MINISTRY OF ENERGY AND ELECTRIFICATION OF THE USSR

MAIN SCIENTIFIC AND TECHNICAL DIRECTORATE OF ENERGY AND ELECTRIFICATION

STANDARD INSTRUCTIONS
OPERATIONAL INSTRUCTIONS
GAS-OIL WATER HEATING
BOILERS TYPE PTVM

TI 34-70-051-86

SOYUZTEKHENERGO

Moscow 1986

DEVELOPED by the Production Association for setting up, improving technology and operating power plants and networks "Soyuztechenergo"

PERFORMERS L.I. BONDARENKO, I.M. GIPSHMAN, O.A. EFROOIMSON, I.V. PETROV

APPROVED by the Main Scientific and Technical Directorate of Energy and Electrification on March 10, 1986.

Deputy Chief D.Ya. SHAMARAKOV

The validity period is set from 07/01/86 to 06/30/96.

Real Standard instructions sets general order, sequence and conditions for performing basic technological operations that ensure trouble-free and economical operation of PTVM type boilers.

The instructions are drawn up in relation to PTVM type boilers equipped with control and measuring equipment, technological protections, interlocks and alarms.

Based on the Standard Instructions and instructions from manufacturers, local instructions should be developed taking into account the characteristics of circuits and equipment, the type and characteristics of the fuel burned. When drawing up local instructions after reconstruction, individual provisions of the Model Instructions are allowed to be changed only on the basis of relevant experimental data after agreement with Soyuztekhenergo.

When operating boilers of the PTVM type, in addition to the Standard Instructions, it is necessary to be guided by the following regulatory and technical documents: Rules for the design and safe operation of steam and hot water boilers (M.: Nedra, 1982); Rules technical operation electrical stations and networks of the Russian Federation: RD 34.20.501-95 (M.: SPO ORGRES, 1996); Standards for the quality of make-up and network water in heating networks (Moscow: SPO Soyuztekhenergo, 1984); Standard instructions for operational chemical cleaning of hot water boilers (M.: SPO Soyuztekhenergo, 1980).

With the release of this Standard Instruction, the “Standard Instructions for the Operation of Gas-Oil Cogeneration Water Boilers of the PTVM Type” (Moscow: SPO Soyuztekhenergo, 1979) becomes invalid.

. STARTING THE BOILER

1.1. Preparatory operations

Light one of the pilot burners on gas according to paragraphs. , , ;

Close the valves on the fuel oil line in front of the burner;

Make sure the burner flame is burning steadily;

Close the burner safety spark plug valve;

Blow steam through the nozzle and remove it from the burner.

Light one of the pilot burners using fuel oil according to paragraphs. , , , , ;

Close the valves on the gas pipeline in front of the burner:

Make sure that the nozzle flame is burning steadily;

Open the safety spark plug valve of this burner.

	Circulation scheme	Minimum permissible water consumption, t/h
PTVM-50	4-way (main mode)
PTVM-50	2-way (peak mode)	1100
PTVM-100	4-way (main mode)
PTVM-100	2-way (peak mode)	1500
PTVM-180	2-way	3000

	Dissolved oxygen O 2, mg/l	Free carbon dioxide CO 2, mg/l	Alkalinity for phenolphthalein mg-eq/l	pH value			Oils and heavy petroleum products, mg/l		Carbonate index IK, (mg-eq/kg) 2
Open	No more than 0.02	Ots.	0,1 - 9,0		No more than 0.3 *	No more than 5.0	No more than 1.0	No more than average annual permissible concentrations (AAC) established by current radiation safety standards
Closed	By more than 0.02	Ots.	0,1 - 0,5 **	8,3 - 9,5	No more than 0.5	No more than 5.0	No more than 1.0
* In agreement with the SES, 0.5 mg/l is possible. ** The upper limit is for deep water softening.


70 - 100	101 - 120	121 - 130	131 - 140	141 - 150

* For operating heat supply systems fed with sodium-cationized water, IK should not exceed 0.5 (mg-equiv/kg) 2 for heating water heating temperatures of 121 - 150 °C and 1.0 for 70 - 120 °C.

	Temperature, °C	The value of the indicator for the heat supply system
	Temperature, °C	open	closed
Dissolved oxygen, mg/l	131 - 150	No more than 0.05
Free carbon dioxide, mg/l
R n		8,3 - 9,0	8,3 - 9,5
Suspended substances, mg/kg		No more than 5.0
Oils and petroleum products, mg/kg		No more than 0.3	No more than 1.0
Carbonate index, (mg-eq/kg) 2	70 - 100
	101 - 120
	121 - 130
	131 - 140
	141 - 150

2.15. The quality of make-up water in open heating supply systems must meet the requirements of GOST 2874-82 “Drinking water”. The make-up water of such systems must be subjected to coagulation if the color of the sample is boiled for 20 minutes. Increases above the norm specified in this GOST.

4.2.14. A rupture of the fuel oil or gas pipeline within the boiler.

	Signs of a violation	Actions of personnel to eliminate the violation
1. Deterioration of the combustion process	The torch is unstable, has dark stripes and luminous “stars”; smoke of the torch, its separation, separation of fuel oil onto the furnace screens and under the boiler; the appearance of products of chemical incomplete combustion, pulsation in the firebox	1. Restore the boiler operating mode in accordance with the operating mode map.
		2. Blow steam through the boiler nozzles one by one; If necessary, remove them, disassemble them and wash them with light fuel. Check the injectors on a water stand.
		3. Check the condition of the burner blades
2. Increase in flue gas temperature	Inconsistency between the flue gas temperature values and the regime map	1. Set the fuel-air ratio in accordance with the regime map.
Limitation of boiler heating output by draft	The boiler does not take the rated load	2. Clean the convective heating surfaces of the boiler from ash deposits.
		3. Check the condition of the boiler lining
3. Fistulas in heating surfaces	Water leak under the boiler	1. Determine the location and nature of the damage and report to the power plant shift supervisor.
		2. Check the quality of make-up water for compliance with established standards; in case of violation of the water-chemical regime, require the head of the chemical workshop to comply with the standards
4. Deterioration in the quality of make-up water	According to the chemical workshop	1. Notify the shift supervisor so that measures can be taken to eliminate the violation.
		2. Reduce the heating output of the boiler to the minimum permissible, temporarily turn off the recirculation system, and if possible, increase the water pressure in the direct heating main.
		3. Increase control over the operation of heating surfaces.
		4. If necessary, by order of the chief engineer of the power plant (head of the heating boiler room), stop the boiler
5. Reducing the water temperature at the boiler inlet to below 60 °C (gas) and 70 °C (fuel oil)	According to the indications of the instrumentation	1. Notify the shift supervisor of the power plant (heating boiler room).
		2. Increase the share of recycled water at the boiler inlet, increase heating of network water in network heaters (at CHP) to maintain the required water temperature at the boiler inlet

. BASIC INSTRUCTIONS FOR SAFETY, EXPLOSION AND FIRE SAFETY

Safety precautions when operating water heating boilers of the PTVM type do not have specific features other than general rules, observed during the operation of steam and other types of hot water boilers, and must satisfy:

"Explosion safety rules when using fuel oil and natural gas in boiler installations" (Moscow: SPO Soyuztekhenergo, 1984);

Annex 1

Gas-oil water heating boilers PTVM-50, PTVM-100 and PTVM-180 are water-tube, direct-flow, forced circulation, tower-type, have a completely screened combustion chamber and convection packages located above it. On PTVM-180 boilers, the combustion chamber is divided into three parts by two-light screens.

PTVM-50 and PTVM-100 boilers can be installed with individual chimneys located above them, or connected to a common chimney. PTVM-180 boilers operate only on a separate chimney.

Basic data on the design of boilers are given in table. P2.1.

The heating capacity of PTVM type boilers is regulated by changing the number of operating burners at a constant water flow and a variable temperature difference. Control range 25 - 100%.

The boilers are equipped with oil-gas burners with individual blower fans. The design of the burners provides for a peripheral gas supply and mechanical sawing of fuel oil. There is no air heating on the boilers.

The convective part is composed of blocks, each of which consists of sections of U-shaped coils with risers located on the front and rear walls of the convective part of the boiler.

The coil pipes of each section are welded in four places using vertical spacer strips.

Along the flow of gases, the convective part is divided into two packages, the repair gap between which is 600 mm.

On the PTVM-50 and PTVM-100 boilers, switching from a two-pass circulation scheme to a four-pass one is provided by installing plugs on the collectors and pipelines connecting the boilers with the direct and return lines (Fig. and).

The PTVM-180 boiler is designed to operate only using a two-pass circulation circuit (Fig.).

To remove ash deposits from the pipes of convective heating surfaces, the project provides for water washing of a stopped boiler. Washing water is supplied to a system of pipes with nozzles located in the gas box above the convective part, and is distributed over the outer surface of the pipes of the convective sections. The boiler lining is lightweight, attached directly to the pipes and consists of three layers of thermal insulation materials: fireclay concrete with alumina cement, mineral wool in the form of mattresses in a metal mesh with a gas-tight sealing coating that ensures waterproofing of boilers from precipitation. The total thickness of the lining is 115 mm.

152,6

184,4

Combustion chamber volume, m 3

Surface of the convective part, m 2

1170

2999

5500

Overall dimensions along the boiler axes, mm

width

5160

6900

12196

depth

5180

6900

Boiler height from floor level to transition flue, mm

13500

14450

13200

Diameter screen pipes, mm

60´3

Pitch between pipes, mm

Diameter of pipes of the convective part, mm

28´3

Steps, mm:

transverse

longitudinal

Diameter of riser pipes of the convective part, mm

83´3.5

Number of burners and blower fans, pcs.

Nominal water consumption, t/h:

with a two-pass scheme

1100

2140

3860

with a four-way scheme

1235

Hydraulic resistance of the boiler, MPa (kgf/cm2):

with a two-pass scheme

0,056 (0,56)

0,096 (0,96)

0,106 (1,06)

with a four-way scheme

0,096 (0,96)

0,215 (2,15)

Inlet water temperature,°C

in peak mode

in main mode

Estimated flue gas temperature at rated load,°C

Aerodynamic resistance of the boiler, mm water column.

26,7

25,7

24,0

21,8

28,5

Estimated efficiency at rated load, %

87,8

83,7

88,6

86,8

89,0

86,8

Estimated fuel consumption at rated load, m 3 /h (kg/h)

7270

6460

14100

Inlet water temperature, °C

Outlet water temperature, °C

Minimum water pressure behind the boiler, MPa (kgf/cm3)

Number of working burners, pcs.

Fuel pressure behind the regulator, MPa (kgf/cm2)

Temperature of fuel oil in front of the burners (when operating on fuel oil),°C

Flue gas temperature, °C

Vacuum at the top of the furnace, Pa

Appendix 4

	Main disadvantages	Solutions
1. Hydraulic diagram	Insufficient stability, presence of downward movement of the medium in the screens	Changing the hydraulic scheme by organizing additional mixing of the medium, installing hydraulic jumpers, switching to the lifting movement of water in the screens. Primarily recommended for peak operation of a two-pass circuit; for boilers operating on a network with low blood pressure; in systems with a possible reduction in flow and pressure (with open water intake); with simplified water treatment methods
2. Network pipelines	Low water pressure behind the boiler due to operating conditions of the heating network	Installation of control valves on the direct pipeline of the heating network. Recommended for objects with pressure behind the boiler below 1.0 MPa
3. Convective surfaces	Increased heat perception and uneven heating of the lower convective package. Small pipe steps in the convective part	Changing the design of convective packages with their additional division and reduction of uneven heating of pipes. Increasing steps in the convective part. Recommended primarily for oil-fired boilers
4. Water method of cleaning external heating surfaces	Increased rate of external corrosion of pipe metal on heating surfaces. The need to organize a scheme for neutralizing flush water	Changing the cleaning method for heating surfaces:
		a) shot blasting cleaning system;
		b) gas pulse cleaning system.
		When using “dry” cleaning methods, the reliability of heating surfaces and their service life increase
5. Lack of acid washing scheme internal surfaces boiler heating	Increase in hydraulic resistance and increase in metal temperature of heating surfaces	Design and install an acid washing circuit
6. No air preheating	Freezing of fan impellers and limitation of their pressure and performance	Organize preheating of the air using air heaters or expired convective surfaces installed in the suction air ducts; in the first case, steam and network water can be used as a heating agent, in the second - network water
7. Significant differences in the performance of blower fans	Disorganization of the combustion regime	Leveling fan performance by reducing the gaps between the impeller and fan housing

Boilers PTVM series are intended to receive hot water with temperatures up to 150 `C in free-standing boiler rooms for use in heating, ventilation and hot water supply systems for industrial and domestic purposes and at thermal power plants.
Hot water heating boiler PTVM- peak heating water heating gas and oil, i.e. can be used to cover the peak portion of the heat load curve.
Initially it stood for “peak heating water heating with fuel oil”, but later in Moscow all these boilers were switched to gas.
PTVM series boilers have the following modifications: PTVM-30, PTVM-50, PTVM-60, PTVM-100, PTVM-120 and PTVM-180, according to the increasing heat output (Gcal/hour).
All PTVM boilers are basically similar in design, have a tower layout and are made in the form of a rectangular shaft, in the lower part of which there is a completely shielded chamber firebox.
Boilers are assembled either from the same or from similar elements, which ensures the unification of their production. The design of these units allows semi-open installation. In this case, only the lower part of the boiler is enclosed in the room, where burners, fittings, automation and blower fans are located. This reduces the cost of constructing a heating station building and creates convenience for summer repairs.
For all boilers except PTVM-180, it is possible to install them both with steel chimney, directly resting on the boiler frame, or with a free-standing reinforced concrete or brick chimney.
PTVM-30 And PTVM-50 are installed at district thermal stations (RTS). PTVM-50 are the main equipment of the RTS of the Moscow fuel and energy complex (at least until 2000). More powerful PTVM-100 and PTVM-120 are installed at both RTS and CHP plants. And finally, powerful PTVM-180 only at thermal power plants.

Specifications boiler "PTVM-30M"

PTVM-Z0 boilers are designed to produce hot water with a pressure of up to 13.5 MPa and a temperature of 150°C, used in heating and hot water supply systems, as well as for technological purposes.
The boiler firebox is completely shielded by pipes Ø160x3 mm, located with a pitch of S=64 mm, and is equipped with six oil-gas burners installed counter-clockwise on the side walls.

Nominal heating capacity - MW - 35
Fuel type - gas/fuel oil
Working water pressure - 5 MPa2
Inlet water temperature - `C 70
Outlet water temperature - `C 150
Hydraulic resistance - 25 MPa0
in relation to the nominal - 30-100%
Calculated boiler weight - 77550 kg
Weight of the pipe system - 31360 kg
Length - 7980 mm
Width - 9100 mm
Height - 14534 mm
Water consumption - 370 t/h
Fuel consumption: gas - 5200 m3/h, fuel oil - 4355 kg
Mean time between failures - at least 5000
Average service life before write-off is at least 15 years or 75,000 hours
Boiler efficiency is not less than: gas - 92.2%, fuel oil - 89.5%
Equivalent noise level in the service area - no more than 80 dB
Temperature of the external (insulated) heating surface of the boiler - `С45
Total aerodynamic drag, kg/m3: gas - 255.47, fuel oil - 316.42
Flue gas temperature, `C gas - 150, fuel oil - 270

Technical characteristics of boilers “PTVM-50 - 120”

Specifications	PTVM-50	PTVM-60	PTVM-100	PTVM-120
Fuel	gas/fuel oil
Heating capacity, MW	58,2	69,8	116,3	139,6
Design (excessive) water pressure at the boiler inlet, MPa	1,6
Inlet water temperature, `С	70
Outlet water temperature, `С	150
Heat output control range in relation to nominal, %	30-100
Hydraulic resistance MPa, no more	0,25
Water consumption through the boiler, t/h	618	743	1235	1399
Specific consumption of equivalent fuel (calculated), m3/MWh / kg/MWh	154/132	156/134	156/134	155/133
Boiler efficiency, gross, %, not less, gas (fuel oil)	92,8 (91,1)	91,7	92,3(90,1)	92,3
Specific emission of nitrogen oxides, no more than, gas (fuel oil)	0,23 (0,34)
Weight of boiler metal, kg, calculated (with pipe)	106000	144000	245500	245500
Average service life before write-off, years, not less	20

Boilers PTVM performance: thirty; 50; 100 MW.

Water heating boilers PTVM are intended for installation in heating boiler houses as the main source of heat supply to produce hot water at a temperature of 150°C, used in heating systems, hot water supply for industrial and household use and at the thermal power plant.

Technical characteristics of PTVM-30 boilers

The boiler is a direct-flow boiler with a U-shaped closed arrangement of heating surfaces. The boiler furnace is completely shielded by pipes 060x3 mm, located with a pitch of S = 64 mm, and is equipped with six gas-oil burners MGMG-6, installed counter-clockwise on the side walls.

Convective heating surfaces are located in a convective flue with side walls, shielded pipes 083x3.5 mm, which are risers of convective sections made of pipes 028x3 mm. Back wall convective flue is screened with 60x3 mm pipes. The pipe system of the PTVM-30 boiler rests on a frame frame at an elevation of 5.14 m.

The range of boiler load regulation is 30 -100% of the nominal output. The heating output of the boiler is changed by changing the number of operating burners. The water flow through the boiler must be maintained constant; when the heat load changes, the difference in temperature of the water at the inlet and outlet of the boiler changes.

By agreement, boilers can be equipped with any foreign or domestic gas burners corresponding performance.

Boilers operating on fuel oil can be equipped with a gas pulse cleaning device (GCP) to remove external deposits from the pipes of convective heating surfaces.

Specifications	PTVM-30

Type of fuel	Gas/fuel oil
Water pressure at the boiler inlet, no more than, MPa

Inlet water temperature, °C


Thermal insulation control range relative to the nominal value, %
Water consumption, t/h
Fuel consumption, m/h-gas/kg/h-fuel oil
Flue gas temperature, °C, gas/fuel oil
Full assigned service life, years, not less
Boiler efficiency, %, not less, gas/fuel oil

It is possible to manufacture a boiler for a pressure of 2.5

Technical characteristics of boilers PTVM-50 and PTVM-100

Boilers PTVM-50 and PTVM-100 can be operated both in main mode and in peak mode (for heating network water), respectively, from 70 to 150°C and from 110 to 150°C.

The boilers have a tower layout: a convective heating surface is located above the vertical combustion chamber. The combustion chamber is screened with pipes 060x3 mm. The convective heating surface of the PTVM-100 boilers consists of eight packages, and the PTVM-50 boiler consists of four packages. It is assembled from U-shaped screens from pipes 028x3 mm. The side walls of the convective flue are closed with pipes 083x3.5 with a pitch of 128 mm and are also risers for convective half-sections. The boiler pipe systems are suspended from the frame by the upper manifolds and freely expand downwards.

The PTVM-50 boiler is equipped with 12 MGMG-6 gas and oil burners - six on each side. The PTVM-100 boiler is equipped with 16 MGMG-8 gas and oil burners - eight on each side. Each burner is equipped with an individual blower fan. By agreement, boilers can be equipped with any foreign or domestic gas burners of appropriate capacity.