Index

Execution of Kotal "Torch"

A.A. Mazurov, head of design bureau No. 2;
A.G. Vereshchagin, Marketing Director;
OJSC "Staroruspribor" Plant (part of the "Splav" Machine-Building Corporation)

A huge number of cast-iron sectional boilers of the KVA type still continue to be used in Russia. As a rule, these boilers are equipped with a two-position blower burner L1 (high combustion - 100%, low combustion - 40% of power) and an automation unit. The boilers, like the burner block, have been in operation for more than 15-25 years. Over such a period, even with proper maintenance, almost all mechanisms and control systems deteriorate, not to mention the actual state of affairs with maintenance in our public utilities. However, the KVA boiler itself has a sectional design and is repairable for a long time, and cast iron sections are quite durable provided there are no sudden temperature changes. The burner block causes great difficulties in repair and maintenance.

The most unequivocal optimal solution in such a situation, replace the boiler with a new, modern one, equipped with a block burner and automatic control. Of course, such investments are advisable and will pay off over time, but as always the question arises: “Where can I get these same funds today, now?”

It’s another matter to follow the repair path, but not just “patch holes” by replacing 2-3 sensors, but to modernize the burner unit and automation. The costs in this case are incomparably lower than when replacing the boiler.

Stages of work and the resulting result of re-equipping a boiler room with two boilers KVA-1.0Gn (Fakel-G)

During the inspection, it was revealed that two KVA-1.0Gn boilers (Minsk Heating Equipment Plant) with L1-N burners (Leninabad Gas Equipment Plant) were installed in the boiler room. The burner valve group is equipped with SVMG valves (Semenovsky Valve Plant). Automatic control - BURS-1M unit complete with sensors (JSC Staroruspribor Plant) (Fig. 1-4).

To regulate the vacuum, a common smoke exhauster is used, installed at the outlet of the common chimney (two smoke exhausters are installed in parallel) and an electromagnetic mechanism on the boiler damper. All equipment is from 1990-91. exhaust, with the exception of smoke exhausters (Fig. 5-6).

During the inspection, it turned out that only one of the two boilers was in working order. The boiler performance and vacuum in the furnace are adjusted manually by the operator. When a “high burn” occurs, the burner flame breaks down. The condition of the valves of the burner armature groups is unsatisfactory, the protection sensors are not operational, the burner flames are monitored visually. Based on the results of the inspection, a decision was made to replace the burners and valve groups, as well as the control automation.

As a replacement, a GBL-1.2D burner with built-in automatic control MG-GBL and a valve group was proposed. The burner delivery set also includes sensors for monitoring boiler parameters: temperature sensor - for monitoring and regulating water temperature; water pressure sensor - for control; vacuum sensor in the furnace - for monitoring and regulation. The presence of all necessary sensors in the delivery package ensured quick installation and commissioning of the entire set of equipment on the boiler. The dismantling of old equipment and installation of new equipment was completed in two days. Testing, adjustment and combustion adjustment took one working day (Fig. 7).

The MG-GBL combustion manager, complete with burner sensors and actuators, ensures safe operation of the burner and boiler (flame control, air and gas pressure control, temperature and water pressure control and other parameters), and also controls the boiler performance in a smooth modulated mode, at the same time maintains the required gas/air ratio (Fig. 8).

The burner valve group (Fig. 9) provides the required gas flow to the burner at low gas connection pressure (4.5 kPa), and electronic ratio control eliminates the influence of changes in connection pressure on the combustion quality. The valve group is equipped with sensors for automatically checking the tightness of the valves and monitoring the connecting pressure.

For normal boiler operation of this type throughout the entire range of capacity control, it is necessary to ensure a constant vacuum in the furnace, while avoiding sudden pops and disruptions of the burner torch. Taking into account that a common smoke exhauster is installed in the boiler room, a two-stage vacuum control scheme was used. The vacuum in the common chimney is maintained by frequency control of the smoke exhaust motors using signals from a separate vacuum sensor and a built-in frequency converter regulator.

The vacuum in the boiler furnace is regulated by a damper on the chimney of each boiler. Control is carried out by the burner manager regulator based on signals coming from the vacuum sensor in the furnace (Fig. 10).

The use of a two-stage vacuum control scheme made it possible to ensure the required vacuum both when operating one boiler and when working together boilers Additionally, use frequency converters reduces electrical energy consumption by smoke exhaust motors.

The results of boiler tuning are presented in operating charts (see tables 1 and 2). For comparison, the operating map before replacing the burner is presented.

A comparison of performance maps shows a real increase in boiler efficiency by 10% and an improvement in the quality of fuel combustion. The increase in the excess air coefficient is associated with the presence of large air suction into the boiler. Before replacing the burner, it is recommended to carry out routine maintenance on the boiler: clean the gas-smoke and water ducts of the boiler and seal it to eliminate air suction.

conclusions

1. The modernization of the boiler room allowed us to increase the level safe operation boiler room Using an automated burner that matches gas fittings with tightness control and sensors monitoring boiler parameters, meets all modern safety requirements.

2. Working in automatic control mode eliminated interference in the work of operators, which prevents errors associated with the “human factor”. Working with boilers has become easier and more convenient.

3. The use of new equipment has reduced maintenance costs. Behind heating season repair services did not appear in the boiler room.

4. High-quality fuel combustion and operation in automatic performance control mode made it possible to reduce gas consumption by 15-20% compared to the previous season.

5. The use of frequency regulators reduces the energy consumption of smoke exhausters by up to 30%, and also increases the protection of engines from various emergency situations and overloads.

6. The high reliability of the burner operation in conditions of unstable electrical power was confirmed rural areas. There were no burner malfunctions noted. Instability of the gas connection pressure does not affect the operation of the burner.

7. Replacing the burner allows you to extend the life of cast-iron sectional boilers KVA-G (Fakel-G) and carry out their further operation.

The experience of using burners confirms the use of burners on earlier series of cast-iron sectional boilers, for example, on boilers of the “Minsk-1” type.

An example of using GBL burners on Minsk-1 boilers

For the appearance of the Minsk-1 boiler after installing the GBL burners, see Fig. 11, and the operating maps before and after installing the burners are given in Table. 3.

Table 3. Regime map before and after replacing the burner on the Minsk-1 boiler.

Modernization of KVA-G (Fakel-G) boilers: increasing the level of reliability and safe operation

A huge number of cast-iron sectional boilers of the KVA type still continue to be used in Russia. As a rule, these boilers are equipped with a two-position blower burner L1 (high combustion - 100%, low combustion - 40% of power) and an automation unit. The boilers, like the burner block, have been in operation for more than 15-25 years. Over such a period, even with proper maintenance, almost all mechanisms and control systems deteriorate, not to mention the actual state of affairs with maintenance in our public utilities. However, the KVA boiler itself has a sectional design and is repairable for a long time, and the cast iron sections are quite durable provided there are no sudden temperature changes. The burner block causes great difficulties in repair and maintenance.

The clear and most optimal solution in such a situation is to replace the boiler with a new, modern one, equipped with a block burner and automatic control. Of course, such investments are advisable and will pay off over time, but as always the question arises: “Where can I get these same funds today, now?”

It’s another matter to follow the repair path, but not just “patch holes” by replacing 2-3 sensors, but to modernize the burner unit and automation. The costs in this case are not comparable to those of replacing the boiler.

JSC Plant Staroruspribor offers to use its experience in such work.

Re-equipment of a boiler room with two boilers KVA-1.0Gn (Fakel-G).

Stages of work and the result obtained

1. During the inspection, it was revealed that two KVA-1.0Gn boilers (Minsk Heating Equipment Plant) with L1-N burners (Leninabad Gas Equipment Plant) were installed in the boiler room.

The burner valve group is equipped with SVMG valves (Semenovsky Valve Plant). Automatic control - BURS-1M unit complete with sensors (JSC Staroruspribor Plant).

To regulate the vacuum, a common smoke exhauster is used, installed at the outlet of the common chimney (two smoke exhausters are installed in parallel) and an electromagnetic mechanism on the boiler damper.

All equipment is from 90-91. exhaust, with the exception of smoke exhausters.

During the inspection, it turned out that only one of the two boilers was in working order. The boiler performance and vacuum in the furnace are adjusted manually by the operator. When a “high burn” occurs, the burner flame breaks down. The condition of the valves of the burner armature groups is not satisfactory, the protection sensors are not operational, the burner flame is monitored visually.

Based on the results of the inspection, a decision was made to replace the burners and valve groups, as well as the control automation.

2. As a replacement, a GBL-1.2D burner with built-in automatic control MG-GBL and a valve group was proposed. The burner delivery set also includes sensors for monitoring boiler parameters: temperature sensor - for monitoring and regulating water temperature; water pressure sensor - for control; vacuum sensor in the furnace - for monitoring and regulation. The presence of all necessary sensors in the delivery package ensured quick installation and commissioning of the entire set of equipment on the boiler. The dismantling of old equipment and installation of new equipment was completed in two days. Testing, adjustment and adjustment of combustion took one working day.

Appearance after installing burners on boilers:

Combustion manager MG-GBL complete with burner sensors and actuators:

The burner valve group ensures the required gas flow to the burner at low gas connection pressure (4.5 kPa), and electronic ratio control eliminates the influence of changes in connection pressure on combustion quality. The valve group is equipped with sensors for automatically checking the tightness of the valves and monitoring the connecting pressure.

For normal operation of boilers of this type throughout the entire range of capacity control, it is necessary to ensure a constant vacuum in the furnace, while sharp pops and disruptions of the burner torch are eliminated. Taking into account that a common smoke exhauster is installed in the boiler room, a two-stage vacuum control scheme was used. The vacuum in the common chimney is maintained by frequency control of the smoke exhaust motors using signals from a separate vacuum sensor and a built-in frequency converter regulator.

The vacuum in the boiler furnace is regulated by a damper on the chimney of each boiler. Control is carried out by the burner manager regulator based on signals coming from the vacuum sensor in the furnace.

The use of a two-stage vacuum control scheme made it possible to ensure the required vacuum both when operating one boiler and when boilers are operating together. Additionally, the use of frequency converters reduces the electrical energy consumption of smoke exhaust motors.

3. The results of boiler tuning are presented in performance maps. For comparison, the operating map before replacing the burner is shown (on the right).

A comparison of performance maps shows a real increase in boiler efficiency by 10% and an improvement in the quality of fuel combustion. The increase in the excess air coefficient is associated with the presence of large air suction into the boiler. Before replacing the burner, it is recommended to carry out routine maintenance on the boiler: clean the gas-smoke and water ducts of the boiler and seal it to eliminate air suction.

1. The modernization of the boiler room made it possible to increase the level of safe operation of the boiler room. The use of an automated burner, appropriate gas fittings with leakage control and sensors that monitor boiler parameters meets all modern safety requirements.
2. Working in automatic control mode eliminated interference in the work of operators, which prevents errors associated with the “human factor”. Working with boilers has become easier and more convenient.
3. The use of new equipment has reduced maintenance costs. During the heating season, repair services did not appear in the boiler room.
4. High-quality fuel combustion and automatic performance control mode made it possible to reduce gas consumption by 15-20% compared to the previous season.
5. The use of frequency regulators reduces the energy consumption of smoke exhausters (approximately up to 50%), and also increases the protection of engines from various emergency situations and overloads.
6. The high reliability of the burner operation under conditions of unstable electrical power in rural areas was confirmed. There were no burner malfunctions noted. Instability of the gas connection pressure does not affect the operation of the burner.
7. Replacing the burner allows you to extend the life of cast-iron sectional boilers KVA-G (Fakel-G) and carry out their further operation.

The Minsk Heating Equipment Plant continues to produce Fakel type boilers to this day. GBL type burners were developed taking into account the use of burners on new boilers, which is confirmed by existing installation experience.

The Fakel-1G cast-iron sectional boiler of the Minsk Heating Equipment Plant is designed for installation in medium-power hot water heating boilers and operating on natural gas.

The advantages of the Fakel-1G boiler are that it is not demanding on water quality in terms of corrosion, and the theoretical possibility of replacing individual sections in the package.

Specifications
Fakel-1G

Boiler design Torch

Cast iron and steel sectional boilers are used in group and local (house) boiler houses to obtain hot water with temperatures up to 95 °C at a pressure in the heating system not exceeding 6 kgf/cm2. It is allowed to heat water up to 115 °C at an operating pressure in the system of at least 3.5 kgf/cm2. If there is a steam trap cast iron boilers can produce steam with a pressure of up to 0.7 kgf/cm2.

During pump circulation, the Fakel-1G boiler operates according to direct-flow circuit water movement. To do this, plug washers are installed between the sections on the coupling bolts in a checkerboard pattern so that water passes sequentially through all sections. In the upper part of the upper washers, cuts must be made to remove air, and in the lower part of the lower washers, cuts must be made to remove water and sludge from the boiler. Water enters the Fakel-1G boiler through the upper rear tee and exits through the upper front tee.

Fakel-1G boilers should be fed with chemically purified water, and the amount of water should not exceed 1% of total number water in the system (boilers and network). Direct water intake from the system and frequent make-up during operation of these boilers are prohibited. The insertion point of the make-up water pipeline must be no closer than 2 m from the boiler.

The L1-N block burner consists of gas, fire and air units. Gas unit includes large and small fire valves, a fire unit - ignition and main burner, a front plate with a flame control electrode, and an air unit - a centrifugal fan and a control damper with an electromagnetic drive. Rated burner power 1 Gcal/h.

Operating instructions for the boiler "FAKEL-G"
This operating manual is intended to familiarize you with the operation and design of the Fakel-G water heating boiler with a cast iron firebox, operating with an automated natural gas burner low pressure, its technical characteristics, as well as operating rules.
Installation, start-up and operation of the boiler must be carried out in accordance with the “Rules for the design and safe operation of steam boilers with a steam pressure of no more than 0.07 MPa (0.7 bar) and hot water boilers with a water heating temperature not exceeding 115? C” and “Rules technical safety in the field of gas supply", "Norm fire safety", SNiP II-35-76 as amended by SNB No. 1 and No. 2, "Rules for the construction of electrical installations" (RUE) and "Rules for the technical operation of electrical installations of consumers and safety precautions during the operation of electrical installations of consumers" (PTE and PTB), as well as this manual manual.
Due to technical improvements in the design of the boiler and its components, there may be some deviations in the operating instructions from the supplied product, which do not affect its basic parameters and operational reliability.
The instruction manual includes:

Description and operation of the boiler;
- boiler installation;
- using the boiler for its intended purpose;
- Maintenance;
- Maintenance;
- storage;
- transportation.

1 Description and operation of the boiler “FAKEL-G”

1.1 Purpose of the “FAKEL-G” boiler

1.1.1 The Fakel-G boiler, equipped with an automatic gas burner unit, is intended for heat supply to residential, public and industrial buildings with an absolute water pressure in the system not higher than 0.7 MPa and a maximum water heating temperature of 115°C. The boiler is designed to operate on water that complies with the “Rules for the design and safe operation of steam boilers with a steam pressure of no more than 0.07 MPa (0.7 bar) and hot water boilers with a water heating temperature of no higher than 115? C”.

1.1.2 Symbol of the automated hot water boiler “Fakel-G” with a heating capacity of 1.0 MW:

Boiler KVA-1.0 Gn (“Fakel-G”) TU 21-26-262-85.
1.2.2 When the boiler operates together with boilers of other types, the water temperature at the outlet of all operating boilers should not differ by more than 1 - 2 °C.
1.2.3 The boiler is operated only with a smoke exhauster (the smoke exhauster is not included in the delivery package).

1.3 Product composition

1.3.1 The product includes:

Package of boiler sections;
- automated gas burner unit with a set of controls (hereinafter referred to as the “burner device”);
- thermal insulation casing;
- fittings;
- headset;
- control and measuring instruments.

1.4 Design and operation of the “FAKEL-G” boiler

1.4.1 Construction of the “FAKEL-G” boiler

1.4.1.1 The main working part of the FAKEL-G boiler is a package of boiler sections, consisting of three types sections - front, rear and middle. The sections are assembled into a package using conical nipples and tightened with coupling bolts.
The inner walls of the section pipes and the joining ribs limiting them form convective flues.
When assembling the package, all joining ribs of the sections are sealed with heat-resistant material.
A burner device is attached to the front section. The gas duct control valve and the explosion valve are attached to the rear section. During installation, the flue valve is connected to the boiler room smoke exhauster and then to the hog. Between the flue valve and the smoke exhauster, the boiler room design must provide a manual gate that disconnects the boiler from the smoke duct.
1.4.1.2 The package of boiler sections is closed with a heat-insulating casing. The casing is made in the form of separate removable panels. If the boiler is installed without a casing, a layer of heat-insulating mastic is applied to the outer surface of the package in accordance with clause 2.7.3.
1.4.1.3 To control the operation of the boiler, an automation kit “Mode - I” or another kit that has permission from Gospromnadzor is used. The automation kit is included in the burner device.
The automation kit is designed for operation in a boiler room with a temperature from plus 5 °C to plus 50 °C with a relative humidity of 30 to 80%.
The automation set “Mode-1” consists of:

Control panel;
- dashboard;
- photosensor for monitoring the presence of a torch;
- regulating digital temperature meter ITRC-01 with resistance thermometer TSM1-120/100;
- maximum water temperature sensor at the outlet of the boiler TSM1-250/100;
- an electromagnetic mechanism installed on the boiler flue valve;
- flow switch RPI-50 or RPI-80, or RPI-100.
BUS, circuit breaker and a magnetic starter with a thermal relay are located on the control panel.
To control gas and air pressure and vacuum in the furnace, RDM type devices are used.
Devices of the RDM type and sensors of the DD or DG type are mounted on the instrument panel, flow switch RPI-50 or RPI-80, or RPI-100 on the boiler return water pipeline.
Sensors are installed on the boiler. Install the instrument panel and control panel in place in accordance with the boiler room design, near the boiler and secure it to a fixed metal structure, wall or column.
The instrument panel and control panel are connected to each other, the burner device and the boiler by electrical communications in accordance with electrical diagrams connections included in the operational documentation of the burner device.
A detailed description of the automation system design is set out in the passport for the L1-n automated gas burner unit with a control panel (FM 34B.00.00.000 PS) and the operating instructions for the set of gas burner controls “Mode-1” (YAATI.421413.001 IE).
1.4.1.4 The safety automatic switches off the gas supply to the burner device in the following emergency situations:

The igniter flame goes out;
- flame goes out in the main burner
- increasing the water temperature at the boiler outlet above 115 °C;
- unacceptable increase in water pressure at the boiler outlet;
- unacceptable decrease in water pressure at the boiler outlet;
- unacceptable decrease in air pressure in front of the burner;
- unacceptable increase or decrease in gas pressure in front of the shut-off solenoid valve;
- unacceptable decrease in vacuum in the boiler furnace;
- unacceptable increase in pressure in the boiler furnace;
- explosion in the combustion chamber or gas ducts;
- interruption of power supply;
- malfunction of the main components of the control and alarm unit;
- non-ignition of gas during ignition;
- turning off the smoke exhauster or stopping the draft;
- breakage of protection circuit wires;
- unacceptable reduction in water flow through the boiler (less than 17 m3/h);
- lack of tightness of gas valves.

1.4.2 Operation of the “FAKEL-G” boiler.

1.4.2.1 Gas, through the “faucet on the burner” and the system of automatic gas valves of the burner device, enters the burner, where it is mixed with air supplied by the fan, ignited by an electric spark igniter and burns.
A detailed description of the design of the burner device, the principle of operation, installation and operation is given in the operational documentation of the burner device.
1.4.2.2 The combustion products, having given up some of the heat to the cast-iron combustion chamber of the boiler, are directed through openings in the lower part of the firebox in two streams into the convective flue ducts of the sections.
In the upper part of the sections, the combustion products are turned, washing the low-temperature gas ducts of the package of sections and removed through a gas duct located at the back of the boiler into a collection gas duct connected to the boiler room flue.
1.4.2.3 Water is supplied to the boiler through the lower pipe and enters the rear section. Due to the fact that the lower manifold has washers welded to the coupling bolt, water rises up the rear section. Further, with the help of special cast inserts installed in the upper heads of the sections, a helical movement of water is ensured through the middle sections of the boiler. The water, having passed sequentially through all sections, is heated and discharged through the pipe at the front of the boiler into the heat supply system.

1.5 Marking of the boiler “FAKEL-G”

1.5.1 The “FAKEL-G” boiler has a plate in accordance with GOST 12971-67.
1.5.2 The following data is marked on the plate:

Name and symbol boiler "FAKEL-G";
- factory number;
- Year of manufacture;
- heating output of the boiler;
- operating pressure water;
- Maximum temperature heating water;
- technical specifications number for the boiler;
- heating surface of the boiler.

2. Packaging of the boiler “FAKEL-G”

2.1. The package of boiler sections is delivered to the consumer in assembled form. Separate assembly units and parts, as well as fittings, a heat-insulating casing, a burner device and instrumentation are packed in wooden boxes for ease of transportation. The complete set is indicated in the boiler passport.

3 Using the FAKEL-G boiler for its intended purpose

3.1 Operating limitations of the “FAKEL-G” boiler

3.1.1 The “Fakel-G” boiler must be operated in accordance with the requirements of the “Rules for the design and safe operation of steam boilers with a steam pressure of no more than 0.07 MPa (0.7 bar) and hot water boilers with a water heating temperature of no higher than 115? C ", "Technical safety rules in the field of gas supply", "Fire safety standards" and operational documentation for the boiler.
It is allowed to operate the boiler from the control panel without constant monitoring of its operation by maintenance personnel if there is an automatic control of the tightness of the gas valves on the burner device, an automatic control of gas contamination in the boiler room, and a design for the operation of the boiler room in automatic mode.
3.1.2 The operator must keep the boiler installation tidy, clean and free of foreign objects.
3.1.3 The operator has no right to allow unauthorized persons into the boiler room without appropriate permission.
3.1.4 In the event of an emergency shutdown of the boiler, the operator must immediately close the gas supply valve to the burner device, open the purge line valve in front of the burner device, notify the person in charge and write down the reason for the shutdown.
3.1.5 If a malfunction of the boiler or fittings is detected, it is necessary to turn it off and notify the manager of the boiler room.
3.1.6 Topping up the heat supply system with water that does not meet the requirements of the “Rules for the design and safe operation of steam boilers with a steam pressure of no more than 0.07 MPa (0.7 bar) and hot water boilers with a water heating temperature not higher than 115? C” is not allowed.
3.1.7 When performing any work, use a portable electric lamp with a voltage of 12 V.
3.1.8 In order to prevent boiler failure, it is prohibited:

Direct water intake from the hot water heating network;
- operation of the boiler with faulty automation;
- in the event of a gas leak, the operation of the burner device is ignition of the fire, turning on of the electrical equipment;
- use the boiler as a water heater;
- start the boiler without filling heating system and boiler with water;
- fill the hot boiler with cold water;
- boiler operation without grounding;
- during the cold season, leave the idle boiler filled with water;
- replenish the boiler with water when draining water from the boiler.
3.1.9 To ensure the safety of operating personnel, install a fencing device on the explosion valve, which is carried out locally installation organization. Operating the boiler without a safety device on the explosion valve is not allowed.
The enclosing device should be welded from sheet steel with a thickness of at least 2 mm and secured to the boiler room floor.
It is permissible to install an enclosing device of a different design, provided that reliable and safe removal of combustion products is ensured when the explosion valve is activated.
3.1.10 During installation, operation and repair of the boiler, these safety requirements must be strictly observed, as well as the safety instructions for the burner unit, automation devices and other components given in their operational documentation.
3.1.11 When dismantling and repairing the boiler, it is necessary to use a device for assembling packages of sections, manufactured by the consumer, in compliance with safety regulations in accordance with the work plan drawn up by the installation organization.

3.2 Preparing the “FAKEL-G” boiler for use

3.2.1 Preparing the “FAKEL-G” boiler for ignition

3.2.1.1 During the preparation of the boiler for ignition, it is necessary:

Check the connection of the boiler to the heating system;
- put all fittings in working position;
- check the operation of the pressure gauge and inspect the boiler at operating pressure;
- check the tightness of the closure of manual and automatic shut-off devices of the burner device (with a portable pressure meter, using plugs on the valves);
- check the condition of gas pipelines, gas fittings and automation devices for compliance with the “Technical Safety Rules in the Field of Gas Supply”;
- fill the thermometer sleeve with mineral oil and install the thermometer;
- check the serviceability of the burner fan, as well as the burner device as a whole, in accordance with their operational documentation. In this case, you should pay attention to the operation (without jamming) of the air damper drive of the burner device and the direction of rotation of the fan.
- check the operation of the circulation pumps using the pressure drop on the pressure gauges, turning them on in series for a short time, check the pressure created by the pumps.
3.2.1.2 After connecting the boiler to the heating system, top up the system with water until water appears from the signal pipe of the expander.
3.3 Ignition of the boiler

3.3.1 Before igniting the “FAKEL-G” boiler, you must:

Turn on circulation pump, open the pump valves;
- open the manual gate behind the boiler.
3.3.2 Initial start gas after installation or overhaul boiler installation should be carried out only after acceptance by the boiler commission in accordance with the “Technical Safety Rules in the Field of Gas Supply”.
3.3.3 Starting the boiler after a long stop (including starting the boiler in each heating season) is permitted if there is a report on checking the tightness of the gas pipeline, boiler, smoke exhaust devices and instrumentation.
3.3.4 Before starting gas to the boiler, you must:

Make sure there are no gas leaks into the boiler room by smell or using a portable gas analyzer. If gas is detected in the room, carry out natural ventilation by opening doors and windows. You cannot bring open fire into the boiler room, smoke or turn on electrical equipment if it is not explosion-proof;

ATTENTION: UNTIL THE GAS LEAK IS CORRECTED, IGNITION OF THE BOILER IS PROHIBITED.

Make sure everything is gas taps and the valves are closed, and the valves of the purge gas lines in front of the burner device are open;
- if there are other non-working boilers in the boiler room, open their dampers completely to ventilate the fireboxes and chimneys.
3.3.5 After finishing the ventilation of the fireboxes and chimneys, close the dampers on the chimneys of boilers not included in operation.
3.3.6 Check the gas pressure in front of the solenoid valve of the gas burner device. It should be 4.5 kPa. Adjust the data for gas consumption.
3.3.7 Open the “down” tap in front of the boiler. Blow the supply gas pipeline through the purge line for 1-2 minutes, then close the tap on the purge line and open the tap on the burner device. On the general boiler panel, turn on the switch that supplies voltage to the boiler.
3.3.8 On the parameter control sensors that provide protection and regulation of the boiler, set the settings to the following parameters:

RDM2-1.6M or DD-1.6, or electrical contact pressure gauge EKM – lower limit of water pressure 0.35 MPa;
- RDM2-1.6M or DD-1.6, or electric contact pressure gauge EKM - upper limit of water pressure 0.6 MPa;
- PRM1-01 or DL1E – vacuum in the furnace 5-10 Pa;
- RDM1-6.0 or DG150V – upper limit of gas pressure before the shut-off solenoid valve (valve) 4.85 kPa;
- RDM1-6.0 or DG50V – lower limit of gas pressure before the shut-off electromagnetic valve (valve) 2.9 kPa;
- RDM1-2.5 or DG50V – lower limit of air pressure 0.3 kPa;
- RDM1-2.5 or DG50V – increase in pressure in the furnace 2.5 kPa;
- TsR8001/2 or ITRTs-01 – set the lower and upper values ​​of the water temperature at the boiler outlet in accordance with the heating schedule;
- set the operation of the flow switch RPI - 50 or RPI-80, or RPI-100 at a water flow of 17 - 17.2 m3/h in accordance with the instructions set out in technical description and operating instructions for the flow switch.
More detailed description installation and commissioning of automation devices is set out in the passport of the automated gas burner unit L1-n with a control panel (Fm 34B.00.00.000 PS) and in the operating instructions for the set of gas burner controls “Mode-1” (YAATI.421413.001 IE).
3.3.9 Start the boiler in the following sequence:

Turn on the automatic power switch on the control panel and the “Network” toggle switch on the front panel of the BUS “Mode-1”, and the “Network” indicator light should light up;
- check the serviceability of the light and sound alarm by pressing the “Control” button (preparation and operating procedure are described in detail in the operating instructions for the set of gas burner controls “Mode-1”);
- apply voltage to the smoke exhauster and put it into operation;
- using the guide vane of the smoke exhauster, set the vacuum in the boiler furnace within 140-160 Pa according to the reading of the TNMP draft pressure meter;
- press the “Start” button. After this, all start-up operations are performed automatically. The fact that the Start program is running is indicated by the On state of the Start indicator light. After the start program is completed, the “Start” indicator turns off and the “Operation” indicator light turns on, indicating that the automatic water temperature controller at the boiler outlet has started working;
- after igniting the main burner, use a valve behind the boiler to set the vacuum in the furnace to 10 Pa.
3.3.10 During operation of the boiler, the gas pressure measured after the gas valves (valves) of the burner device must be at least 260 kPa in the “low combustion” mode and no more than 2.0 kPa in the “high combustion” mode, and the air pressure - 650 Pa and 1.15 kPa, respectively.
The vacuum in the furnace when operating in the “small combustion” mode should be 10 - 25 Pa, in the “high combustion” mode - within 25-35 Pa.
Gas flow, gas pressure in front of the burner, as well as air pressure are finally specified during commissioning.
3.3.11 Visually check the operation of the burner device through the peephole on the front wall of the boiler furnace.
3.3.12 Make sure that the burner device is burning normally and that the electromagnetic actuators of the flue damper and the burner air damper are operating normally.
3.3.13 Further operation of the boiler is carried out automatically.

3.4 Using the “FAKEL-G” boiler

3.4.1 Water mode boiler "FAKEL-G"

3.4.1.1 The water mode must ensure operation without scale and sludge deposits on heat-receiving surfaces. The quality of supply and make-up water must comply with the requirements of the “Rules for the design and safe operation of steam boilers with a steam pressure of no more than 0.07 MPa (0.7 bar) and hot water boilers with a water heating temperature of no higher than 115? C”.
3.4.1.2 For heating boiler houses that have boiler water treatment installations, the commissioning organization must develop instructions and a regime map indicating quality standards and the procedure for analyzing raw, boiler make-up and network water, the procedure for servicing water treatment equipment, and the timing of stopping the boiler for cleaning and washing.
3.4.1.3 A water treatment log must be kept in the boiler room to record the results of water tests, the implementation of the boiler purging mode, make-up time and water treatment maintenance operations (operational and regeneration).
3.4.1.4 Operation of the boiler with rated power is allowed only if the boiler room has a sodium-cation chemical water treatment system (XBO), which ensures the carbonate hardness of the makeup water is not more than 700 mcg eq/kg in accordance with the “Rules for the design and safe operation of steam boilers with steam pressure” no more than 0.07 MPa (0.7 bar) and hot water boilers with a water heating temperature not higher than 115? C.” The quality of the make-up water is specified in the boiler passport.
In the event of an emergency failure of the water treatment system, the boiler power should be reduced to 40%, i.e. the burner device must operate at “low combustion.” Operation of the boiler without chemical cooling water is not allowed.
3.4.1.5 Before starting the boiler thermal system must be washed with the boiler turned off. Acid flushing of a boiler operating on softened water must be carried out at least once per heating season. If the boiler is operating in emergency mode, it must be subjected to an extraordinary acid flush.
3.4.1.6 Cleaning times inner surface from deposits are determined according to a schedule approved by the management of the enterprise or institution to which the boiler room is subordinated. The frequency of boiler cleaning should be such that the thickness of deposits on the most heat-stressed areas of the boiler heating surfaces does not exceed 0.5 mm by the time it is stopped for cleaning.
No allowed.

3.4.1.8 Frequent refilling of the system is prohibited. The amount of make-up water should not exceed 1% of the total volume of water in the system (boiler and network). When topping up, the water temperature in the boiler should not drop by more than 1 °C.
3.4.1.9 Pipeline tapping is prohibited cold water in the return line at a distance closer than 2-3 m from the boiler.

ATTENTION: THE BOILER HAS INCREASED HYDRAULIC RESISTANCE. WHEN ITS OPERATION WITH OTHER TYPES OF BOILERS, THE OUTLET TEMPERATURE FROM ALL OPERATING BOILERS SHOULD NOT DIFFER BY MORE THAN 1-2 °C.

3.4.1.10 The temperature of the make-up water should be 5 °C higher than the dew point temperature (i.e. 60 - 65 °C).
3.4.1.11 Blowing is carried out systematically. The duration of purging is determined by a schedule developed by a specialized organization.

3.4.2 Operation of the boiler “FAKEL-G”

3.4.2.1 Operation of the boiler is permitted only if the supply and make-up water complies with the requirements of the “Rules for the design and safe operation of steam boilers with a steam pressure of no more than 0.07 MPa (0.7 bar) and hot water boilers with a water heating temperature of no higher than 115? C” .
3.4.2.2 When operating the boiler, fire safety and safety regulations must be strictly observed.
3.4.2.3 At the beginning of each shift, it is necessary to record in the log the temperature of the hot and return water, the gas pressure in front of the solenoid valve, the gas and air pressure in front of the main burner, gas consumption, time of replenishing the system with water, vacuum in the combustion chamber, time of starting and stopping the boiler, information about the forced termination of his work.
3.4.2.4 When the boiler is operating in the “high burning” mode, the transition to the “low burning” mode is made 20 minutes before the boiler stops (except for emergency shutdown).
3.4.2.5 Regulation of the heating output of the boiler in the “small” and “large” combustion modes is carried out automatically using the electric actuator mechanisms of the boiler flue damper, the air damper and the “large combustion” gas valve of the burner device.
3.4.2.6 When the load increases while the boiler is operating in the “low burning” mode, the latter automatically switches to the “high burning” mode.
3.4.2.7 When the boiler is turned off, its subsequent restart is carried out by the operator after completion of the automatic stop program.

3.4.3 Stopping the boiler “FAKEL-G”

3.4.3.1 For a planned shutdown of the FAKEL-G boiler operating in autonomous control mode, or interruption of the boiler start-up program, the operator must:

Press the “Stop” button on the front panel of the control and alarm unit, after which the stop program is executed automatically. At the same time automatic shut-off valves are turned off, the gas supply to the burner is stopped, the combustion chamber and chimneys are purged with air;
- close the shut-off valve in front of the burner device;
- after stopping the fan, turn off the “Network” toggle switch on the front panel of the control and alarm unit and the automatic power switch on the control panel. In this case, the “Network” indicator should turn off. The gas and air dampers are automatically set to the minimum power position, corresponding to the “low combustion” mode;
- open the taps on the purge lines.

3.4.3.2 Disconnect the voltage from the boiler automation.
3.4 3.3 When stopping or repairing, it is necessary to close the manual gate behind the boiler.
3.4.3.4 After 30 minutes (provided that the other boilers are not working), turn off the circulation pump.
3.4.3.5 Close the valve at the water inlet to the boiler.

3.4.4 Emergency stop of the boiler “FAKEL-G”

3.4.4.1 If there is a smell of gas or an accident, close the gas valve at the inlet to the boiler room, turn off the gas safety valve on the main control unit and the tap on the burner device. Turn off the power supply to the boiler, open the windows, doors and take measures to eliminate the accident, notifying the person in charge of the boiler room. If necessary, call emergency services: gas authorities, fire department, etc.
3.4.4.2 If emergency situation, i.e. If any of the controlled parameters of the burner device or boiler are violated, an emergency stop of the boiler occurs automatically, with the root cause of the emergency being memorized. At the same time, a sound signal is sent to the boiler room.
3.4.4.3 In the event of an emergency shutdown of the burner device due to one of the controlled parameters, the manual shut-off device on the burner must be closed. In this case, the operator must close the valve on the “lower” and open the valves of the purge lines.
3.4.4.4 The sound alarm is turned off by pressing the “Reset sound alarm” button.
3.4.4.5 The emergency light indication should be turned off only after the cause of the emergency stop of the boiler has been identified and eliminated by pressing the “Reset light alarm” button.
3.4.4.6 After this, the automation kit is ready for operation.
3.4.4.7 Until the sound and light alarms are turned off, restarting the boiler is impossible.
3.4.4.8 The operator must immediately inform the responsible person about an emergency shutdown of the boiler.
3.4.5.2 Eliminate malfunctions in the burner device, instruments and automation devices in accordance with the factory instructions for the specified products.
3.4.5.3 Carry out all troubleshooting work with the burner device inoperative and the automation system de-energized.

4 Maintenance of the boiler “FAKEL-G”

4.1 Maintenance procedure for the “FAKEL-G” boiler

4.1.1 During operation, it is necessary to monitor the condition of the boiler as a whole and its components.
4.1.2 Periodically, at least once a month, visually check the tightness of the explosion valve to the valve base. Carry out the check with the boiler not running.
4.1.3 Check and clean the burner device if a disturbance in the combustion process is noticed, but at least once per heating season.
4.1.4 Maintenance of boiler control automation and other automation system devices and components consists of performing preventive measures and eliminating noticed malfunctions in accordance with the operational documentation for these products.
4.1.5 When stopping the boiler at the end of the heating season, you should:

Close the valve behind the boiler;
- drain water from the boiler;
- perform an acid wash to remove scale and fill it with water again.

ATTENTION: ACID WASHING MUST BE CARRIED OUT BY A SPECIALIZED ORGANIZATION IN COMPLIANCE WITH THE NECESSARY SAFETY PRECAUTIONS.

4.1.6 During operation, it is necessary to monitor the condition of the lubricant in the engine bearing shields, as well as in the bearings and connections of the burner device screws. Periodically, but at least once per heating season, replenish the lubricant in the listed connections. Lubricate the electric motor, fan and rotary mechanism carry out in accordance with the requirements of its operating instructions, other places - CIATIM-203 GOST 8773-73.
The nuts securing the flange of the burner device to the boiler must be lubricated with graphite grease SKA 2/6-gZ in accordance with GOST 3333-80 each time they are installed.
4.1.7 The burner device must be kept clean, all bolted connections must be securely tightened. During operation, bolted connections and electrical contacts must be tightened periodically, but at least once a month.
4.1.8 Once a shift, the tightness of threaded and flanged connections of pipelines and fittings must be checked using the soaping method and recording the test results in a log.
Before each start-up of the burner device, in addition to the above check, the tightness of the closure of the gas valves and the igniter valve must be checked using a pressure gauge.
4.1.9 Periodically, at least once every three months, it is necessary to check the reliability of the bolted connection of the air damper to its axis on the burner device. The check should be carried out in the following sequence:

Disassemble the connection between the fan and the burner body;
- tighten up bolted connection attach the air damper to the axle and lock them;
- assemble the connection between the fan and the burner body.
4.1.10 Periodically, at least once every 3 months, it is necessary to check the size of the axial gap between the impeller and the inlet pipe of the burner fan, for which it is necessary:

Measure the gap size;
- if the gap is greater than I mm, loosen the screw fastening and axial movement of the pipe to establish a gap of I mm, then tighten the screws.
4.1.11 During operation, it is necessary to lubricate the rubbing surfaces of the axes of the flue valve blades, as well as the hinges and threaded connections blade rotation mechanism
4.1.12 All operations on maintenance boiler inspections should be carried out with the voltage removed on the boiler room panel.
4.1.13 When carrying out maintenance activities on electrical equipment, you should be guided by the “Rules for the technical operation of consumer electrical installations and safety precautions during the operation of consumer electrical installations” - PTE and PTB.

4.2 Preservation of the “FAKEL-G” boiler (re-preservation, re-preservation)

4.2.1 Before storing the boiler, all machined surfaces of parts and assembly units should be temporarily preserved in accordance with GOST 9.014-78 according to option VZ-1 with preservation oils K-17 GOST 10877-76 or other preservation agent providing protection against corrosion.
4.2.2 The burner device is stored in consumer warehouses without updating the conservation lubricant - 2 years. After this period, the burner device must be reactivated and inspected. If there are traces of corrosion, the defective areas are cleaned, after which re-preservation is carried out in accordance with GOST 9.014-78.

5 Maintenance boiler "FAKEL-G"

5.1 Possible malfunctions in the operation of the boiler, probable reasons and methods for eliminating them are indicated in clause 3.4.5.1.

5.2 Repair of a package of boiler sections “FAKEL-G”

5.2.1 Repair of a package of sections should only be carried out on an idle, cooled boiler, disconnected from the heat supply system. The gas mains taps must be closed and the automation system must be de-energized.
To assemble a boiler with a helical movement of water, make devices and use them when assembling a package of sections.
5.2.2 Before repairs, it is necessary to remove the burner device, panels and casing frame from the boiler.
5.2.3 Determine the failed section at the location of the leak.
5.2.4 Drain water from the package of sections.
5.2.5 Remove the outlet and pipe of the sensors at the outlet of hot water from the boiler, having previously removed the TSM or TUDE and EKM resistance thermal converters from the sensor pipe and the indicating pressure gauge, and from the outlet - the frame with the thermometer.
5.2.6 Remove the flanges from the nozzles on the upper and lower nipple channels, disconnect the support brackets and remove the coupling bolts from the lower and upper nipple channels.
5.2.7 Remove the flue valve and the explosion valve.
5.2.8 Remove the side tie rods.
5.2.9.Release the defective section and remove it from the package. Remove the insert and stand from the upper nipple head of the remote section, which ensure the helical movement of water in the boiler.
5.2.10 Insert nipples coated with red lead into the new section, insert a stand and an insert into the upper nipple head, and apply “Vixisant” mastic or its substitute to the joining ribs of the section, then insert the section into the bag and pull the bag together using tools for assembling boiler rooms sections. Install the side tie rods.
5.2.11 Remove the devices, install the coupling bolts in their original place, and secure them to the support brackets.
5.2.12 Install flanges on the nozzles.
5.2.13 Fill the bag with water and perform a hydraulic test with excess water pressure of 0.9 MPa for at least 10 minutes.
5.2.14 If, when testing the package, a leak or sweating is detected, eliminate the defect and perform a repeated hydraulic test.
5.2.15 Install the sensor outlet and pipe, as well as the flue valve and the explosion valve on the package.
5.2.16 Assemble the boiler casing or apply thermal insulation.
5.2.17 Install TCM resistance thermal converters and an indicating pressure gauge or TUDE and EKM into the sensor branch pipe, and a frame with a thermometer into the outlet.
5.2.18 Install and secure the burner device on the boiler.
5.2.19 Prepare the boiler for operation after repair and carry out the operation procedure in accordance with this operating manual.

6 Storage of the boiler “FAKEL-G”

6.1 The package of transport boiler sections must be stored under a canopy or platform, protecting it from exposure to precipitation in macroclimatic areas with temperate and cold climates at air temperatures from minus 50 ° C to + 50 ° C, relative average annual humidity up to 80% and rain intensity not more than 3 mm/min.
6.2 Should the burner device, fittings, fittings, instrumentation and casing be stored in the manufacturer’s packaging? wooden non-dismountable boxes in accordance with GOST 2991-85.
6.3 The burner device and its components, casing, fittings, fittings and instrumentation should be stored in a heated, ventilated room at an ambient temperature of + 5 °C to + 50 °C and relative humidity up to 80%.
6.4 It is not recommended to unpack boxes during storage.

7 Transportation of the boiler “FAKEL-G”

7.1 Boilers are transported by all types of transport in accordance with the rules for the transportation of goods in force for this type of transport.
Transportation by railway- in open cars by carload or small shipments.
7.2 Transportation of packages of transport boiler sections in terms of exposure to climatic factors - according to group Z 1 GOST 15150-69 (in open areas in macroclimatic areas with moderate and cold climates in a conditionally clean atmosphere at air temperatures from minus 50 ° C to plus 50 ° C and average annual relative air humidity up to 80% rain intensity not more than 3 mm/min, and in terms of mechanical factors - according to group C GOST 23170-78.

Transportation conditions C mean:

1) transportation by road with a total number of transshipments of no more than 4:
- on roads with asphalt and concrete coverings(roads of the 1st category) for a distance from 200 to 1000 km;
- on cobblestone (roads of 2-3 categories) and dirt roads at a distance of 50 to 250 km at a speed of up to 40 km/h.
2) transportation various types transport - air, by rail in combination with each other and with road transport, classified under transportation conditions L GOST 23170-78 with a total number of overloads of no more than four;
3) transportation by water

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