CO – first stage, further conservation depends on the subsequent repair period, reserve
Notes:
1. On boilers with a pressure of 9.8 and 13.8 MPa without treatment of feed water with hydrazine, it is recommended to carry out maintenance at least once a year.
2. A – filling the heating surfaces of the boiler with nitrogen.
3. Hydraulic fracturing + CO – hydrazine treatment at boiler operating parameters followed by dry shutdown; GO+ZShch, TO+ZShch, FV+ZShch – filling the boiler with an alkaline solution with previous reagent treatment;
4. TO+CI – preservation with a contact inhibitor with previous trilon treatment;
5. “Before”, “after” – before and after repairs.
5. Methods for preserving hot water boilers
5.1. Preservation with calcium hydroxide solution
5.1.1. The method of preservation with calcium hydroxide solution is based on the highly effective inhibitory abilities of calcium hydroxide solution Ca(OH)2. The protective concentration of calcium hydroxide is 0.7 g/kg or higher.
This method is regulated.
5.1.2. When preserving the heating surfaces of hot water boilers by filling them with calcium hydroxide solution and following the proposed measures, the following effect is achieved:
Formation of sustainable protective film in contact with metal calcium hydroxide solution for 3 – 4 weeks
Preservation of the protective effect of films for 2–3 months when the boiler is emptied of solution after contact for 3–4 weeks or more.
Completely filling the hot water boiler with calcium hydroxide solution during conservation
Possibility of draining the solution for repair work after soaking in the boiler for 3 - 4 weeks
Application of the method for the preservation of hot water boilers of any type at power plants with water treatment plants with lime facilities.
Preservation with calcium hydroxide solution when putting the boiler into reserve for up to 6 months. or removal for repairs for up to 3 months.
5.1.3. It is recommended to preserve the heating surfaces of hot water boilers filled with calcium hydroxide solution by implementing the proposed measures, maintaining the following parameters and maximizing the capabilities of the scheme:
Preparation of calcium hydroxide solution in wet lime storage cells with a floating suction device (Figure 4)
Letting the milk of lime settle for 10–12 hours until the solution is completely clarified after pouring lime (fluff lime, building lime, calcium carbide slaking waste) into the cells and mixing
Maintaining the concentration of calcium hydroxide in solution no more than 1.4 g/kg due to its low solubility at a temperature of 10 – 25°C
Controlling the position of the floating suction device when pumping solution out of the cell, preventing sediment from being captured from the bottom of the cell
Possibility of using the acid washing scheme for hot water boilers shown in Figure 6 to fill boilers with solution
Draining water from the boiler before filling it with preservative solution
By pumping calcium hydroxide solution from lime cells into the reagent preparation tank
By flushing the pipeline with water before pumping to prevent lime milk supplied through this pipeline from entering the tank for preliminary cleaning of the water treatment plant
Filling the boiler while circulating the solution along the circuit “tank - pump - solution supply pipeline - boiler - solution discharge pipeline - tank”
Determining the amount of lime mortar to be prepared, based on ensuring the filling of the preserved boiler and the circulation circuit, including the tank. When filling the boiler with a pump from the tank without organizing circulation through the boiler, the volume of prepared lime milk depends only on the water volume of the boiler. The water volume of the PTVM-50, PTVM-100, PTVM-180 boilers is 16, 35 and 60 m3, respectively
Preservation of the preservative solution in the boiler for the entire period of downtime in reserve, with tight closure of all shut-off valves on the boiler
1 – tank for preparing chemical reagents;
2 – pump for filling the boiler with a solution of chemical reagents;
3 – make-up water; 4 – chemical reagents;
5 – lime milk into pre-cleaning mixers;
6 – cells of lime milk; 7 – hot water boilers;
8 – to other hot water boilers; 9 – from other hot water boilers.
Figure 6 – Preservation scheme for hot water boilers.
Possibility of draining the solution if it is necessary to carry out repair work after soaking in the boiler for at least 3 - 4 weeks with the expectation of putting the boiler back into operation after completion of the repair.
By checking the pH value of the solution at least once every two weeks while keeping the preservative solution in the boiler during downtime
Organizing the circulation of the solution through the boiler for the selection of control analyzes
By taking a sample from the air vents during circulation
By draining the solution from the entire circuit if the pH value is ³ 8.3 and filling with a fresh calcium hydroxide solution
By draining the preservative solution from the boiler at a low flow rate and diluting it with water to the pH value< 8,5
By draining and flushing the boiler with network water until the flush water is hard before starting, if the boiler was filled with a preservative solution.
5.2. Preservation with sodium silicate solution
5.2.1. Sodium silicate (liquid sodium glass) forms a strong, dense protective film on the metal surface in the form of Fe3O4·FeSiO3 compounds. This film shields the metal from the effects of corrosive agents (CO2 and O2).
5.2.2. The formation of a protective film occurs when the preservative solution is kept in the boiler for several days or when the solution is circulated through the boiler for several hours.
5.2.3. It is recommended to preserve the heating surfaces of hot water boilers with sodium silicate by maintaining the following concentrations and implementing the proposed organizational and technical measures:
Complete filling of the hot water boiler with a sodium silicate solution with a SiO2 concentration in the preservative solution of at least 1.5 g/kg
The use of sodium silicate for the preservation of hot water boilers of any type
Preservation with sodium silicate when putting the boiler into reserve for up to 6 months. or for repairs for up to 2 months.
Using the scheme for acid washing of hot water boilers shown in Figure 6 to fill boilers with solution
Possibility of using existing tanks with a pump for conservation of energy boilers (Figure 2)
Preparing a sodium silicate solution using softened water, since using water with a hardness higher than 3 mEq/kg can lead to sodium silicate flakes falling out of the solution
Preparation of a preservative solution of sodium silicate in a tank with water circulation according to the “tank-pump-tank” scheme with pouring liquid glass into the tank through the hatch
Determination of the approximate consumption of liquid commercial sodium silicate at the rate of no more than 6 liters per 1 m3 of preservative solution volume
Draining water from the boiler before filling it with preservative solution
Setting the working concentration of SiO2 in the preservative solution at the level of 1.5 - 2 g/kg
Determining the amount of solution to be prepared, based on ensuring the filling of the preserved boiler and the circulation circuit, including the tank. When filling the boiler with a pump from the tank without organizing circulation through the boiler, the volume of prepared lime milk depends only on the water volume of the boiler. When filling the boiler without organizing circulation, the volume of the prepared solution depends only on the volume of the boiler.
Preservation of the preservative solution in the boiler for the entire period of downtime in reserve
Possibility of draining the solution if it is necessary to carry out repair work after soaking in the boiler for at least 4 - 6 days with the expectation of putting the boiler back into operation after completion of the repair.
Draining solution from the boiler for repairs after circulating the solution through the boiler for 8 - 10 hours at a speed of 0.5 - 1 m/s
Maintaining an excess pressure of 0.01 - 0.02 MPa with network water by opening the bypass valve at the entrance to the boiler while maintaining the preservative solution in it for the entire shutdown period
Taking a sample from the vents during the conservation period once a week to monitor the concentration of SiO2 in the solution
Adding the required amount of liquid sodium silicate and organizing the circulation of the solution through the boiler into the tank until the required concentration is achieved while the SiO2 concentration decreases to less than 1.5 g/kg
Displacement of the preservative solution into the network water pipelines in small portions (by partially opening the valve at the outlet of the boiler) at 5 m3/h for 5 - 6 hours for the PTVM-100 boiler and 10 - 12 hours for the PTVM-180 boiler when depreserving the hot water boiler before his kindling.
Russian joint stock company
energy and electrification "UES of Russia"
Department of Science and Technology
METHODOLOGICAL INSTRUCTIONS
ON PRESERVATION
THERMAL POWER EQUIPMENT
RD 34.20.591-97
Expiration date set
from 07/01/97 to 07/01/2002
Developed by the company for setting up, improving technology and operating power plants and networks "ORGRES" and JSC VTI
Performers IN AND. Startsev (JSC Firm ORGRES), E.Yu. Kostrikina, T.D. Modestova (JSC VTI)
Approved Department of Science and Technology of RAO "UES of Russia" 02.14.97
Chief A.P. BERSENEV
These Guidelines apply to power and hot water boilers, as well as turbine units of thermal power plants.
Guidelines determine the main technological parameters of various conservation methods, establish criteria for choosing methods or a combination (combination) of methods, the technology for their implementation on boilers and turbine units when put into reserve or repair, taking into account the sharp increase in power plants in both the number of shutdowns and the duration of equipment downtime.
With the introduction of these Methodological Instructions, the “Methodological Instructions for Heat Conservation” become invalid energy equipment: RD 34.20.591-87" (M.: Rotaprint VTI, 1990).
1. GENERAL PROVISIONS
The water discharged from the boiler must be used in the steam-water cycle of the power plant, for which purpose at block power plants it is necessary to provide for the pumping of this water to neighboring blocks.
During treatment, hydrazine levels are monitored by taking water samples from a sampling point in the feedwater line upstream of the boiler.
At the end of the specified processing time, the boiler is stopped. When shutting down in reserve for up to 10 days, the boiler does not need to be drained. In case of longer downtime, a CO should be performed after hydraulic fracturing.
If the concentration of hydrazine in the first hour of treatment decreases by 25 - 30% compared to the initial one, then it is necessary to introduce additional amounts of reagents into the boiler.
The treatment ends when the hydrazine content in the water of the salt compartment decreases by 1.5 - 3 times compared to the original. The total processing time should be at least 3 hours.
During the processing, the pH and hydrazine content in the clean and salt compartments are monitored.
At the end of the treatment, the boiler is stopped and when it is taken out for repairs, after the pressure has been reduced to atmospheric, the boiler is emptied, sending the solution for neutralization.
When putting the boiler into reserve, the preservative solution can be drained before starting the boiler.
At the end of the PV, the boiler is stopped and, after reducing the pressure to atmospheric pressure, it is emptied, sending the solution for neutralization.
Rice. 3. Preservation scheme for KI power boilers:
preservation pipelines
During treatment, hydrazine levels are monitored by taking water samples from a sampling point in the feedwater line upstream of the boiler.
At the end of the GO, the CO is performed.
The inhibitor solution from the preparation tank is supplied to the deaerator.
It is also necessary to provide for draining the solution from the feed lines and the boiler after conservation into the storage tank using drainage tanks for this purpose.
Notes: 1. On boilers with a pressure of 9.8 and 13.8 MPa without treatment of feed water with hydrazine, maintenance must be carried out at least once a year.
5.2.9. When put into reserve, the boiler is left filled with a preservative solution for the entire idle time.
5.2.10. If it is necessary to carry out repair work, drainage of the solution is carried out after keeping it in the boiler for at least 4 - 6 days in such a way that after the completion of the repair the boiler is put into operation.
The solution can be drained from the boiler for repairs after circulating the solution through the boiler for 8 - 10 hours at a speed of 0.5 - 1 m/s.
The duration of repairs should not exceed 2 months.
5.2.11. If the boiler is left with a preservative solution during downtime, an excess pressure of 0.01 - 0.02 MPa is maintained in it with network water by opening the bypass valve at the inlet to the boiler. During the conservation period, samples are taken from the air vents once a week to monitor the concentration of SiO2 in the solution. When the SiO2 concentration decreases to less than 1.5 g/kg, the required amount of liquid sodium silicate is added to the tank and the solution is recirculated through the boiler until the required concentration is achieved.
6.1.2. Preservation of a turbine unit with heated air is carried out when it is put into reserve for a period of 7 days or more.
Conservation is carried out in accordance with the instructions “Methodological instructions for the conservation of steam turbine equipment of thermal power plants and nuclear power plants with heated air: MU-34-70-078-84” (M.: SPO Soyuztekhenergo, 1984).
6.1.3. If the power plant does not currently have a conservation installation, it is necessary to use mobile fans with a heater to supply heated air to the turbine unit. Air can be supplied to the entire turbine installation, or at least to its individual parts (DCS, LPC, boilers, to the upper or lower part of the condenser or to the middle part of the turbine).
To connect a mobile fan, it is necessary to install an inlet valve.
6.3.2. To preserve the turbine unit, air saturated with the inhibitor is sucked through the turbine. Air is drawn through the turbine unit using a seal ejector or starting ejector. Saturation of the air with the inhibitor occurs when it comes into contact with silica gel impregnated with the inhibitor, the so-called linasil. Impregnation of linasil is carried out at the manufacturer. To absorb excess inhibitor, the air at the outlet of the turbine unit passes through pure silica gel.
Preservation with a volatile inhibitor is carried out when put into reserve for a period of more than 7 days.
6.3.3. To fill the turbine with inhibited air at its inlet, for example, to the steam supply pipeline to the front seal of the HPC, a cartridge with linasil is connected (Fig. 5). To absorb excess inhibitor, cartridges with pure silica gel are installed at the outlet of the equipment, the volume of which is 2 times greater than the volume of linasil at the inlet. In the future, this silica gel can be additionally impregnated with an inhibitor and installed at the entrance to the equipment during the next conservation.
Rice. 5. Preservation of turbines with a volatile inhibitor:
Main steam valve; 2 - high pressure stop valve; 3 - high pressure control valve; 4 - medium pressure safety valve; 5 - medium pressure control valve; 6 - chambers for suction of the steam-air mixture from the end seals of the cylinders; 7 - sealing steam chamber; 8 - sealing steam pipeline; 9 - existing valves; 10 - manifold of steam-air mixture for seals; 11 - steam-air mixture suction manifold; 12 - inhibitor supply pipeline; 13 - cartridge with linasil; 14 - newly mounted valves; 15 - seal ejector; 16 - exhaust into the atmosphere; 17 - cartridges with pure silica gel to absorb the inhibitor; 18 - pipeline for suction of the steam-air mixture from the chambers; 19 - intermediate superheater; 20 - air sampling; 21 - flange; 22 - valve
To fill the turbine with inhibited air, standard equipment is used - a seal ejector or a starting ejector.
To preserve 1 m3 of volume, at least 300 g of linasil is required; the protective concentration of the inhibitor in the air is 0.015 g/dm3.
Linasil is placed in cartridges, which are sections of pipes with flanges welded to both ends. Both ends of the pipe with flanges are tightened with a mesh with a mesh size that prevents the laminate from spilling out, but does not interfere with the passage of air. The length and diameter of the pipes are determined by the amount of linasil required for preservation.
Linasil is loaded into the cartridges with a spatula or gloved hands.
6.3.4. Before conservation begins, to eliminate possible accumulation of condensate in the turbine, pipelines and valves, they are drained, the turbine and its auxiliary equipment are de-steamed, and disconnected from all pipelines (drains, steam extraction, steam supply to seals, etc.).
To remove possible accumulation of condensate in undrained areas, the turbine is dried with air. To do this, a cartridge with calcined silica gel is installed at the inlet and air is sucked through the ejector along the circuit “cartridge - HPC - CSD - LPC - collector for suction of the steam-air mixture from the seals - ejector - atmosphere.”
After the turbine metal has cooled to approximately 50 °C, it is sealed with a packing of asbestos impregnated with sealant at the air inlet from the turbine room into the suction chamber of the steam-air mixture of the end seals.
After drying the turbine, cartridges with linasil are installed at the inlet, and cartridges with pure silica gel are installed at the outlet, the ejector is turned on and air is sucked through the circuit “cartridge-pipeline for supplying steam to the seal - HPC - suction manifold for the steam-air mixture - cartridges with silica gel - ejector - atmosphere”. When a protective inhibitor concentration of 0.015 g/dm3 is reached, conservation is stopped, for which the ejector is turned off, a plug is installed at the air inlet into the cartridge with linasil and at the entrance of inhibited air into the cartridges with silica gel.
1 . Reagents used:
hydrochloric acid, chemical grade concentration 0.01 mol/kg;
sodium hydroxide, chemical grade concentration 0.01 mol/kg;
the indicator is mixed.
2 . Determination of concentration
Through a bottle containing 0.1 kg of solution of hydrochloric acid concentration of 0.01 mol/kg, using an aspirator, slowly pass 5 kg of air containing the inhibitor; which is absorbed by the acid solution, after which 10 cm3 of the acid solution is taken and titrated with sodium hydroxide with a mixed indicator.
Where V- volume of air passed, dm3;
k 1, k 2 - respectively, correction factors for acid and alkali solutions having a molar concentration of equivalents of exactly 0.01 mol/dm3;
Aqueous solutions of hydrazine with a concentration of up to 30% are non-flammable; they can be transported and stored in carbon steel vessels.
When working with hydrazine hydrate solutions, it is necessary to prevent porous substances and organic compounds from getting into them.
Hoses must be connected to the places where hydrazine solutions are prepared and stored to wash off spilled solution from the floor and equipment with water. To neutralize and render harmless, bleach must be prepared.
If repairs are necessary to equipment used to prepare and dispense hydrazine, it should be thoroughly rinsed with water.
Any hydrazine solution that gets on the floor should be covered with bleach and washed off with plenty of water.
Aqueous solutions of hydrazine can cause skin dermatitis, and its vapors irritate the respiratory tract and eyes. Hydrazine compounds entering the body cause changes in the liver and blood.
When working with hydrazine solutions, you must use safety glasses, rubber gloves, a rubber apron and a KD brand gas mask.
Drops of hydrazine solution that get on the skin or eyes should be washed off with plenty of water.
2 . Water solution ammonia NH4(OH)
An aqueous solution of ammonia (ammonia water) is a colorless liquid with a strong, specific odor. At room temperature and especially when heated, it releases ammonia abundantly. The maximum permissible concentration of ammonia in the air is 0.02 mg/dm3. Ammonia solution is alkaline.
The ammonia solution should be stored in a tank with an airtight lid.
Spilled ammonia solution should be washed off with plenty of water.
If it is necessary to repair equipment used for preparing and dispensing ammonia, it should be thoroughly rinsed with water.
The aqueous solution and ammonia vapor cause irritation to the eyes, respiratory tract, nausea and headache. Getting ammonia into your eyes is especially dangerous.
When working with ammonia solution, you must use safety glasses.
Ammonia that gets on the skin or eyes must be washed off with plenty of water.
3 . Trilon B
Commercial Trilon B is a white powdery substance.
Trilon solution is stable and does not decompose during prolonged boiling. The solubility of Trilon B at a temperature of 20 - 40 °C is 108 - 137 g/kg. The pH value of these solutions is about 5.5.
Commercial Trilon B is supplied in paper bags with a polyethylene liner. The reagent should be stored in a closed, dry room.
Trilon B does not have a noticeable physiological effect on the human body.
When working with commercial Trilon, you must use a respirator, gloves and safety glasses.
4 . Trisodium phosphate Na3PO4×12 H2O
Trisodium phosphate is a white crystalline substance, highly soluble in water.
In crystalline form it has no specific effect on the body.
In a dusty state, getting into the respiratory tract or eyes, irritate the mucous membranes.
Hot phosphate solutions are dangerous if splashed into the eyes.
When carrying out work involving dust, it is necessary to use a respirator and safety glasses. When working with hot phosphate solution, wear safety glasses.
In case of contact with skin or eyes, rinse with plenty of water.
5 . Caustic soda NaOH
Caustic soda is a white, solid, very hygroscopic substance, highly soluble in water (1070 g/kg dissolves at a temperature of 20 °C).
Caustic soda solution is a colorless liquid heavier than water. The freezing point of a 6% solution is minus 5 °C, and a 41.8% solution is 0 °C.
Caustic soda in solid crystalline form is transported and stored in steel drums, and liquid alkali in steel containers.
Any caustic soda (crystalline or liquid) that gets on the floor should be washed off with water.
If it is necessary to repair equipment used for preparing and dispensing alkali, it should be washed with water.
Solid caustic soda and its solutions cause severe burns, especially if they come into contact with the eyes.
When working with caustic soda, it is necessary to provide a first aid kit containing cotton wool, a 3% solution of acetic acid and a 2% solution of boric acid.
Personal protective equipment when working with caustic soda: cotton suit, safety glasses, rubberized apron, rubber boots, rubber gloves.
If alkali gets on the skin, it must be removed with cotton wool and the affected area should be washed with acetic acid. If alkali gets into your eyes, rinse them with a stream of water and then with a solution of boric acid and go to a medical center.
6 . Sodium silicate (sodium liquid glass)
Commercial liquid glass is a thick solution of yellow or gray, SiO2 content is 31 - 33%.
Supplied in steel barrels or tanks. Liquid glass should be stored in dry indoors at a temperature not lower than plus 5 °C.
Sodium silicate is an alkaline product, soluble in water at a temperature of 20 - 40 °C.
If liquid glass solution gets on your skin, it should be washed off with water.
7 . Calcium hydroxide (lime solution) Ca(OH)2
Lime mortar is a transparent liquid, colorless and odorless, non-toxic and has a weak alkaline reaction.
A solution of calcium hydroxide is obtained by settling the milk of lime. The solubility of calcium hydroxide is low - no more than 1.4 g/kg at 25 °C.
When working with lime mortar, people with sensitive skin are recommended to wear rubber gloves.
If the solution gets on your skin or eyes, wash it off with water.
8 . Contact inhibitor
Inhibitor M-1 is a salt of cyclohexylamine (TU 113-03-13-10-86) and synthetic fatty acids of the C10-13 fraction (GOST 23279 -78). In its commercial form it is a paste or solid substance from dark yellow to Brown. The melting point of the inhibitor is above 30 °C; mass fraction of cyclohexylamine - 31 - 34%, pH of an alcohol-water solution with a mass fraction of the main substance 1% - 7.5 - 8.5; the density of a 3% aqueous solution at a temperature of 20 °C is 0.995 - 0.996 g/cm3.
M-1 inhibitor is supplied in steel drums, metal flasks, steel barrels. Each package must be marked with the following data: name of the manufacturer, name of the inhibitor, batch number, date of manufacture, net weight, gross.
The commercial inhibitor is a flammable substance and must be stored in a warehouse in accordance with the rules for storing flammable substances. An aqueous solution of the inhibitor is non-flammable.
Any inhibitor solution that gets on the floor must be washed off with plenty of water.
If it is necessary to repair the equipment used for storing and preparing the inhibitor solution, it should be thoroughly rinsed with water.
The M-1 inhibitor belongs to the third class (moderately hazardous substances). MPC in the air working area for an inhibitor - 10 mg/m3.
The inhibitor is chemically stable, does not form toxic compounds in the air and Wastewater ah in the presence of other substances or industrial factors.
Persons working with inhibitors must have a cotton suit or robe, gloves, and a hat.
After finishing work with the inhibitor, you must wash your hands. warm water with soap.
9 . Volatile inhibitors
9.1. The volatile atmospheric corrosion inhibitor IFKhAN-1 (1-diethylamino-2-methylbutanone-3) is a transparent yellowish liquid with a sharp, specific odor.
The liquid inhibitor IFKHAN-1, in terms of the degree of impact, is classified as a highly hazardous substance; the maximum permissible concentration for inhibitor vapors in the air of the working area is 0.1 mg/m3. The IFKHAN-1 inhibitor in high doses causes excitation of the central nervous system, irritating effect on the mucous membranes of the eyes and upper respiratory tract. Prolonged exposure of unprotected skin to the inhibitor may cause dermatitis.
The IFKHAN-1 inhibitor is chemically stable and does not form toxic compounds in air and wastewater in the presence of other substances.
Liquid inhibitor IFKHAN-1 is a flammable liquid. The ignition temperature of the liquid inhibitor is 47 °C, the auto-ignition temperature is 315 °C. When a fire occurs, fire extinguishing agents are used: fire felt, foam fire extinguishers, DU fire extinguishers.
Cleaning of premises should be carried out using a wet method.
When working with the IFKHAN-1 inhibitor, it is necessary to use personal protective equipment - a suit made of cotton fabric (robe), rubber gloves.
9.2. The inhibitor IFKHAN-100, also an amine derivative, is less toxic. The relatively safe exposure level is 10 mg/m3, the ignition temperature is 114 °C, the self-ignition temperature is 241 °C.
Safety measures when working with the IFKHAN-100 inhibitor are the same as when working with the IFKHAN-1 inhibitor.
It is prohibited to carry out work inside the equipment until it is re-opened.
At high concentrations of the inhibitor in the air or if it is necessary to work inside the equipment after its re-preservation, a gas mask of grade A with a filter box of grade A (GOST 12.4.121-83 and GOST 12.4.122-83) should be used. The equipment should be ventilated first. Work inside the equipment after re-preservation should be carried out by a team of two people.
After finishing working with the inhibitor, you must wash your hands with soap.
If the liquid inhibitor gets on your skin, wash it off with soap and water; if it gets into your eyes, rinse them with plenty of water.
Water heating boilers KVR.
1. INTRODUCTION
The technical description is a guide for the installation, operation and transportation of the ASK Group of Companies water heating boiler. Contains information about the boiler design.
2 . PURPOSE
A hot water boiler with a heating capacity of 0.688 Gcal/hour is designed to heat water up to 95 0 C, intended for heating systems in residential, industrial and warehouse premises with a total area of up to 8000 m 2 . Simultaneously with the boiler, a heater can be used to produce hot water used for domestic and industrial purposes to be discharged.
The water-tube boiler creates natural circulation of water in the heating system, in which you need to have top point expansion tank, open type. When using a circulation pump creating a pressure of up to 6.0 kg/cm 2 , the heating system is made closed using safety valve at the boiler outlet.
The boiler is designed for layer combustion of any type solid fuel(firewood, coal, peat). AtWhen installing the boiler in a specially equipped room, using additional devices, it is allowed to burn liquid and gaseous fuels (clarified kerosene, diesel fuel, diesel oil, natural or liquefied gas).
The high degree of softness of the water used creates conditions for long-term operation of the boiler and heating system. On the outside, the boiler pipe system is thermally insulated with mineral wool and covered with a casing made of steel sheet 2 mm thick.
Installation of a hot water boiler and heating system carry out in accordance with the heating scheme of the building. To ensure normal circulation in horizontal areas, it is necessary to create a slope of at least 0.01 0 hot water pipelines from the highest point, with a decrease to the heating elements, and the slope of the return water pipeline with a decrease to the boiler.
3. TECHNICAL DATA
Basic technical data and parameters of the hot water boiler.
|
Options |
Boiler brand |
|||
|
KVR-0.2 |
KVR-0.5 |
KVR-0.8 |
KVR-1 |
|
|
Heating capacity, MW (Gcal/h) |
(0,172) |
(0,430) |
(0,688) |
(0,860) |
|
Estimated efficiency, % |
||||
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Temperature water chart, o C |
60-95 |
60-95 |
60-95 |
60-95 |
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Working pressure, MPa (kgf/cm 2 ) |
0,6 (6) |
0,6 (6) |
0,6 (6) |
0,6 (6) |
|
Fuel consumption (coal), kg/hour |
39,2 |
|||
|
Boiler volume, m 3 |
10,4 |
12,4 |
17,7 |
|
|
Boiler heating surface, m 2 |
||||
4. PRODUCT COMPOSITION
The product includes an all-welded design of the boiler pipe system block. The boiler is thermally insulated with mineral wool, covered with a casing, and equipped with three doors: firebox, ash pan and ash pan. Pressure gauges and thermometers, five grate bars, safety valves.
Installation, brickwork and adjustment work can be carried out at the request of the customer, by a visiting team of the enterprise, at the boiler installation site.
By agreement with the customer, the boiler can be equipped with furnace tools and auxiliary equipment
5. STRUCTURE AND OPERATION OF THE BOILER
5.1 Boiler design
The boiler is a transportable, non-dismountable block in the form of a firebox and a convective part, installed on an ash pan block (Fig. 1). At the bottom of the boiler there is a belt of collectors (longitudinal Ø159x5, transverse Ø133x5 mm), to which water cooled in the heating system is supplied through a DN 100 supply pipe. 5 grates measuring 900x220 mm are placed inside the lower belt of the collectors.
The boiler firebox is a closed volume, shielded by walls made of pipes Ø51x2.5mm.
In the front part of the firebox there is a door measuring 400x400 mm. Under the firebox, in the ash pan block, there is an ash pan with a door measuring 400x400mm and a blow air input window measuring 250x250mm.
The convective part of the boiler is made in the form of downward and upward flue ducts, each of which has 12 sections. Riser pipes Ø83x4 mm, convection pipes Ø51x2.5mm.
The flue ducts of the convective part are separated from the firebox and betweenconsisting of two-light gas-tight walls (4x30mm strip). Under the convective block, in the block, there is an ash pan, which has on the left or right side door dimensions 400x400 mm. In the upper part of the boiler there is an upper belt of collectors made of pipes (longitudinal Ø159x5, transverse Ø133x5) with 4 sling eyes. The boiler ceiling is screened with pipes Ø83x4mm, embedded in a collecting manifold Ø133x5mm from which it is discharged hot water, through the DN100 pipe, and then into the heating system of the building.
On the outside, a 4x30 mm strip is welded between the pipes. The entire pipe system of the boiler is lined with heat-insulating mats made of basalt wool and sheathed with a casing made of 2 mm sheet.
Water flows through the shielding walls and elements of the boiler in accordance with the circulation scheme.
5.2 Operation of the hot water boiler
5.2.1. The flue gases, having reached the top of the firebox, turn 180 O and through the convective part are directed into the flue, from where they enter the chimney of the boiler room.
5.2.2. Water enters the boiler through the inlet pipeline. It is possible to install a mixing water pump, which is installed between the direct and return water supply. With the help of a mixing pump, the temperature of the return water entering the boiler rises to 60°C.Water is discharged from the boiler through the outlet pipeline.
5.2.3. Construction and operation of instrumentation and automation according to the documentation supplied with the kit.
6. CONTROL AND MEASURING INSTRUMENTS
An indicating pressure gauge and thermometer are installed on the return water pipe.
A pressure gauge is installed on the direct water inlet pipe.
7. PLACEMENT AND INSTALLATION
7.1. The boiler must be installed in separate rooms that meet the requirements of SNiP 2.01.02-85
7.2 Installation 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 0.7 kgf/cm 2 : hot water boilers and water heaters with water heating temperature not exceeding 115 °C” and according to the boiler room design.
7.3 During installation, care should be taken to ensure that the boiler is installed strictly horizontally to the boiler room floor level.
8. TRANSPORTATION AND STORAGE
8.1. Boilers can be transported by any type of transport in compliance with measures to ensure their safety.
8.2. The boiler may only be lifted using the lifting eyes installed for this purpose. When lifting and installing, special care must be taken to avoid dropping or shaking the boiler so as not to damage the lining or insulation of the boiler.
The conditions for transportation and storage of boilers must comply with the requirements of group 5 of GOST 15150-69.
8.3. Storing boilers for 1 to 3 months is considered short-term. Over 3 months - long-term.
8.4. Short-term storage is allowed under enclosing structures that protect the boiler from precipitation.
8.5. Long-term storage should be carried out in special rooms that must meet the following requirements:
the premises must be dry, ventilated, and protect the boiler from precipitation;
positive temperatures are maintained in the premises in winter;
The dimensions of the room ensure free placement of the boilers.
8.6. During storage, the outer surfaces of boilers must be cleaned of dirt, washed and dried.
8.7. Clean boiler flues from contamination. Drain the water completely. After draining the water inner space dry the boiler.
9. STARTING AND STOPPING THE BOILER
At the same time, in order to avoid the formation of condensation in the heat exchange elements, the initial start-up of the boiler and its transition from a cold to a hot state must occur slowly. The recommended heating rate of water in the boiler should not exceed 1+1.5 °C/min.
When starting the boiler after a short period of inactivity, the boiler load and water heating temperature can be increased somewhat faster, but not more than 2 °C/min.
If these requirements are violated during the initial start-up of the boiler, condensation may form in the heat exchange elements.
9.1. Stopping the boiler in all cases, with the exception of an emergency stop, must be carried out only with a written order from the administration.
When stopping the boiler you must:
Stop fuel supply to the firebox;
Disconnect the boiler from the pipeline after combustion in the furnace stops. If, after disconnecting the boiler from the pipeline, the pressure in the boiler increases, refuel the boiler and purge;
Cool down the boiler and drain water from it;
Ventilate the firebox and flue for 10-15 minutes, turn off the pump and vent;
De-energize the voltage shield;
It is prohibited to drain water from the boiler without the order of the person responsible for its proper condition and safe operation boiler room The drainage of water should be carried out slowly; the pipe part should communicate with the atmosphere using an air collector and three-way valve pressure gauge.
The procedure for preserving a stopped boiler must comply with the instructions in these instructions.
To stop the boiler for a short time, there is no need to interrupt the water circulation.
Despite the fact that the necessary technological equipment is installed in the boiler room, and all the necessary measures for the preparation of boiler water have been carried out, however, during long-term operation, due to the lack of proper control on the part of the operating organizations over the operation of the water treatment equipment, solids are formed on the internal walls of the boiler heat exchange elements deposits in the form of scale. To remove scale, boilers are chemically cleaned. Chemical cleaning boilers are produced using alkalis or acids (trisodium phosphateNa 3 P.O. 4. sodium hydroxide NaOH, hydrochloric acidHCL).
Cleaning with trisodium phosphate is carried out in the following sequence:
The boiler is disconnected from the heating network, the water pressure in the boiler is reduced to 0.5 Atm and chemicals are introduced into the boiler from a special tank. reagents trisodium phosphate at the rate of 1.5 kg per 1 m 3
boiler water, turn on the mixing pump. After 2 hours, part of the boiler water is drained into the drainage and additional trisodium phosphate is introduced at the rate of 0.75 kg per 1 m 3
boiler water. The mixing pump is turned on again to circulate water in the boiler and the boiler is “boiled down” for 5-6 hours, while it is necessary to monitor the temperature and pressure of the water in the boiler, after which the boiler is cooled, the water is drained, the boiler is washed and filled with chemically purified water.
Acid cleaning of boilers is more effective in removing scale, compared to alkaline cleaning. But since acid washing is classified as a hazardous type of work, its implementation can only be entrusted to organizations licensed for this type of activity.
9.2 Emergency stop of the boiler
9.2.1. The boiler must be immediately stopped and disabled by protection or personnel in the following cases:
Safety valve malfunction detection;
If cracks, bulging or gaps in welds are found in the main elements of the boiler;
Reducing water flow through the boiler below the minimum permissible value;
Reducing the water pressure in the hydraulic circuit of the boiler below the permissible level;
The pressure has risen above the permitted limit by 10% and continues to rise, despite the cessation of fuel supply and increased water supply to the boiler;
The feed pump has stopped working;
The power supply has been interrupted, and the boiler elements have been damaged, creating a danger for service personnel or threat of boiler destruction;
Malfunctions of automatic safety or alarm systems, including loss of voltage in these areas;
A fire occurs in the boiler room that threatens personnel or the boiler.
9.2.2. The procedure for emergency shutdown of the boiler must be specified in production instructions. The reasons for the emergency shutdown of the boiler must be recorded in the shift log.
10. OPERATION AND MAINTENANCE
10.1 Operating procedure
After installing the boiler and connecting it to the space heating system, it is necessary to fill the system and boiler with water and carry out an inspection. The grate bars are installed after hydraulic testing and inspection.
When lighting the boiler, perform the following work:
1. open the chimney damper, firebox and ash door;
2. remove slag and ash from the firebox and from the ash pit;
3. put the required amount of firewood into the firebox on the grates;
4. Place lump coal on the firewood;
5. light firewood in the firebox;
6. close the firebox door and adjust the supply of the blower fan or the opening of the blower door according to combustion;
7. When burning wood and coal is stable, add the required amount of coal evenly throughout the firebox.
10.2 Maintenance
10.2.1 Maintenance consists of periodic inspections, blowing, cleaning of the boiler and its repair.
10.2.2 List of maintenance activities.
In order to ensure reliable operation of the hot water boiler, it is recommended to carry out the following measures:
Visual inspection of leaks;
Checking the drainage pipe;
Checking flange connections;
Blowing;
Complete cleaning, checking heating surfaces.
10.3 Blowing and cleaning the boiler
10.3.1. In order to ensure flawless and more economical operation of the boiler, blowing should be done quite often. As the temperature rises flue gases by 30-40 O With a higher gas temperature of a clean boiler at the same load, the boiler should be blown. Blowing the boiler should also be carried out if the resistance of the boiler gas path increases significantly.
10.3.2. The boiler is cleaned from soot through the doors of the firebox and ash pan. Cleaning can be done either manually or with a mechanized brush (brush). When cleaning with a power brush, care must be taken to avoid damaging the pipes.
10.3.3. Internal inspection and cleaning of the firebox is carried out during summer downtime boiler All accumulated soot and dirt are removed from the walls of the firebox and convective part using a steel brush.
10.3.4. Internal inspection, flushing and cleaning of the water path should be carried out annually during the summer period of boiler downtime. Inspect the boiler through the firebox and ash pan doors.
The boiler is cleaned of boiler stone and sludge using a chemical method. Chemical cleaning is carried out with a 5% solution of hydrochloric acid, inhibited by a mixture of PB-5 - 0.1% with hexamine - 0.5%; or a mixture of PB-5 with urotropine and OP-10 at a temperature of 60-65°C. The circulation time of the solution is from 6 to 8 hours at a speed along the path of 1-1.5 m/sec.
After cleaning, flush the boiler by removing all deposits of dissolved scale and sludge from it through the lower drain pipe. After which it is necessary to fill the boiler with treated water as quickly as possible. If such a composition is not available, the boiler should be heated to operating temperature and aerated effectively.
10.4 Boiler repair
Boiler repair during warranty period may only be produced with the written permission of the manufacturer.
After the warranty period, boiler repairs can only be carried out by a company that has technical means necessary for high-quality performance of work.
10.5 Safety precautions
10.5.1. Strict adherence to safety precautions is required during maintenance. Repair work must be carried out in strict accordance with the norms and rules for the production of repair work.
10.5.2. Repairs, cleaning and inspection of the boiler may only be carried out after appropriate instruction at the workplace.
10.5.3. Work inside the boiler can only be carried out when the boiler is sufficiently cooled. Before starting work, the boiler must be ventilated.
10.5.4. It is prohibited to work in the firebox and convective part with a temperature above 60°C.
10.5.6. Boiler repairs should be carried out with water and air turned off, and power removed from the automation system.
10.5.7. Inspection, lubrication and repair of component equipment is carried out in accordance with the operating instructions for the relevant products.
10.5.8. Do not allow burning coal to fall onto the floor. The distance from the boiler to combustible structures must be at least 2000 mm.
10.5.9. It is unacceptable to leave firewood, coal, flammable objects or dry clothes near a lit boiler.
10.5.11. It is prohibited to use flammable fuel or explosive substances (gasoline, kerosene, acetone, etc.) to light the boiler.
10.5.12. When the boiler is running, the water temperature must not rise above 100 0 C, when the temperature rises, it is necessary to reduce fuel combustion by closing the blower fan gate or the blower door and reducing the draft or increasing the water flow.
11. PRESERVATION OF THE WATER BOILER
The procedure for preserving the boiler for long-term storage must comply with these instructions.
Preservation of the boiler for a period of up to one month should be carried out using the wet method, for this it is necessary:
Stop the boiler according to the instructions;
Disconnect the boiler pipeline from the general lines;
Fill the internal volume of the boiler with a protective solution: sodium hydroxide 1000 mg/l, phosphoric anhydride 100 ml/l and sodium sulfate 200 mg/l;
Before starting a boiler that has undergone wet conservation, open the system, release the alkaline solution and rinse with clean water;
If the boiler is stopped for a long time (more than one month), preservation must be done using a dry method, for this it is necessary:
Stop the boiler according to the instructions;
When the pressure in the boiler is equal to half the working pressure, purge the boiler according to the instructions;
After the temperature drops to 50-60ºС, drain the water from the boiler;
Clean the heating surface from scale and sludge;
Dry the inside of the boiler by blowing with compressed air;
Place previously prepared baking trays filled with quicklime into the collector (1 kg in each collector, or anhydrous calcium chloride, 0.5 kg each in each collector).
Before putting a dry-preserved boiler into operation, it is necessary to remove the trays with lime (calcium chloride) from the collectors.
Preservation and re-preservation of devices, protection, control and auxiliary equipment in accordance with the installation and operation instructions of the manufacturers of these devices and equipment.
Power supply to a boiler that is undergoing conservation must be excluded.
12. GENERAL INSTRUCTIONS
12.1. Capital and current repairs hot water boilers must be produced in accordance with specially developed schedules. Minor defects discovered during operation must be eliminated as soon as possible with the boiler running (if operating rules allow) or whenhis stop.
12.2. Safety measures during operation, preparation for work, operating procedure, measurement of parameters, adjustment and configuration, checking technical condition during operation, characteristic malfunctions and methods for eliminating them and Maintenance must be carried out according to the relevant sections technical description boiler
Equipment conservation is an event that is carried out to protect metal elements from corrosion during the shutdown of boilers for an indefinite (long) period. There are four preservation methods: gas, liquid, dry and overpressure. In this article we will look at each of them, and you can choose best option for your conditions.
Preservation of hot water boilers with gas
Reducer for argon.
First, let's look at preserving boilers with gas. The bottom line is that gas is pumped into the heater, which, when in contact with wet metal surfaces, does not trigger oxidation processes, that is, corrosion. The gas completely squeezes out the air that contains oxygen. Can be used:
- argon;
- nitrogen;
- helium;
- ammonia.
The instructions for preserving hot water boilers contain a clear algorithm of actions. First you need to fill the heater with deaerated water - this is water from which the air has been removed. But in principle, you can fill it with ordinary water. Then a gas cylinder is connected to the upper pipe of the heater.
The pressure in the gas cylinder is enormous, about 140 atmospheres. If you apply such pressure directly to it, it will rupture. Therefore, a reducer is screwed onto the cylinder.
It has two pressure gauges. One pressure gauge shows the pressure that comes from the cylinder, and the second pressure gauge shows the pressure that is supplied to the boiler. You can set the required pressure on the reducer and when this value is reached, the gas supply from the cylinder stops. Thus, it is possible not only to safely fill the boiler with gas, but also to increase the pressure to the required value (recommended 0.013 mPa).
The process goes something like this:
- the gas slowly squeezes water out of the boiler (the lower pipe must be open);
- after all the liquid has come out, the lower pipe is closed;
- when the pressure in the boiler reaches 0.013 MPa, gas stops flowing;
- the upper pipe to which the gearbox is connected is blocked.
From time to time you need to check the gas pressure and make adjustments if necessary. The main thing is to prevent air from entering the boiler.
Wet method for heating preservation
The wet method is suitable for preserving boilers and the heating system as a whole. The method is to fill the circuit with a special liquid that will prevent the metal from rusting. If the house is not heated at all and there is a risk of freezing, then only (non-freezing liquids based on propylene glycol) can be used as a preservation liquid. Concentrates do not freeze even at -60, but they thicken strongly. They can be diluted to the required consistency, thereby adjusting the minimum operating temperature. The disadvantage of antifreeze is that they are expensive, dry out the rubber, have a high degree of fluidity, and turn into acid when overheated.
If you do not plan to use it for several months, then it needs to be preserved.
The same applies and this significantly prolongs their life.
If you need to preserve the boiler and there is no risk that the liquid in it will freeze, then in addition to antifreeze, you can use water with added sodium sulfate. Its concentration must be at least 10 g/l. After this, the liquid is heated to remove air from it and all pipes are clogged. The liquid is pumped using a pressure test pump. They are different: manual, automatic, household and professional. We have already written about that.
Dry method of preservation of water heaters
Preservation of a boiler room using dry methods provides the same high guarantees of equipment safety as the methods described above. The essence of the matter is to completely dry the internal channels from moisture. You can do this in several ways:
- blow with strong pressure of warm air;
- evaporate moisture.
It has gained authority in the Russian Federation, so its sales volumes are constantly growing.
In Italian, malfunctions occur only in case of improper operation.
You can evaporate the moisture by turning on the burner or lighting a flame in the firebox of an empty (without liquid) boiler. It is important that the flame is very slow so that the heat exchanger does not burn out. Air remains in the heater channels, and there is always moisture in it in the form of steam. This moisture may condense under certain conditions. The presence of moisture in the air, although slowly, still leads to the destruction of the metal. Therefore, you need to add a moisture-absorbing substance. Granular potassium chloride or quicklime is suitable for this. Desiccant powders need to be changed periodically (every two months).
Preservation of the boiler with excess pressure
This method is used only if the boiler needs to be stopped for no more than 10 days and there is no risk of the system defrosting. All that is needed is to fill the heater with deaerated water and raise the pressure above atmospheric pressure. In this case, the possibility of oxygen entering the unit is eliminated.
