启动锅炉说明书

源牌启动锅炉说明书

ENVIRONMENT® Start-up Boiler Manual

Hangzhou Huadian Huayuan Environment Engineering Co., Ltd 杭州华电华源环境工程有限公司

杭州华源前线能源设备有限公司

Hangzhou Huayuan QianXian Energy Equipments Co., Ltd

地址：杭州市余杭区塘栖镇工业园区（莫家桥） 邮编：311106

Add: Tangxi Industrial Park (Mo Jiaqiao), Yu Hang District, Hangzhou 311106

电话：0571－88191366 传真：0571－88180836

Tel: 0571－88191366 Fax: 0571－88180836

前 言

Foreword

非常感谢您购买我司制造销售的SZS型燃油（气）启动锅炉。本产品是我公司研制开发的新一代环保型、节能型产品。它具有热效率高、操作简便等优点。但如果安装、使用、维护不当，不但不能充分发挥该产品的优良性能，反而可能出现危险。

Thank you very much for purchasing our oil/gas-fired steam boiler, the new generation environment-friendly and energy efficient product we has developed, which is characterized by high thermal efficiency and easy operation. However, in the event that the boiler is not properly installed and used, danger may even occur, not to mention the normal performance it is due to have.

因此，在安装、使用该产品前请认真阅读本说明书、配套的燃烧器等辅机说明书！

Therefore, prior to installation and use of this product, this manual and the instructions of auxiliary units like the burner must be observed.

目 录

Contents

Ⅰ、设计说明 ............................................................................................. 5 I. Description of Design

一、锅炉规范 ....................................................................................... 5 i. Specifications for Boiler

二、结构简介 ....................................................................................... 8 ii. Brief Introduction to Structure

三、锅炉运行参数.............................................................................. 12 iii. Boiler Operational Parameters

Ⅱ、安 装 说 明 ..................................................................................... 14 II. Instructions for Installation

一、安装前准备 ................................................................................. 14 i. Pre-installation Preparations

二、本体安装 ..................................................................................... 15 ii. Boiler Body Installation

三、烘炉（暖炉）.............................................................................. 17 iii. Furnace Drying (Furnace Heating)

四、煮炉 ............................................................................................. 21 iv. Boiling-out

五、总体验收 ..................................................................................... 24 v. Overall Acceptance

Ⅲ、锅炉运行操作 ................................................................................... 26 III. Boiler Running & Operating

一、基本要求 ..................................................................................... 26 i. Basic Requirements

二、停炉保养 ..................................................................................... 30 ii. Furnace Blow-out & Maintenance

Ⅳ、电控操作说明 ................................................................................... 32 IV. Operating Instructions for Electric Controls

一、开机例行检查.............................................................................. 32 i. Routine Inspections during Boiler Start-up

二、启停顺序及控制流程 .................................................................. 32 ii. Start-stop Sequence & Control Procedure

三、联锁保护及故障处理 .................................................................. 39 iii. Interlocking Protection & Troubleshooting

四、触摸屏（或上位机）操作........................................................... 41 iv. Operation on Touch Screen (or Host Computer)

Ⅰ、设计说明

I. Description of Design

为了缩短电厂建设周期，确保安装进度，我司引进国外先进技术，开发了第二代快装式（整装式）启动锅炉。锅炉受热面全部在工厂内组装完成，现场只需安装相关的平台、扶梯、保温、外包装、管道、阀门、仪表等即可，大大减轻了现场的安装工作量，缩短了安装周期。锅炉可以采用雨棚式室外布置的形式不仅可以防止雨水的侵蚀,而且大大降低了建筑成本。当然也可以室内布置。

To shorten the power plant construction cycle and ensure the installation schedule, we have developed the second-generation package start-up boiler by introducing in the advanced technologies. Since the heating surface of boiler and its components are assembled in the factory, only the platform, ladder, insulation facilities, external packaging, pipelines and ducts, valves, and instruments have to be separately installed at the user’s site, which not only cuts done the workload for site installation but also shortens the installation cycle. The boiler can be provided with canopy for outdoor application to prevent rainwater corrosion and make the construction cost more efficient. Of course, indoor application is also permissible.

同时为了减轻运行人员的操作强度，锅炉运行也可以做到一键启停。

Meanwhile, to lessen the operator’s workload, the boiler can also be started or stopped by pressing only one key during operation.

一、锅炉规范

i. Specifications for Boiler

1、设计参数表

3

额定蒸汽压力 Rated Ste

am Pressure

MPa ℃

1.25

4

额定蒸汽温度 Rated Steam Temperature

350

5

给水温度 Feed Water Temperature

℃

20

6

进风温度 Air Intake Temperature

20 ℃ ~ 150 About 150 % 93.1 室燃 Chamber Burning kg/h 1515

7

排烟温度 Fume Temperature

8

锅炉设计效率 Boiler Designed Efficiency

9

燃烧方式 Combustion Method

10 二、 设计燃料： II. Designed Fuel 1

耗油量 Oil Consumption

低位发热值 Net Calorific Power

kJ/kg

43685

三、 水质要求： III. Water Quality Requirement 1 标准 Criterion 四、 主要尺寸要求 IV. Requirements on Main Dimensions 1 锅炉外形尺寸 Boiler External Dimension mm 12410x5380x4265 (包括平台) 12410x5380x4265(including the platform) 最大件运输尺寸 Maximum Dimension for Transportation-6-

符合 GB1576 《工业锅炉水质》 In conformity with GB1576 Water Quality for Industrial Boilers

2

mm

9860x3690x3800

2、安全门参数表

3、运行整定参数表

二、结构简介

ii. Brief Introduction to Structure

锅炉形式为双锅筒纵置式D型结构，并采用了密封性能可靠、炉膛承压能力高的全膜式水冷壁结构方式。炉膛前墙膜式水冷壁上布置了水平燃烧器，炉膛出口处布置了水平式过热器（采用与烟气逆流布置），而后是对流管束，烟气为“之字型”横向冲刷对流管束。最后经过省煤器由烟囱排出。本锅炉既可采用平衡通风方式，也可选用微正压方式。

The boiler is laid out in two-drum D-type lengthwise structure, and adopts the membrane water wall that had reliable airproof performance and whose furnace chamber is excelled at pressure-bearing capacity. The front wall of the furnace chamber is arranged with horizontal burner, and its exit is with the horizontal super-heater (arranged to have reverse flow relative to the fume). Following the super-heater is the convection bank. The flume flushes across

the convection bank in zigzag type, and is discharged out of the stack through the coal economizer. This boiler can use either the balanced draft method or the micro-positive pressure way.

（1）锅筒及内部装置（具体尺寸与锅炉压力等参数有关）

(1) Boiler Drum & Internal Devices (Its specific dimension is concerned with parameters like boiler pressure)

锅炉上锅筒内径为Φ1000，壁厚为18mm，下锅筒内径为Φ800，壁厚为16 mm，均采用20g钢板卷制而成。上锅筒装有监控水位的平衡容器、电接点水位计、差压变送器，以及就地显示液位的水位计，并设置有连续排污、加药、气体保护等管座。上锅筒上还装有两只弹簧式安全阀、压力表，以及锅炉超压保护用的压力控制器等。正常水位一般设置在上锅筒中心线处，最高及最低水位分别位于正常水位±50mm处。同时在上锅简内还设置有合理有效的汽水分离装置，在蒸发强度大的水冷壁上升管处装设了缝隙挡板、波纹板，对流管束区域设置了水下孔板，并在主蒸汽出口处设置了不锈钢丝网分离器。下锅筒设三个锅筒支座，两个滑动支座，一个固定支座。锅炉膨胀中心设置在下锅筒中间的固定支座处，

The internal diameter and wall thickness of the steam drum are Φ1000 and 18mm, respectively, while these two values for the water drum are Φ800 and 16mm, respectively. Both of them are rolled up by using 20g steel plate. The steam drum is provided with equilibrium container that monitors the water level, the electric-point hydrological gauge, differential pressure transmitter, and the hydrological gauge that indicates the local liquid level, as well as the tube holders for continuous blow-down, chemical dosing, gas protection, and so on. There are also two spring-loaded pressure relief valves, pressure gauge, and the pressure control used for boiler overpressure protection on the steam drum. Normal water level is usually set at the center line of the steam drum, and the HH and LL water levels are located at places respectively 50mm over and below the normal level. Meanwhile, the steam drum has steam-water separator, baffle plate and corrugated plate on the riser tube of water wall where there is more evaporation, the water hole plate in the convection bank zone, and stainless steel mesh separator at the main steam outlet. The lower drum is provided with three boiler supports, i.e. two sliding supports, and one fixed

supports. The boiler expansion center is just located on the fixed support in the middle of the water drum.

（2）水冷系统

(2) Water Cooling System

水冷系统由上下锅筒间的对流管束、前膜式水冷壁、侧膜式水冷壁、后膜式水冷壁等组成。前、后膜式水冷壁由Φ60X4的管子组成，与上、下集箱焊接连接，集箱再与锅筒焊接。侧膜式水冷壁、中水冷壁（炉膛与对流管束的隔墙）也由Φ60X4的管子组成，直接与锅筒焊接连接。对流管束采用Φ51X3管材，与锅筒直接焊接连接。管子材料为20/GB3087。

The water cooling system is composed of the convection bank between the steam and water drums, and the front, side, and rear membrane walls. The front and rear membrane walls are made up of Φ60X4 tubes, and welded together with the upper and lower headers, the latter of which is then welded with the boiler drum. The side membrane wall and the middle water screen (the partition between furnace chamber and convection bank) are also made up of Φ60X4 tubes and reaches to the boiler drum by welding. The convection bank uses Φ51X3 tubing and is welded with the boiler drum directly. The code of the tube material is 20/GB3087.

（3）过热器

(3) Super-heater

过热器布置在炉膛出口、对流管束入口处，采用单级水平布置方式，由Φ42X3.5的12Gr1MoVG管子组成，蒸汽由进口集箱进入过热器蛇形管，再到出口集箱。经喷水减温调节蒸汽温度后进入汇流集箱。

Super-heater is located at the connection of furnace chamber and convection bank and arranged in horizontal single-stage structure. It consists of Φ42X3.5 12Gr1MoVG tubes. The steam flows into the multiloop super-heater from the inlet header and then out into the outlet header. When the steam temperature is decreased by the water sprinkling, the condensate flows into the collector.

（4）省煤器

(4) Coal Economizer

省煤器（确切说应称为省油器）设计成可分式的单独结构，采用高效传热的螺旋鳍片管，管子采用φ32x3.5的无缝钢管。

Coal economizer (As more exactly, it should be called the oil economizer) is designed to be the sectional separate structure, and made up of highly efficient heat-transfer spiral finned tubes which are the φ32x3.5 seamless steel tubes

（5）燃烧系统

(5) Combustion System

燃烧器选用中间回油压力雾化轻油燃烧器，水平布置于前墙。燃烧器配备了高能点火装置、火焰检测装置，以及用于负荷调节的风门执行器、油量调节阀等。为了确保点火的可靠性和安全性，专门设置了点火油枪（耗油量约在200kg/h），保证锅炉点火的成功率，以及避免点火时产生爆燃等突变现象。锅炉燃烧排放符合GB13271-2001《锅炉大气污染物排放标准》的要求。

Burner is selected among the light-fuel-fired burners that are characterized by middle oil return and pressure atomizing. It is located on the front wall. The burner is provided with high-energy ignition device, flame detector, and air damper actuator and oil control valve responsible for relevant load adjustment. To ensure the ignition reliability and safety, the burner is particularly provided with ignition oil gun (its oil consumption is about 200kg/h) to guarantee the boiler ignition success and prevent unexpected phenomenon like explosion. Boiler’s emission resulting from the combustion conforms to provisions of GB 13271-2001 Criteria for Air Pollutant Emission of Boiler.

燃烧负荷调节比不小于1:3，也即锅炉最小负荷可以在30％时仍能达到额定的参数要求。

Combustion load turndown ratio reaches 1:3 and over, which means that the boiler meets with the rated value even when the minimum load is at 30%.

（6）炉墙

(6) Chamber Wall

本锅炉采用安装简便的轻型炉墙，使用的绝热材料主要有：硅酸铝纤维板、耐火混凝土、耐火砖等。

The boiler use light-weight chamber wall that is easy and convenient for

installation and the thermal insulating materials it uses mainly include the alumina silica fiber plate, refractory concrete, and fire bricks.

（7）平台扶梯

(7) Platform Ladder

本锅炉在需要频繁操作、监测、检修的部位均设置了操作平台和相关的连接扶梯。平台和连接扶梯符合GB4053.3《固定式工业防护栏杆安全技术条件》的要求。

The boiler is provided with operating platform and relevant connecting ladders at the place that may require frequent operations, monitoring, and inspection and repairs. The platform and connecting ladder conform to GB4053.3 Safety Requirements for Fixed Industrial Protective Railings.

（8）其它相关附件：

(8) Other Relevant Accessories:

锅炉炉膛上设置了检修人孔、观察孔、防爆门、炉膛风压测点及风压保护开关，炉膛出口及相关受热面的出口均设置了温度检测点。蒸汽/热水侧也设置了相关的压力、温度测点，便于运行控制和安全保护。

The furnace chamber is provided with access manhole, observation hole, explosion door, measuring point for chamber’s air pressure, and air pressure protection switch. The chamber’s exit and the exits of related heating surfaces are all provided with temperature monitoring points. Places for steam/hot water are also provided with related pressure and temperature measuring points, for the purpose of operating control and safety protection.

三、锅炉运行参数

iii. Boiler Operational Parameters

1、 各部件热力计算总表：

1. Summary of Heat Calculations of All Parts

2.锅炉烟风阻力参数：

2. Drag Parameters of Boiler’s Fume & Air

3.过热器壁温：

3. Super-heater Wall Temperature 过热器管材质采用的12GrlMoVG，其最高使用温度范围为580℃，经过炉内热负荷过热器区域的强度情况来看：进口处烟温最高处其壁温 525 ℃，出口处烟温最高处其壁温为 460 ℃。壁温均小于580℃，合格。

The super-heater tubing uses 12GrlMoVG, whose maximum permissible temperature is 580℃. In the view of thermal load intensity in super-heater zone, the highest wall temperatures for inlet fume and outlet fume are 525 ℃ and 460 ℃, respectively, which are all below 580℃.

Ⅱ、安 装 说 明

II. Instructions for Installation

一、安装前准备

i. Pre-installation Preparations

锅炉安装前必须做好下列准备工作：

The following jobs should be achieved before boiler installation:

1、安装使用登记手续请参照当地技术监督部门的有关规定。

1. For boiler installation and operation registration procedures, please refer to regulations set forth by local technical and supervision department

2、安装单位必须持有技术监督部门颁发的相应级别安装许可证且在有效期内方可担任施工任务。

2. The contractor responsible for installation should not undertake any boiler construction until it has obtained the installation license of the level corresponding to the boiler to be installed issued by the technical and supervision department concerned during the term of license validity.

3、安装前应认真查阅锅炉技术性文件，严格按照相关标准和产品图纸有关技术要求进行安装。

3. Technical documents of the specific boiler should be read through

carefully before installation, and the boiler should be installed in strict line with technical requirements set forth in relevant standards and drawings.

4、安装地点的确定：

4. Determination of Installation Location:

（1）锅炉房的布置应符合GB50041-92《锅炉房设计规范》中的规定，且布局要合理、美观。

(1) The boiler house should be laid out properly and pleasantly in conformity with provisions of GB50041-92 Code for Design of Boiler Houses.

（2）消防通道应畅通，给水和排污要合理。

(2) Fire passages should be kept free of any obstacles, and the water supply and blow-down systems should be properly designed.

（3）燃料的存放要安全，取用要方便。

(3) Fuel should be stored safely and convenient for access.

（4）本体安装地点最好能接近蒸汽使用地点，以便缩短蒸汽输送管路，减少管路散热损失，降低基本建设费用。

(4) It is recommended that the boiler body be located in the vicinity of the site of steam use so as to shorten the steam pipeline, reduce pipeline thermal loss, and cut down the infrastructure construction costs

5、检查安装所需的配件以及采购材料是否齐全，规格型号是否符合标准要求（特别要注意计量仪表的计量单位）。

5. The accessories and purchased materials necessary for installation should be checked for their completeness and conformity of models and specifications with the standards (particularly the measurement units of meters and gauges).

二、本体安装

ii. Boiler Body Installation

锅炉安装中对各部件的要求，应按GB50273《工业锅炉安装工程施工及验收技术规范》要求执行。若因锅炉超宽超高无法整体运输的，须进行现场组装。

The requirements for each part during boiler installation should be carried out in accordance with GB50273 Technical Codes for Construction and Acceptance of Industrial Boiler Installation Engineering. Where the boiler is unable to be transported as a whole due to extra width or height, it should be

assembled at the construction site.

现将一些要注意的事项申述如下：

Aspects that should be noted are stated as follows:

1、根据锅炉、锅炉房设计图纸、技术文件并对照锅炉图纸的要求，校验锅炉土建基础的正确性。

1. Correctness of the boiler’s foundation should be reviewed and verified in accordance with the design drawings (for boiler and boiler house) and technical documents, and by referring to the boiler’s drawings.

2、根据炉体重量，准备好吊装工具，吊装就位后炉体应符合图纸要求。

2. The hoisting tool should be provided in accordance with the boiler body weight. When the hoisting tool is put in place, the boiler body should be placed as required by the drawing

3、检查锅炉底脚与基础面接触是否良好，如有空隙加垫铁片使锅炉保持受力均匀。

3. Check if the boiler footings are well contacted with the ground surface. Where there is any gap, iron plate can be used under the footing to give the boiler uniform stress.

4、烟道法兰连接处均应采用硅酸铝绳等，使各接头密封严密，以防泄露。烟囱吊装应保持铅垂度、直线度和图纸要求。

4. Flue flange should be wound with alumina-silicate rope at the connection to seal all the joints and prevent leakage. The stack that is to be hoisted should be kept vertical and linear, and as required by drawings.

5、安装燃烧器应严格按照燃烧器制造单位提供的技术资料和说明进行；燃料管路及电气线路的安装应符合锅炉房设计规定及有关规范如《蒸汽锅炉安全监察规程》和消防安全方面等规定进行。

5. The burner should be installed strictly in compliance with the technical information and instructions provided by the burner manufacturer; the combustion ducts and electric wiring should conform to boiler house design and relevant specifications such as the Specifications for Safety Supervision of Steam Boiler and fire protection requirements.

6、热工仪表、阀门和管道的组装。

6. Assembly of thermodynamic instruments, valves and pipelines and ducts.

7、安全阀应在水压试验后安装，安装必须垂直，并应连接排放管引至安全处。

7. The relief valve should be installed vertically after the hydraulic test, and led to safe place after connecting with the discharge pipe.

8、安装压力表时，应使刻度盘垂直，压力表刻度盘上应画出红线，以示锅炉最高许可工作压力，压力表旋塞旋转要灵活，不得漏水，存水管应通畅。

8. When the pressure gauge is to be mounted on, its dial should be held vertical and drawn with a red line to indicate the boiler’s highest permissible working pressure. The gauge faucet should be agile and with no leakage, and the disconnection trap should be maintained free of obstacles.

9、由合格操作人员连接总电源进线（此线为三相四线，AC380/220V ±10%），为确保安全，锅炉本体应接地线连接，对地电阻应小于10Ω。

9. The main power lead-in line (three-phase four-wire line, AC380/220V±10%) should be connected by the qualified electrician. To ensure the safety, the resistance to ground should be less than 1Ω when the boiler body is grounded.

10、燃料贮存罐应设置在便于观察又符合消防要求的地方。

10. The fuel storage tank should be installed at the place that is accessible for observation and conforms to fire protection requirements

11、根据有关标准和要求，将燃料供应管路、水路、电路等全部接通后，准备水压试验。

11. When the fuel supply pipe, water pipeline and circuits are all connected up in accordance with relevant standards and requirements, the hydraulic test then can be started

12、在总体验收前应对供汽、进油、回油及给水管路进行安装后吹扫，以避免管路氧化皮等杂质进入过滤器。

12. Pipelines for gas supply, oil supply, oil return, and feed water should be purged after installation before the overall acceptance so as to prevent contaminants like pipeline oxide skin getting into the filter.

三、烘炉（暖炉）

iii. Furnace Drying (Furnace Heating)

新安装锅炉和连续停用3个月以上都应进行烘炉（暖炉）；

The new boiler and the boiler that has not been used for the past three months or above should be dried in the furnace;

1、烘炉前的准备工作

1. Preparations before Furnace Drying

编制烘炉方案及烘炉曲线，对参加人员进行技术交底，并准备好有关烘炉记录。炉墙上布置好测温点或取样点，并准备好温度计或取样工具。

Furnace drying plan and curve should be prepared; and all participants involved should be trained and take a good note of all records about the drying. The chamber wall should be furnished with points for temperature measurement or sampling, and provided with thermometer or sampling appliances.

2、烘炉

2. Furnace Drying

本锅炉采用火焰烘炉法进行烘炉，其中前期为开火种阀小火烘炉，后期~15%燃烧器负荷烘炉。

This boiler adopts flame drying method, in which the furnace is dried at mild fire during earlier and transitional stages, and at about 15% of the burner’s load at the final stage.

前期烘炉阶段（小火）：首先开启引风机前调节门1/5到1/6左右，点燃燃烧器小火，根据升温的情况调整火焰的大小，使炉膛保持微负压，烟气缓慢流动，根据各测点显示数据，然后逐渐加大火焰，以过热器后部的烟气温度为监控调节值。

Furnace Drying at Earlier Stage (mild fire): Turn on the front regulating valve of the induced fan to 1/5–1/6 and ignite the burner’s mild fire. Regulate the flame shape relative to temperature rise and make sure that the furnace chamber is maintained at micro-negative pressure and the fume flows slowly. Then increase the blaze and take the fume temperature at the tail of the super-heater as the value for regulation.

后期烘炉阶段（~12.5%燃烧器负荷）：当用小火已不能使过热器后温度再提高的时候（一般为2-3天）应加大燃料投入量烘炉，并启动引风机、逐步增大送风量，加强燃烧，使烟气温度不断提高。

Furnace Drying at Final Stage (about 12.5% of the burner’s load): When the super-heater is unable to reach higher temperature by mild fire (this usually takes 2-3 days), more fuel should be fed into the furnace, and the induced fan should be turned on to deliver the input air gradually, intensifying the combustion and increasing the fume temperature.

3、烘炉时间的温度控制

3. Time and Temperature Control of Furnace Drying

烘炉期间，控制温度很重要，升温的速度对烘炉的效果有着直接影响，因此，采用测量过热器后部的烟气温度的办法来控制燃料供给量及送、引风量。

During furnace drying, temperature control is very critical, and the heating-up rate plays a direct role on drying effects. Therefore, by measuring the fume temperature at the tail of the super-heater, the fuel feeding and air input rate can then be controlled.

第一天温升不得超过50℃，以后每天升温不得超过30℃，每小时不得超过10℃，烘炉后期，烟温不得超过220℃。在最高温度范围内，烘炉持续时间不得少于24小时。如果炉墙特别潮湿应适当减慢温升速度。

Temperature rise on the first day should not exceed 50℃, and the temperature rise per day and per hour for subsequent days should not exceed 30℃ and 10 ℃ respectively. At the final drying stage, the fume temperature should not exceed 220℃. Within the highest temperature vicinity, the drying duration should not be less than 24 hours. Where the chamber wall is especially damp, heating-up rate should be appropriately slowed down.

4、控制燃烧火焰

4. Combustion Flame Control

烘炉时燃烧要均匀，按时记录温度读数，并且要注意观察炉体膨胀情况和炉墙情况，以便出现异常时及时处理。

During furnace drying, the combustion should be maintained uniform. The temperature readings should be recorded on schedule, and the furnace body expansion and the chamber wall should not be watched carefully for their changes and be properly handled in case of atypical conditions.

5、及时排出水蒸汽

5. Timely Discharge of Water Vapor

为了及时排出烘炉期间产生的水蒸汽，在烘炉时，应打开上部检查门，当发现炉墙的温度比较大时，还应减缓升温速度并加强通风，以便使炉墙中的水分及时蒸发并顺利排出。

To discharge the water vapor generated during furnace drying betimes, the upper access door should be opened during drying. Where chamber wall has a higher temperature, the heating-up rate should be slowed down and the ventilation should be enhanced so that the moisture inside the chamber wall

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