AQC Waste Heat Boiler

安 装 使 用 说 明 书
Installation and Operation Manual
(258AY00-AMSY)

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南通万达锅炉有限公司
Nantong Wanda Boiler Co., Ltd.
 目录 CONTENTS
前言 Foreword.................................................................................................................1
Ⅰ．设备的保管和保护 The storage and the protection of the equipment……….…...3
Ⅱ．安装前的准备工作 The preparatory work prior to installation…………..…..…..4
Ⅲ．建议安装顺序（供参考）The recommended sequence of the installation (for
reference only)……………………………………………………………………..4
Ⅳ．受压元件的安装 Installation of pressure parts………………..…………………..5
Ⅴ．钢架及平台扶梯的安装 Installation of steel structure, platforms and ladders…….8
Ⅵ．管路、阀门、仪表的安装 Installation of piping, valves and instruments………….9
Ⅶ．水压试验 Hydro-test……………………………………………………..………10
Ⅷ．烟气进出口的安装 Installation of inlet and outlet sections of the gas passes……12
Ⅸ．门类、护板的安装 Installation of the access doors and casing sheets…………….12
Ⅹ．煮炉与烘炉 Boiling-out and furnace drying………………………………..…….12
Ⅺ．锅炉运行监视与调整 Monitoring and tuning-up of the boiler…………….…….16
Ⅻ．停炉 Boiler shutdown…………………………………………………………….25
ⅩⅢ．水质要求 Requirement for the water quality………………………………….26
ⅩⅣ．锅炉的维护保养 Maintenance of the boiler…………………………….…….27
ⅩⅤ．锅炉检验和水压试验 Inspection and hydro-test of the boiler…………….….29
ⅩⅥ．电控基本要求及联锁保护 Requirement for electric control system and
the interlock protection…………………………………..…….…………………30
ⅩⅦ．附加说明 Additional notes……………………………………………………31
ⅩⅧ．锅炉运输、装卸注意事项 Notes for transportation & load and unload of the
boiler………………………………………………………………………………31
 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

前言
Foreword
本台余热锅炉是应用于水泥生产线窑头 AQC 余热锅炉，是水泥窑余热发电系统中
回收窑头废气余热的关键设备，它具有节能、低耗、环保、结构紧凑等特点。其具体
设计参数如下：
This waste heat boiler is applied for cement production line in the item, and plays a key
role in the kiln hood heat recovery for power generation. This boiler is featured with energy
saving, low consumption, environmental friendliness and compact construction. The
detailed design parameters are listed as follows:

锅 炉 规 范
Boiler specification

锅炉入口烟气量
450,000Nm3/h
Inlet gas amount
锅炉入口烟气温度
600℃
Inlet gas temperature
锅炉入口烟尘浓度
50g/ Nm3
Inlet smoke dust density
锅炉出口烟气温度
～144.7℃
Exhaust gas temperature
锅炉总漏风
≤1%
Total air leakage

蒸汽段参数
Steaming boiler
锅炉蒸发量
110.7t/h
Boiler output
设计压力
2.4MPa（g）
Design pressure
额定蒸汽压力
1.75 MPa（g）
Rated Steam pressure

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

额定蒸汽温度
475℃
Rated steam temperature
给水温度
125℃
Feed water temperature
锅炉水压试验压力
3.6MPa（g）
Hydrostatic test pressure

额定吸热量
2.9MW
Rated absorption
设计压力
3.4MPa（g）
Design pressure
出水量
32t/h
Amount of water
出水温度
125℃
Outlet water temperature
给水温度
48℃
Feed water temperature
锅炉水压试验压力
5.1MPa（g）
Hydrostatic test pressure

锅炉安装工作是锅炉制造工作的延续。为保证锅炉能安全经济、可靠运行，从事
本锅炉安装维修的单位必须具有国家有关部门颁发的相应级别的资格证书。安装前，
安装单位专业技术人员必须充分了解锅炉有关图纸和技术文件，并据之编制安装工艺、
程序和细则。当工厂图纸与设备有疑问时，应及时与工厂联系解决。
The boiler installation is deemed as an extended part of the boiler manufacture. To
ensure the boiler’s safe, economical and reliable operation, the contractor responsible for the
installation or maintenance of this boiler shall have a properly graded license granted by an
appropriate state authority. Before the installation, the technicians of the contractor must
fully understand the corresponding drawings and technical documents, based on which the
relevant procedures shall be prepared in details for the installation. When the drawings or
equipment are found to be questionable, the timely communication with the manufacturer is
required.
本锅炉的操作运行必须由合格司炉工进行，且须持证上岗。
The operation of this boiler can only be performed by the qualified boiler operators,

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

who shall be licensed when working on the boiler operation.

Ⅰ．设备的保管和保护
The storage and the protection of the equipment
到现场的设备由用户根据设备的种类、质量、外形尺寸、包装方式的不同或露天
放置或入库保管，并进行必要保护。
The equipment shall be properly stored when delivered to the site either in open yard or
in warehouse depending on the types, quality, dimensions and packaging. The proper
protection might be applied, if necessary.
1．如下设备可以露天保管
The following items of the equipment may be stored in open area:
锅炉钢架、平台扶梯、锅筒、蒸发器、过热器、省煤器、热水器、各种集箱、下
降管、上升管、护板等。
Boiler steel structure of the platform and ladder, the boiler drum, evaporator,
superheater, economizer,water heater, all kinds of headers, downcomers, risers, boiler casing
sheets.
锅炉钢架的柱和梁、平台等放在预先制好的、经过校正的支架上，以防止变形。
The columns, beams and platforms of the boiler steel structure shall be laid on the
prefabricated stands that are properly set up and leveled to avoid distortion.
锅筒应垫起，使锅筒及锅筒上的管接头离地，并将管接头盖好，以防杂物进入。
The boiler drum should be leveled up to have the drum and its connectors lifted from
the ground. All the connectors shall be plugged up to prevent foreign matter from getting in.
管子管组和集箱均应垫起，离开地面应有一定的距离，管口应盖好罩壳，大直径
管子堆放时弯头朝下，管口应盖好罩壳且不要触地，以上零件要防止碰撞、变形，影
响安装和使用。
All the tubing banks and the headers shall be leveled up, too, to keep an appropriate
distance from the ground. Plugging is also needed for the tube and pipe ends. The pipe
bends of large diameters shall be laid downward to the ground when piled up, the pipe ends
must be covered up without touching the ground. All the parts and components mentioned
above shall be protected from being bumped and deformed, otherwise the installation or
operation might be impacted.
所有露天放置的设备，表面防腐油漆应完好，个别油漆脱落部位应及时清理擦掉、
补刷油漆防护。
All the items stored in the open area shall be in good condition of the surface painting,

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

for the individual spots with paints peeled off, clean-up and touch-up are necessarily needed
to keep the protection.
2．下列设备应入库保管
The following items shall be indoors stored in the warehouse:
各类阀门、水位表、压力表、温度计、取样器、冷却器等。
All kinds of valves, water level gauges, pressure gauges, thermometers, sampling
devices, coolers, etc.
Ⅱ．安装前的准备工作
The preparatory work prior to installation
1．用户在收到订货后，要按制造厂的发货清单，清点和检查零部件及设备是否完
整，运输过程中有否损坏及变形，对损坏及变形的零部件要进行修理和校正。
After the user receives the shipment of the ordered goods, he shall check out the
quantity and completeness of the delivered goods for any damage or deformation due to the
transportation. The repair and redressing must be done in case of the component damage
and deformation.
2．载重车辆、起吊设备、卷扬机等要有足够的载重能力。
The vehicles, lifting devices, hoisters for handling the boiler equipment shall be
sufficiently capable of handling the loads.
3．按设计院提供的基础图进行地基施工，基础深度应根据锅炉使用地区地质条件
及锅炉荷重表由土建部门确定，基础预埋铁应符合图纸要求。
The construction of the subgrade shall be performed in accordance with the foundation
drawings provided by the design institute. The depth of the subgrade shall be determined by
the civil engineering department based on the geological conditions where the boiler is
erected and the boiler load map. The embedded parts shall be arranged in conformity with
the drawings.
Ⅲ．建议安装顺序（供参考）
The recommended sequence of the installation (for reference only)
1．安装下部钢架
The installation of lower steel structure
，同时安装平台扶梯
2．安装受热面管箱和集箱（从下至上）
Installation of heating surface tubing banks and headers (from the lower to the upper),
in addition, the platform and ladder can be installed in parallel.
3．安装上部钢架
Installation of the upper steel structure.
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4．安装锅筒（包括锅筒内部装置和锅筒支座）
Installation of the drum (including the internals of the drum and the drum supports).
5．安装下降管和上升管
Installation of the downcomers and risers.
6．安装管路阀门及各种仪表
Installation of the valves and various instruments on the lines.
7．水压试验
Hydro-test.
8．安装防雨装置
Installation of rain protection structures
9．安装烟气进出口
Installation of gas inlet and outlet sections.
10．安装护板、炉墙、门类、测点等
Installation of boiler casing, paneling, walls, doors, measuring provisions, etc.
11．护板的现场密封及锅筒、集箱、管道的保温
Sealing of the boiler casing and insulation of the drum, headers and piping.
Ⅳ．受压元件的安装
Installation of pressure parts
1. 设备的转移和堆放：
Handling and piling up of the equipment:
安装单位把锅筒、集箱、管子等运往安装现场，堆放时需注意下列事项：
When the installation contractor have delivered the boiler drum, headers, tubing and
pipes to the site, the following precautions shall be taken when piling them up on the site:
（1） 载重车辆起吊设备、绑扎需用的钢丝绳、卷扬机等都具有足够的载重能力，
符合技术规范。
The vehicles, lifting facilities, slings and ropes, and hoisters for lifting the boiler
components shall be sufficiently capable of handling the loads and complying with the
technical specifications.
（2） 锅筒下应垫木衬，勿使锅筒外壁与地面接触、摩擦，以防表面损坏。
The wood pads should be laid under the drum to prevent the drum shell from
contacting or rubbing the ground to avoid the surface damage.
（3） 用钢丝绳捆绑锅筒时，禁止穿在管接头孔中或绕在短管上，钢丝绳与锅筒
外壁接触处，应垫以木板或麻绳，以防损坏锅筒表面。

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

When tying down the drum for lifting, no sling or wire rope is allowed to penetrate
through the tubing or wind around the nipple. Any contact between the sling or wire rope
and the drum shell shall require wood spacer block or hemp rope to protect the drum surface
from being scratched or bumped.
（4） 管子和集箱堆放时，应用道木垫平，管子与管子之间用木板隔开，以防压
伤和损坏管子。
When tubing and headers are piled up, use wood sleepers to level them up, and use
wood blocks to segregate the tubes to protect them from being damaged and bumped.
2. 检查和校正：
Inspection and redressing
（1） 观察锅筒外表有无因运输损坏的痕迹，锅筒短管焊接处应详细检查。
Check the drum external surface for defective indications resulting from the
transportation, and detailed inspection of drum nipple welding must be carefully conducted.
（2） 在锅筒两端找出中心线，并用颜色标志，作为安装基准点。
The centerlines of the drum’s both ends shall be indicated with color marking as the
reference point for the installation.
（3） 管子检查须在管子校正台进行，在校正台上根据图纸检查水管尺寸，各种
管子的允许误差可按相关技术条件验收，工地上需对接的管子，施工时应符合标准。
The inspection of the tubes or pipes shall be carried out on the truing bench. The
drawings shall be referenced to for dimension and size check on the bench. All the tube
parameter tolerance can be verified for acceptance based on allowable tolerance. For those
tubes that are to be butt connected on site, the specifications shall also be applied.
（4） 钢管上不得有裂纹、折叠、辗皮和深的刻痕等缺陷存在，个别小缺陷允许
存在，其深度不得超过厚度的 10%。深刻痕及裂纹等缺陷，允许用砂轮式锉刀去除，
缺陷处有效壁厚应不低于其最小需要厚度（强度计算）。
On the steel tubes, no defects such as cracks, folding, creeping and deep scratches are
allowable, except for minor flaws, but the depth of defects shall not be greater than 10% of
the thickness. Wheel grinders could be used to remove the defects of deep scratches and
cracks. The effective thickness where the defects are located should not be less than the
minimum allowed thickness (as calculated for strength).
（5） 集箱的验收按相关规定执行。
The acceptance inspection of the boiler headers shall comply with the related
stipulations
3. 安装质量：
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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

The installation quality

（1） 锅筒安装时，允许最大误差：
The installation of the boiler drum allows the following max. tolerance:
锅筒标高偏差 ±2mm
Elevation of the drum ±2mm
锅筒中心线与炉体中心线偏差 2mm
Alignment of drum centerline with the boiler centerline 2mm
锅筒水平度 2mm
Leveling of the drum 2mm
锅筒与前柱中心距偏差 ±2mm
Distance between the drum and the front column centerlines ±2mm
锅筒膨胀间隙 ±2mm
Drum expansion gap ±2mm
（2） 锅筒支座的位置应与锅筒支承座图规定一致。
The location of the drum supports shall be complying with the drum support drawing.
（3） 清理检查锅筒内部装置，旋风分离器需拆下重装，并安装到位，所有螺栓、
螺母连接件须拧紧牢固。
Clean and check the drum internals, and cyclone steam separator need taken
down and reset. Screw all bolt and nut.
（4） 锅筒内部进行检查或补焊时，应防止金属物、杂物掉进管孔，焊条头应带
出锅筒。
During the inspection or repair welding, metal material and debris falling down into
the tubes or holes should be avoided. Any weld residues must be picked up and removed
from the drum.
（5） 本体管路安装时，应严格按管路图把各种不同的连接件用于合适的部位。
During the installation of the tubing and piping on the boiler proper, all the fittings to
the tubing and piping shall be suitably selected and used on the correct locations in
accordance with the drawings.
4. 特别注意事项
Special matters need attention
蒸发器集箱固定装置中部分 M20×60 的螺栓是起临时固定作用的，以确保在运
输过程中蒸发器不发生变形和相对位移，现场就位后应按 258AY02-2-0 集箱固定装置
图纸的技术要求将这些螺栓卸下，以保证后期锅炉安全运行。

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

The foundation of partial bolts M20*60 in the header anchor of generator is for
temporary fixation, so as to avoid distortion and comparatively displacement in the
process of transportation. During installation on site, these bolts should be dismantled
as per notes described in drawing of header anchor 258AY02-2-0 as to assure boiler
running safety.
Ⅴ．钢架及平台扶梯的安装
Installation of steel structure, platforms and ladders
1．锅炉钢架的基础安装：应按设计院提出的要求执行。
The installation of the boiler steel structure foundation: to comply with the
requirement of the design institute.
2．安装前检查各部件是否在运输过程中产生变形，如有变形需校正后方可安装。
Prior to the installation, inspection of the different parts for any deformation resulting
from the transportation, if deformation is located on these parts, correction shall be
performed before installation.
3．锅炉钢架的组合与安装公差：
Tolerance are to be applied for the steel structure assembling and installation as
detailed as follows:
（1） 柱子弯曲度 1mm/m，全长不得超过 10mm
Straightness of the column is 1mm/m, but not exceeds 10mm in full length;
（2） 对接元件边缘允许偏移值： 厚度≤18mm ≤1.5mm
厚度＞18mm ≤2.0mm
Edge alignment of butt-connected members: for thickness≤18mm: ≤1.5mm
for thickness＞18mm: ≤2.0mm
（3） 柱中心线间距离公差 ±3mm
Distance between column centerlines ±3mm
（4） 组合件对角线公差为长度的 1.5/1000 且≤10mm
Diagonal length of the assemblies not more than 1.5/1000 but ≤10mm
（5） 组合件的平面弯曲度公差 1mm/m，全长不得超过 10mm
Plane flatness of the assemblies not more than 1mm/m, but no greater than 10mm in
full length;
（6） 柱子垂直度（在两个互相垂直面上）1mm/m，全长不得超过 10mm
The verticality of the column (in two planes perpendicular to each other) less than
1mm/m, but no greater than 10mm in full length;

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

（7） 梁的标高公差 ±3mm

Elevation of the beam ±3mm
（8） 梁的水平公差 1mm/m，全长不得超过 3mm
Leveling of the beam 1mm/m, but no greater than 3 mm in full length;
（9） 支承锅筒组件梁的标高公差（以柱子距离底一公尺处标高线为准）为±2mm
Elevation of the beam of the drum supporting assembly (based on 1 meter elevation
line above the column base) ±2mm
（10）支承锅筒组件梁的水平公差 ±2mm
Leveling of the beam of the drum supporting assembly ±2mm
（11）各立柱间一公尺标高的偏差（以一根柱为准） ±1mm
One meter elevation of the columns above the base(taking one column as the reference)
±1mm
4．钢架组装定位后，经检查合格，再进行焊接。
After the steel structure is positioned in place, an inspection for the correctness shall be
conducted before welding.
5．在平台扶梯的平台槽钢框及托架等构件上，应特别注意尽量不切割孔洞，必须
切割时，在切割后应予加固。
On the channel frame and bracket of the platform and ladder, cutting for holes shall be
minimized. When the cutting is inevitably necessary, the strengthening measures shall be
taken after the cutting.
Ⅵ．管路、阀门、仪表的安装
Installation of piping, valves and instruments
1．管路的安装按锅炉房的设计进行，管子的弯曲半径应不小于 4 倍的管径。
The installation of the piping shall comply with the design of the boiler building, and
the bending radius of the pipe shall not be less than 4 times the pipe diameter.
2. 阀门应装在便于操作的位置,安全阀在水压试验完成后,再进行安装。
The installed valve shall be positioned such that the valve shall be easily accessible and
manipulated. The safety valve shall be installed after the hydro-test is completed.
3. 安全阀的调整按 2015 年第 2 次修订版《印度锅炉规范 1950》和 2015 版 ASME
第Ⅰ卷《动力锅炉建造规则》。
The safety valve shall be set up and calibrated in compliance with “Indian Boiler
Regulations, 1950 up to and include amdt.2, 2015” and “ASME Section Ⅰ-Power Boiler
2015 Edition.

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4. 压力表弯管不得保温。
The trap tube of the pressure gauge shall not be thermal-insulated.
5. 水位表应装排水管,并接到安全地点,以免冲洗水位表时汽水伤人。
Drains should be installed on the water level gauge leading to a safe place to prevent
the drained water from scalding when washing the gauge.
6. 所有的排污管均应接到安全地点，以免伤人。
All the blow-down piping shall be led to safe places to avoid the scalding.
Ⅶ．水压试验
Hydro-test
锅炉受压部件安装完毕后，进行锅炉整体水压试验和热水器单独水压试验，用来
检查锅炉的严密性和各部件在试验后有无破裂和残余变形，水压试验合格后方可进行
保温和密封部件的施工。
After the boiler proper is completed with installation, the hydro-test for the whole
boiler and a separate hydro-test for the water heater shall be carried out to check the boiler
for the tightness and check the components for breakage and residual distortion. The thermal
insulation can only be installed after the hydro-test is finished and accepted.
1．锅炉本体(再热器、过热器、蒸发器、省煤器、热水器)及管路仪表阀门安装完
毕后，检查及清理锅炉内部，关闭人孔、手孔，准备进行水压试验。
After the boiler proper (reheater,superheater, evaporator, economizer, water heater) and
the instruments and valves on the pipelines, check and clean the boiler internals, close
manholes, handholes to get ready for hydro-test.
2．本台余热锅炉蒸汽段整体水压试验压力为 3.6MPa（g），热水器单独水压试验
压力为 5.1MPa（g）。
The test pressure for the boiler hydro-test for steam part is 3.6MPa（g）.The test
pressure for the separate water heater hydro-test is 5.1MPa（g）.
3．水压试验应在周围气温高于 5℃时进行，低于 5℃时必须有防冻措施。水压试
验用的水应保持高于周围露点的温度以防锅炉表面结露，但也不宜温度过高以防止引
起汽化和过大的温差应力，一般为 20～60℃。
The ambient temperature during the hydro-test shall be higher than 5℃, otherwise the
measures against freezing must be taken. The test water temperature shall be kept higher
than the ambient dew point to prevent the condensation on the boiler surface, but not too
high to avoid boiling away and thermal stress due to excessive temperature differential,
normally 20～60℃ is preferable.

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

4．锅炉上水时应将最高点的空气阀打开，将水全部注满后，再关闭空气阀，如无
漏水即可升压。
When filling the water to the boiler, the vent valve on the boiler top shall be opened
until the boiler is filled up with water. In case no leak is indicated, pressurization could be
started.
5．升压速度不得太快，并且要均匀上升。
The pressurization shall be proceeding not faster than necessary, and in an
evenly-rising manner.
6．压力升到 0.3～0.4MPa 时应暂停升压，检查锅炉有无渗漏和异常，并严格禁止
压力超过 0.4MPa 时再紧法兰、人孔、手孔上的螺母，以防发生危险。升压到试验压
力后要保持 20 分钟，此时不可进行敲击检查，降压到工作压力后关闭进水阀，做全面
检查。
When the steam section pressure is raised to 0.3-0.4Mpa, the pressure should be held
for a moment to allow for check for leaks and abnormality. No further tightening of the
flanges, manholes and access holes are allowed when the pressure is higher than 0.4Mpa to
avoid the risks and dangers. When the pressure is jacked up to the test pressure, the pressure
should be held for about 20 minutes, during which no tapping or hammering for a check is
allowed. The inlet water valve can be closed for an overall inspection when the pressure is
dropped down to the working pressure.
锅炉进行水压试验，符合下列情况时为合格：
The test result can be deemed as acceptable if the following is satisfied:
a.在受压元件金属壁和焊缝上没有水珠和水雾；
No water droplet or mist is found on the metal walls or welds of pressure parts.
b.当降到工作压力后胀口处不滴水珠；
When the pressure is dropped down to the working pressure, no droplet is found on the
expanded tube joints.
c.水压试验后，没有发现残余变形。
After the hydro test, no residual torsion is found.
7．水压试验后便可以放水、降压，放水时要将空气阀打开。
Water may be discharged and boiler de-pressurized after the test is finished. Water
discharge shall be carried out with the vent valve opened.
8．水压试验方法及试验结果应严格按照 2015 年第 2 次修订版
《印度锅炉规范 1950》
和 2015 版 ASME 第Ⅰ卷《动力锅炉建造规则》的有关规定执行。

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

The hydro-test procedures and the test result evaluation shall comply with the related
stipulations in “Indian Boiler Regulations, 1950 upto and include amdt.2, 2015” and
“ASME Section Ⅰ-Power Boiler 2015 Edition”.
9．锅炉检查结果应存入锅炉技术档案，并有检查人员签字。
The boiler inspection results shall be filed into the boiler technical archives with the
inspectors’ signatures included.
Ⅷ．烟气进出口的安装
Installation of inlet and outlet sections of the gas passes
烟气进出口安装前应对零件进行必要检查，有条件的话可进行试装，安装时需保
证各接口与原设计一致，或在允许的安装偏差以内，与系统连接时应保证烟气进出口
可以自由膨胀。
Necessary inspection shall be carried out before the installation of inlet and outlet
sections of the gas passes. Trial installation is preferred if the condition permits. During the
installation, all the connections shall be in conformity with the design requirement or within
the installation tolerance. The connections to the systems shall allow for the free expansion
of the inlet and outlet.
特别注意事项
Special matters need attention
1. 锅炉需设置合格的泄放灰系统，运行过程中确保连续清灰；如遇清灰不畅，积灰
荷载过大，需要及时排查，以保证锅炉安全运行。
Eligible dust discharge system needs to be arranged for the boiler to guarantee the
continuous ash removal when the boiler runs. In case of too much dust load due to
unsmooth ash removal, you need to check in time to ensure the safe operation of boiler.
2. 258AY12-3-5-0 膨胀节的组装需使用特制夹具，并按附件二要求进行组装。
Special fixture is provided for the assembling of expansion joint, drawing no.
258AY12-3-5-0, and please refer to appendix II for the assembly instruction.
Ⅸ．门类、护板的安装
Installation of the access doors and casing sheets
门类、护板的保温层要完整无缺保证绝热性能和密封性能，确保锅炉漏风率控制
在设计值之内。
The insulation on the access doors and boiler casing shall be completely installed with
no missing parts to ensure the thermal maintaining and sealing effect, and the boiler leaks
within the design level.

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

Ⅹ．煮炉与烘炉
Boiling-out and furnace drying
(一)煮炉
Boiling-out
1. 煮炉目的：
Purpose of the boiling-out
新安装锅炉在投入运行之前，采用一定的物理、化学方法清除在制造、安装过程
中滞留在锅筒、集箱、管子内部等处的铁锈、油脂、污垢等。使其沉淀于锅炉对流管
束下集箱和下降管底部，经排污管排出，从而避免蒸汽品质恶化或因受热面管壁温度
过高导致烧坏。
Using physical or chemical methods, the newly installed boiler shall be cleaned to
remove rust, grease, dirt, debris left over in the drum, headers and tubing and piping from
the manufacturing and installation. As a result of the boiling-out, all the foreign matters can
be settled down on the bottoms of the lower headers of the boiler convection tubing and the
downcomers, to be discharged out via blowdown piping so as to avoid the degraded steam
quality or heating surface burning-out due to excessively high temperature on the tube
walls.
2. 煮炉用药及数量：
Chemicals to be used and the dosing
煮炉是指在锅水内加入碱水，使之与管内、集箱内的油垢等物起皂化作用生成沉
渣，其所用化学药品及数量见下表：
The boiling-out refers to adding alkaline to allow for saponification effect to produce
dregs. The chemicals and their dosing are detailed as follows:
序号 药品名称 铁锈不多的锅炉 腐蚀较多的锅炉
No. Description Less corroded Heavily corroded
氢氧化钠(NaOH)
1 2~3 (kg/m3) 3~4 (kg/m3)
Sodium dioxide (NaOH)
磷酸三钠(Na3PO4·12H2O)
2 2~3 (kg/m3) 2~3 (kg/m3)
Tri-sodium phosphate
注：所加药品按 100%纯度
Note: The chemicals dosed as 100% in purification
本锅炉蒸汽段满水容积~187.1m3 ，运行容积~115.2m3 ；热水器满水容积
~5.26m3 .

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

The water cubage of this boiler(steam section) is about 187.1m3 in full state, and it
is about 115.2m3 in running state; The water cubage of waterheater is about 5.26m3 .
3. 煮炉方法：
Procedures for the boiling-out
煮炉方法和操作步骤按 GB50273-2009《锅炉安装工程施工及验收规范》的规定进
行。其加药量为氢氧化钠和磷酸三钠各 3～5kg/m3(按 100%纯度)。药品应溶解。
The method and procedures used for boiling-out shall comply with GB50273-2009
《Specifications for Installation and Acceptance of the Boilers》. The dosing applied for the
boiling-out shall be 3-5kg/ m3 for each chemical: sodium dioxide and tri-sodium phosphate
(as 100% in purification). The chemicals shall be dissolved.
煮炉的步骤为：
The procedures for the boiling-out:
1）将药液注入锅水使其成为浓度适当的碱水，并使之保持适当的水位(保持锅筒
内最高水位)。
Put the chemicals into the boiler water to make an appropriately concentrated alkaline
solution and keep the solution at the proper level (to maintain the highest level of the drum
water).
2）加热升温升压，工质压力为 0.1MPa 时，冲洗水位计，升至 0.1MPa 时，排污
一次，使锅炉所有排污阀开启半分钟左右，与此同时注意适当浓度的碱水的补偿，以
保持锅水水位。
Heat and pressurize the boiler water, up to pressure 0.1 MPa for washing out the water
level gauge. At the pressure of 0.1 MPa, blow down once by opening up all the blow-down
valves for a half minute, meanwhile, keep watching for a make-up of proper concentrated
alkaline solution, to maintain the boiler water level.
3）汽压升到 0.3MPa 时，紧闭所有阀门，有螺栓连接处拧紧螺栓并在 0.5MPa 压
力下煮炉 12 小时，这期间可将所产生的蒸汽通过放汽阀或安全阀排空，同时应注意监
视锅水水位。
When steam pressure rises to 0.3 MPa, close all the valves and check all the bolts for
looseness and tighten the bolts if necessary. Under the pressure of 0.5 MPa the boiling-out
can be continued for 12 hours. During the course of boiling-out, all the evaporated steam
may be released through vent valves or safety valves. Always monitor the boiler water level.
4）上述过程结束后，使汽压降至 0.3～0.4MPa，放掉 10－15%锅水，再注水并加
药至所要求的浓度，再煮 8－10 小时，如此反复煮炉 2－3 次后，上除氧水，并通过上

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

水放水，使锅水中碱度合格后即可结束煮炉工作。
When all the above mentioned steps are finished, the pressure can be dropped down to
0.3MPa-0.4MPa, then discharge 10-15% of the boiler water, and refill the water with
chemicals up to the required concentration for further 8-10 hours of boiling-out. Likewise,
the boiling-out shall be repeated for 2-3 times. Fill in the de-aerated water and discharge the
boiler water until the alkalinity in the boiler water meets the required concentration.
Satisfaction of the above could mean the boiling-out is completed.
4. 煮炉时注意事项：
The precautions to be taken during the boiling-out
1) 煮炉时，不可使炉水进入过热器内，过热器仅用蒸汽冲洗铁锈，吹洗时，打开
过热器主汽集箱上的向空排汽阀门，保持锅炉压力为工作压力的 75%左右，同
时保持适当的蒸汽流量，吹洗时间不少于 15 分钟。
During the boiling-out, boiler water is prohibiting into superheater. Rust in
superheater shall be washed by steam. When washing, open the emergency blast
valve on terminal header of superheater, keep 75% working pressure and appropriate
steam flux, washing time shall more than 15 min.
2) 煮炉期间应从锅筒、各部受热面下集箱等处取样，对锅水碱度及磷酸根的变化
进行分析和监视。
During the boiling-out, sampling shall be carried out at the lower header of each
heating surface to analyze and monitor the change in boiler alkalinity and phosphate
in the boiler water.
3) 一般取样时间为开始升压后每小时一次，排污前后各一次，换水后期每小时一
次。
Normally the interval for the sampling shall be once per hour after the pressurization
is started, once before and after a blowdown, and once per hour after water refilling.
4) 在煮炉过程中，应按要求制作好煮炉汽压温升曲线并参照执行，作好记录。
During the boiling-out, the steam pressure vs. steam temperature rising curve shall
be ready to be followed for use in the boiling-out, and the record shall be made
properly.
5) 煮炉后应打开人孔、手孔等以检查锅筒、集箱、管子内壁，如呈黑褐色说明煮
炉合格。
After the boiling-out, the manholes and handholes should be opened for a look into
the internal walls of the drum, headers and tubing. The color of browny-black

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

indicates the acceptable result of the boiling-out.

6) 煮炉时只允许石英玻璃管水位计参与煮炉，用于监视水位，煮炉期间和煮炉结
束及时冲洗，其余水位计均不得参与煮炉。
Only color water level gauge could be involved in the process of boiling-out, with
function of monitoring boiler water level. Washing them in time during and after the
boiling-out. Any other water level gauge is prohibiting to join the process of
boiling-out.
(二)烘炉
Furnace drying
1．烘炉前的准备
Preparatory work before the furnace drying
1) 锅炉本体及辅机全部施工完毕，本体水压试验合格。
After all the installation of the boiler proper and all the auxiliary equipment is
finished and the boiler proper hydro-test result is accepted.
2) 烘炉所需的辅助设备试运转合格。
The auxiliary equipment needed for the furnace drying is acceptable after the test
run.
3) 锅炉安装完后，打开人孔门（炉门），自然通风干燥 2~3 天。
Natural ventilation and drying for 2-3 days with all the manholes(boiler accesses)
opened following the completion of the boiler installation.
4)上软化水至正常水位。
The boiler is filled up with demineralized water to the normal level.
2．烘炉过程
Procedures of the furnace drying
1）烘炉燃料: 根据现场条件可用木材和柴油
Fuel for the furnace drying: firewood or diesel oil as available on site.
2）烘炉过程: 先用木材在烟道点火，开始时火要小，可采用自然通风，慢慢升温，
温升以过热器后的烟温控制,第一天的温升不宜超过 50℃，以后每天温升不宜
超过 20℃，后期烟温不应超过 160℃。
Steps for the furnace drying: Ignite the firewood in the flue. Initially the fire shall
be controlled by natural ventilation to gradually raise the temperature. The
temperature might be controlled through the temperature control of the flue gas
after the superheater. The temperature rise shall not be more than 50℃ for the first

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

day, and not more than 20℃ per day from the second day on. The flue gas
temperature at the later stages shall not exceed 160℃.
注：也可以采用热烟气或热风烘炉。
Note: Hot gas or hot air stove are also acceptable for the furnace drying.
Ⅺ．锅炉运行监视与调整
Monitoring and tuning-up of the boiler
余热锅炉运行工况同炉窑工况有直接关系，为保证锅炉运行参数的稳定和运行的
绝对安全，必须与炉窑的运行人员保持密切联系及运行协调一致的同时，对锅炉参数
的变化，运行工况进行严密的监视，并加以分析，随时调整。
The operating conditions of the waste heat boiler are directly related with that of the
kiln. To ensure the stability of the operating parameters and the highest safety of the
operation, the close communication with the kiln operators is extremely necessary for the
best coordination; meanwhile, the change of the boiler operating parameters, and the
operating conditions shall be closely monitored and analyzed for timely tuning and
adjustment.
在运行中，监视与调整的主要任务有：在炉窑正常运行的条件下，注意调整使系
统正常运行，维护工质压力正常，均匀给水使锅炉保持正常水位，保证蒸汽品质合格，
保证除灰系统正常运行等。
During the operation, the main purpose for the monitoring and tuning is: under the
normal kiln operating conditions, to tune up the system to keep the normal operation and
maintain the normal pressure of the medium, maintain the normal water level by evenly
feeding water to the boiler to ensure the steam quality, and ensure the normal operation of
the ash handling system.
1．锅炉运行中注意事项：
Precautions for the boiler operation:
1) 锅炉运行后，应注意监视蒸汽压力、蒸汽温度、锅筒水位、水流量、给水温度、
给水压力、锅炉入口烟气温度、负压等。如炉窑送入锅炉的烟气量及温度发生变化，
经调整无效时，就及时联系有关部门调整其锅炉的进口烟温，以保证锅炉的安全运行
和锅炉参数的稳定。
When the boiler is operating, pay attention to the steam pressure, steam temperature,
drum level, water flow, feed water temperature, feed water pressure, the exhaust gas
temperature at boiler inlet, furnace minus pressure etc. In case there is a change in the
exhaust gas flow and temperature at boiler inlet but no effective result after tuning-up,

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

timely communication is needed with the related department for an adjustment of inlet gas
temperature in order to ensure the boiler safe operation and the stable parameters of the
boiler.
2) 巡视检查：为了保证安全运行，每班至少进行四次全面巡视检查，检查的项目
有：锅炉房的全部设备。护板是否完好无损，护板上的人孔门是否漏风。锅炉上的各
种阀门是否完好，水位计、压力表、温度计等仪表是否正常工作，各部位受热面积灰、
磨损情况及锅炉排烟温度等。
Walk-down inspection: In order to ensure the safe operation, at least 4 walk-down
inspections shall be carried out for each operation shift. The items included in the
inspections are: all the equipment in the boiler building; Check of the boiler casing for any
damage and air leak of the manholes; Check of all the valves for abnormality; check of all
the water level gauges, pressure gauges, temperature gauges for abnormality, check of all
the sections and portions of the heating surfaces for soot deposition, wear and tear and
check of the boiler flue gas temperature.
3) 记录抄表连续进行，日常记录是每一小时（或每半小时）进行一次，记录的目
的在于分析运行工况以及综合分析整个系统（包括炉窑）的负荷变化规律，合理改进
操作。
Continuous recording on the logs. Once-per-hour (or half hour) logging shall be carried
out. The purpose of the recording and logging is to analyze the operation conditions and
overall regularity of loading alteration of the entire systems (including the kiln) for better
and reasonable operation.
4) 对锅炉的给水、锅水、排污水、蒸汽及出水应定期取样分析化验，达到经济运
行的目的。
The regular sampling on the boiler feed water, boiler water, blowdown water, steam
and produced water shall be carried out for chemical analysis to achieve the goal for
economical operation.
5) 根据水质情况和化验结果，对锅炉的对流管束按期进行定期排污，放水量根据
化验结果而定。
Based on the water quality and the chemical examination, the regular blowdown of the
boiler convection tubing banks will be executed. The amount of blowdown water shall be
determined based on the chemical examination result.
6) 定期检查给水水样，以保证出水品质。
Feed water samples shall be inspected regularly to ensure the feed water quality.

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

7) 严格履行交接班制度，并在日常记录抄表中记录明确。
Regulation and rules for shift alternation shall be strictly followed and the clear records
shall be kept on the daily logs.
2．锅炉的正常运行
Normal operation of the boiler
锅炉正常运行时，要求做到水位正常，压力稳定，蒸汽温度正常，要加强对各种
设备和仪表的监察，确保安全运行。
During the normal operation of the boiler, the water level shall be maintained normal,
the pressure stable, and the steam temperature normal. The monitoring of all the equipment
and instruments shall be continued to ensure the safe operation.
1) 给水要求：锅炉给水必须经过软化处理，软化水水质应符合国家相关水质要求
的规定。
Requirement for the feed water: the boiler feed water shall be demineralized, and the
quality of the demineralized water shall comply with the appropriate national criteria on the
water quality.
2) 锅内水位应保持在正常水位 75mm 范围内，并有轻微晃动为正常，若水位不动
则有可能堵塞，应对水位表进行冲洗。
The boiler water shall be kept within 75 mm of normal level, however slight
fluctuation shall be considered as normal. If the water level stays fixed, it might indicate a
plugging, requiring a washout of the water level gauge.
3）安全附件的操作与管理
Operation and management of the safety accessories
<1> 水位计 水位计的冲洗，每班至少进行一次，须保持水位计清洁、不漏水、
不漏汽，保持明亮度，以便于观察水位位置。
Water level gauge: water level gauge shall be washed out at least once per shift to keep
the water level gauge clean, free of water-leak and gas-leak, and the visual glass clear to
facilitate the monitoring.
<2> 压力表 经常保持压力表的清洁(在校表时应把工作压力用红线标在刻度
盘上)，使表针指示清晰可见。
Pressure gauge: always keep the pressure gauge clean (the working pressure shall be
marked with red line on the gauge dial when calibrated) to provide clear indication on the
gauge.
须定期冲洗压力表弯管，冲洗后，在存水弯管内凝结冷凝水后再缓慢接通压力表。

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The trap tubing of the pressure gauge shall be washed regularly. After washing, the
connection shall not be immediately made until the water is condensed in the trap tubing.
在运行中发现锅筒等处的压力表指针有异常变化时应及时查明原因，压力表如有
损坏，如表针动作不灵、玻璃蒙破损等，应及时更换新压力表，初次使用或更换新压
力表须有检验合格证，并加铅封。
During operation, if the pointer of the pressure gauge is found abnormal, the cause for
that abnormality shall be located. Any malfunction of the pressure gauge such as retarded
move of the pointer, broken glass, etc. should be corrected by replacing a spare gauge in a
timely manner. Replacement of a gauge or initial use of a gauge requires the availability of
the certificate for conformity, and the gauge should be lead-sealed.
<3> 安全阀 Safety valve
a. 安全阀的调整和校验：
The setting and calibration of a safety valve:
锅炉在初次运行时必须调整安全阀。方法为：拆去开口销，去除顶盖，松开锁紧
螺母，拧动调节螺杆，使安全阀的整定压力符合 2015 年第 2 次修订版《印度锅炉规范
1950》和 2015 版 ASME 第Ⅰ卷《动力锅炉建造规则》的规定。锅炉投入运行后，应
定期校验安全阀并将整定压力、回座压力、阀芯提升高度等检验结果记入锅炉技术档
案，安全阀调整或校验完毕后应加锁或打铅封。
During initial operation of the boiler, the safety valve must be set as follows: remove
the split pin and the top cover, loosen the lock nut. Adjust the setting-screw to meet the
pressure setting as specified in “Indian Boiler Regulations, 1950 up to and include amdt.2,
2015” and “ASME SectionⅠ- Rules for Construction of Power Boiler 2015 Edition.
When the boiler is in service, regular calibration is needed for the safety valve and the
records of all the calibration data such as lift pressure, re-seating pressure value, valve-core
lift height etc. shall all be filed into boiler technical archives. After completion of the safety
valve setting or calibration, the safety valve shall be locked or lead-sealed.
b. 为防止安全阀的阀瓣和阀座粘住，应定期对安全阀进行手动排放试验。
The lift test shall be carried out manually at a regular interval to avoid the binding of
the valve flap and seat.
<4> 排污 Blowdown
a. 定期排污应在低负荷时进行，每班至少一次，还可以根据炉内加药以及炉水品
质情况增加排污次数。
Regular blowdown shall be carried out when the boiler is operated at a low load, at

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

least once per shift. In addition, more blowdowns may be applied in consideration of the
dosing and the boiler water quality.
b. 每次排污前，必须检查管路、阀门是否正常，并将水位调整到高于正常水位
35mm 左右，每次排污量的控制约使水位下降 35mm 左右。
Before each blowdown, the check with the piping and valves for abnormal conditions
shall be conducted. Besides, the water level shall be adjusted to about 35mm higher than
normal, and each blowdown shall be controlled such that the water level drops down by
about 35 mm.
c. 严禁使用长杠杆、锤子等类工具，强力拧动或敲击阀门，以防发生危险，当两
台以上锅炉共用一根排污母管时，严禁两台锅炉同时排污。
No long lever, nor hammer is allowed to forcedly open the valve or peen the valve to
prevent the dangers. When two or more than two boilers share the same blowdown header,
the simultaneous blowdowns for these boilers are strictly prohibited.
4) 其它有关运行问题，按锅炉操作规程进行。
Other issues regarding the operation of the boiler may refer to the related regulations
on the boiler operation.
3. 事故处理及预防：
Prevention of accidents and their solutions
1) 缺水事故：
Lack of water:
较为明显现象是锅炉水位低于最低水位或看不到，水位警报器发出低水位信号，
或者蒸汽流量可能大于给水流量。
The apparent phenomenon is the boiler water level drops to lower than the minimum or
even the level indication is unseen, at this time, the level alarm would give out the low-level
signal or the steam flow may be greater than the feed water flow.
造成缺水事故的原因是由于运行人员的疏忽，对水位监视不严，如给水自动调节
器失灵，因水位计脏污或连通管堵塞而形成的“假水位”，给水箱缺水或给水泵、给水
管路发生障碍，锅炉放水阀、定期排污阀等泄漏，并联锅炉抢水或厂用电中断，汽动
备用给水设备未能及时启动或无汽动备用泵等。
The cause for the water lacking may result from the negligence of the operators or the
careless monitoring of the water level. For instance, the failure of the feed water auto
regulator, false indication of the level because of the dirt clogging or connection tubing
plugging, water shortage in the feed water tank, or failure of feed water piping or feed water

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

pump, leakage of boiler discharge valve or regular blowdown valve, boilers in parallel
operation scrambling for water or in case of the house power interruption, spare
steam-driven feed water pumping is lagging to start up or even no steam-driven feed water
pumping equipment in spare.
为防止缺水事故的发生，运行人员应严格按照规程和岗位责任制工作，加强监视
水位，确保给水参数正常。
To prevent the lack of water, the operators shall strictly follow the regulations and take
the responsibility for the duty to closely monitor the water level to keep the normal
parameters of the feed water.
2) 锅水膨胀事故
Boiler water expansion
当锅水含盐量大，锅水表面上呈现大量的泡沫，蒸汽逸出的水膜破裂，溅出水滴
并被蒸汽带走，就会发生锅炉水膨胀事故。
When the boiler water has high salt-content, lots of bubbles will come up on the water
surface. The escaping steam breaks the water film to splash water droplets, which could be
carried away by the steam, thus causing the boiler water to expand.
发生锅水膨胀事故时，锅筒水位剧烈波动，往往水位看不清并冒汽泡，饱和蒸汽
的盐份及水份增加，严重时管道也会发生水冲击，法兰处冒白汽。
When the boiler water expands, the drum water level may intensively fluctuate. At this
time, water level is not easily visible, and lots of bubbles are coming up. The salt content
and moisture content in saturated steam increases a lot. In worse case, the water hammering
would occur with “white steam” leaking from the flange.
锅水膨胀事故的处理办法：开大连续排污阀门进行放水（排污），通知用汽设备负
责方降低负荷，并加强管道疏水，停止向锅水加药，并取水样化验，同时加强换水，
迅速改善锅水的品质。
The solution to the boiler water expansion: wide open the continuous blowdown valve
to discharge water (blowdown), and notify the steam user (equipment) to reduce the load.
The piping drains should be wide opened to drain water, and adding chemicals into the
boiler should be ceased. Sampling is now needed for chemical examination. Meanwhile,
water refilling shall be sped up to quickly improve the boiler water quality.
防止发生锅水膨胀事故的主要措施：有效地控制锅水的含盐量，给水的质量，锅
水的加药量，这就要求坚持严格的锅水化验制度，加强给水的处理工作，并适当调整
排污量，同时要求负荷变化不要过急，如并炉时锅内汽压不要高于主蒸汽管内的压力。

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

The main purpose of the solution is to effectively control the water salt content, water
quality and chemical dosing. To achieve that, the water sample examination shall be
normalized in a strict manner, feed water treatment shall be properly carried out, and the
blowdown shall be adjusted to meet the demand. In addition, the boiler shall be gradually
loaded and, when boilers are configured in parallel operation, the steam pressure in the
boiler shall not be higher than in the main steam piping.
3) 压力过高事故
Excessively high pressure
余热锅炉在运行中的出口压力超过规定压力的 1.1 倍时，就可认定为压力过高事
故。原因可能是用户负荷突然降低所致，也可能是因为安全阀失灵，或压力表指示失
灵，或运行人员的操作不当所造成的。处理方法是减少或是切断窑头烟气，以手动装
置开启安全阀降低出水压力，并校对压力表，加强排污等，必要时应采取紧急停炉的
措施。
During the operation of the waste heat boiler, when the outlet pressure is higher than
the rated pressure by 1.1 times, it should be deemed as excessive high pressure. The cause
may be the result of the sudden unloading made by the user, or may be the malfunction of
the safety valve, or the pressure gauge failure, or the misoperation of the operators. The
solution may be to reduce or cut off the exhaust gas from the kiln hood and manually open
the safety valve to reduce the outlet water pressure. The pressure gauge should be checked
and calibrated, the blowdown shall be carried out more than often. In top urgent cases, the
boiler can be shutdown as for emergency.
4) 锅炉爆管事故
Boiler tubing failure
锅炉爆管是重大的设备事故，此时会有大量水喷出，必须迅速正确地予以处理。
Boiler tubing failure is a major accident of the equipment damage, which causes huge
quantity of water to gush. For this, an immediate and correct action has to be taken.
锅炉爆管的原因很多，其中主要有给水品质不好，引起受热面管内结垢，致使局
部过热或腐蚀，也可能因炉窑烟气中粉尘浓度大，磨损了管子。
The causes for this accident may involve many aspects, mainly including poor quality
of water resulting in serious deposits on the heating surfaces and hot or corroded spots on
the tubing; another possible cause may be the high content of soot in the kiln exhaust gas
eating away the tubing.
爆管发生应采取紧急停炉措施。
The emergency shutdown of the boiler shall be required when the tubing failure occurs.
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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

5) 蒸汽管道发生水击事故
Water hammering on the steam piping:
往往是由于送汽前没有充分的暖管和疏水，或管道支架、吊架损坏松脱，而造成
水击事故发生。
Usually, the water hammering accidents are caused by insufficient warm-up or draining
before supplying steam to the system, or by loose piping supports or hangers.
处理时应采取相应的有效措施。
The appropriate measures shall be taken to handle the accidents.
开启蒸汽管道的疏水阀门，进行充分的疏水，如有满水事故迅速加以处理，如管
道支架、吊架损坏应及时修复。
Open the drains on the steam piping for enough drainage. Excessive boiler water shall
be promptly taken care of. Timely repair or maintenance shall be carried out if there is
damage to the piping supports or hangers.
6) 给水管道中发生水击事故
Water hammering on the feed water piping
给水管道中发生水击事故的主要原因：可能是由于管道内集箱存有空气，或水泵
止回阀门失灵忽开忽关，或给水温度剧烈变化，给水压力不稳定，或管道支架、吊架
松脱。
Major causes for the water hammering on the feed water piping may include: air is
collected on the piping header, or the check valve of the feed water pump fails causing
frequent opening and closing, or sudden and sharp change in the feed water temperature, or
instable feed water pressure, or loose piping supports and hangers.
发生上述事故时，应排除给水管道内积存的气体，检查止回阀、给水压力表、温
度计，如有不正常的现象发生应及时清除，检查给水管道的支架、吊架，如有损坏和
松脱应及时更换或修复。
When these are occurring, actions shall be taken to remove the cumulated air, inspect
the check valve, feed water pressure gauge and thermometer. If the inspection shows any
abnormality, immediate measures shall be taken to eliminate the trouble. In case the
inspection shows the damage or looseness to the piping supports or hangers, replacement or
repair shall be effected in a timely manner.
7) 余热锅炉用电中断事故
Interruption of power supply to the boiler
本余热锅炉为室外布置，因某种原因停电或工业用电亦同时中断供电，锅炉辅机

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

的电机停运，造成烟气继续进入，使锅炉的安全受到威胁，在此情况下应迅速使用备
用汽泵，迅速启动水泵，继续余热锅炉的安全运行，如无备用汽泵，应立即与炉窑系
统联系，停止窑的燃料供给，即切断热源，保证余热锅炉的安全，与此同时，切断辅
机所用电源，以防止来电时造成辅机二次事故。
The boiler is arranged outdoors, for some reasons, power may be cut off or the
industrial power supply may be interrupted at the same time, which could result in stoppage
of boiler auxiliary equipment motors, causing continuous exhaust gas entering into the
non-operational equipment, thus imperils the boiler safety. This situation shall be turned
over by starting up the spare steam-driven pump and the water pump to continue the boiler
operation. If no spare pump is available, immediate communication with the kiln operators
shall be required to cease the fuel feeding to the kiln, i.e. to cut off the thermal source to
ensure the boiler safety. Meanwhile, all main breakers of the power supply to the auxiliary
equipment shall be opened to prevent the accidents when power is recovered.
Ⅻ．停炉
Boiler shutdown
锅炉停炉，当然一方面取决于窑的运行情况，另一方面也取决于锅炉运行情况。
一般根据停炉时间长短，可分为暂时停炉，完全停炉和紧急停炉。
The boiler shutdown is depending on the kiln operation on one hand, and the boiler
operation on the other hand. Boiler shutdown may proceed in three ways based on how long
the shutdown shall last: temporary shutdown, complete shutdown and emergency shutdown.
1. 暂时停炉、完全停炉步骤如下：
Temporary shutdown and complete shutdown may proceed in the following steps:
（1）开启旁通烟道，关闭进口烟气蝶阀。
Open the by-pass flue, and close the inlet gas butterfly valve
（2）注意水位，不断补充给水。
Watch the water level and continue to make up for the feed water
（3）使锅内压力降到零后，再关闭主汽阀。
Reduce the boiler pressure to the “0”, and then close the main steam stop valve.
4． 紧急停炉
Emergency shutdown:
锅炉运行中遇有下列情况之一时，应采取紧急停炉（紧急停炉步骤见暂时停炉）：
One of the following situations calls for the emergency shutdown (the steps for the
emergency shutdown are similar to the temporary shutdown):

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

（1）锅炉水位降低到锅炉运行规程所规定的水位下极限以下时；
The water level of the boiler drops down beyond the lowest limit of the specified
level range;
（2）不断向锅内加大给水及采取其它措施，但水位仍继续下降时；
Water level continues to drop down despite the increased water feeding or other
necessary action for water filling;
（3）锅炉水位已升至运行规程规定水位的上限以上时；
The water level of the boiler rises beyond the upper limit of the specified level
range;
（4）给水设备全部失效；
Feed water equipment is all in malfunction.
（5）水位表、压力表或安全阀全部失效；
Failure of all the instruments such as the water level gauges, pressure gauges and
safety valves.
（6）炉墙严重损坏、钢架烧红等，严重威胁锅炉安全运行时；
Serious damage to the boiler walls, steel structure overheated, periling the safe
operation of the boiler.
（7）烟道中发生爆炸或二次燃烧，严重危及锅炉和运行人员安全时；
Explosion or burning in the flue, severely threatening the safety of the boiler and
personal life.
（8）窑本身要求锅炉紧急停炉时；
Kiln requires boiler emergency shutdown
（9）其它运行异常情况，超出安全运行允许范围时。
Other abnormality requires the emergency shutdown of the boiler because of the
safety limits are exceeded.
ⅩⅢ．水质要求
Requirement for the water quality
1．给水必须经过软化处理且符合下表要求，未经处理的水不可直接给入锅炉。
Feed water must be demineralized; no water without such treatment shall be
allowed to be fed into the boiler.

项目 数值 单位
Item Value Unit

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

总硬度
≤0.03 mmol/L
Hardness
溶解氧
≤0.1 mg/L
Dissolved oxygen
悬浮物
≤5 mg/L
Suspended solids
PH(25℃) ≥7

油
≤2.0 mg/L
Oil
2．锅炉运行中应对炉水定期化验，每班至少一次。
Regular chemical examination is required during boiler operation, at least once per
shift.
ⅩⅣ．锅炉的维护保养
Maintenance of the boiler
锅炉运行五至六个月以后，应停炉检修。
After 5-6 months of boiler operation, the boiler should be shutdown for maintenance.
（1）清除锅筒、联箱内部的水垢、泥渣。
To clean off the deposits in the drum, headers of the boiler
（2）清除受热面外表面上的灰垢。
To clean off the soot on the heating surfaces.
（3）对锅炉内外进行检查，如受压部件的焊缝及钢板内外有无腐蚀现象，若发现
有严重缺陷，应立即处理，若发现有可疑之处，但并不影响安全运行时，应
做好记录，以便日后参考。
Inspection on the internal or external sections of the boiler, such as check of the
welds of the pressure parts and steel sheets for corrosion. Severe defects shall be
subject to immediate remedy action. If the suspicious defects are located but not
impacting the safe operation, records shall be taken for future reference.
（4）检查引风机的滚动轴承是否正常，叶轮和外壳的磨损程度，使用单位应经常
保持叶轮的备件。
Check the induced draft fan for bearing abnormality, check the impeller and the
casing for wears and tears. The user shall keep sufficient spare parts for the
impellers.
（5）必要时可拆除部分炉墙进行彻底检查，如有发现严重损坏，必须修妥后方可

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

继续使用。同时将检查结果及修理情况，填入锅炉安全技术本上。
Some portions of the boiler walls can be removed for thorough inspection, if
necessary. When the inspection locates the serious damage, the complete repair
has to be carried out before start-up. All the findings from the inspection and the
repairs after the inspections shall be entered into the boiler safety technical logs.
（6）锅炉长期不用的保养：
Preservation for the boiler out of service for a long time:
a. 湿保养法：用经过处理的水灌满锅炉，将锅水煮沸排除空气后，将锅炉的所
有门孔关严，或用碱度较高的软化水注满锅炉，防止腐蚀，通常往软化水中
加 入 药 剂 有 NaOH(2kg/m3) 或 Na3PO4(5kg/m3), 往 锅 水 中 注 入 的 药 剂 有
NaOH(5Kg/m3)或 Na3PO4(15-20g/m3)，此法用于短期停炉保养，并要求锅
炉受热面外部及炉墙干燥。
Water preservation: fill up the boiler with the treated water, and then boil up the
water to remove the air. Fully close all the doors and openings. Or fill up the
boiler with the demineralized water of high alkalinity to prevent the corrosion.
The chemicals added into the demineralized water usually are NaOH(2kg/m3) or
Na3PO4(5kg/m3), and that added into the boiler water are NaOH(5kg/m3) or
Na3PO4(15-20kg/m3). This method is only for short time shutdown preservation
with the heating surfaces and the boiler walls properly dried.
b. 压力保养法：锅炉除垢后，并闭所有阀门，加入保护液至锅炉出口集箱最低
点，加热产生 0.1-0.2MPa 压力，并在该压力下保持 2-3 小时，降压后，再用
保护液灌满整个锅炉，然后用液压方法使锅炉保持 0.2MPa 压力。保护液的
成份和浓度为：苛性钠 100mg/L，五氧化二磷 100mg/L，硫酸钠 250mg/L，
在保养期间必须定期地检查保护液的浓度，当硫酸钠的浓度降低到 50mg/L
以下的时候，应以予以补充。
Pressure preservation: After removal of deposits from inside the boiler, all the
valves shall be closed. Preservation solution is to be added up to the lowest point
of boiler outlet header. Heat up the boiler to create a pressure of 0.1-0.2MPa, and
then hold the pressure for 2-3 hours. After pressure is dropped down, the
preservation solution should be used again to fill up the boiler, and then keep the
pressure of 0.2MPa by using a hydraulic way. The preservation solution is
composed of caustic soda (100mg/L), phosphorus pentoxide (100mg/L)，sodium
sulfate(250mg/L). During the preservation period, regular inspection for the

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

proper concentration of the solution is required. When the concentration of

sodium sulfate is found to be lower than 50mg/L, more of that chemical shall be
added to keep the specified concentration.
c. 充氮保养法：（略）
Nitrogen preservation (omitted)
当锅炉需要长期停炉时可采取充氮保养法。
When the boiler is down for a quite long time, the nitrogen preservation can be applied.
ⅩⅤ．锅炉检验和水压试验
Inspection and hydro-test of the boiler
（1）锅炉运行后的检验工作，包括外部检验，定期停炉内外部检验和水压试验。
Major inspection after a certain period of the boiler operation, including external
inspection, regular shutdown inspection and hydro-test shall be conducted.
（2）运行的锅炉应每年进行一次外部检验，每两年进行一次内部检验，每六年进
行一次水压试验。
The boiler in operation shall be subject to an external inspection once per year,
and an internal inspection once per two years, and one hydro-test per 6 years.
（3）除定期检验外，锅炉有下列情况之一时，也应进行内外部检验和水压试验。
Besides the regular inspections, one of the following would require additional
internal or external inspection or hydro-test:
（4）移装或停止运行一年以上，需要投入或恢复运行。
Restore of operation after moved to a new erection place or shutdown for more
than one year.
（5）受压元件经重大修理或改造后及重新运行一年后。
Pressure parts have experienced a major repair or retrofit and restore of operation
is longer than one year.
（6）根据锅炉运行情况，对设备状态有怀疑，必须进行检验时。
The boiler operation conditions may indicate suspected defects in the equipment,
requiring an inspection.
（7）水压试验前，应进行内外部检验，必要时还应做强度校核计算，不得用水压
试验方法确定锅炉的工作压力。
Before the hydro-test, an internal and external inspection is required, and it
might be necessary to recheck the strength of the boiler for verification. The
hydro-test could not be used as a method to determine the working pressure.

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

（8）定期检验时重点如下：
The regular inspection would concentrate on the following items:
a. 上次检验有缺陷的部位；
The parts or portions where defects were located during the last inspection.
b. 受压元件内外表面、开孔、焊缝等处有无裂纹、裂口和腐蚀；
Internal and external surfaces, openings and welds of the pressure parts to be
checked for cracks, ruptures or corrosion;
c. 受压元件有无凹陷、弯曲、鼓包和过热；
Pressure parts to be checked for concaves, bending, bulges or overheating.
d. 受压元件与其他各部接触处有无腐蚀；
Pressure parts to be checked for corrosions on the contacts with other parts;
e. 受压元件或钢架，有无因护板等损坏而发生过热；
Pressure parts or steel structure to be checked for overheating due to damaged
boiler casing;
f. 给水管和排污管与锅筒接口处有无腐蚀、裂纹，排污阀与排污管是否正常；
Feed water piping and blowdown piping to be checked for corrosion, cracks, on
the connection with the drum, and the blowdown valves and piping to be
checked for abnormality;
g. 安全附件是否可靠,通向水位表、压力表、安全阀等开孔有无堵塞；
The safety accessories to be checked for reliability, and the openings for
connection to the water level gauge, pressure gauge, safety valves to be checked
for plugging;
h. 自动水位报警及控制系统、仪表是否。灵敏可靠。
Automatic water level alarms, control system and instruments to be checked for
reliability and sensitivity.
ⅩⅥ．电控基本要求及联锁保护
Requirement for electric control system and the interlock protection
1. 锅炉电控系统应与燃烧炉控制系统联锁。
The boiler electric control system shall be interlocked with kiln control system.
2. 锅炉电控接收电接点压力表信号，当锅炉超压时，实施报警和联锁保护，切断
炉窑燃烧系统或关闭锅炉烟气进口阀门。
Boiler electric control system receives the signal from the electric contact of the
pressure gauge to alarm and provide interlock protection when the boiler exceeds

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the normal pressure. It will then cut off kiln combustion system or shut off the
boiler inlet gas valve.
3. 与平衡容器连接的水位自动控制系统应设有高低水位报警及联锁保护，极限高
水位时，停止给水泵并报警；极限低水位时报警并切断炉窑燃烧系统或关闭
锅炉烟气进口阀门。
The boiler electric control system should be provided with high & low level alarms
and interlock protection. In case of ultimate hi-level, it shall shutdown the feed
water pump and alarm; while at ultimate lo-level, it shall alarm and cut off the kiln
combustion system or shut off the boiler inlet gas valve.
4. 超压报警和极限高、低水位报警的声光信号应能区分。
The acoustic and optic signals for over-pressure and ultimate high & low levels
shall be distinguishable.
ⅩⅦ．附加说明
Additional notes
本说明书所列条文，若与当地颁发的有关规定、规程、标准、规范或新标准相抵
触时，应按照当地颁发的有关规范执行。
If the above provisions or clauses are conflicting with the related regulations, rules,
standards, specifications or new codes issued in the locality, it shall be governing.
ⅩⅧ．锅炉运输、装卸注意事项
Notes for transportation & load and unload of the boiler
1、 由于锅炉部件的轻重、长短、高矮、大小不一，所以运输要根据实际情
况调派相适应的车辆运输；
Because of the difference of weight, length, height and size between the
boiler parts, the truck of enough capacity shall be considered first;
2、 如果车上装有超高、超长、超宽、超重四超之一的部件，须按交通规定，
事先办理相关通行证，按规行驶，否则会造成运输途中不必要的麻烦；
If the size or weight of the boiler parts is beyond local traffic code,
correlative traffic pass shall be transacted beforehand. Otherwise, maybe
there will be some trouble on the road;
3、 严格按照起吊标志挂钩起吊，并选用与货物重量相符的起重器具，作业
现场应有专人指挥；
The hanging shall be according to the hanging mark strictly, and the crane
shall be chosen according to the weight of the parts. The director is needed

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

when hanging;
4、 货物装车、船时应做到长不压短、重不压轻、大不压小，并轻起轻卸，
放稳垫平；
When load and unload is operated on trucks or cargo ship, the shorter one,
lighter one and smaller one shall be put on top, and the operation shall be
gently, on an even keel;
5、 为防止运输途中货物震动，要用钢丝绳做好加固，钢丝绳与货物接触处
要用木料或橡皮等垫好，不能因加固不当造成对货物的磨损；
To prevent shake of the goods, tightwire for reinforcement is needed. Batten
and rubber shall be put between the goods and the tightwire to prevent
abrasion;
6、 运输、装卸过程要体现安全和质量；
Safety and quality must be ensured during transportation & load and unload;
7、 运输、装卸过程须符合当地法律、安全要求。
Operation of transportation & load and unload shall be according to local
laws and safety requirements.

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 258AY00-AMSY 安装使用说明书 Installation and Operation Manual

附一：管道保温材料清单
Appendix: List of Pipe Heat Insulating Material
保温厚度(mm)
序号 名称 管子规格 管子长度(m)
Thickness of
Item Description Specification Length
Heat Insulating
上升管
2 Φ273x9.27 100 15
Raiser Pipe
上升管
3 Φ141.3x6.55 100 70
Raiser Pipe
下降管
4 Φ273x9.27 100 50
Downcomer Pipe
下降管
5 Φ141.3x6.55 100 35
Downcomer Pipe
本体管路管道
6 Φ88.9x5.49 80 100
Piping of Boiler
本体管路管道
7 Φ60.3x3.91 80 100
Piping of Boiler
本体管路管道
8 Φ33.4x3.38 50 930
Piping of Boiler
本体管路管道
9 Φ26.7x2.87 50 60
Piping of Boiler
本体管路管道
10 Φ21.3x2.77 50 200
Piping of Boiler

说明 Notes：
1、管道保温采用无石棉硅酸钙瓦，一周用两块合成，该材料体积密度为 220kg/m3，
导热系数为 0.06w/m.K（常温），最高使用温度为 650℃，抗压强度为 6kgf/cm2 的硬
质材料。
Heat insulating material is calcium silicate tile without asbestos, two composite in circle.
Volume density is 220kg/m3, coefficient of heat conductivity is 0.06w/m.K(normal
temperature), highest used temperature is 650℃, tensile strength is 6kgf/cm2.
2、保温施工按照当地颁发的有关规范进行。
Construction of heat insulating shall be according to specifications or codes issued in the
locality
3、锅筒及锅炉本体的保温见 258AY13-0 炉墙金属件图。
Heat insulating of drum and boiler details as 258AY13-0.

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