Boiler Operation & Maintenance Instructions

连封面共 57 页
Total 57 Pages
型号:Q110/950-49.2-11.65/540
Type
锅炉使用维护说明书
Boiler Operation&Maintenance Instructions
编号：091104SM2
SER. No.
版本：A
Rev
版本日期编制审核批准修改-说明
Rev. Date Designed by Reviewed by Approved by Modification-Observation
本文件之产权属于杭州锅炉集团股份有限公司。未获本公司许可，任何人不得擅自使用、复制、传递或泄漏
该文件。
This document is the property of HBG. It must not be used, reproduced, transmitted or disclosed without the prior
written permission of HBG.
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Boiler Operation&Maintenance 版本
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Instructions Rev
目录
Content
1 序言
Prologue
2 试运行的准备工作
Preparation for trial operation
2.1 锅炉整体水压试验
Overall hydrostatic test of the boiler
2.2 烘炉
Refractory curing
2.3 清洗方式
Types of cleaning
2.4 其它注意事项
considerations
2.5 安全阀的调整
Safety valve adjustment
3 锅炉的运行及操作
Running and operation of the boiler

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3.1 锅炉运行上的监视事项
Monitoring matters for boiler running
3.2 锅炉的运行操作
Boiler operation
3.3 操作注意事项
Precautions for operation
4 锅炉维护
Boiler maintenance
4.1 正常运行期间的检查
Inspection during normal operation
4.2 定期检查工作
Periodic inspection work
4.3 启动期间或机组停炉后的即时维护
Instant maintenance during start-up or stop
5 锅炉保养
Boiler maintenance
5.1 短期防腐
Short-term anticorrosion
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5.2 长期防腐
Long-term anticorrosion
日期
签字
更改文件号
编制校对审核批准
处数
Design Verify Review Approved

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标记
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1. 序言
Prologue
本说明书简单介绍了印度 BMM 海绵铁余热锅炉使用维护过程中所应该
注意的事项：
These instructions simply introduce precautions for use and maintenance heat
recovery boiler of india BMM sponge iron.
(1) 用适当的使用维护手段充分发挥锅炉的性能。
Bring boiler performance into full play by means of appropriate Operation and
maintenance method
(2) 防止由于误操作而产生的故障和损害。
Prevent fault and damage caused by misoperation.
然而，本说明书只是提出了锅炉使用维护中必要的原则事项，由于本锅
炉设备为余热锅炉，受作业状态（锅炉入口烟气量，烟气温度等）的直接影
响，锅炉操作者应充分熟悉工艺规程的作业特性，充分掌握锅炉的性能特性，
以便在实际操作中迅速且适当地采取措施，能完善、安全地进行锅炉使用维
护。
But, these instructions only put forward necessary principle matters in use and
maintenance of boiler, since this boiler is waste heat boiler, under direct influence
of working state (boiler inlet flue gas flow, flues gas temperature etc), boiler
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operator should sufficiently get familiar with work characteristic process
regulations, grasp performance characteristic of the boiler sufficiently, so as to
take measures rapidly and properly in practical operation, operation and maintain
the boiler perfectly and safely.
2. 试运行的准备工作
Preparation for trial operation
锅炉首次启动前应至少满足以下条件：
Before the first start-up of boiler, at least the following conditions should be
satisfied:
(1) 锅炉安装工作结束
Boiler installation work is finished
(2) 锅炉整体水压试验合格
Overall hydrostatic test of the boiler is qualified
(3) 松开所有弹簧支吊架的插销，且支吊架调整到位
Spigot of all spring brackets and hangers are loosened, brackets and hangers are
adjusted properly
(4) 安全阀能有效地作用
Safety valve could act effectively
(5) 给水设备做好运行准备
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Feed water equipment is prepared for operation
(6) 辅助设备均处于备用状态
Auxiliaries are in stand by state
2.1 锅炉整体水压试验
Overall hydrostatic test of the boiler
锅炉承压系统及有关焊接件安装完毕后，按照 IBR 进行锅炉整体水压试验
以最终检查承压部件的制造、安装焊接质量、材料质量或残余变形情况，并作
最终消除缺陷处理。水压试验要点如下：
After boiler bearing system and relevant weldment are installed, conduct overall
hydrostatic test of the boiler according to IBR, so as to finally check manufacture,
installation welding quality, material quality or residual deformation condition of
bearing parts, and eliminate defects finally. Key points of hydrostatic test are as
follows:
2.1.1 水压试验前应做好下列工作：
Carry out the following work before hydrostatic test:
(1) 进行所试部件的内部清理和表面检查。
Clean up inside of the part to be tested and check the surface
(2) 装置校验合格的压力表。
Set up acceptable pressure gauge

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(3) 装设好排水管道和放空气阀。
Set up drain pipe and air release valve
2.1.2 试验压力以锅筒为测量基准点，试验时应装设两套以上经校验合格的压
力表，锅炉整体水压试验压力为 1.5 倍锅筒设计压力，即 20.9MPa。
Test pressure takes drum as measurement reference point, set up more than two
sets of acceptable pressure gauge for the test, boiler overall hydrostatic test
pressure is 1.5 times of the design pressure of drum, namely 20.9MPa.
2.1.3 水压试验时水质和温度要求：
Water quality and temperature requirements for hydrostatic test:
(1) 试验用水应为除盐水。
Test water should be demineralized water.
(2) 水压试验时，周围空气温度应高于 5℃，否则应有防冻措施。
During hydrostatic test, ambient air temperature should be higher than 5℃,
otherwise anti-freezing measures should be provided.
(3) 试验水温为 20~50℃。
Test water temperature should be 20~50℃.
2.1.4 锅筒水位表只做工作压力试验，不参与超压试验。
Drum water gauge is only used for operating pressure test, will not be used for
overpressure test
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2.1.5 按 IBR 技术条件进行锅炉整体水压试验。
Conduct overall hydrostatic test of the boiler according to technical conditions
of IBR.
2.1.6 水压试验压力升降速度一般不应超过每分钟 0.3MPa。
Rise/fall speed of pressure in hydrostatic test generally should not exceed
0.3MPa per minute.
2.1.7 锅炉充满水后金属表面结露应清除，当压力升至试验压力的 10%左右
时，应作初步检查，清除异常现象。
After boiler is filled with water, dew on metal surface should be eliminated,
when the pressure rises to about 10% of test pressure, carry out preliminary
inspection, eliminate abnormity.
2.1.8 水压试验升至工作压力时，应进行全面检查，并且保证工作压力值无下
降情况，则可继续缓慢均匀地升压，进行超压试验。在试验压力下保
持 30 分钟后降至工作压力再进行全面检查。检查期间压力应保持不变，
检查中若无破裂、变形及漏水现象，则可认为水压试验合格。
When hydrostatic test rises to the operating pressure, carry out comprehensive
inspection, ensure operating pressure value not to drop, continue to boost
pressure slowly and uniformly, conduct overpressure test. Keep 30 minutes at
test pressure, then drop to operating pressure, carry out comprehensive

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inspection. Pressure should remain constant during inspection, if no rupture,
distortion and water leakage is found in the inspection, hydrostatic test will be
deemed as qualified.
2.1.9 整体水压试验后，应将水放尽，尤其是水压后至启动间隔时间较长时，
更应考虑汽水系统内部的防腐措施。
After overall hydrostatic test, drain out the water, especially when the interval
time after hydrostatic test to start-up is long, anticorrosion measures inside the
steam and water system should be considered even more.
2.2 烘炉
Refractory curing
锅炉炉墙砌筑安装完毕后，在投入试运行前必须进行烘炉。根据锅炉炉墙
材料和结构，需按以下烘炉升温曲线进行烘炉操作：
After boiler furnace wall is laid and installed, always carry out Refractory curing
before putting it into test run. According to material and structure of boiler furnace
wall, carry out furnace drying operation according to the following furnace drying
temperature rise curve:

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Temperature℃
Note: this Refractory drying curve is for reference. Pay attention to temperature
points during furnace drying (critical temperature point for discharge of free water
2.3 清洗方式
Types of cleaning
按锅炉的条件、运行范围、工地处理设备，采用不同的清洗工艺。
Depending on the WHRB condition, operating range, and site disposal
facilities, a variety of cleaning procedures is available.
2.3.1 手工清理
手工清理是清理可以清理区域。打开所有人孔盖，尽最大可能清理掉油脂、
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油和其他杂物，仔细的手工清理可以减少其它进一步清理的时间。
Hand Cleaning: The first step should always be to clean accessible
areas by hand. Remove all manhole covers on the steam, collector,
and mud drums. Remove and clean out by hand as much grease, oil,
and other foreign material as possible. Careful hand cleaning will
reduce the time required for further cleaning.
2.3.2 有机物的去除
手工清理后，任何剩余的有机物(如油，油脂或管子保护涂层)必须从锅炉
的内表面清除掉，残留在管子上的有机物会阻碍热交换，妨碍金属的正常
钝化，并遏制清洗。另外，任何滞留于管子内表面的杂物必须冲洗掉。
Organic Material Removal: Following hand cleaning, any remaining
organics (such as oil, grease, or tube protective coatings) must be
removed from the interior of the WHRB. Organics left on the tubes will
impede heat transfer, prevent proper passivation of the metal, and
inhibit cleaning. In addition, any loose foreign materials clinging to the
inner tube surfaces should be flushed out.
2.3.3 化学除垢:
这一步用来去除氧化皮或其他沉淀物，一般用酸或其它溶剂方法清洗，先
加热，在锅炉内保持或循环预定的时间，直至测试到反应率下降为止。酸
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清洗完成后，pH值应上升以促使钝化，或疏水后加入碱溶液循环。人孔应
该打开并冲洗密封面，并用上新的垫圈。化学除垢后，必须采取相应措施
进行锅炉维护，以确保有害物质不会进入系统。
Chemical Scale Removal: This step is used to remove scale or other
deposits. The solution is generally heated, and allowed to stand in the
WHRB or circulated for a prescribed time or until testing shows the
reaction rate has decreased. After the cleaning has been completed,
the pH of the solution should be raised to promote passivation, or the
solution should be drained and an alkaline solution circulated.
Manholes should be opened, the seating surfaces flushed, and new
gaskets installed. Proper procedures must be implemented for laying up
the boiler after the chemical cleaning to insure that damaging
contaminants do not enter the system.
警告：采用酸洗法必须彻底冲洗所有的内表面以防止损害。
CAUTION: THE CLEANING SOLUTION MUST BE COMPLETELY
REMOVED FROM ALL THE INTERNAL SURFACES TO PREVENT
DAMAGE.
2.3.4 一般余热锅炉蒸气吹扫过程 General WHRB Steam Blow Procedures

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原理 Theory
为确保初步安装后从锅炉的锅筒到过热器出口有干净的蒸汽管道，需要进
行彻底的清洁工艺。通常，它采用蒸汽吹扫、空气吹扫或化学清洗/蒸汽(空
气) 吹扫相结合的工艺手段。
蒸汽吹扫工艺采用高速蒸汽通过蒸汽管道从而达到足够的清洗倍率(CR)，
CR为吹扫蒸汽和基本设计工况下蒸汽密度(ρ)和蒸汽速度平方(V2)在乘积
的比。
(ρV2)吹汽
CR = ------------
(ρV2)设计
对管壁产生的清洗力和介质通过管道的动压成正比，因此清洗倍率越大则
清洗力越大(即管壁清洗越好)，一般动力锅炉要求不小于1.6的清洗倍率。
In order to insure a clean steam path after initial erection from the
evaporator sections of the WHRB to the superheater outlet points, it is
necessary to perform a thorough cleaning procedure. In general, this is
accomplished through a steam blow, air blow, or a combination chemical
clean/ steam (air) blow.
A steam blow procedure entails passing high velocity steam through the
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steam path in order to generate a sufficient cleaning ratio (CR). The
cleaning ratio is defined as the ratio of the product of the density (ρ) and
the square of the steam velocity (V) at the steam blow conditions to the
same product at the design base load conditions.
( ρ V 2 ) steam blow
CR =
( ρ V 2 ) design
The shear force generated on the tube walls is proportional to the velocity
head of the flowing fluid through the pipe network. Therefore, the larger
the cleaning ratio the larger the shear force (i.e. the better the cleaning of
the tube walls). A cleaning ratio greater than 1.6 is normally required in
power boilers to insure adequate cleaning of all steam path surfaces.
2.3.5 蒸汽吹扫时的锅炉操作 WHRB Operation for Steam Blowing
此章节概述了蒸汽吹扫时WHRB的操作。这里的指南和建议仅供参考，建
议WHRB的清洗由合格的专业清洗承包商进行。
在建立蒸汽吹扫规程时应注意以下事项：
The intent of this section is to present general information pertaining to
operation of the Waste Heat Recovery Boiler (WHRB) during the steam
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blow process. The guidelines and advice provided are for information
purposes only and the party responsible for the WHRB cleaning is
advised to seek the services/advise of a qualified cleaning professional.
Many of these issues are operational in nature and several are
highlighted below for consideration when developing a site specific steam
blow procedure.
锅炉负荷：WHRB Loads
大多数蒸汽吹扫可以在锅炉较低负荷进行。
Most steam blows can be accomplished at low loads of the WHRB.
汽包水位：Steam Drum Water Levels
所有汽包内在蒸汽吹扫期间必须保持水位以防止损坏。汽包水位的过高和
过低都将可能造成锅炉的损坏。
蒸汽吹扫期间汽包水位在允许的范围内波动。当采用连续蒸汽吹扫时，锅
炉可以达到平衡条件而汽包水位保持在相当平稳的状态。但是，间断性蒸
汽吹扫会产生汽包水位有较大的波动，汽包水位必须保持在低低水位
（LLWL）和高高水位（HHWL）之间。
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在间断蒸汽吹扫时，汽包压力的不同会引起汽包水位剧烈的波动，操作工
必须在开始时让汽包压力变化很小然后在作较大的压力变化以确保汽包水
位的可控制性。
Water level must be maintained in all steam drums during a steam blow
to prevent damage.
The extent of drum level fluctuation during a steam blow is a function of
the cleaning method applied. When a continuous blow is utilized, the
boiler is able to reach an equilibrium condition and subsequently, the
drum level should remain fairly constant. However, the flashing nature of
an intermittent steam blow will generate very large swings in drum level.
The water level must be maintained between the LLWL and the HHWL.
During an intermittent type of steam blow where the drum pressure
varies, the water level fluctuations will be significant. The operator
should start with a small drum pressure change and work up to larger
pressure changes to assure that the water level can be controlled.
启动：Start-Up
为蒸汽吹扫加热锅炉时，必须用临时的蒸汽吹扫阀门来控制锅炉的温度梯
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度变化率，相关启动要求请查阅该操作和维护手册。
吹扫用蒸汽不可以从锅炉的主启动阀门排放，因为此阀门的密封面可能会
损坏。
When heating up the boiler for the steam blow process, temporary steam
blow valves should be utilized to control the WHRB ramp rates. Refer to
the startup requirements in the HBG O&M Manual.
Steam blow steam must not be discharged through the WHRB main
start-up valves. The valve seats would be subjected to damage.
水的品质/水化学：Water Quality / Water Chemistry
蒸汽吹扫用的水质应该和正常运行水质一样，WHRB在蒸汽吹扫期间可能
会从汽包带水，所带的水应该尽可能干净以避免在管道和受热面上附着化
学沉积物。给水pH值应通过注氨达到9，氨当量浓度为0.3ppm左右。
除非用除氧水，蒸汽吹扫后的水必须彻底疏水。
The quality of water used for steam blows should be the same quality as
the water intended for normal operation. WHRB will carryover water from
the steam drums during the steam blow. This water should be as clean
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feedwater pH should be increased to 9 by injecting ammonia. This is
equivalent to an ammonia concentration of about 0.3 ppm.
The boiler must be drained after steam blows unless deaerated water
was used.
减温器操作：Desuperheater Operation
HBG建议在蒸汽吹扫时减温器应隔离。不正确条件下的喷水会导致锅炉损
坏。如果采用减温器，必须有足够的蒸汽流量和过热蒸汽来蒸发水，减温
后的蒸汽必须有50℃的最小过热度。当没有足够的蒸汽通过时，在任何情
况下减温器阀门都不能打开。
HBG advises that the water flow to the desuperheaters be isolated during
steam blows. Water sprayed under the wrong conditions can lead to
damage. If desuperheaters are utilized, there must be adequate steam
flow and steam superheat to vaporize the water. The steam must have
a minimum of 50 ℃ of superheat after the desuperheater. In no
case ,must the desuperheater block valve be opened with insufficient
steam flow past the desuperheater.
警告：当蒸汽流量较小时投入减温器，会造成锅炉的损坏。
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Caution:if desuperheaters are utilized when steam flow is relatively
small,it will bring damage to WHRB.
安装：Erection
必须仔细检查所有WHRB的部件都是良好的安装状态。
Care has been taken to supply all WHRB components in a good
condition.
测量仪表：Measurement Devices
蒸汽吹扫过程可能影响蒸汽流量计，这些仪表的精度随内表面的完成而决
定，如果可行这些仪表应该拆出。
The steam blow process may affect steam flow meters. The accuracy
of these devices is dependent upon the finish of the interior surface.
These devices should be removed if practical.
止回阀：Non-Return Valves
蒸汽吹扫期间主蒸汽阀必须100%打开以避免破坏阀门的密封面。止回阀供
应商要求止回阀的阀盘（阀笼）在蒸汽吹扫期间拆出。如果安装方在蒸汽
吹扫期间没有拆出止回阀内件而引起损坏，我们公司不负责任。
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在很多情况下，当首次有很多热量通过WHRB时就可能进行蒸汽吹扫，因
此，应检查锅炉的热膨胀，锅炉部件热膨胀的异常情况并消除。
The main steam valve must be 100% open during steam blows so as not
to cause undo wear on the valve seats. Non-return valve vendors require
that the non-return valve disc (cage) be removed during a steam blow.
HBG will not be responsible for damage to the non-return valve in the
event that the erector chooses to leave the non-return valve internals in
line during the steam blows.
In many cases, the steam blow may represent the first time that large
quantities of heat have been passed through the WHRB. Therefore,
during the heat up process, items typically associated with first fire of the
boiler (i.e. thermal expansion of pipelines) must be addressed and
inspected to insure proper working order.
2.4 其它注意事项 Considerations
本章节强调了WHRB的清洗、保护和其他承包商不提供的计划/工作时需要
考虑的事项。
This section highlights considerations on when to clean the WHRB,

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protection of the WHRB, and other planning/work that may not be
provided by the contractor.
2.4.1 锅炉安装后经常要作检查和清洗，对以后的清洗要按检验和性能监控要
求提出计划。
The WHRB should always be inspected and cleaned after initial
erection. Future cleanings should be scheduled as required based on
inspections and monitoring of performance.
2.4.2 是否清理氧化皮应由业主及电厂水处理单位决定。
The decision on whether cleaning for mill scale removal will be
necessary should be made by the owner in conjunction with those who
will be doing the water treatment of the plant during operation.
2.4.3 给清洗承包商 P&I 图以便其布置循环管路。
P&I should be supplied to the cleaning contractor to lay out the
circulation path.
2.4.4 所有锅炉外部管道，包括给水储存/处理设备，当锅炉清洗时也应该进行
清洗。
All pre-boiler piping, including feedwater storage/treatment facilities,
should be cleaned when the WHRB is cleaned.
2.4.5 调节阀、孔板和其他可能在清洗过程中损坏的设备需在清洗过程中拆掉或
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旁路掉。
Control valves, orifices, and other instrumentation that could be
damaged during the cleaning should be removed or bypassed.
2.4.6 清洗承包方应该提供必要的用于清洗工艺的临时水位计，告知清洗承包
商这个临时水位计的最大工作温度和压力。
A temporary gauge glass is provided for use during the cleaning
procedure, if deemed necessary by the cleaning contractor. Inform the
contractor of the maximum working pressure and temperature on this
temporary glass.
警告：常用于清洁工艺的水位计玻璃不能用于正常运行，它可能会受压而破碎
损坏和伤害人。必须在锅炉投运前将这些临时用的水位计拆除。
WARNING: THE DISPOSABLE TUBE TYPE GAUGE GLASS TYPICALLY
USED DURING THE CLEANING PROCESS IS NOT SUITABLE FOR
STEAM SERVICE. THIS GLASS COULD SHATTER UNDER SERVICE
PRESSURE AND RESULT IN DAMAGE OR PERSONAL INJURY. A
LOCKOUT PROCEDURE SHOULD BE EMPLOYED TO INSURE THE
REMOVAL OF THIS TEMPORARY GAUGE GLASS AFTER THE
CHEMICAL CLEAN HAS BEEN COMPLETEED AND PRIOR TO
PERMANENT OPERATION.
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2.4.7 由于在锅炉中循环的清洗液将会冷却，清洗液的温度在锅炉的进口和出
口处都要监控以保持有效的温度。清洁介质的加热一般由清洗承包商自
带外置的加热器完成。
As it circulates through the WHRB, the cleaning solution will cool.
Solution temperature should be monitored at the inlet and outlet points
of the WHRB to ensure an effective temperature is maintained.
Restricting air flow through the duct (by covering the stack or closing
access doors) will reduce the amount of heat lost in the WHRB.
Heating of the cleaning and rinsing fluid is normally accomplished in an
external heat exchanger supplied by the cleaning contractor.
2.4.8 清洗承包商必须有步骤地确保清洗液在锅炉所有部件中循环。
The contractor should take steps to ensure circulation of the cleaning
solution through all sections of the WHRB.
2.4.9 化学清洗时汽包内件可以装在汽包内一起清洗。注意，钢丝网是由不锈
钢板制成的，如果清洁液对其有损害则应事先取出。然后在蒸汽吹扫后
和运行前在装入，波纹板分离器如果取出检查或做额外清洗则必须以同
样的方位装回去。
Steam drum internals can remain installed during the chemical cleaning.
Note, however, that the mesh pads are made of stainless steel, and
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must be removed if the cleaning solution will attack this material.
Re-install the mesh pads before steam blow or operation. If the
chevron separators are removed for inspection or additional cleaning,
they must be reinstalled with the same orientation.
警告：如果在汽包内件上附有外部物质会导致蒸汽纯度的问题。必须按要求进
行检查和清理。
CAUTION: FOREIGN MATTER ON THE INTERNALS COULD
RESULT IN STEAM PURITY PROBLEMS. THEY SHOULD BE
INSPECTED AND CLEANED AS REQUIRED
2.4.10 蒸汽吹扫或化学清洗时取样管必须关闭以免堵塞。
Sample lines should be closed during steam blow and chemical
cleaning to avoid plugging.
2.4.11 全部清洗工艺的记录包括所用的化学品要由用户保存。
The customer should retain records of the entire cleaning procedure
including the chemicals used in the process.
2.4.12 任何化学清洗必须采用安全的工艺。
Safety procedures should be reviewed or developed as necessary prior
to any chemical cleaning
2.4.13 当清洗完成后，业主和清洗承包商必须检查机组是否已完全干净且所有
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的管屏已完全疏水。
When the cleaning is completed, the customer and contractor should
verify that the unit is clean and all the coils have been completely
drained
2.4.14 清洗液的处理费用占整个工艺很重的一部分，弱清洗溶液长循环时间的
费用可由更多的腐蚀/酸性溶液处理费用弥补。
Disposal of the cleaning solutions may contribute substantially to the
cost of the process. The cost associated with longer circulation times
of weaker cleaning fluids may be offset by the disposal cost of more
caustic/acidic fluids
2.4.15 清洗后，应按照合适的保养规程。
Following cleaning, proper maintenance procedures should be followed.
2.4.16 HBG不认可或推荐任何特别的化学清洗/蒸汽吹扫（包括热冲击蒸汽吹
扫）方法。上面所述是仅供参考。
HBG does not endorse or recommend any particular type of chemical
clean / steam blow (including thermal shock steam blows). The above
information is provided for information only.
2.4.17 建议在化学清洗前拆除汽包内分离器的钢丝网。在化学清洗后，蒸汽吹
扫前将丝网再装回去。
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It is advisable to remove the steam drum mesh pads prior to
commencing with a chemical cleaning which will circulate through the
steam path. The mesh pad will act as a sieve in such a situation and
would require an extensive cleaning after the chemical cleaning is
accomplished. The mesh pads should be reinstalled prior to
commencing with steam blows
2.5 安全阀调整
Safety valve adjustment
本锅炉共有 3 个安全阀，安全阀调整应符合 IBR 的要求。3 个安全阀整定
压力（开启压力）如下：
This boiler has totally three safety valves, safety valve adjustment should refer to
IBR require, Setting pressure of 3 safety valves (open pressure) is as follows:
过热器出口安全阀 1个 12.2 MPa
Superheater outlet safety valve one
锅筒安全阀 2个 13.93 MPa
Drum safety valve two
对备用或停用的锅炉，必须采取有效的防腐措施，做好保养工作。
For stand by or idle boiler, take effective anticorrosion measures for maintenance
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work.
3. 锅炉的运行及操作
Running and operation of the boiler
3.1 锅炉运行上的监视事项
Monitoring matters for boiler running
3.1.1 锅炉升压/降压时的压力监视
Pressure monitoring during boiler pressure up/down
锅炉从冷却状态到升至操作压力，为了不让锅筒、过热器等主要部位产生
急遽的热应力，升压时，锅炉水温上升速度要控制在每小时 55℃以下。在控
制过热器的管壁温在 600℃以下的情况下，可以按照下面的启动压力温度线图，
将温度换算成压力以进行控制、监视。另外，当进行热风干燥及 WHRB 升温
时的升压时，锅炉水温上升速度要控制在每小时约 30℃。同时，降压时也要
控制锅炉水温的下降速度，每小时 55℃以下。
Boiler is boosted from cooling state to operating pressure, in order to prevent
sudden thermal stress generated in main parts such as drum, superheater etc, during
boost, boiler water temperature rise speed should be controlled below 55℃ per hour.
In case control superheater tube wall temperature is below 600℃, temperature may
be convered to pressure for control, monitoring according to the following start-up
pressure temperature profile. In addition, when boost during hot air drying and
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WHRB oven temperature rise, boiler water temperature rise speed should be
controlled at about 30℃ per hour. At the same time, fall speed of boiler water
temperature should also be controlled for pressure drop, below 55℃ per hour.
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3.1.2 蒸汽温度的监视
Monitoring of steam temperature
注意锅炉各部的蒸汽温度不要超出下面的限制值，如果超出此限制值
时，请降低锅炉进口气体温度。
Pay attention that steam temperature of boiler parts should not exceed the
following limit value, if the temperature is exceeded, please reduce boiler inlet
gas temperature
锅炉蒸汽温度的限制值（最高使用温度）
Limit value of boiler steam temperature (maximum service temperature)
低温过热器出口蒸汽温度 450℃以下
Outlet steam temperature of low temperature superheater below 450℃
高温过热器进口蒸汽温度 420℃以下
Inlet steam temperature of high temperature superheater below 420℃
高温过热器出口蒸汽温度 540℃
Outlet steam temperature of high temperature superheater below 540℃
3.1.3 锅炉水质的监视
Monitoring of boiler water quality
锅炉给水及锅炉炉水按相关标准和规定进行管理。
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Boiler feed water and boiler water should be managed according to relevant
standards and provisions
3.1.4 锅筒的监视
Monitoring of boiler drum
锅炉运行中，最危险的状况是锅筒水位低下。
During boiler operation, the most dangerous condition is drum water level Of
drum
锅筒设置了就地水位计和水位平衡容器，请不要过分依赖这些仪表，
锅炉日常运转中的水位计检查至少每班进行一次。运行中的水位请控制在
±50mm 以内。
Drum is provided with local water gauge and water level balance container,
please do not depend on these instruments too much, water level gauge should
be checked at least once per shift during routine operation of the boiler. Please
control the water level during operation within ±50mm
另外，锅炉在产生蒸汽中必须保证水的供给，哪怕是短时间也绝对不
许停止。如果水位计上看不见水位时，必须采取适当的处置措施，立即全
面停止循环气体的通入。
In addition, water supply must be ensured for boiler to generate steam, what
water supply stop is not permitted absolutely even for a short time. If water
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level cannot be seen from water level meter, take appropriate treatment
measures, stop all supply of circulating gas immediately.
3.1.5 其他运行监视
Other operation monitorings
(1) 压力表的指示灵敏度低时，有必要进行检查。请注意要保持压力表截
止阀的常开。另外，寒冷时期请注意输送管等有可能冻住。压力表进
行定期校准，如有必要请更换。
When indication sensitivity of pressure gauge is low, check it immediately.
Please pay attention to keep stop valve of pressure gauge to be normally open.
Additionally, in cold period, please pay attention that conveying pipe etc might
be frozen. Pressure gauge should be calibrated periodically, if necessary please
replace
(2) 安全阀启动时，读出起跳压力和回座压力，将此读数与安全阀调整压
力做比较，确认安全阀的动作和压力表的准确度。
When safety valve starts, read popping pressure and blowdown pressure,
compare this reading valve with adjustment pressure value of safety valve,
confirm action of safety valve and accuracy of pressure gauge.
(3) 其他有可能漏气的地方要定期进行检查，确认无异常。
Check periodic other places where flue gas leakage might occur, confirm
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without abnormity.
(4) 要经常注意各受压部件有无泄漏，如果发现有异样，请立即处理。耐
压部分的修补要在完全没有压力的状态下进行。
Regularly pay attention whether leakage exists on pressure parts, if there is any
abnormity, please treat immediately. Pressure part may be repaired only when
there is completely no pressure.
3.2 锅炉的运行操作
Boiler operation
3.2.1 锅炉运行前的各项准备
Preparation before operation of the boiler
(1) 确认以下事项：
Confirm the following matters
受压件无异物
There are no foreign matters in pressure parts
明确全体人员的所在位置
Definitude position of all personnel
所有人孔及测量孔已关闭
All manholes and measuring holes are closed
用于启动的装置及联锁装置无异常
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Device and interlock device for start free of abnormity
确认锅炉周围的各个阀的动作
Confirm action of each valve around the boiler
(2) 锅炉升温升压
Boiler temperature rise and pressure rise
首先开启锅炉给水泵，向省煤器、蒸发器、锅筒中送入除盐水，同
时打开蒸发器及水冷壁等的排污阀，另外，过热器及主蒸汽管的疏水阀、
放气阀要事先打开。达到锅筒正常水位后，打开锅炉前面的烟气挡板门，
让余热烟气按照特定的流量和特定的温度进入锅炉，同时操作各部的排
污/疏水阀、放气阀，进行锅炉的升温升压过程（锅筒压力 0.4MPaG 之
前），在此期前必须监控过热器的管壁温度，必须保证管壁温度在 600
℃以下，同时要控制锅筒的升温速度 55℃/H 以下。
Firstly start boiler feed water pump, demineralized water into economizer,
evaporator, drum, at the same time, open blow down valve of evaporator
and water wall etc, in addition, drain valve, exhaust valve of superheater
and main steam pipe should be opened in advance. After normal water
level of boiler drum is reached, open the flue gas baffle in front of boiler,
let flue gas enter the boiler according to specific flow and specific
temperature, at the same time, operate blowdown/drain valve, exhaust

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valve of individual parts, carry out boiler temperature rise pressure and rise
process (before drum pressure 0.4mpag), in this period, monitor
superheater tube wall temperature, ensure superhater tube wall temperature
below600℃, at the same time, control rise speed of drum temperature
below 55℃/H.
由于本锅炉是全自然循环锅炉，为了缩短锅炉启动的时间，把锅
炉的启动旁路阀门打开，给蒸发器受热面一定的推力，使锅炉尽快循
环起来，在此期间根据现场的实际情况，可以开启紧急放水阀，加快
锅炉中水的流动促进锅炉的循环。
Since the boiler is full natural circulation boiler, in order to reduce boiler
start-up time, open boiler start bypass valve, give certain thrust to evaporator
heating surface, so that boiler may circulate as soon as possible, during this
period emergency drain valve may be opened according to actual situation
on site, so as to quicken water flow in boiler and promote circulation of the
boiler.
（3）阀门开闭状态的确认
Confirm valve open/closed state
无特殊标记的阀门按汽水系统图所示。
Valves without special mark should follow the provisions shown in steam
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and water system diagram
(i) 起闭锁作用的阀门
Valves for locking
锅炉给水泵出口电动闸阀
Boiler feed water pump outlet electric electric slide valve
锅炉给水调节阀
Boiler feed water regulating valve
减温器喷水总阀
Desuperheater spray master valve
炉水紧急排放阀、炉水连续排放阀
Boiler water emergency drain valve, boiler water continuous drain valve.
主蒸汽切断阀、旁通阀
Main steam cut-off valve, by-pass valve
(ii) 起开放作用的阀门
Valves for opening
锅筒饱和蒸汽管放气阀-微开
Drum saturated steam pipe exhaust valve -slightly open
过热器疏水阀-微开
Superheater drain valve -slightly open

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主蒸汽管疏水阀-微开
Main steam pipe drain valve -slightly open
主蒸汽启动排气阀-调整开度
Main steam start venting valve –adjust to open degree
与锅炉相关的仪表及控制装置的总阀
Instruments related with boiler and master valve of control device
3.2.2 锅炉的负荷
Boiler load
(1) 水位计按以下要领试验
Water level meter should be tested according to the following main points
(i) 疏水阀微开，水位计预热。
Slightly open drain valve, warm up water level gauge
(ii) 接着，适当开大疏水阀。
Then, open drain valve properly.
(iii) 关闭水侧阀，蒸汽从水位计向疏水管排出，确认蒸汽连接管内无异物。
Close the valve on water side, steam is discharged from water level gauge to
drain tube, confirm steam connecting pipe to be free of foreign matters.
(iv) 将水侧阀微开。
Slightly open the valve on water side.

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(v) 关闭蒸汽阀，炉水从水位计向疏水管排出，确认水连接管无异物。Close
steam valve, boiler water is discharged from water level gauge to drain pipe,
confirm water connecting pipe to be free of foreign matters
(vi) 蒸汽侧阀微闭。
Slightly close the valve on steam side.
(vii)疏水阀关闭，炉水水位立即回到水位计的正确位置。水面的不规则的
运动，导致水及蒸汽侧管内部分被堵塞，水面不能反映正确水位。水
面稳定后，将蒸汽侧、水侧阀门全部打开。
Close drain valve, boiler water level returns to the correct position of water
level gauge immediately. Irregular motion of water surface leads to blocking
of the part in the pipeline on water and steam side, water surface could not
reflect correct water level. After water surface becomes stable, open all
valves on steam side, water side.
(viii) 锅炉加热、升压期间，要不断检查本体的热膨胀量，调查各部是
否适当地顺应热膨胀。
During boiler heating, boosting, continuously check thermal expansion
amount of the proper, investigate whether the parts follow thermal expansion
properly.
(2) 当锅筒的工作压力升至 1MPa 左右时，关闭锅炉启动旁路。

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When operating pressure of drum rises to about 1MPa, close boiler start
bypass.
(3) 蒸汽产生，锅筒的放气阀猛烈排出蒸汽，锅筒的压力开始上升后，放
气阀关闭。
Steam is generated, exhaust valve of drum discharges steam drastically, after
pressure of boiler drum begins to rise, close exhaust valve
(4) 升压、升温中的过热器的保护
Protection of superheater during boost, temperature rise
(i) 升压、升温中过热器内及主蒸汽管内的疏水由各疏水阀排放，各疏水阀
通常在锅炉启动时打开，升压中适当关小或关闭，断续地打开使其排放。
另外，监控锅筒压力和过热器管壁温度，避免过热器的壁温超温和锅筒
压力的急遽变化，在必要时调整锅炉启动阀的开度，将蒸汽少量的放出
一些。
Drainage in superheater and main steam pipe is discharged by drain valves
during boost and temperature rise, drain valves are generally open during
boiler start-up, during boost, close properly or close at all, intermittent
open for discharge. In addition, monitor drum pressure and superheater
tube wall temperature, avoid superheater wall temperature overtemperature
and sudden change of drum pressure, adjust the opening of boiler start
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valve when necessary, discharge a small quantity of steam.
(ii) 升压中过热器出口的的温度计不一定能准确地指示过热器传热管内
的蒸汽温度，一定要注意。
During boost, thermometer at superheater outlet might not certainly
indicate steam temperature in superheater heat transfer pipe accurately,
always pay attention.
(5) 负荷升高后，锅筒水位开始降低，手动调整锅炉给水泵出口旁通阀，
开始连续给水。
After load increases, drum water level begins to reduce, bypass valve of
boiler feed water pump outlet are adjusted manually, feed water are gived
continuously.
(6) 锅筒压力达到 5.0MPaG 前，手动调整锅炉给水泵出口旁通电动阀。然
后将锅炉给水流量调节阀调成自动控制，关闭锅炉给水泵出口旁通阀
（锅炉给水泵出口电动阀全开）
Before drum pressure reaches 5 MPaG, bypass electric valve of boiler feed
water pump outlet are adjusted manually, Then adjust boiler feed water flow
regulating valve to automatic control, close boiler feed water pump outlet
bypass valve (electric valve at boiler feed water pump outlet is fully open)
(7) 主蒸汽温度调节，在蒸汽压力 5.0MPaG、蒸汽温度 450℃前，不要使

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用自动温度调整装置。
Main steam temperature adjustment, before steam pressure reaches 5 MPaG,
steam temperature reaches 450℃, do not use automatic temperature
regulating device
3.2.3 正常运行
Normal operation
(1) 锅炉进入运行状态后，进行锅炉给水、炉水处理及炉水浓度调节。
After boiler enters operating state, carry out boiler feed water, boiler water
treatment and boiler water concentration adjustment.
(2) 就地水位计，原则上每隔 8 小时缓慢打开疏水阀排放，用疏水阀的开
闭观察水面的动向，确认锅筒水位的正确表示。水面动向有问题时，
用水和蒸汽的各个配管排放以除去管内异物。当然，操作疏水阀，水
位正确表示，可以确认管内无异常情况下，也没必要进行配管排放。
Local water level gauge, in principle, slowly open drain valve to discharge
every 8 hours, use opening/closing of drain valve to observe the trend of
water surface, confirm correct indication of drum water level. When water
surface trend is in question, use water and steam pipes to discharge foreign
matters to pipes. Of course, when operate drain valve, correct indication is
given for water level, it is confirmed that no abnormal condition exists in the
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pipe, pipe discharge is not required
(3) 炉水的排放，用炉水连续排放电动节流阀实施。
Discharge of boiler water should be carried out using boiler water
continuous discharge electric choke valve
(4) 有压力的热炉水或蒸汽流向冷管时，要缓慢进行。炉水排放时，边监
视水位计边进行。
Pressurized hot boiler water or steam should flow slowly to cold pipe. When
discharge boiler water, discharge while monitoring water level gauge.
3.2.4 给主蒸汽管道送汽
Supply steam to main steam pipe
(1) 达到余热锅炉规定的送汽压力前，请对主蒸汽管道进行暖管。使用
主蒸汽切断阀旁通阀（调整开）进行主蒸汽连接管的暖管。此时，管系
统内的疏水阀打开，进行排放，保持蒸汽的流动。
Before steam supply pressure specified for waste heat boiler is reached, please
preheat the main steam pipe. Use main steam cut-off valve by-pass valve
(adjust to open degree) to preheat main steam connecting pipe. Now, open
drain valve in pipe system for discharge, keep steam flow.
(2) 锅炉产生的蒸汽，除暖管所需要的蒸汽外，其余通过锅炉启动排汽阀
流向消音器。
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For the steam generated by boiler, except the steam required to preheat pipe,
the rest steam flows to silencer via boiler start exhaust steam valve
(3) 暖管要缓慢而不是急遽的进行。
Pipe should be preheated slowly rather than suddenly.
(4) 主蒸汽温度、压力达到规定值（540℃，11.65MPaG 交接点处）时，主
蒸汽切断阀打开，开始向主蒸汽管道送汽。
When main steam temperature and pressure reach the specified value (at 540℃,
11.65MPaG interface point), open main steam cut-off valve, supply steam to
main steam pipe.
3.2 操作注意事项
Precautions for operation
3.3.1 蒸汽排放及连续排放时的注意事项
Precautions for steam discharge and continuous discharge
(1) 用主蒸汽管等配管中的蒸汽排放进行清洗时，在以排出口为中心的危
险区域设置危险标志，并设置监视人。
When use steam discharge in main steam pipe etc for cleaning, arrange danger
marking in the dangerous zone centered at discharge outlet, arrange person to
monitor.
(2) 进行排放时，确认排出口安全后，缓慢打开。
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For discharge, confirm discharge opening to be safe, then open slowly.
(3) 间歇排放是在低负荷或者熄火时进行，请不要急遽打开
Intermittent discharge should be carried out at low load or flameout, please do
not open valve suddenly.
3.3.2 关于安全性的注意事项
Safety precautions
锅炉和配管压力达到大气压以上情况下，绝对不可向安全阀里面看。
另外，安全阀的排放管附近绝对不许靠近！
When boiler and pipeline pressure is above atmospheric pressure, it is
absolutely prohibited to view into the safety valve. In addition, never approach
discharge pipe of the safety valve !
3.3.3 定期检查及内部检修时的注意事项
Precautions for periodic inspection and internal repair
(1) 锅筒内检修时，为防止真空状态和缺氧带来灾害，请打开放气阀及并
确认通气。
When repair in drum, in order to prevent disaster caused by vacuum state and
lack of oxygen, please open exhaust valve and confirm ventilation
(2) 打开锅筒的人孔时，内部处于接近真空状态，作业人员有可能受到伤
害。要缓慢打开人孔门，打开后要使锅筒内通风，注意防止由于缺氧
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给作业者带来伤害。
When open manhole of drum, inside drum is approaching vacuum state, work
personnel might be injured. Open manhole door slowly, after opening, ventilate
the drum, pay attention to prevent injury of worker due to lack of oxygen
(3) 进入锅炉烟道内时，务必在传热管上设置临时脚手架。
When entering boiler duct, always provide temporary scaffold on the heat
transfer pipe.
(4) 排出 N2 时，不许进入 N2 排放管所在地，并挂上“危险区域”的标志。
（用 N2 进行干燥密封时）
When discharge N2, do not enter N2 discharge pipe location, hang up
“ dangerous zone ” marking. (when use N2 for dry sealing)
4. 锅炉维护
Boiler maintenance
4.1 正常运行期间的检查
Inspection during normal operation
操作人员必须在运行期间定时检查，检查中发现的所有缺陷都要立即排除
或记录在运行日志中。下述事项在检查中都需观察：
Operating personnel must check timly during operation, all defects found in
inspection should be eliminated immediately or recorded in operation log. The

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following matters should be observed during inspection
4.1.1 热水
Hot water
(1) 可视性泄漏；
Visual leakage
(2) 与热水接触很危险并可导致严重烫伤；
Contact with hot water is very dangerous and might lead to severe scalding;
(3) 如果可能，立即封住泄漏点，或警戒现场。
If possible, seal leak source immediately, or alert the site
4.1.2 饱和蒸汽
Saturated steam
(1) 无声、不可视性泄漏；
Soundless, invisible leak;
(2) 与饱和蒸汽接触只在泄漏点的邻近区域有烫伤危险，只要可能，立即
封堵泄漏点或警戒现场。
For contact with saturated steam, scalding danger only exists in adjacent area of
leak source, as long as possible, immediately plug the leak source or alert site.
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4.1.3 过热蒸汽
Superheated steam
(1) 泄漏不能清楚地看到，取决于环境温度，从泄漏点开始的很大距离内
会发生冷凝。在较高环境温度下，泄漏根本看不清，然而可通过发出
的噪声来判断；
Leak cannot be seen clearly, it depends on ambient temperature, condensation
might occur in a far distance from the leak source. At relatively high ambient
temperature, leak cannot be seen at all, but it may be judged through noise
generated;
(2) 与过热蒸汽接触会留下非常严重的烧伤；
Contact with superheated steam might cause very severe burning;
(3) 泄漏点的定位可以用比如在一个扫把上缠一根布带，然后缓慢并小心
地举着向噪声发出点前进。当布带开始飘动，蒸汽泄漏的地点可基本
确定，这个区域必须立即封闭，尽早进行修复。
Leak source may be positioned, for example, wrap a cotton tape on a besom,
then hold it and go forward to the noise point slowly with care. When the
cotton tape begins to flap around, steam leak place may be determined
basically, this area must be closed immediately, repair as soon as possible

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4.2 定期检查工作
Periodic inspection work
4.2.1 安全阀
Safety valve
为了安全运行，安全阀必须检查，任何未经批准的人为调整，尤其是
任何超负荷或导致失效的调整都是禁止的。
For safe operation , safety valve must be checked, any unapproved man-made
adjustment is prohibited, especially any overload adjustment or adjustment
leading to faillure.
4.2.2 就地水位计
Local water gauge
在运行中，水位不能低于最低水位点，如果水位看不清楚并且水位控
制器没有反应就应立即停止加热。就地水位计必须经常使用并且通过定期
的冲洗保持清洁通畅。
During operation, water level should be no lower than the lowest water level
point, if water level cannot be seen clearly and water level controller does not
react, stop heating immediately. Local water gague must be used regularly, kept
clean and smooth by means of periodic flushing

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4.2.3 压力表
Pressure gauge
为了运行可靠和通道畅通，压力表及其连接管必须仔细检查，特定情
况下无论怎样检查，压力表的减压要缓慢，指针不能突降至零；同样也要
升压缓慢，不能突升至先前的压力。
For reliable operation and clear channel, pressure gauge and connecting pipe
must be checked carefully, in specific condition, no matter how to check,
pressure of pressure gauge should be reduced slowly, pointer should not drop to
zero suddenly; also boost slowly, do not rise to the previous pressure suddenly.
4.2.4 温度计
Thermometer
用于设备安全运行所需要的温度计必须检查，并且如果需要，需与一
个精确测温计进行比较标定。
Thermometer required for safe operation of the equipment must be
checked, if required, carry out comparison calibration with a precise
thermodetector.
4.2.5 温度控制/压力控制
Temperature control/pressure control
设定的开关点必须进行检查，对此测量必须定期间断地进行。
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The set ON/OFF point must be checked, this measurement must be carried out
periodically and intermittently.
4.2.6 法兰连接
Flange connection
法兰连接处泄漏时必须用交叉紧固螺栓的方法再密封，泄漏孔的扩展
会损坏垫片，最终将不得不更换新的垫片。
When flange joint leaks, always use the method of fasten bolt crosswise, then
seal, expansion of leak hole might damage the washer, at last new washer have
to be replaced.
4.2.7 支撑架和弹簧吊架
Support and spring hanger
松动的支撑架和弹簧吊架必须重新紧固。
Loose support and spring hanger must be fastened again.
4.2.8 绝热保温
Thermal insulation
受损和掉落的绝热保温材料应立即修复或更换。必须注意热烟气从炉
内往炉外的泄漏。
Damaged and fallen heat insulating material should be repaired or replaced
immediately. Always pay attention to leak of hot flue gas from inside of boiler
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to outside.
4.3 启动期间或机组停炉后的即时维护
Instant maintenance during start or unit furnace shutdown
4.3.1 锅炉阀门
Boiler valve
对机组安全有重要作用但不经常工作的所有阀门必须定期检查，以便
以后的顺利运行。
All valves that play important role for safety of the unit but do not work
frequently must be checked periodically, for successful operation later
4.3.2 带压情况下对排污疏水阀的检查
Check blowdown drain valve in pressurized condition
所有排污疏水阀在启动期间或机组停机的过程中必须用水冲洗以便排
除进出口集箱中的杂物（水垢等）。同时这也保证了在排污疏水阀前的沉淀
物能冲走，避免了对阀门的损害。
All blowdown drain valves must be flushed using water during start or unit
shutdown, so as to eliminate foreign matters (scale etc) in inlet/outlet header. At
the same time, this also ensures deposit in front of blowdown drain valve to be
washed away, avoid damage to the valves
冲洗程序：
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Flushing procedure
(1) 进出口集箱的第一个开关阀必须开启。
The first on-off valve of inlet/outlet header must be opened
(2) 下游第二个开关阀必须开启后再关闭。只有完全开启第二个开关阀
以冲走阀座和阀栓间的杂物，才能关闭它，然后再关闭第一个开关
阀。
Downstream the second on-off valve must be opened, then closed. It may
be closed only after the second on-off valve is fully opened to wash away
the foreign matters between valve seat and valve cock, then close the first
on-off valve.
注意：阀门必须总是缓慢开启以避免热冲击。
Note: valve must be opened slowly to avoid thermal shock
5. 锅炉保养
Boiler maintenance
锅炉停炉后，应当认真做好锅炉的防护保养工作，采取必要的防腐、防
冻措施。
After boiler stop, carry out protective and maintenance work for boiler
carefully, take necessary anticorrosion and anti-freezing measures.
锅炉的防腐办法一般可以采用：
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Anticorrosion methods for boiler may generally adopt
(1) 短期降腐（15-30 天）
Short-term anticorrosion (15- 30 days)
锅炉余热烘干法
Boiler waste heat drying method
氨液保护法
Ammonia liquor protection method
(2) 长期防腐（30 天以上）
Long-term anticorrosion (above 30 days)
充氮保护法
Nitrogen blanketing method
干燥剂防腐
5.1 短期防腐
Short-term anticorrosion
5.1.1 锅炉余热烘干法
Boiler waste heat drying method
(1) 锅炉停止供汽后，禁闭各孔，门及有关风门的挡板，减少热量的损失。
After steam supply to boiler is stopped, close the holes, doors and relevant
damper baffles, reduce heat loss

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(2) 适当开启过热器疏水门，逐渐降低汽压（降压速度以每分钟不超过
。
0.3MPa，锅筒壁温差不超过 40℃为限）
Open superheater drain valve properly, gradully reduce steam pressure
(pressure drop speed should not exceed 0.3MPa per minute, drum wall
temperature difference should not exceed 40℃).
(3) 锅炉缓慢冷却，当压力降至 0.3-0.5MPa 表压时,炉水温度不超过 80℃，
可将炉水放尽。
Cool down the boiler slowly, when pressure drops to 0.3-0.5MPa gauge
pressure,boiler water temperature does not exceed 80℃, dain off boiler water.
5.1.2 氨液保护法
Ammonia liquor protection method
(1) 控制炉水含氨深度为：
Control ammonia concentration of boiler water to be
用凝结水或除盐水配制的 500-600mg/l
500-600mg/l prepared using condensate or demineralized water
用软化水含配制的 800-1000mg/l
800-1000mg/l prepared using demineralized water
氨液软化水含盐量小于 150mg/l，氨离子小于 45mg/l。
Salinity of ammonia liquor demineralized water is less than 150mg/l,

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ammonium ion less than 45mg/l.
(2) 锅炉须严密关闭与蒸汽、给水、疏水系统连接的阀门及仪表阀门。
Boiler valve and instrument valve connected with steam, feed water, drain
system must be closed tightly.
(3) 防腐期间须经常保持满水状态及定期测定炉水含氨浓度。
During anticorrosion, keep full water state regularly, determine ammonia
concentration of boiler water periodically.
(4) 注意防止氨液进入汽轮机。
Prevent ammonia liquor from entering steam turbine.
(5) 严寒地区由于易结冻，故不宜采取。
It is not advised for frigid district where frezzing tends to occur.
5.2 长期防腐
Long-term anticorrosion
5.2.1 充氮保护法
Nitrogen protection method
(1) 锅炉炉水全部排放干净并清除内部污垢。
Drain off all boiler water, eliminate internal dirt.
(2) 严密关闭锅炉所有门孔，使其与外界隔绝。
Close all door openings of the boiler tightly, isolate from surroundings
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(3) 将氮气从锅筒充入，氮气压力应维持 0.02-0.05MPa，氮气纯度＞98%。
Fill in nitrogen gas from drum, nitrogen gas pressure should keep 0.02-0.05MPa,
nitrogen gas purity> 98%.
(4) 为防止烟道侧各受热面的腐蚀，应清灰和投放干燥剂。
In order to prevent corrosion of heating surfaces on flue side, deash and add
desiccant.
5.2.2 干燥剂防腐
Desiccant anticorrosion
(1) 锅炉内部的水垢、铁锈杂物，并将其清洗干净。
Boiler internal scale, iron rust foreign matters, clean up
(2) 放净锅筒、蒸发器、省煤器内部的存水及吹灰管道、过热器内部的积
水。
Drain off water in drum, evaporator, economizer and blowing pipe, superheater
internal seeper.
(3) 将盛有干燥剂的无盖容器放入锅筒和集箱内部保持干燥状态。
Place the uncovered container containing desiccant into drum and header, keep
the inside in dry state.
(4) 干燥剂可采用无水氯化钙或生石灰，放入数量为每立方米容积 1-2 公
斤无水氯化钙或者 2-3 公斤生石灰。

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Desiccant may adopt anhydrous calcium chloride or quicklime, added quantity
is 1-2 kg anhydrous calcium chloride or 2-3 kg quicklime per cubic meter of
volume
(5) 每月检查数次，及时更换失效干燥剂。
Check for several times per month, replace ineffective desiccant timely

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连封面共 57 页

Preparation for trial operation

Overall hydrostatic test of the boiler

Safety valve adjustment

Running and operation of the boiler

Monitoring matters for boiler running

Precautions for operation

Inspection during normal operation

Periodic inspection work

Instant maintenance during start-up or stop

Design Verify Review Approved

Date Date Date Date

本说明书简单介绍了印度 BMM 海绵铁余热锅炉使用维护过程中所应该

recovery boiler of india BMM sponge iron.

Prevent fault and damage caused by misoperation.

operator should sufficiently get familiar with work characteristic process

regulations, grasp performance characteristic of the boiler sufficiently, so as to

the boiler perfectly and safely.

Preparation for trial operation

Boiler installation work is finished

Overall hydrostatic test of the boiler is qualified

Safety valve could act effectively

Feed water equipment is prepared for operation

Auxiliaries are in stand by state

Overall hydrostatic test of the boiler

锅炉承压系统及有关焊接件安装完毕后，按照 IBR 进行锅炉整体水压试验

hydrostatic test of the boiler according to IBR, so as to finally check manufacture,

installation welding quality, material quality or residual deformation condition of

Carry out the following work before hydrostatic test:

Clean up inside of the part to be tested and check the surface

Set up acceptable pressure gauge

Set up drain pipe and air release valve

力表，锅炉整体水压试验压力为 1.5 倍锅筒设计压力，即 20.9MPa。

pressure is 1.5 times of the design pressure of drum, namely 20.9MPa.

Water quality and temperature requirements for hydrostatic test:

Test water should be demineralized water.

(2) 水压试验时，周围空气温度应高于 5℃，否则应有防冻措施。

otherwise anti-freezing measures should be provided.

(3) 试验水温为 20~50℃。

Test water temperature should be 20~50℃.

2.1.5 按 IBR 技术条件进行锅炉整体水压试验。

Conduct overall hydrostatic test of the boiler according to technical conditions

2.1.6 水压试验压力升 降速度一般不应超过每分钟 0.3MPa。

Rise/fall speed of pressure in hydrostatic test generally should not exceed

0.3MPa per minute.

2.1.7 锅炉充满水后金属表面结露应清除，当压力升至试验压力的 10%左右

inspection, eliminate abnormity.

inspection, ensure operating pressure value not to drop, continue to boost

pressure slowly and uniformly, conduct overpressure test. Keep 30 minutes at

test pressure, then drop to operating pressure, carry out comprehensive

inspection. Pressure should remain constant during inspection, if no rupture,

steam and water system should be considered even more.

temperature rise curve:

Depending on the WHRB condition, operating range, and site disposal

facilities, a variety of cleaning procedures is available.

Hand Cleaning: The first step should always be to clean accessible

areas by hand. Remove all manhole covers on the steam, collector,

and other foreign material as possible. Careful hand cleaning will

reduce the time required for further cleaning.

Organic Material Removal: Following hand cleaning, any remaining

organics (such as oil, grease, or tube protective coatings) must be

impede heat transfer, prevent proper passivation of the metal, and

inhibit cleaning. In addition, any loose foreign materials clinging to the

2.1.6 水压试验压力升降速度一般不应超过每分钟 0.3MPa。