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| 个人信息 |
| 姓 名： |
K译员 [编号]:3136 |
性 别： |
男 |
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| 擅长专业： |
机械、贸易、文学、工程等 |
出生年月： |
1976/3/1 |
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| 民 族： |
汉族 |
所在地区： |
山东 青岛 |
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| 文化程度： |
大专 |
所学专业： |
内燃机车 |
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| 毕业时间： |
1997 |
毕业学校： |
济南铁道技术学院 |
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| 第一外语： |
英语 |
等级水平： |
高级 |
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|
| 口译等级： |
高级 |
工作经历： |
14 年 |
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| 翻译库信息 |
| 可翻译语种： |
英语 |
|
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| 目前所在地： |
山东 青岛 |
| 可提供服务类型： |
笔译、口译、家教 |
| 每周可提供服务时间： |
周一 至 周六 晚间；周日全天。 |
| 证书信息 |
| 证书名称： |
TOEIC |
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| 获证时间： |
2005/11/1 |
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| 获得分数： |
850 |
|
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| 工作经历 |
| 工作时期： |
2009/8/1--2011/11/1 |
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| 公司名称： |
WinBAIntlTradeInc. |
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| 公司性质： |
外商独资 |
| 所属行业： |
采购/贸易 |
| 所在部门： |
外贸部 |
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| 职位： |
主管 |
| 自我评价： |
认真、热情、悟性、责任、钻研、诚信 |
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|
| 笔译案例信息 |
| 案例标题： |
卧式水火管锅炉 |
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| 原文： |
卧式水火管锅炉
安装使用说明书
文件编号TDGWJ010
编写：______________
校对：______________
审核：______________
批准：______________
XXX工业有限公司
目 录
一、 结构简介 1
二、 性能特点 1
三、主要规格 3
四、出厂简况 4
五、安装前的准备工作 4
六、锅炉本体的安装 5
七、引风机、电线和开关的接装 5
八、烟囱的安装 6
九、鼓风机的安装 6
十、 燃料投放装置的安装（DZG2-BMF（AⅡ)） 6
十一、节能器的安装 7
十二、除尘器和烟气管道的安装 7
十三、管道阀门仪表的安装 7
十四、水压试验 8
十五、初次升火前的检查 9
十六、煮炉 9
十七、升火 10
十八、调整安全阀 11
十九、供汽 11
二十、正常运行 12
二十一、排污 15
二十二、停炉 16
二十三、维护保养 17
二十四、受压元件的检验和水压试验 19
说 明 21
一、 结构简介
该系列锅炉是一种卧式三回程水火管混合式锅炉，在锅筒内布置二束火管，炉膛左右二侧装有密集水墙管。采用蜂窝式大块统一的炉排，机械或手工投放燃料（二吨配有燃料投放装置），配有鼓风机，引风机和除尘器。
燃料在炉排上燃烧后，高温烟气经过矮墙到燃烬室，由燃烬室向上通过烟室进入第一管束到前烟箱，再由前烟箱折回第二管束到后烟室，到达尾部的节能器，经过除尘器然后由引风机抽引通过烟囱排出。
二、 性能特点
锅炉有下列优点：
1. 结构紧凑，体积小，安装使用方便。
2. 整装出厂，到使用现场后，安装阀门，管道及水电等即可运行。
3. 安装移动方便，节省大量的基建投资。
4. 燃料适应性广，生物质燃料（可掺煤燃烧）。
三、主要规格
项目名称 单位 锅 炉 型 号
DZG0.5-0.7-BMF(AⅡ) DZG1-0.7-BMF(AⅡ) DZG2-0.7-BMF(AⅡ) DZG2-1.0-BMF(AⅡ)
额定蒸发量 t/h 0.5 1 2 2
额定蒸汽压力 MPa 0.7 0.7 0.7 1.0
额定蒸汽温度 ℃ 170.4（饱和） 170.4（饱和） 170.4（饱和） 184（饱和）
给水温度 ℃ 20 20 20 20
受热总面积 m2 18.8 31.24 66.17 66.17
燃烧方式 层燃加室燃 层燃加室燃 层燃加室燃 层燃加室燃
炉排有效面积 m2 1.14 1.37 2.68 2.68
热效率 ％ ～77 ～77 ～77 ～77
烟囱 mm φ360×25000 φ360×25000 φ400×25000 φ400×25000
适应燃料 生物质燃料（可掺煤） 生物质燃料（可掺煤） 生物质燃料（可掺煤） 生物质燃料（可掺煤）
运输尺寸 m 3.2×2.1×2.5 4.0×2.1×2.7 4.3×2.3×3.1 4.3×2.3×3.1
锅炉主体重量 t 7.23 8.79 12.8 13.1
水容积 m3 1.6 2.7 4.2 4.2
注水器 型号 Zh24W-2-7 Zh24W-2-7 Zh24W-2-7 Zh24W-2-7
通径 32 32 40 40
旋涡泵 型号 配射水器 3/4W1.44-10 1W2.4-10.5 1W2.5-12
电机 Y90S-2,1.5KW Y100L-2，3KW Y100L-2，3KW
鼓风机 型号 4-72-11，3.2A
(右0°) 4-72-11，3.2A
(右0°) 4-72-11，3.6A
(右0°) 4-72-11，3.6A
(右0°)
电机 Y90L-2，2.2KW Y90L-2，2.2KW Y100L-2，3KW Y100L-2，3KW
引风机 型号 Y5-47N04C
（右180°） Y5-47N05C
（右180°） Y5-47 №5C
（右180°） Y5-47 №5C
(右180°)
电机 Y100L-2,3KW Y100L-2,3KW Y132S2-2,
7.5KW Y132S2-2,
7.5KW
除尘器 XZZ-450 XZZ-550 XZZ-750 XZZ-750
（表一）
四、出厂简况
锅炉出厂时，一般分件包装情况如下：
1. 锅炉本体，包括底座、清灰孔、检查门、保温层、炉门、前后烟箱和炉墙等的组合件。
2. 鼓风机，包括电动机、鼓风机座。
3. 节能器（包括前后接头），软水箱与管道循环泵用户自行解决。
4. 引风机，包括电动机、后烟箱联接管和电动机座，除尘器与引风机的联接管（软接管用户自行解决）。
5. 烟囱和司炉工具。
6. 给水设备和部分管道零件。
7. 平台扶梯的栏杆。
8. 仪表阀门零件和备品备件。
9. 除尘器。
10.燃料投放装置（DZG2-BMF才有配置），包括微型螺旋喂料机、鼓风机和接料管，风管用户自行解决。
11技术文件：锅炉安装图纸及受压元件强度计算书各二份；安装使用说明书二份；产品质量证明书一份；能耗测试报告复印件一份。
安 装 说 明
五、安装前的准备工作
1. 锅炉安装前，使用单位必须将锅炉平面布置图及标明与有关建筑物距离的图纸，锅炉总图和申请安装书（有安装单位印章），送交当地锅炉压力容器安全监察机构审查同意。安装单位必须是经锅炉压力容器安全监察部门审查批准的锅炉专业安装单位。
2. 使用单位应组织有关人员学习《蒸汽锅炉安全技术监察规程》，熟悉锅炉图样，安装使用说明书等资料，以了解锅炉的结构、性能，掌握锅炉安装和运行操作要求。
3. 按制造厂的出厂清单，清点有关的技术资料，锅炉的零配件，根据图样复核设备的质量或在运输途中是否有损坏、丢失、变形等情况。发现有缺陷应及时作记录，并报制造厂或进行处理。
4. 锅炉的地基应按锅炉设计单位的地基图施工（锅炉厂的地基图可作参考）安装前应对地基的浇灌质量、强度、标高、表面的不平度、外形尺寸等进行检查，如有缺陷应及时修正。
六、锅炉本体的安装
锅炉本体搬运到安装地点后，应先校核锅炉中心线和轮廓线，是否与地基上划出的锅炉中心线和轮廓线相符合，然后检查底座和地基的接触是否良好，如有空隙处应加垫铁。
注：DZG型锅炉底座的底面系一斜面，当锅炉平放在水平的地基上时，锅筒已有一定斜度，锅筒轴向中心线前端应高出后端约25毫米以利排污。
七、引风机、电线和开关的接装
锅炉本体安装完毕后，将引风机、电动机和引风机接管按图纸要求装配，装妥后检查有无轧住或漏气缺点，然后接装电线和开关（由使用单位自备），最后接通电源试车，检查电动机转向是否正确，有无磨擦振动现象，电动机温度是否正常。为了加强引风机轴承的散热，在引风机轴上装有风叶轮，风叶轮的螺栓，不可松动，应注意拧紧。为了保证引风机轴承在高温下的润滑作用，应注意定时间在轴承座内加油，以后每周加油一次，引风机冷态试运转以及冷炉起动时，应关闭烟气调节门，但运转时间最多不超过五分钟，因为在冷态情况下电机负荷会几倍增加，对电动机有烧坏的可能。
八、烟囱的安装
锅炉的烟囱配有五节，全长25米。烟囱的安装要求垂直，高度一般不限，但要求比周围建筑物高3米，或按环保部门的有关标准确定。
九、鼓风机的安装
先将鼓风机底座安装于本体底座右侧，再安装鼓风机。安装后检查部件是否正确，连接部分是否牢固严密，调风门启闭是否灵活，然后接装电线和开关（由使用单位自备）接通电源试车。
检查电动机转向是否正确，有无磨擦或振动现象，电动机和轴承温度是否正常，一般升温不高于自然空气温度40度。
十、燃料投放装置的安装（DZG2-BMF(AⅡ)）
先将接料管与锅炉主体炉面板上的进料管座相接，同时将WLS型螺旋喂料机装在机架上，妥当后将螺旋喂料机的出料口插入接料管，然后调整机架的调整螺栓直至喂料机不顶到接料管内壁，接着安装鼓风机和风管，鼓风机的安放位置可以离开炉前以免影响炉前的操作,鼓风机应以膨胀螺栓紧固在地面上，接通电源即可试车，如果喂料机和接料管连接处漏气严重影响投料，可在接料管内放一橡胶O型圈（规格140×5.3）来增强密封。
十一、节能器的安装
节能器的前后接头分别与锅炉的引凤接管、烟风管道相接，各个连接处应加橡胶石棉垫片以确保密封。节能器的进出水接口应与软水箱相连接，并在管道中加装循环水泵，软水箱的安放应根据锅炉房的实际情况尽量减少与节能器的距离，管路安装后不能有滴漏现象；节能器的排污口应装截止阀，排污水由管道排至地沟。
十二、除尘器和烟气管道的安装
1. 配用除尘器：DZG2-1.0-BMF（AⅡ)， 配用XZZ-D750型
DZG2-0.7-BMF（AⅡ)， 配用XZZ-D750型
DZG1-0.7-BMF（AⅡ)， 配用XZZ-D550型
DZG0.5-0.7-BMF（AⅡ)，配用XZZ-D450型
2. XZZ型除尘器应装于锅炉与引风机之间，参阅XZZ型除尘器的安装使用说明书。
3. 各段接管和弯管两端连接处必须填加垫片，确保密封良好，各段管道应加保温材料包裹以确保其表面温度不超过环境温度25℃。
4. 烟风管与除尘器、引风机和烟囱的中心距离，用户可根据场地安排情况自行确定。
十三、管道阀门仪表的安装
1.按照管道、阀门、仪表图纸进行安装。配电动泵的、将电动泵固定在适当的位置，并应先浇制好基础，接通电源后试运转。
2.安全阀应铅直安装。同时应装设排汽管，直通室外安全地点，并有足够的截面积，保证排汽畅通，排汽管底部应装有接到安全地点的疏水管，在排汽管和疏水管上都不允许装设阀门。
3.主汽阀以外的蒸汽管引出的直段应大于0.5米，蒸汽管道至少要有一个弯头，或伸缩管，管道外壁应予保温。
4.排污管接至排污箱或其他安全地点，管道应固定，防止排污时移位或发生反击烫伤等事故。
5.水位表下部泄水管必须接入安全地点，水位表旋塞阀旋转要灵活，不得漏水，水位表处必须安装照明灯具，便于观察。
6.安装压力表时，应使刻度盘面垂直，压力表面上应画出红线，以示锅炉额定蒸汽压力。
十四、水压试验
1. 锅炉的水压试验必须在锅炉压力容器安全监察机构对锅炉的安装质量和安装验收资料等进行检查，并认为合格后方可进行。锅炉的水压试验压力按《蒸汽锅炉安全技术监察规程》第207条的规定。（P<0.8MPa，试验压力为1.5P,但不小于0.2MPa；0.8≤P≤1.6MPa，试验压力：P+0.4MPa）
2. 在水压试验前，应将试压部分内部的污物清理干净，检查所有人孔、手孔和阀门的封闭情况，试压的压力表管道是否畅通等。
3. 水压试验的环境温度应高于5℃，否则应考虑采取防冻措施。灌入锅炉的水温应比室温高一些，以免水温低时使金属表面结露而难以检查渗漏处。
当锅炉充满水后，关闭放空气阀，并初步检查有无漏水，然后用水压泵缓慢升压，当升压至0.29-0.39MPa时，应进行一次检查，必要时可拧紧人孔、手孔和法兰等螺栓（但超过0.39MPa时严禁再拧紧所有的螺栓）。当水压继续升至工作压力时，应暂停升压，检查各部分有无漏水，然后再升至规定的试验压力，保持20分钟，然后回降至工作压力再进行检查。若符合下列情况时：
1.在受压元件金属壁和焊缝上没有水珠和水雾；
2.当降到工作压力后胀口处不滴水珠；
3.水压试验后，没有发现残余变形。
则认为水压试验合格，若发生异常则应由有关部门处理。
使 用 说 明
十五、初次升火前的检查
锅炉初升火前，必须详细检查锅炉的各零部件，检查项目如下：
1. 人孔、手孔是否严密，附属零件装置是否齐全。
2. 炉排、炉墙是否正常，烟箱是否严密。
3. 烟气道是否正确畅通，各段接管和弯管的连接处是否密封。
4. 鼓风机、引风机、给水设备试运转是否正常。
5. 蒸汽管路、给水管路、排污管路装置是否完整。
6. 应检查除尘器的排灰阀是否密封。
十六、煮炉
新锅炉在投入运行前，必须进行烘炉和煮炉。烘炉的目的在于使砖墙缓缓干燥，避免损裂，煮炉的目的是为了清除锅炉内部的污物、铁锈和油污等。
煮炉的药物为每吨锅水中加入磷酸三钠2－3公斤（或碳酸钠3－3.5公斤）和氢氧化钠2－4公斤，但不得将固体药物直接加入锅筒内，应事先在容器中溶化后，从锅筒的上部的人孔或安全阀座法兰孔中注入，煮炉升压时应将空气阀开启，待蒸汽冒出时即可关闭。当锅炉内产生压力时，可冲洗水位表和压力表。当压力升到0.2－0.3MPa时，对锅炉范围内的法兰、螺栓进行一次检查、紧固。并保持此压力10－12小时，煮炉后期应使蒸汽压力保持在工作压力75％左右，时间为10－12小时，煮炉完毕，应让锅炉自然冷却，然后排出炉水，并及时用清水清洗干净。
十七、升火
升火的步骤如下：
1. 关闭排污阀，开启一只安全阀，让炉内空气可以排出。
2. 将已处理的水注入锅炉内，水温一般不高于40℃，让炉内水位升至水位表最低水位处，关闭给水阀门，待炉内水位稳定后观察水位是否降低。
3. 用木柴等引燃物放置在炉排上，点火前先开引风机（应调小烟气调节门）。待引燃物燃烧旺盛后，开始添加燃料，这时可开鼓风机，并调节引风机，使燃烧正常。
4. 升火时温度不可增加太快，避免各部分受热不均产生过大应力，影响锅炉寿命。
5. 升火后应随时注意炉内水位，因为加热后水位线会上升，如超过最高水位时可进行排污。
6. 当开启的一只安全阀内冒出蒸汽时，即应关闭安全阀，并冲洗压力表弯管和水位表，当汽压升到0.2－0.3MPa时，检查人孔及手孔盖是否渗漏，如有渗漏应拧紧人孔及手孔盖螺栓，同时检查排污阀是否严密无漏。
7.当锅内汽压逐步升高时。应注意锅炉各部件有无特殊响声，如有应立即检查，必要时立即停炉检查。
8.锅炉初次升火，从冷炉到汽压升至工作压力，需要的时间不少于4小时，以后升火，从冷炉起不少于1小时，从热炉起不少于半小时。
十八、调整安全阀
安全阀应在初次升火时进行调整：
按照《蒸汽锅炉安全技术监察规程》（96）第143条表7－2规定的压力进行调整（表二）
表二
额定蒸汽压力
MPa 安全阀的始启压力
≤0.8 工作压力＋0.03MPa
工作压力＋0.05MPa
0.8＜P≤5.9 1.04倍工作压力
1.06倍工作压力
1. 安全阀调整方法：
拆去开口销，除去顶盖，拧松六角锁紧螺母，然后拧动调节螺杆，使弹簧放松或压紧，来达到安全阀要求的排汽压力。调整后，拧紧锁紧螺母，再将其余零件装妥。
2. 安全阀的开启压力：
当锅炉的额定工作压力为0.7MPa，安全阀的开启压力，一只调整到0.73MPa，另一只调整到0.75MPa；当锅炉的额定工作压力为1.0MPa，安全阀的开启压力，一只调整到1.04MPa，另一只调整到1.06MPa。
十九、供汽
当锅内汽压接近工作压力，准备向外供汽时火势宜缓，供汽前炉内水位线不宜超过正常水位。
供汽时应将主汽阀稍微开启，让微量蒸汽进行暖管，同时将管路上的泄水阀开启，泄去冷凝水，暖管时间根据管道的长度、直径、蒸汽温度等情况决定，一般不少于半小时，暖管时应注意管道的膨胀和管道支架的情况，如发现有不正常时应停止暖管，并消除故障和缺陷。待管已热，管路上冷凝水逐步减少后，方可全开主汽阀，开启时宜缓慢进行，同时注意锅炉各部是否有特殊响声，如有应即检查，必要时停炉检查。主汽阀完全开启后，应将主汽阀手轮退还半圈，以防热胀后不能转动。锅炉供汽后，再一次校验附属零件、阀门、仪表有无漏水漏汽等情况，工作是否正常。
二十、正常运行
正常运行时要求做到保持炉内水位正常，蒸汽压力稳定，保持锅炉房的整洁，做好交接班工作。
1. 给水要求：
锅炉给水需要进行处理，给水总硬度≤0.03毫克当量/升
2. 炉内水位
炉内水位应保持在正常水位±50毫米的范围内，不得高于最高或低于最低水位，水位表内的水位一般有微微晃动现象，如水面静止不动，则水位表内可能有堵塞情况，应即进行冲洗。
3. 水位表：
每班须试水位表至少一次，目的在于使水位表玻璃管保持清洁，确保水位清晰正常可见。如发现玻璃管垫圈漏水、漏气时应上紧填料。如玻璃模糊不清，或水位线看不明确，虽经吹洗仍没有效果时，应予更换。每台锅炉装有二具水位表，若其中一具发现损坏，应即进行修理，如二具同时损坏，应立即临时停炉，直至有一具水位表恢复正常后方可继续运行。
4. 给水设备
（1） 每班至少应对每台给水设备启动一次，检查设备是否运行正常，如有故障应即进行修理。
（2） 给水设备有注水器（用于小容量锅炉），旋涡泵或蒸汽往复泵（注水器二台中一台为备用平时只用其中一台）。
5. 蒸汽压力：
尽可能保持工作压力和稳定，汽压不得超过额定蒸汽压力。
6. 压力表：
压力表弯管每班应冲洗一次，检视压力表是否正常，如发现压力表损坏，应即停炉修理或更换。为了保证压力表正确性，每年应校验一次。
7. 安全阀：
注意安全阀的作用是否正常，为了防止安全阀的阀芯和阀座粘住，应定期拉动安全阀提升手柄，作排汽试验，每隔2－4星期应升高汽压一次，作排汽试验以校验安全阀是否能正常工作。
8. 排污阀：
定期排污（参阅第十九“排污”）。
9. 操作的一般要求：
锅炉运行时要求汽压稳定，而汽压稳定又和负荷、给水量、燃料量的波动和燃烧稳定有关，为了达到燃烧稳定，每个司炉工必须在实际操作中不断总结，掌握燃烧的规律，一般要求勤看火、勤看水、勤联系、勤分析、勤调整，投料要勤要快，每次投料量要少而且均匀。如燃料层厚薄不均，薄的地方先燃烬，这样就有大量空气进入炉膛，而厚的地方由于通风差空气不足，燃烧就慢，甚至还没有燃烧。根据一般情况炉膛温度高燃烧比较稳定，为了达到炉膛温度高，必须供给适当风量，注意调整引风量及鼓风量，保持炉膛负压在4－2毫米水柱，不使火焰和烟从炉门口喷出，避免烧坏炉门及炉面板，炉膛负压过高，从炉门口吸入过量冷空气，降低炉膛温度使燃烧不稳定，锅炉效率下降。为了在负荷变动时，汽压能达到稳定，必须掌握每天24小时内负荷变动的规律，应预先准备。例如：负荷增加时，汽压会降低，同时水位也会降低，因此在负荷增加前，应预先添燃料和进水。负荷减少时，气压会上升，因此在负荷减少前，应减弱通风，减少添燃料量，降低水位，以便在负荷减少后汽压上升时进水。负荷增加时，最好缩短二次添燃料相隔的时间，不要增加每次的添燃料量，负荷减少时，可延长二次添燃料相隔的时间，在以上二种情况下，都要适当调整引风和鼓风量，负荷增加时先调整引风，再增加鼓风，负荷减少时先减少鼓风，后调整引风，并随时注意节能器后安装的排烟温度表应在170℃以下，否则先检查循环水泵是否正常工作，若无异常则要清刷锅炉烟管及对节能器进行清灰，若循环水泵损坏则应先更换后才能继续正常运行。
10. 清炉：
运行时，炉排上的灰渣逐渐增多，影响通风，这时就需清炉。清炉工作最好选择在低负荷时进行。清炉前，应使炉内水位高出正常水位，以防清炉后燃烧未正常时，蒸汽供不应求，水位下降。清炉时不要进水，避免汽压下降，清炉动作要快，防止冷风大量进入炉膛。
11. 燃烬室清灰：
矮墙后两侧通道及燃烬室的积灰应经常清除。
12. 锅炉房清洁：
（1） 锅炉房应保持整洁，锅炉房里不应堆放其他杂物。
（2） 注意室内照明，对水位表，压力表尤应有良好照明，使司炉看得清楚，经常巡视锅炉周围，检查锅炉及附属零件是否正常。
13. 交接班
为了保证每班能安全经济运行，司炉在交接班时，要切实做好以下工作：
（1） 接班的司炉工要在规定时间前到达锅炉房，做好接班准备。
（2） 交班的司炉工要做到：
a. 锅炉蒸汽压力和水位正常。
b. 锅炉安全附件灵敏可靠。
c. 锅炉本体没有异状。
d. 清炉完毕燃烧正常。
e. 锅炉房整齐，清洁明亮。
（3） 交接班双方要做到交得彻底，接得认真，同时将交接中的情况和问题记入运行记录。
二十一、排污
一般给水内含有或多或少的矿物质，给水进入锅炉汽化后，矿物质留在炉内，浓缩到一定程度后，就在炉内沉淀下来。蒸发量越大，运行时间越长，沉淀物就越多。为了防止由于水垢、水渣沉积而引起锅炉损坏，必须保持每班排污一次。每次排污量，以降低水位25－50毫米范围内为适宜。
排污前应注意下列事项：
1. 如二台或三台以上锅炉使用一个总排污管路，排污时注意下列事项：
（1） 禁止二台锅炉同时排污。
（2） 如另一台锅炉正在检修，则排污前必须将检修中的锅炉与总排污管路隔断分开。
2. 排污应在低负荷，高水位时进行。
排污时具体操作如下：
每台锅炉上串装有二只排污阀，排污时应将第二只（离锅炉远的一只）全部开启，然后操纵第一只（近锅炉的一只）先微开一点，待管路预热后再缓慢开大，排污完毕后，先缓慢关小第一只，关闭后再关第二只，如此操作的目的，是用第一只控制排污，以保持第二只的严密性。在第一只渗漏时，仍可使用第二只控制排污。渗漏的排污阀可留待日后停炉时修理或调换。排污时如发现排污管内有冲击声，应即关小排污阀，直至冲击声消失后再缓慢开大，排污不宜连续长期进行，以免影响水循环。
二十二、停炉
锅炉停炉一般的有如下三种：
1.遇到休息或其他情况，短期内不使用蒸汽时应暂时停炉。
2.为了清洁，检查或修理，必须在炉水放完前应完全停炉。
3.遇到特殊情况为了安全起见必须紧急停炉。
（一） 暂时停炉：
暂时停炉是有计划的，因此停炉时注意安全和妥善维护设备外，还须做到节煤、节水。具体步骤如下：
1.停炉前，适当减少添燃料量，同时相应减弱通风。
2.炉排上的燃料在停止供汽前应尽量烧完。
3.锅炉冷却后水位要降低，因此停炉时水位宜高于正常水位。
4.停止供汽后应关断主汽阀及烟气调节门。
（二） 完全停炉
完全停炉应该是有计划的，一般运行1－3个月应停炉一次，停炉时注意安全和维护设备。停炉后，待炉水缓慢冷却到70℃以下时，才可把炉水放出，这时须先将安全阀抬起，让炉筒内部和大气相通。如须缩短炉水冷却时间，也可通过给水管道进入冷水，同时通过排污管道放出热水。但水位不应低于正常水位。炉水放完后，然后开启人孔、手孔，用清水冲洗水污。
（三） 紧急停炉：
锅炉运行中，遇到下列情况之一时，应即紧急停炉，并通知有关部门：
1. 水位低于最低水位，锅炉严重缺水。
2. 给水设备全部失效。
3. 所有水位表、压力表、安全阀，其中有一种全部失效。
4. 锅炉元件或墙损坏，严重威胁锅炉安全运行。
紧急停炉应着重防止事故扩大，具体步骤如下：
1. 先关鼓风机后关引风机。
2. 清除炉排上的燃料。
二十三、维护保养
(一)锅炉运行2－3星期，应进行检查一次。
1. 清除炉膛及燃烬室内的积灰检查炉排、炉墙、出灰装置、风机等工作是否正常。
2. 刷清烟管，清除前后烟箱内的积灰，检查烟箱是否严密，管端有无渗漏。
3. 阀门管道等处是否渗漏。
4. 应清除除尘器及节能器内部积灰。
(二)锅炉运行每隔3－6个月后，应停炉进行全面的检查维修。
除做上述各项工作外，尚须进行下列工作：
1. 清除锅炉水垢并用清水洗清。特别是两只集箱每半个月应打开手孔清除污垢一次，防止阻塞影响水循环。
2. 清除水墙管及锅筒着火面烟炱、燃料灰。
3. 对锅炉内外进行检查，例如锅炉焊缝，钢板内外有无腐蚀现象，若发现严重缺点应及早修理，若缺点并不严重，也可留待下次停炉时修理，如果发现有可疑之处，但并不影响安全生产时，应作出记录以便日后参考。
4. 检查完毕后可在着水面涂锅炉漆，以防腐蚀。
5. 对锅炉附属零件、设备进行检查，对引风机叶轮和外壳检查磨损程度，滚动轴承是否正常。
6. 必要时清除烟囱内积灰。
7. 必要时将炉墙及外面罩壳、保温层等卸下，以便彻底检查，如发现有严重损坏部分，必须修妥后方可继续使用，同时将检查结果及修理情况，记录在锅炉安全技术登记簿。
8. 将除尘器各接头拆除，清理内部污垢和积灰。
9. 打开节能器清灰门，用压缩空气吹除节能器内管壁的积灰。
（三）锅炉保温层罩壳（外包皮），每年至少要油漆一次。
（四）锅炉长期不用的保养方法：有干法和湿法二种。停炉一个月以上，应采用干保养法，停炉一个月以下可采取湿保养法：
1.干保养法：
锅炉停炉后放出炉水，将内部污垢彻底清除，洗冲干净。在炉膛内用微火烘干（注意不要大火），然后将10－33毫米块状的生石灰（CaCO3）装盘，置锅筒内，不使生石灰与金属接触，生石灰的重量，以锅炉容积每立方米8千克计算，按表三。
表三
锅炉型号 生石灰重量（千克）
DZG0.5-0.7-BMF(AⅡ)
DZG1-0.7-BMF(AⅡ)
DZG2-0.7-BMF(AⅡ)
DZG2-1.0-BMF(AⅡ) 12
24
40
40
然后将所有的人孔、手孔、管道阀门关闭。每三个月检查一次，如生石灰碎成粉状，须即更换。锅炉重新运行时应将生石灰和盘取出。
2.湿保养法：
锅炉停炉后，放出炉水将内部污垢彻底清除，冲洗干净。重新注入已处理的水至全满，将炉水加热到100℃，让水内的气体排出炉外，然后关闭所有阀门。气候寒冷的地方不宜采用湿保养法，以免炉水冻结，损坏锅炉。
二十四、受压元件的检验和水压试验
1. 根据《蒸汽锅炉安全技术监察规则》规定定期检验外，锅炉有下列情况之一时，也应对各受压元件进行内外检查和超压水压试验。
（1）新装、改装和移装后。
（2）停止运行一年以上，需要恢复运行时。
（3）受压元件经过重大修理后。
（4）根据锅炉运行情况，对设备状态有怀疑，必须进行检验时。
2. 检验前锅炉应完全停炉，并彻底清除内部水垢、外部烟炱、燃料灰，必要时须拆除炉墙外面罩壳和保温材料，检查重点如下：
（1）锅筒和焊缝、管孔等是否正常，有无渗漏情况。
（2）锅炉钢板内外有无腐蚀起槽变形等情况。
（3）火管有无弯曲，管端与管板连接处有无裂纹渗漏。
（4）水墙管有无弯曲变形腐蚀膨大等情况。
（5）给水管、排污管与锅筒连接处有无缺点。
3. 如腐蚀严重，做水压试验前还应做强度核算。
4. 试验压力按表四：
表四
名称 锅筒（锅壳）工作压力P 试验压力
锅炉本体 ＜0.8MPa 1.5P但不小于0.2MPa
锅炉本体 0.8－1.6MPa P＋0.4MPa
（1）水压试验应在周围气温高于5℃时运行，进水温度应保持在20－70℃左右，温度过低，易使锅炉外壁凝有露水，与发生渗水等不严密情况混淆不清，增加检查困难，温度过高则易引起不均匀胀缩，且外表温度太高促使水滴蒸发，使渗漏不易发现。
（2）水上满后，逐步升高压力至0.39MPa时，即进行一次严密性检查，必要时可再拧紧一次法兰、人孔盖和手孔盖螺栓。
（3）水压试验时，水压应缓慢地上升，当水压上升到工作压力时应暂停升压、检查有无漏水或异常现象。然后再升至试验压力保持二十分钟，若压力没有下降，即将压力降至工作压力进行检查，检查期间压力应保持不变。
（4）发现任何渗漏情况都应做好记录，以便降低到大气压时进行修理。
（5）严格禁止在压力超过0.39MPa时拧紧法兰螺栓。
（6）在水压试验时，应注意安全问题，避免在人多嘈杂环境中进行试验以免发生伤人事故。
5.水压试验符合下列情况，即认为合格。
（1）受压元件金属和焊缝上没有任何水珠和水雾。
（2）管口处在降到工作压力后不再漏水。
（3）水压试验后用肉眼观察没有发现残余变形。
说 明
1. 用户需向制造厂查询有关DZG型锅炉的技术资料时，应说明合同及总图号。
2. 查询锅炉制造质量时，应注明锅炉编号（在锅炉铭牌及管板人孔圈上）。
3. 使用单位的锅炉如要转移，应将全部技术文件同时移交。
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其中有表格部分，应客人要求没有翻译。
HORIZONTAL FIRE TUBE BOILER
INSTALLATION & OPERATING INSTRUCTION
DOCUMENT No.:TDGWJ010
Written by： ______________
Collated by： ______________
Checked by： ______________
Approved by：______________
XXX Boiler Industrial Co., Ltd
Contents
Structure Profile 1
Features 1
Main Specifications 3
Composition 4
Before You Start 4
Assembling the Boiler Body 5
Assembling the Induced Fan,Wire and Switch 5
Assembling the Chimney
Assembling the Blower 6
Assembling the Fuel-feeding Device（DZG2-BMF（AⅡ)） 6
Assembling the Energy Device 7
Assembling the Dust Collector and the Flue 7
Assembling the Pipes, Gage and Valves 7
Hydrostatic Test 8
Inspection before First Starting the Boiler 9
Boiling Up 9
Fire Up 10
Regulating the Relief Valves 11
Steam Supply 11
Normal Operation 12
Blowdown 15
Shutdown 16
Maintenance 17
Pressure Parts Examination and Hydrostatic Test 19
Explanation 21
Structure Profile
This is a horizontal three-stroke fire tube boiler. There are two bunches of fire tubes inside the boiler and the two water-wall-tubes at both right and left sides of the burner. Fuel-feeding automatically or manually (the boiler of 2T has fuel-feeding device). Honey-comb grate, blower, induced fan and dust collector are used in this boiler.
Fuel burned on the grate→High temperature flue-gas→Ember room→Smoke box→First pipe-bundle→Front smoke box→Second pipe-bundle→Rear smoke box→Energy device→Dust collector→Induced fan→Chimney→Atmosphere
Features:
1. Compact construction，small in size，easy for both installation and operation
2. Self-contained boiler，after assembling the valves, pipes, water and electric power supply, it can run, normally.
3. It is easy for installation and movement, saving plenty of investment in capital.
4. Many kinds of fuel can be used, including biofuel(coal can be mixed in)
三、主要规格
项目名称 单位 锅 炉 型 号
DZG0.5-0.7-BMF(AⅡ) DZG1-0.7-BMF(AⅡ) DZG2-0.7-BMF(AⅡ) DZG2-1.0-BMF(AⅡ)
额定蒸发量 t/h 0.5 1 2 2
额定蒸汽压力 MPa 0.7 0.7 0.7 1.0
额定蒸汽温度 ℃ 170.4（饱和） 170.4（饱和） 170.4（饱和） 184（饱和）
给水温度 ℃ 20 20 20 20
受热总面积 m2 18.8 31.24 66.17 66.17
燃烧方式 层燃加室燃 层燃加室燃 层燃加室燃 层燃加室燃
炉排有效面积 m2 1.14 1.37 2.68 2.68
热效率 ％ ～77 ～77 ～77 ～77
烟囱 mm φ360×25000 φ360×25000 φ400×25000 φ400×25000
适应燃料 生物质燃料（可掺煤） 生物质燃料（可掺煤） 生物质燃料（可掺煤） 生物质燃料（可掺煤）
运输尺寸 m 3.2×2.1×2.5 4.0×2.1×2.7 4.3×2.3×3.1 4.3×2.3×3.1
锅炉主体重量 t 7.23 8.79 12.8 13.1
水容积 m3 1.6 2.7 4.2 4.2
注水器 型号 Zh24W-2-7 Zh24W-2-7 Zh24W-2-7 Zh24W-2-7
通径 32 32 40 40
旋涡泵 型号 配射水器 3/4W1.44-10 1W2.4-10.5 1W2.5-12
电机 Y90S-2,1.5KW Y100L-2，3KW Y100L-2，3KW
鼓风机 型号 4-72-11，3.2A
(右0°) 4-72-11，3.2A
(右0°) 4-72-11，3.6A
(右0°) 4-72-11，3.6A
(右0°)
电机 Y90L-2，2.2KW Y90L-2，2.2KW Y100L-2，3KW Y100L-2，3KW
引风机 型号 Y5-47N04C
（右180°） Y5-47N05C
（右180°） Y5-47 №5C
（右180°） Y5-47 №5C
(右180°)
电机 Y100L-2,3KW Y100L-2,3KW Y132S2-2,
7.5KW Y132S2-2,
7.5KW
除尘器 XZZ-450 XZZ-550 XZZ-750 XZZ-750
（表一）
Compositions:
1. Boiler body, including base, cleaning door, inspection door, insulation layer, boiler door, front & rear smoke box, and furnace wall.
2. Blower, including electromotor and blower base
3. Energy device, including front & rear connectors, but excluding soft water tank and circulation pump
4. Induced fan, including electromotor, connecting tube for rear smoke box, electromotor base and connecting tube between dust collector and induced fan, but excluding hose
5. Chimney and stoking tools
6. Water supply facilities and some fittings
7. Handrail of Platform ladder
8. Gage valves and spare parts
9. Dust collector
10. Fuel-feeding device (only for DZG2-BMF), including mini screw feeder, blower and fuel-feeding tube, but excluding air tube
11．Technical document: boiler assembling drawing (2pcs), pressure parts strength calculation table (2pcs), installation and operation instruction (2pcs), quality certificate (1pc), energy consumption test report(1pc,copy)
Installation Instructions
Before You Start
1. Floor plan of boiler, drawing indicating distance between boiler and neighboring building, drawing of boiler and requisition of installation should be approved by the local Boiler and Pressure Vessel Safety Supervision Bureau. Installation must be performed by a qualified installer in accordance with all local and national codes.
2. Steam boiler safety technique supervision procedure, boiler drawing and this instruction must be read and followed carefully. They will save you valuable time in assembling boiler properly.
3. According to the components list, check all of the technical documents and components; according to the drawings, a careful inspection of all components should be made to detect possible shipping damage, lost or deformation. Record and direct all questions to your distributor.
4. The boiler should be installed on a level, flat, concrete floor or pad that is structurally sound and will support the weight of the boiler. DO NOT use any base other than the one specially designed.
Assembling the Boiler Body
The central line (CL) of the boiler must be accordance with CL of the base. There is no gap between the boiler-base and the concrete-base; to add some shim if there is gap.
Note: The boiler-base is an inclined plane which keeps the front end of the boiler 1’’higher than the rear end—blowing down is easy.
Assembling the Induced Fan, Wire and Switch
After boiler body being installed, assemble the induced fan, electromotor and adapter tube according to the drawings and check if they are properly assembled; assemble the wire and switch(provided by the servicing agency); plug in and test run, to check if the electromotor runs normally, especially its temperature. The fan blade assembled on the shaft of the induced fan can cool the bearing of the induced fan. The screws fixed the fan blade should be tightened properly. In order to keep the lubrication action under high temperature, the bearing pedestal should be oiled in, weekly afterwards. When the induced fan cold test running or cold starting, the flue gas governing valve should be shut down. The running time should not over 5 mins, otherwise, the electromotor may probably be damaged.
Assembling the Chimney
The chimney has 5 sections, 25meters in total. The chimney must be assembled vertically. The height of the chimney must be 3 meters higher than neighboring buildings or comply with the relative standard established by environmental protection division.
Assembling the Blower
Assemble the blower base on the right side of the boiler body, then assemble the blower on the base. Before assembling the wire and switch (provided by the servicing agency) and test running, you have to check relative components, sealing condition and air shutter.
The rotation direction of the electromotor must be correct; friction and vibration are not allowed. If the temperature of either the electromotor or the bearing is 40 °C higher than the air temperature, it is not allowed.
Assembling the Fuel-feeding Device（DZG2-BMF（AⅡ)）
The fuel-catching pipe and the feed pipe on the boiler body should be connected, meanwhile, the WLS screw feeder connected on its base, then connect the fuel catching pipe with the outlet of the screw feeder, the adjusting bolt need to be adjusted till that the feeder does not touch with the inside wall of the fuel-catching pipe. Next step, the blower and the air pipe need to be assembled. The blower should not be located right front of the furnace door, otherwise, it may give negative influence when servicing. The blower should be fastened on the ground with expansion bolt. If it is air-leaking between the fuel-catching pipe and feeder during test running, a rubber O-ring(140*5.3mm) can be put in between.
Assembling the Energy Device
The front joint of the energy device should be connected with the pipe connecting to the induced fan, and rear joint with the flue gas pipe; both of the jointing position should be sealed by asbestos pad. Both the water inlet and the water outlet of the energy device should be connected with the soft water tank; a circulating pump is needed in this pipe network. The soft water tank should be located as near as possible to the energy device. Any leakage is not allowed. The drain outlet of the energy device should be connected with a check valve and the sewage should be discharged to the trench.
Assembling the Dust Connector and the Flue
1. Type of dust connector：
DZG2-1.0-BMF（AⅡ)， adapting XZZ-D750
DZG2-0.7-BMF（AⅡ)， adapting XZZ-D750
DZG1-0.7-BMF（AⅡ)， adapting XZZ-D550
DZG0.5-0.7-BMF（AⅡ)，adapting XZZ-D450
2. The type of XZZ dust collector should be assembled between the boiler and the induced fan, please see the installation and operation instruction of XZZ dust collector for detail.
3. The gasket-seal should be put in between the end of the pipes which are connected together; also, the insulation layer should be packed around the pipes to avoid that its temperature will be 25℃ higher than the environment.
4. The distance between the flue, dust connector, induced fan and the chimney can be determined by the user.
Assembling the pipes, Gage and Valves
1. The pipes, gage and valves should be assembled according to their drawings. The electromotor should be located on a concrete base if there is an electromotor equipped. Test running is a must.
2. The safety valve should be assembled vertically. The exhaust steam pipe connected with the safety valve and the outdoor safe site should have adequate diameter. There is a drain pipe connected to the end of exhaust steam pipe (outdoor section). It is not allowed to assemble other valves on either exhaust steam pipe or drain pipe.
3. The direct section of the steam pipe connecting to the main steam valve should not be shorter than 0.5m. The steam pipe should have at least one elbow or extension pipe. The steam pipe should be wrapped with insulation layer.
4. The drain pipe should be connected to the blow-down tank or other safe site. Preventing displacement and scalding, the pipe should be fastened properly.
5. The water-shoot under the water gage must be connected to the safe site. The plug valve of the water gage should be turned freely, no leakage. Be convenient for monitoring, a light should be assembled near the water gage.
6. The panel of pressure gage should be kept vertically when assembled; the nominal steam pressure should be marked with red line.
Hydrostatic Test
1. After the quality of boiler-assembling and the assembling documents are checked and approved by the Boiler and Pressure Vessel Safety Supervision Bureau, then the boiler hydrostatic test can be performed. The test pressure should be 1.5P (P<0.8 MPa, no less than 0.2 MPa) or P+0.4 MPa (0.8≤P≤1.6MPa).
2. Before testing, all of the testing components should be cleaned up. The sealing of the manhole, handhole and valves should be checked, as well as the pipe network of the pressure gage.
3. The environmental temperature must be higher than 5℃ during testing. The temperature of the water poured into the boiler should higher than the environmental temperature;
Filling the boiler with water and bleeding any air off through air release valve, have a check to see if the boiler is leaked.
If no leakage start the pump and raise the pressure to 0.29-0.39MPa, have another check. Tighten the screws of manhole, handhole and flanges (Note: if the pressure is higher than 0.39MPa, it is forbidden to tighten the screws): When the pressure is as high as the working pressure, keep it and check if the boiler is leaked. At last, raise the pressure to the testing pressure; keep it for 20 mins, then reduce it to the working pressure and have the final check. If
1. There is no sweat and/or water mist on the compressed components and welding line;
2. When reduced to the working pressure, there is no sweat at the openings;
3. There is no residual deformation after pressure testing.
If above items are confirmed then the pressure test is passed; if not, failed.
Operating Instructions
Inspection before First Starting the boiler
Before first starting the boiler, all of the components below must be checked.
1. The sealing of both manhole and handhole, q’ty of accessories.
2. The grate and the furnace wall are in normal condition; the flue gas chamber is in good sealing condition.
3. The flue gas network has been assembled correctly. All of the joints are in good sealing condition.
4. Blower, induced fan and water supply facility work normally.
5. Steam pipe network, water supply network and blowdown network are completely assembled.
6. The ash valve of the dust collector has been shut down.
Boil up
Before servicing, the boiler must be roasted and boiled up.The purpose of roasting the boiler is to make the brick wall slowly drying, avoiding crack; also, the purpose of boiling up is to clean up the dirt, rust and oil stain inside the boiler.
The boiler should be boiled up by chemicals which should not be put in the boiler directly; on the contrary, they should previously be dissolved in a special tank and fill in through the manhole or the flange hole of the safety valve base. The recipe is 2-3kgs of triSodium Phosphate (or 3-3.5kgs of sodium carbonate) per 1000kgs of water.
When the pressure is raising, open the air valve; when it starts steaming, close the air valve.
When there is pressure in the boiler, the water level gage and pressure gage can be cleaned.
When the pressure is 0.2-0.3MPa, all of the flanges and screws of the boiler should be checked and re-tightened. After keeping the pressure (0.2-0.3MPa) for 10-12 hours, adjust the pressure as high as 75% working pressure and keep it for 10-12 hours.
After boiling up, let the boiler cool naturally. Drain the boiler and clean it by clear water immediately.
Fire Up
Processes of firing up:
1. Close the drain valve and open one safety valve, providing an access for the air to escape out of the boiler.
2. Fill the treated water in the boiler (water temperature is under 40℃). Close the water supply valve as soon as the water reaching the lowest section of the water level gage. After the water level is stable, keep watching carefully that if the water level is reducing.
3. Start the induced fan (to adjust the governing valve to a little discharge). Fire the wood of other tinder on the grate.
4. When firing up, the temperature should not be raised suddenly; otherwise, the components of the boiler will suffer different temperature and create over-stress which will give negative influence to the servicing life of the boiler.
5. After firing up, pay more attention to the water level—the water level may raise when heated. Drain the water as soon as the water going over the highest level.
6.As soon as the steam going out from the safety valve, close it; meanwhile, wash down the elbow pipe of the pressure gage and the water level gage. When the pressure is 0.2-0.3MPa, check the manhole and the handhole; tighten the screws if there is leakage. The sealing of the blow-down valve also need to be carefully checked.
7. As the pressure rising, carefully listen to the boiler, if any abnormal noise, check it. Stop the boiler if necessary.
8. Since it is the first time to fire up, from cool boiler to reaching the working pressure, it takes at least 4 hours. Afterwards, from cool boiler to reaching the working pressure, it takes only 1 hour; from warm boiler, half hour is enough.
Adjusting the Safety Valve
The safety valve should be adjusted according to figure 2 before first firing up.
Figure 2
nominal steam pressure
(MPa) opening up pressure of the safety valve
≤0.8 working pressure＋0.03MPa
working pressure＋0.05MPa
0.8＜P≤5.9 1.04*working pressure
1.06*working pressure
1. Adjusting Method:
Remove the split-pin and the cover→loosen the nut→rotate the adjusting spindle→adjusting the opening pressure of the valve→tighten the nut→assemble the cover and the cover
2. Adjusting the Opening Pressure
When the working pressure is 0.7MPa, the opening pressure of one safety valve should be 0.73MPa, the other should be 0.75MPa; When the working pressure is 1.0MPa, the opening pressure of one safety valve should be 1.04MPa, the other should be 1.06MPa;
Steam Supply
When the pressure inside the boiler is reaching the working pressure and going to supply the steam, the fire should be controlled stably and the water level should be under the normal level.
When first supplying the steam, slightly open the main valve. Little steam will go into warm the pipe network. Meanwhile, open the water escape valve, draining the condensation water. According to the length， diameter and steam temperature, the time of warming the pipe should not be less than 30mins. If there is any abnormality, stop warming the pipe and solve the problems. When the pipe is warmed and the condensation water is reducing, fully open the main valve, slowly. Carefully listen to the boiler, if any abnormal noise, check it. Stop the boiler if necessary.
Avoiding not to be rotated after being heated, the wheel of the main valve should be counter rotated for semi circle. After steam supplying, check the accessories, valves, gages.
Normal Service
When operating the boiler, the water level should be normal, the steam pressure should be stable, and the boiler room should be clean.
- Water feeding:
The water fed should be treated previously. Water hardness should be ≤0.03mg equivalent/L.
- Water level
The water level should be kept as normal water level ±50mm. If the water in the water gage keeps deadly still, the water gage may be jammed and need to be cleaned.
- Water level gage
The water level gage should be tested every shift and should be replaced if necessary. There are 2 water level gages on every boiler, if one of them is abnormal, repair it at once; if both of them are abnormal, stop the boiler and repair them at once.
Water supply facility
a. Start the water supply facility at least one time per shift, repair it if any faults.
b. Water supply facility includes refiller(specially for small volume boiler), vortex pump or steam reciprocating pump ( one of two refillers is as a spare part)
c. Steam Pressure
Keep the working pressure stable, over-nominal steam pressure is forbidden.
d. Pressure Gage
Clean up the elbow pipe of the pressure gage per shift. Stop the boiler and repair the pressure gage once damaged. The pressure gage should be verified yearly.
e. Safety valve
Avoiding that the valve insert is pasted with its base, the lifting handle should be lifted from time to time. Raise the pressure every 2-4 weeks and check if the valve can exhaust the steam when needed.
f. Blow-down Valve
Blow down on schedule.
g. requirements of operation
It is better to make the boiler run stably which will require the fireman to observe the water level and fire as frequently as possible. It is better to feed the fuel quickly and frequently, modicum and uniformity. Adjust both the induced fan and the blower to keep the negative pressure in the furnace at 4-2 mmHg. When the load is increasing, add fuel and water in advance; on the contrary, when the load is reducing, lower the fuel and water supplying as well as the air blowing. The temperature indicated by the thermometer connected to the rear side of the energy device should be controlled under 170℃.
h. Cleaning up the Boiler
When servicing, more and more boiler-ash will remain on the grate which should be removed on time. It would be better if the boiler cleaned at low load. Before cleaning, add water and keep the water level higher than normal level. During the cleaning process, water adding is not allowed. Avoiding that plenty of cool air coming into the furnace, the cleaning process should be performed quickly.
i. Cleaning the Ember Chamber
The dust in the ember chamber and at the back of the short wall should be cleaned up frequently.
j. Cleaning the Boiler Room
The boiler room should be kept clean; no ir-related things are allowed to be placed in this room.
The lighting system in the boiler room should be sound.
k. Shift Exchanging
The successor should arrive in the boiler room on time.
The fireman who will handover the shift should:
1. Make the steam pressure and water level normal.
2. Keep the safety facilities sensitive and reliable.
3. Keep the boiler body sound.
4. Clean up the boiler and keep the combustion sound
5. Clean up the boiler room.
The shift exchanging condition and problems met should be recorded.
Blow-down
Since the supplied water is not clear enough, blow-down MUST be performed per shift. It is better to reduce the water level from 25 to 50mm when blow-down every time.
Before blow-down:
If 2 or 3 boilers are using the same blow-down pipe network:
a. It is not allowed that 2 boilers blow down together;
b. If one of the boilers is being overhauling, its blow-down pipe network must be separated with the total network.
When blowing down, the load must be low and the water level must be high.
There are 2 blow-down valves series connected on the blow-down pipe network. When blowing down, fully open the second valve (far from the boiler) and slightly open the first one (near the boiler). Slowly open the first valve after the pipe warmed. When closing the valves, slowly close the first valve and then close the second one. If there is abnormal noise during blowing down, slowly close the valve till that the noise disappears, and then re-open the valve slowly. Continuous blowing down will bring negative influence to the water circulation.
Stop the Boiler
1. Normally stopping the boiler
2. Stopping the boiler for cleaning, examining or repairing
3. Urgently stopping the boiler
- Temporarily stopping the boiler
a. Before stopping the boiler, reduce volume of the fuel and the air
b. Burn up all of the fuel on the grate.
c. Make the water level higher than normal level before stopping the boiler
d. Close the main valve and flue gas governing valve after stopping the steam supply.
- Completely stopping the boiler
Every 1-3 months, the boiler should be stopped and examined. The water should not be drain out till the temperature is as low as 70℃. The safety valve should be firstly opened, making the inside boiler connect with the air. Draining out all of the water inside, open the manhole, handhole and wash the boiler by clear water.
- Urgently stopping the boiler
The boiler MUST be stopped if the below problem occurred:
a. The water level is too low;
b. Water supply facility is out of work
c. Any of the water level gage or pressure gage or safety valves is out of work
d. Boiler components or wall are damaged.
- If urgently stopping the valve, below processes must be performed:
a. Firstly shut off the blower, secondly the induced fan.
b. Remove the fuel on the grate.
Maintenance
Every 2-3 weeks, the boiler should be examined.
- Remove the dust in the furnace and ember chamber and check the grate, furnace wall and blower.
- Clean up the fire tube, the front and rear smoke box. Check the sealing of the smoke box and the pipes.
- Check the sealing of the valves and pipes.
- Clean up the dust collector and the energy device.
- Every 3-6 months, the boiler should be stopped and examined completely.
- Except for above works, the following works also should be performed:
a. Remove the water scale and wash the boiler by clear water.
b. Remove the smuts and fuel ash on the water-wall pipes and the side being touched by fire.
c. Examine the inside of the boiler, the welding line, for example. If some problems but not serious, record them as reference.
d. After examination, paint the side touching with water.
e. Examine the accessories, including the blade of the induced fan, the cover and the bearing.
f. Remove the dust in the chimney if necessary.
g. Demount the furnace wall, cover and insulation layer, and then examine them completely.
h. Demount all of the joints of the dust collector and clean up them.
i. Open the shoot door of the energy device, clean up it by the compressed air.
- The cover of the insulation layer should be painted yearly.
- If the boiler will not be used for over 1 month, it must be maintained by dry maintenance; if the boiler will be used within 1 month, it must be maintained by wet maintenance.
a. Dry maintenance：
After stopping the boiler, clean up it completely. Dry the furnace by a gentle fire (raging fire is not allowed) and then put the CaCO3 (diameter 10-33mm) on a plate which is put inside the boiler. (Note: the CaCO3 should not be touched with the metal). The weight of the CaCO3 depends on figure 3.
Figure 3
Boiler Model Weight of CaCO3（kgs）
DZG0.5-0.7-BMF(AⅡ)
DZG1-0.7-BMF(AⅡ)
DZG2-0.7-BMF(AⅡ)
DZG2-1.0-BMF(AⅡ) 12
24
40
40
All of the openings of the boiler, including manhole, handhole, and valves must be closed. Every 3 months, it should be examined. Replace the CaCO3 if it becomes powder.
b. Wet Maintenance
After stopping the boiler, clean up it completely. Make the boiler full of water and heat it to 100℃. The gas inside the water will escape, and then close the valves. If the temperature is below 0℃, wet maintenance is not allowed.
Pressure Parts Examination and Hydrostatic Test
Except for the examination required by steam boiler safety technique supervision regulation, the pressure parts examination and hydrostatic test should be performed if one of the below situation occurred.
- The boiler was new assembled, refit, or moved.
- The boiler will be re-started after being stopped servicing over one year.
- The pressure parts were heavy repaired.
- According to the servicing of the boiler, it was doubted that it may have some problems.
- Before the examination, the boiler must be completely stopped and cleaned; remove the cover and insulation layer if necessary. The below items MUST be examined:
a. Sealing of the boiler drum, welding line, and pipe holes
b.The corrosion and deformation of the steel plate
c.The deformation of the fire tube, the sealing between the ends of the pipes and the pipe plate
d.The deformation and corrosion of the water-wall pipes
e.The faults at the joints between water supply pipe/blow down pipe and the boiler drum
If seriously eroded, the strength should be re-calculated before the hydrostatic test.
The pressure of hydrostatic test should follow figure 4.
Figure 4
items working pressure of boiler drum(P) testing pressure
boiler body ＜0.8MPa 1.5P but no less than 0.2MPa
boiler body 0.8－1.6MPa P＋0.4MPa
When hydrostatic testing, the temperature in the boiler room must be over 5℃, the temperature of water supplied must be 20－70℃.
After the boiler is full of water, raise the pressure to 0.39MPa and have a examination of sealing. Tighten the screws of the flanges, manhole cover, and hanhole cover if necessary.
When hydrostatic testing, the pressure should be raised slowly. Examine sealing at the working pressure. And then rise the pressure the testing pressure and keep it for 20 mins. If the testing pressure has no reduction, reduce the pressure to the working pressure again and make the examination.
Recording the leakages will offer help for repairing.
If the pressure is over 0.39MPa, DO NOT tighten the screws of the flange.
When hydrostatic testing, pay attention to safety of persons.
The hydrostatic test is qualified if the below conditions are satisfied.
a. There is no sweat of water mist on the pressure parts and welding line.
b.There is no leakage at the mouth of pipe when the pressure is the working pressure.
c. There is no residual deformation left after the hydrostatic test.
Declaration
- If you inquiry about the technical documents from the factory, please provide the No. of both contract and assembling drawing.
- When inquiring about the quality, please provide the boiler serial No.
- When the boiler will be moved, all of the documents should be followed.
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