Fill the boiler with feed water. (For a steam boiler, the water level should be between the lower permissible level and the upper permissible level, slightly above the average value.
· Make sure that the water level in the boiler does not drop.
· Close the valve on the supply line.
Preparation for firing up a hot water boiler
· Check the condition of the boiler headset.
· Check the serviceability of the pipelines connected to the boiler. Make sure that there are no plugs on the pipelines.
· Check the serviceability of instrumentation.
· Check serviceability of safety automation.
· Check the serviceability of the mains pumps.
· Close the taps on the drain lines.
· Open the valve on the boiler inlet line.
· Open the valve on the boiler outlet line.
· Open the air vents. Wait until water flows steadily from the air vents and close them.
· Make sure there is water circulation through the boiler. The inlet water pressure must be higher than the outlet.
· Make sure there is no water leakage from the boiler.
· Fill the system with water using the booster pump.
· After creating pressure in the system, about 2.5 kgf / cm2, turn on the circulation pump.
· Make an entry in the log about the preparation of the boiler for firing up.
III. Firing up (kindling) the boiler.
· The boiler is fired up according to the written order of the head of the boiler room.
Firing up the steam boiler:
· Make sure that the boiler is full of water.
· Check the tightness of the shut-off valves. Record the results of the check in a removable log.
· The steam shut-off valve on the boiler must be closed.
· The valve on the continuous blowdown line must be closed.
· The valve on the boiler feed line must be closed.
· Open the valve on the squeegee line.
· The air vents on the steam boiler must be open.
· Check the serviceability of the water-indicating glasses.
Check the serviceability of the safety valves (by detonating)
· The boiler is fired up at minimum load.
· Close the air vents after steam has escaped steadily.
· At a steam pressure of 3 kgf / cm2, once again check the serviceability of the water-indicating glasses, check the safety valves by the detonation method.
· Carry out periodic boiler blowdown.
Ignition of hot water:
· When firing up the boiler, observe the inlet and outlet pressure and temperature.
· Monitor the water flow through the boiler. (by flow meter)
· Record the ignition result in the shift log.
IV. Putting the boiler into operation.
V. Boiler operation, maintenance.
· During the operation of the boiler, it is necessary to monitor the condition of the boiler, the operability of the safety automation, and the instrumentation.
· It is necessary to observe the operating mode of the boiler in accordance with the regime card and temperature schedule.
· Monitor the burners. Burning must be complete and stable.
· It is necessary to control the operation of pumps, smoke exhausters and fans.
· Periodically monitor the temperature and composition of the flue gases.
Steam boiler operation:
· It is necessary to maintain a normal water level in the steam boiler, to ensure uniform water supply to the boiler.
The water level should be at the horizontal axis of the upper drum.
· Perform periodic blowdown once per shift.
· It is necessary to control the work of the economizer. Monitor the pressure and temperature of the water entering and leaving the economizer. Write to the shift journal at least once per shift.
Hot water boiler operation:
· During the operation of the boiler, it is necessary to monitor the temperature of the water at the inlet and outlet of the boiler. The water in the boiler must not boil.
· Observe the pressure at the inlet and outlet of the boiler.
· It is forbidden to leave the boiler equipment unattended until the fuel has stopped burning and the boiler has cooled down.
Vi. Scheduled boiler shutdown.
· Should be carried out by written order of the head of the boiler room.
· The planned shutdown of the boiler is carried out with a gradual decrease in the load on the burners.
· Switch off continuous blowdown.
· Shut off gas supply at minimum load.
· If the steam pressure in the boiler steadily rises, open the safety valves.
· If the temperature of the water in the economizer rises, open the discharge line.
· Ventilate the furnace and gas ducts - 10 - 20 minutes.
· After completion of ventilation, turn off the smoke exhauster and the fan, the guides must be closed.
· On a hot water boiler, you can turn off the water circulation when the water inlet and outlet temperatures are the same.
· The boiler must be supervised until it cools completely.
· Record information about the planned shutdown of the boiler in the shift log.
Draining water from the boiler:
· Drainage of water from the boiler is carried out according to the written order of the head of the boiler room.
· Open the air vents and the shut-off device on the drain line and drain the boiler.
Vii. Emergency stop of the boiler.
Emergency stop is performed immediately, without a gradual decrease in load
and without the written permission of the head of the boiler room.
Emergency stop of the steam boiler:
In the event of a malfunction safety valve.
· Extinguishing the flame on the burner.
· Failure of all feed pumps of the steam boiler.
· Raising the pressure in the boiler drum above the permissible level by 10% with the continuation of the increase.
· Decrease of the water level in the upper drum below the lower permissible level.
· The water level in the upper drum rises above the upper permissible level.
· Failure to operate all water level indicators.
· Switch off fans.
· Shutdown of smoke exhausters.
Emergency stop of the hot water boiler:
· The increase in water pressure at the outlet of the boiler is higher than the permissible one.
· Decrease in water pressure at the outlet of the boiler below the permissible level.
· Increase in the water temperature at the outlet of the boiler to a value of 20 ° C below the boiling point (in accordance with the working water pressure).
· Malfunction of safety automation.
· Power outage.
· Fire in the boiler room. In the event of a fire, personnel must act in accordance with these instructions and the plan for the elimination and localization of emergency situations.
· Make an entry in the shift log about the time and reason for the emergency stop of the boiler.
· Report to the head of the boiler room.
VIII. Reception and delivery of the shift.
· Inspect all equipment in operation, as well as in reserve and under repair.
View all log entries since the last watch
· Clarify the current situation in the boiler room orally.
· Make an entry in the journal about the acceptance of the shift.
IX. Final provisions.
· Maintenance personnel of the boiler house is responsible for violation of the requirements of the production instructions in accordance with the requirements of the internal labor regulations - material, administrative and in accordance with the law.
This manual has been developed on the basis of: - Rules for the technical operation of thermal power plants, approved by the Ministry of Energy of Russia No. 115 dated March 24, 2003 - Rules for the construction and safe operation of steam boilers with a steam pressure of no more than 0.07 MPa (0.7 kgf / cm water heating temperature not higher than 338K (115 ° C), approved by the Ministry of Construction of Russia No. 205 dated 28.08.92. 1.1. The boiler room must be assigned a person responsible for safe operation boiler room from among the engineering and technical personnel of the EMU service. 1.2. Persons who are at least 18 years old are allowed to service the boiler house: the operator of the EMU boiler service and persons from the operational dispatch service who have completed the training, passed the exams of the attestation commission, who have a certificate of the established form for the right to service boiler installations and who are authorized by the order of the enterprise to perform these works. 1.3. The boiler is fired up before the heating season after the written permission in the passport of the boiler house of the person responsible for the safe operation of the boiler house. 1.4. Purpose of the boiler: production of high-temperature heat carrier ( hot water); Type of fuel - natural gas; design parameters: water pressure, MPa (kgf / cm 2) - 0.7 (7.0) water temperature, ° С - up to 115 heating capacity, Gcal / h - 2.0. 1.5. Maintenance and repair of boiler equipment is carried out by: - heat and power equipment - by the EMU service; - instrumentation and automation by the instrumentation and control department - gas equipment- by the State Registration Service.
2.PREPARATION OF THE BOILER FOR OPERATION
2.1. In preparation for the start-up of the boiler room, it is necessary to carry out the FOLLOWING MEASURES: - ventilating the boiler room with a fan or opening windows and doors for 10-15 minutes; - after ventilation with a gas analyzer, the gas content in the room is checked. - inspection of pumps, pipelines, supports, fittings, insulation flange connections, filter-settling tank; - inspect all gas taps and valves, normal position - all purge plugs must be open; - after opening the valves at the inlet and outlet of the boiler, fill the heating system with network water, release the air through the air vents from the heating system - turn on the circulation pump and bring the water pressure in the heating system to 2.0-4.0 kgf / cm 2 - conduct an external inspection of the gas equipment. 2.2. Before starting the boilers, an external inspection of the chimneys is carried out, and if there is a break for long time, internal surfaces are also inspected. Supports, expansion joints, control valve, explosive valve, insulation, manhole gaskets are subject to external inspection. There is a blocking that will prevent the boiler from starting when the control valve is closed. 2.3. When gas is supplied, the valve opens and the corresponding valve to the boiler takes about 5-10 minutes to purge the gas pipelines, after which the valve for purging is closed. 2.4. When filling the network, it is necessary to open the valves. The supply of softened water to the boilers is carried out through the taps. When filling the network and the water circuit with water, close all valves to remove air. 2.5. To turn on the mains pumps, after filling with water - open the valves and close the valves and then turn on the selected mains pump 2.6. If, during the heating season, the temperature of hot water at the inlet and outlet from the boiler room is adjusted, then the water temperature at the inlet to the network pumps should not exceed 80 ° C. 2.7. Turning off one mains pump automatically turns on the other. If both pumps fail, the control valve opens, to carry out natural circulation When the boiler room is turned off, the network pump is stopped and the shut-off valve is closed after it. 2.8. Mains cold water flows through a filter-settler, feed pumps (one is in operation, the other is in reserve), a heater, cation exchange filters and enters the suction manifold of mains pumps.3. STARTING THE BOILER
3.1. Turn on the "NETWORK" toggle switch, turn off the network and sound signaling. In this case, the "MAINS" and "OPERATION" indicators light up and the program for monitoring the boiler status sensors starts. In case of deviation of the sensor parameters from the norm, the corresponding indication lights up. 3.2. After supplying fuel to the boiler burner, start the start-up program by moving the "START - STOP" toggle switch to the "START" position. 3.3. The boiler is started up and controlled by the KSUM-1 automatic equipment.4.BOILER OPERATION
4.1. The boiler is fully automatic. 4.2. Boiler automation is subdivided into: a) safety automation; b) automatic control. 4.3. Automatic temperature control includes: b) automatic switching on of the boiler; v) automatic maintenance pressure of network water in the return pipeline; a) automatic regulation of the temperature of hot water in the supply pipeline within the specified limits; d) automatic shutdown of the boiler from operation. 4.4. Safety automation includes: a) emergency automation; b) alarm automation. 4.5. Emergency automation includes; - protection for the lower pressure of air gas after the fan; - protection against emergency excess of water temperature (115 ° С); - contactor protection of the burner (interference in the burner). 4.6. Alarm automation includes: a) alarm“Burner failure“; b) alarm of the gas supply system; c) alarm of circulation pumps; d) emergency signal of injection pumps; e) alarm of the upper and lower limits of the temperature of the hot water of the supply pipeline; e) low temperature alarm; g) alarm signal of the upper and lower limits of water pressure at the entrance to the boiler. 4.7. It is necessary to check the safety valve by “blowing” every shift. 4.8. During the operation of the boiler, it is necessary to monitor the pressure and temperature of the supply and return water supply. 4.9. More than important parameters water and gas in the boiler room. 4.10. The operation of boilers and water heaters with faulty automation and equipment is not allowed! 4.11. When the boiler is turned off by the general boiler control device, the boiler is ignited by the operator after the end of the automatic stop program.5 STOPPING THE BOILER
5.1. To stop a boiler running on offline regulation, the operator is obliged:- press the "stop" button on the front panel of the KSUM-1 unit, after which the stop program is executed automatically;
- close the tap on the burner;
- open the valve on the purge line;
- after the fan stops working, turn off the automatic power switch on the unit and the “Network” switch on the front panel of the KSUM-1 unit. In this case, the "Network" indicator light should turn off.
- Turn off after 30 minutes. circulation pump if the other boilers in the boiler room are not working.
6. EMERGENCY STOP OF THE BOILER
6.1. The emergency stop of the boiler is carried out automatically when the emergency automatic system is triggered in case of: - damage to the gas pipeline in the boiler room (gas contamination); - damage to the external gas pipeline to the boiler room; - destruction of the boiler; - spontaneous increase or decrease in pressure in the boiler room control cabinet; - an increase in the water pressure in the heating system above the permissible value; - a rupture of the heating main. 6.2. If the boiler works in emergency mode and the emergency automatics do not work, it is necessary to turn off the emergency switch of the boiler room.I approve:
Chief Engineer
______________________
________________________
___________________
Manufacturing instruction
for boiler room service personnel
gas hot water boilerVitoplex 100
General Provisions
1.1. Persons at least 18 years of age who have undergone special training, a medical commission, and have a certificate for the right to service boilers are allowed to service a hot water boiler.
1.2. Re-check boiler room personnel is carried out at least once every 12 months.
1.3. The boiler operator must:
To be re-instructed on occupational safety at the workplace at least every three months;
Pass a knowledge test on the rules for the design and safe operation of steam and hot water boilers, steam and hot water pipelines.
Undergo a medical examination;
Perform only the work that is included in his duties;
1.4. The operator must know:
Rules for the construction and safe operation of steam and
hot water boilers;
Installation of internal and external gas pipelines of the boiler room, auxiliary equipment, alarm systems and control automation;
The action on a person of hazardous and harmful factors arising during work;
Requirements for industrial sanitation, electrical safety, fire safety;
Internal labor regulations;
Requirements of this manual;
Appointment of personal protective equipment;
To be able to provide first aid in case of an accident.
1.5. During work, the operator may be exposed to the following hazardous production factors:
High pressure and temperature of heating surfaces;
High voltage in the electrical network;
Increased levels of noise and vibration;
1.6. The boiler room operator must use the following PPE:
Suit "Mechanizer-L" or Overalls for protection from general industrial pollution and mechanical stress;
Yuft boots with oil and petrol resistant soles;
Polymer coated gloves;
Protective goggles;
Anti-noise headphones or earbuds;
Jacket with insulated soles;
Warm yuft boots with oil and frost-resistant soles.
1.7. Upon entering on duty, the personnel must familiarize themselves with the entries in the log, check the serviceability of the equipment, the serviceability of the lighting and the telephone.
1.8. After accepting the shift, the operator must check the readings of the pressure gauge 9 (located on the gas pipeline in front of the burner), the readings must correspond to 18-21 kPa.
1.9. The acceptance and delivery of duty should be made out by the operator by an entry in a shift log indicating the results of checking the boilers and related equipment (pressure gauges, safety valves, automation equipment). In the shift log at 9.00, the operator must record the readings of manometers and thermometers of the supply and return pipelines, a manometer and a thermometer on the boiler, take readings of a heat and gas meter, and water consumption.
1.10. For unauthorized persons, access to the boiler room is permitted by the manager.
1.11. The boiler room, boilers and all equipment, passages must be kept in good condition and properly clean.
1.12. Doors for exiting the boiler room should easily open outward.
1.14. It is not allowed to accept and hand over the shift during the liquidation of the accident.
Gas preparation and start-up
Check the water filling of the boiler up to an operating pressure of 2.5 bar.
Check the condition of the shut-off valves in the supply and return pipelines; it must be in the open position.
Check the performance of the mains pump No. 2
Check the presence of gas in the ShRP at the outlet, the readings on the pressure gauge 9 should correspond to 21 kPa
Open smoothly ball valve on the gas pipeline after the ShRP (at the entrance to the boiler room).
Open the ball valve No. 4 at the lowering and after the counter No. 7
Purge the gas line (ball valve no. 10 must be open) for 10 minutes.
Close the purge plug (no. 10 ball valve).
Make sure that there is no gas leakage from gas pipelines, gas equipment and fittings by soaping them.
If there are no leaks, open ball valve no. 12 (in front of the burner).
When leaks are found close valves no. 7 and no. 4, open the purge plug (ball valve no. 10) and make a phone call:
89217100582 - Chief Engineer (Responsible for Gas Facilities of DGS) A.G. Efimov
2. 89210084628 - boiler room foreman (responsible for the operation of the boiler room) A.Ananiev;
3.96-00-24, 96-14-31 96-14-81 - repair service of LPM-Service LLC (internal gas pipeline and hot water boiler)
4.21-09-41 or 04 - emergency service JSC "Kaliningradgazifikatsiya" (ShRP, external gas pipeline)
The boiler burner starts up automatically.
Switch on the mains switch on the Vitotronic 100 and 333
The boiler operates in automatic mode, set during commissioning
Boiler operation
3.1. While on duty, the boiler room personnel must monitor the health of the boiler and all boiler room equipment. Record in a removable log the temperature and pressure readings on the boiler, as well as the pressure and temperature at the supply and return of the heating network. Malfunctions revealed during the operation of the equipment should be recorded in a shift log. Personnel must take remedial action. If the malfunction cannot be eliminated on our own, then it is necessary to inform the boiler room master by phone. 89062305265 or 47333 or the person responsible for the gas facilities of the boiler house, tel. 89217100582.
4. Emergency stop of the boiler
4.1. At emergency stop boiler you need:
4.1.1. Switch off the boiler mains switch E on the Vitotronic 100
4.1.2. Switch off the boiler mains switch G at the Vitotronic 333
4.1.3. Turn off the burner on the switch No. 1
4.1.4. Shut off the gas supply to the boiler room, open the purge plug (Close the cocks on the burners and the gas pipeline)
4.1.5. Report the accident to the boiler room master by phone 89062305265 or 47333
Stopping the boiler
5.1. The stoppage of the gas hot water boiler is carried out by the master of the boiler room.
Final provisions:
7.1. The management of the enterprise should not give instructions to personnel that contradict the instructions and may lead to an accident or accident.
7.2. Workers are liable for violation of instructions related to the work they perform in the manner prescribed by the internal labor regulations and in accordance with the criminal code of R.F.
The instructions were drawn up by: __________ boiler room master
Agreed by: Engineer O.T. __________
Poroshenko Petr Alekseevich
Premonition of the Apocalypse: World War III in the predictions of analysts and the Holy Fathers
Hereditary prisoner petr poroshenko-waltsman