Operation of boiler plants. Operation of steam and hot water boilers Safety rules for the operation of boilers

Canceled due to release.

Device rules and safe operation steam and hot water boilers establish requirements for the design, construction, materials, manufacture, installation, commissioning, repair and operation of steam boilers, autonomous superheaters and economizers with an operating pressure of more than 0.07 MPa (0.7 kgf / cm 2), hot water boilers and stand-alone economizers with water temperatures above 115°C.

The rules are obligatory for execution by managers and specialists engaged in design, manufacture, installation, adjustment, repair, technical diagnostics, examination and operation of boilers, autonomous superheaters, economizers and pipelines within the boiler.

In connection with the entry into force of these Rules after their official publication, the Rules for the Design and Safe Operation of Steam and Hot Water Boilers are considered invalid (Order of the Gosgortekhnadzor of Russia dated July 17, 2003 No. 156).

I. General provisions

1.1. Purpose and scope of the Rules

1.2. Responsibility for violations of the Rules

1.3. Boilers and semi-finished products purchased abroad

1.4. Procedure for Investigation of Accidents and Accidents

II. Design

2.1. Project development

2.2. Changing boiler projects

III. Design

3.1. General provisions

3.2. Water level position

3.3. Manholes, hatches, covers and furnace doors

3.4. Safety devices for furnaces and flues

3.5. Cast iron economizers

3.6. Bottoms and tubesheets

3.7. Welded joints, location of welds and holes

3.8. Curved elements

3.9. Rolling joints

3.10. Purging, emptying and draining systems

3.11. Burner devices

IV. Materials and semi-finished products

4.1. General provisions

4.2. Steel semi-finished products. General requirements

4.3. Sheet steel

4.4. Steel pipes

4.5. Steel forgings, stampings and rolled products

4.6. Steel castings

4.7. fasteners

4.8. Cast iron

4.9. Non-ferrous metals and alloys

4.10. Requirements for steels of new grades

V. Manufacture, installation and repair

5.1. General provisions

5.2. Cutting and deformation of semi-finished products

5.3. Welding

5.4. Heat treatment

5.5. The control

5.6. Visual and measuring control

5.7. Radiographic and ultrasonic testing

5.8. Capillary and magnetic particle testing

5.9. Steeloscopy control

5.10. Hardness measurement

5.11. Metal ball sweep control

5.12. Mechanical tests, metallographic studies and tests for intergranular corrosion

5.13. Quality assessment standards

5.14. Hydraulic tests

5.15. Correction of defects in welded joints

5.16. Passport and marking

VI. Fittings, devices and feeding devices

6.1. General provisions

6.2. Safety devices

6.3. Water level indicators

6.4. Pressure gauges

6.5. Temperature measuring instruments

6.6. Shut-off and control valves

6.7. Safety devices

6.8. Nutrient Devices

VII. Boiler room

7.1. General provisions

7.2. Lighting

7.3. Placement of boilers and auxiliary equipment

7.4. Platforms and stairs

7.5. Fuel supply and ash removal

VIII. Water-chemical regime of boilers

8.1. General requirements

8.2. Feed water quality requirements

8.3. Boiler water quality requirements

IX. Organization of safe operation and repair

9.1. Organization of safe operation

9.2. Service

9.3. Checking instrumentation, automatic protection, fittings and feed pumps

9.4. Boiler emergency stop

9.5. Repair organization

X. Registration, technical examination and operating permit

10.1. Registration

10.2. Technical certification

10.3. Commissioning works

10.4. Permission to operate newly installed boilers

XI. Additional requirements for boilers operating with high temperature organic heat transfer fluids

11.1. General provisions

11.2. Design

11.3. fittings

11.4. Liquid level gauges

11.5. Pressure gauges

11.6. Temperature measuring instruments

11.7. Safety valves

11.8. Expansion vessels

11.9. Automatic protection

11.10. Pumps

11.11. Installation and operation

XII. Additional requirements for recovery boilers

12.1. General provisions

12.2. Design, equipment and control

12.3. Installation and operation

XIII. Additional requirements for gas-tube boilers

13.1. General provisions

13.2. Design

13.3. Automatic protection

XIV. Monitoring compliance with these Rules

Annex 1. Brief table of relationships between units international system(SI) and other units of physical quantities adopted in these Rules

Annex 2. Basic terms and definitions

Annex 3. Symbols and units of measurement

Annex 4. Passport of the boiler (autonomous superheaters and economizer)

Annex 4a. Boiler passport

Appendix 5. Materials used for the manufacture of boilers, superheaters, economizers working under pressure

Appendix 6. Division of steels into types and classes

Appendix 7. Definition of the concepts of the same type and control welded joints

Appendix 8. Standards for assessing the quality of welded joints

1. These Rules determine the requirements for the design, manufacture and operation of steam boilers, superheaters and economizers with an operating pressure of more than 0.7 kgf / cm2 and hot water boilers with a water temperature above 115 ° C.

2. Boilers covered by these Rules include:

a) steam boilers with a furnace;
b) waste heat boilers;
in) boilers-boilers;
G) hot water boilers with firebox.

3. The requirements of these Rules do not apply to:

a) boilers and superheaters of steam locomotives and heating boilers wagons of railway rolling stock;
b) boilers, superheaters and economizers installed on sea and river vessels and on other floating craft;
in) nuclear reactors;
G) boilers with electric heating.

Basic definitions

1. Steam boiler - a device that has a furnace, heated by the products of the fuel burned in it and designed to produce steam with a pressure above atmospheric, used outside the device itself.

2. Hot water boiler - a device that has a furnace, heated by the products of the fuel burned in it and designed to heat water at a pressure above atmospheric pressure and used as a heat carrier outside the device itself.

3. Waste-heat boiler - steam or hot water, in which hot gases of the technological process are used as a heat source.

4. Boiler-boiler - a steam boiler, in the steam space of which there is a device for heating water used outside the boiler itself, as well as a steam boiler, in the natural circulation of which a separate boiler is included.

5. Stationary boiler - installed on a fixed foundation.

6. Mobile boiler - having a chassis or installed on a mobile foundation.

7. Superheater - a device designed to increase the temperature of the steam above the saturation temperature corresponding to the pressure in the boiler.

8. Economizer - a device heated by the products of fuel combustion and designed to heat or partially evaporate water entering the steam boiler. If there is a shut-off device on the pipeline between the boiler and the economizer, the latter is considered to be switched off by water; if there is a bypass gas duct and dampers for disconnecting the economizer from the gas duct, the economizer is considered to be disconnected for gas.

Responsibility for compliance with the rules

1. These Rules are binding on all officials, engineering and technical workers and workers involved in the design, manufacture, installation, repair and operation of boilers, superheaters and economizers.

2. Officials at enterprises, organizations, as well as engineering and technical employees of design and design institutes and organizations guilty of violating these Rules, bear personal responsibility, regardless of whether this violation led to an accident or an accident. They are also responsible for the violations committed by their subordinates.

3. The issuance by officials of instructions or instructions forcing their subordinates to violate safety rules and instructions, the unauthorized resumption of work stopped by the Gosgortekhnadzor bodies or the technical inspection of trade unions, as well as their failure to take measures to eliminate violations of the rules and instructions that are allowed by workers or other subordinates to them in their presence are gross violations of these Rules. Depending on the nature of the violations and their consequences, all these persons are liable in disciplinary, administrative or judicial proceedings.

4. Workers are liable for violations of the requirements of these Rules or special instructions relating to the work they perform, in accordance with the procedure established by the internal labor regulations of enterprises and the criminal codes of the Union republics.

Manufacturing permit, passport and labeling

1. Boilers, superheaters, economizers and their elements must be manufactured at enterprises that have the permission of the local Gosgortekhnadzor body, in accordance with the Instructions for Supervising the Manufacture of Facilities, Boiler Supervision.

2. The project and technical specifications for the manufacture of boilers, superheaters and economizers must be agreed and approved in the manner established by the ministry (department), which is subordinate to the design organization, the manufacturer of these facilities.

3. Any changes in the project, the need for which may arise during the manufacture, installation, repair or operation of boilers, superheaters and economizers, must be agreed with the organization that carried out the design of these facilities, and for boilers, superheaters and economizers purchased abroad - with a specialized organization for boiler building.

4. Each boiler, superheater and economizer must be supplied by the manufacturer to the customer with a passport of the established form and instructions for installation and operation.

5. On the bottoms of the drum or on the boiler body near the water-indicating fittings, as well as on the ends or on the cylindrical part of the collectors and chambers of the boiler, superheater and economizer, the following passport data must be stamped: manufacturer or its trademark; serial number of the product; Year of manufacture; design pressure; design wall temperature and steel grade (only on superheater headers). In addition to the stamps, a metal plate with the above passport data must be attached to the bottom of the drum or the boiler body.

6. Boilers, superheaters, economizers and their elements, as well as materials for the manufacture of this equipment, purchased abroad, must comply with the requirements and norms of these Rules. Deviations from these Rules must be agreed with the USSR Gosgortekhnadzor before purchasing equipment or material abroad.

Fittings, instrumentation and safety devices

General requirements

1. To control the operation and ensure normal operating conditions, boilers, superheaters and economizers must be equipped with fittings, instrumentation and safety devices available for monitoring and maintenance.

Safety valves

1. Each boiler with a steam capacity of more than 100 kg/h must be equipped with at least two safety valves, one of which must be a control valve. On boilers with a steam capacity of 100 kg / h or less, it is allowed to install one safety valve.

2. Total throughput safety valves installed on the boiler must be at least the hourly output of the boiler.

3. If the boiler has a non-switchable superheater, a part of safety valves with a capacity of at least 50% of the total capacity of all valves must be installed on the outlet header of the superheater.

4. On non-switchable superheaters of locomobile boilers, locomotive type, vertical with fire tubes and other boilers, in which the temperature of the gases washing the superheater, but can cause overheating of its elements, the installation of safety valves is not necessary.

5. It is allowed to use lever-load or spring-loaded (direct action) or impulse (indirect action) safety valves. The auxiliary valve for impulse safety valves must be direct acting with a diameter of at least 15 mm and equipped with an electromagnetic actuator.

6. On the steam boilers pressure above 39 kgf/cm2 (with the exception of waste heat boilers and mobile boilers) only impulse safety valves should be installed; on mobile boilers, the installation of lever-weight valves is not allowed. The diameter of the passage of lever-load and spring valves must be at least 20 mm. It is allowed to reduce the nominal passage of valves to 15 mm for boilers with a steam capacity of up to 0.2 t / h and a pressure of up to 8 kgf / cm2, provided that two valves are installed.

7. The throughput of safety valves must be confirmed by the relevant tests of the head sample of the valve of this design, carried out at the valve manufacturer, and indicated in the valve passport.

8. On steam boilers with an operating pressure of more than 39 kgf / cm2, impulse safety valves (indirect action) must be installed on the outlet manifold of a non-switchable superheater or on the steam pipeline to the main shut-off device, while for drum boilers up to 50% of the valves in terms of total throughput are steam extraction for pulses must be generated from the boiler drum. On the block installations if the valves are located on the steam pipeline directly at the turbines, it is allowed to use superheated steam for the impulses of all valves, while for 50% of the valves an additional electrical impulse must be supplied from a contact pressure gauge connected to the boiler drum.

9. In power units with intermediate superheating of steam after the cylinder high pressure turbines (HPC), safety valves must be installed with a throughput capacity of at least the maximum amount of steam entering the intermediate superheater. If there is a shut-off valve behind the HPC, additional safety valves must be installed. These valves are designed for the total capacity of the pipelines connecting the reheater system with sources of higher pressure that are not protected by their safety valves at the inlet to the reheat system, as well as for possible steam leaks that may occur if the high pressure pipes of steam and gas steam are damaged. heat exchangers for steam temperature control.

10. On once-through steam boilers, in which the first (along the water flow) part of the heating surface is turned off during the kindling or stopping of the boiler from the rest of the heating surface by shut-off devices, the need for installation, the number and dimensions of safety valves for the first part are determined by the boiler manufacturer.

11. At least two safety valves must be installed on hot water boilers, it is allowed to install one valve when the shut-off devices on the line hot water from the boiler to the expansion vessel, they have bypasses with pipes with a diameter of at least 50 mm with check valves installed on them to pass water from the boiler to the expansion vessel, while being connected to the atmosphere. On once-through hot water boilers with chamber combustion of fuel, equipped with automatic device according to paragraph 4 of these Rules, the installation of safety valves is not mandatory.

12. At least two safety valves with a diameter in the passage of at least 32 mm each must be installed on the water-switched economizer. One valve is installed at the outlet of the water from the economizer to the shut-off valve (in the direction of the water), the other is installed at the inlet to the economizer after the valve (in the direction of the water). The calculation of safety valves installed on the economizer must be carried out according to the formula for calculating safety valves for hot water boilers, given in paragraph 21 of these Rules.

13. Safety valves must be installed on branch pipes connected directly to the boiler drum or to the steam pipeline without intermediate shut-off devices. When several safety valves are located on one branch pipe, the area cross section branch pipe must be at least 1.25 the sum of the cross-sectional areas of all safety valves. It is forbidden to extract steam from a branch pipe on which one or more safety valves are located. For once-through boilers, the installation of safety valves is allowed in any chute of the steam pipeline up to the shut-off device.

14. The design of safety valves must provide for the possibility of checking their proper operation in working condition by forcibly opening the valve. Impulse safety valves must be equipped with a device that allows forced opening of the valve remotely from the position of the boiler driver (fireman). If the force required to open the valves exceeds 60 kgf, the valves must be provided with suitable lifting devices.

15. Safety valves must have protective devices (branch pipes) that protect operating personnel from burns when actuated, and control valves, in addition, must have signaling devices (for example, a whistle) if the exit of the medium from them is not audible from the workplace of the driver (fireman) boiler. The medium leaving the safety valves must be discharged outside the room; the outlet must not create a back pressure behind the valve; discharge pipes must be equipped with a device for draining the condensate accumulating in them.

16. The drain pipe from the economizer safety valves must be connected to the free water drain line, and there should not be any shut-off devices on it or on the drain line; the arrangement of the system of drainage pipes and free drain lines must exclude the possibility of burns to people.

17. Impulse safety valves (indirect acting) must have a device that prevents the possibility of shock when opening and closing them. Auxiliary valves are not subject to this requirement.

18. The design of spring valves should exclude the possibility of tightening the spring beyond the specified value. The valve springs must be protected from direct influence of the escaping steam jet.

19. Safety valves must protect boilers and superheaters from exceeding the pressure in them by more than 10% of the calculated (allowed). Exceeding the pressure when the safety valves are fully opened by more than 10% of the calculated value can only be allowed if the possible pressure increase is taken into account when calculating the strength of the boiler and superheater.

20. The amount of steam that the safety valve can pass when fully opened is determined by the following formulas:

a) for pressure from 0.7 to 120 kgf/cm2; saturated steam

where Gn.p, Gp and G - valve capacity, kg/h; a - steam flow rate, taken equal to 90% of the value determined during testing of the head samples of valves of this design, produced by the manufacturer; F - the smallest area of ​​the free section in the flow part of the valve, mm2; P1 - maximum excess pressure in front of the safety valve, which should not exceed 1.1 design pressure, kgf/cm2; Vn.p - specific volume of saturated steam in front of the safety valve, m3/kg; Vp.p - specific volume of superheated steam in front of the safety valve, m3/kg; V - specific volume of steam (saturated or superheated before the safety valve), m3/kg.

Formulas (1), (2) and (3) can be applied under saturated steam conditions if

where P2 is the excess pressure behind the safety valve in the space into which steam flows from the valve (in case of outflow into the atmosphere P2=0), kgf/cm2.

21. The number and diameter of the passage of safety valves installed on hot water boilers are determined by the formula

where n is the number of safety valves; d - diameter of the valve seat inside, cm; h - valve lift height, cm; K - empirical coefficient, taken equal to: for low-lift valves (h / d<= 1/20) K=135; для полноподъемных клапанов (h/d >= 1/4) K=70; Q - maximum heat output of the boiler, kcal/h; P is the absolute maximum allowable pressure in the boiler with the valve fully open, kgf/cm2; i - heat content of saturated steam at the maximum allowable pressure in the boiler, kcal/kg; tin is the temperature of the water entering the boiler, °C.

22. Safety valves on steam boilers and superheaters must be adjusted to a pressure not exceeding the values ​​given in the table.

When adjusting direct-acting valves installed on the drum and impulse valves with impulse sampling from the drum, the pressure in the boiler drum is taken as the working pressure. When adjusting direct acting valves installed on the outlet manifold of the superheater, and pulse valves with pulse sampling downstream of the superheater, the pressure in the outlet manifold of the superheater (steam pipeline) is taken as the working pressure. If the boiler is equipped with two safety valves, then the direct acting safety valve installed on the superheater outlet manifold or a pulse valve with pulse take-off downstream of the superheater must be the control valve. The control valve must have a device that does not allow maintenance personnel to adjust the valve, but does not interfere with checking its condition. On boilers of power trains, in the absence of automatic control of superheated steam pressure, the safety valve installed after the superheater is considered a working valve.

23. The safety valves of the water economizer to be switched off must be adjusted to start opening on the side of the water inlet to the economizer at a pressure exceeding the operating pressure in the boiler by 25%, and on the side of the water outlet of the economizer - exceeding 10%. The safety valves of hot water boilers must be adjusted to start opening at a pressure of not more than 1.08 of the operating pressure in the boiler.

24. The safety valve must be supplied to the customer with a passport that includes a characteristic of its throughput.

Water level indicators

1. On each newly manufactured steam boiler, for constant monitoring of the position of the water level in the drum, at least two direct-acting water-indicating instruments must be installed. Water-indicating devices can not be installed on once-through and other boilers, the design of which does not require control over the position of the water level.

2. For boilers with a steam capacity of less than 0.7 t / h, as well as for locomotive-type and locomotive boilers, it is allowed to replace one of the water-indicating devices with two test taps or valves that allow them to be cleaned in a straight direction. The installation of the lower tap or valve must be carried out at the level of the lowest, and the upper - at the level of the highest permissible water level in the boiler. The internal diameter of the test cock or valve must be at least 8 mm.

3. A direct-acting water indicator must be designed so that the glass and body can be replaced during the operation of the boiler.

4. If the distance from the site from which the water level in the steam boiler is monitored to direct-acting water-indicating instruments is more than 6 m, and also in cases of poor visibility of the instruments, two reliably operating reduced remote water-level indicators with calibrated scales must be installed, on which the lowest and highest water levels must be marked on a water-indicating device installed on the same boiler. In this case, it is allowed to install one direct-acting water-indicating device on the boiler drums. Reduced or remote water level indicators must be connected to the boiler drum on separate fittings, regardless of the upper water indicators and have damping devices.

5. On the drums of boilers with staged evaporation, which monitor the water level, at least one water-indicating device in each clean and each salt compartment must be installed, and on the remaining drums - one water-indicating device in each clean compartment. In the case of a brine compartment with independent separators, the installation of water-indicating devices on the separators is not necessary.

6. On boilers with several upper drums connected in series, at least two water-indicating devices must be installed on the drum, through which the water level is constantly monitored, and one water-indicating device each on the remaining drums filled with water and steam.

7. If the steam boiler has several upper drums included in parallel circulation systems, i.e. connected by water and steam, at least one water-indicating device must be installed on each drum.

8. For locomotive-type boilers, power trains, direct-acting level indicators in the presence of columns are installed: one on the column, the other on the frontal sheet of the boiler. In the absence of columns, it is allowed to install one level indicator and three-trial taps.

9. Water-indicating instruments of direct action must be installed in a vertical plane or tilted forward at an angle of not more than 30 ° and must be located and illuminated so that the water level is clearly visible from the driver's (fireman's) workplace.

10. Hot water boilers must be provided with a test valve installed in the upper part of the boiler drum, and in the absence of a drum - at the outlet of water from the boiler into the main pipeline to the shut-off device.

11. On water-indicating devices, a fixed metal indicator with the inscription "Lower level" must be installed against the permissible lowest water level in the boiler. This level must be at least 25 mm above the lower visible edge of the transparent plate (glass). Similarly, the indicator of the highest acceptable level water in the boiler, which must be at least 25 mm below the upper visible edge of the transparent plate of the water indicator.

12. When installing water-indicating devices consisting of several separate water-indicating glasses, the latter must be placed so that they continuously indicate the water level in the boiler.

13. Each water indicator or test valve must be installed on the boiler drum separately from one another. It is allowed to install two water-indicating devices on a connecting pipe (column) with a diameter of at least 70 mm. When connecting water-indicating devices to the boiler using pipes up to 500 mm long, the inner diameter of these pipes must be at least 25 mm, and with a length of more than 500 mm, their diameter must be at least 50 mm. Pipes connecting water gauges to the boiler must be accessible for internal cleaning. Installation of intermediate flanges and locking elements on them is not allowed. The configuration of the pipes connecting the water-indicating device with the boiler drum must exclude the possibility of the formation of water bags in them.

14. Pipes connecting water-indicating devices with the drum (body) of the boiler must be protected from freezing.

15. In direct-acting level indicators for steam boilers, only flat transparent plates (glasses) should be used. At the same time, for boilers with a working pressure of up to 39 kgf / cm2, the use of corrugated glasses and glasses with a smooth surface on both sides is allowed. For boilers with a working pressure of more than 39 kgf / cm2, smooth glasses with a mica gasket should be used to protect the glass from direct exposure to water and steam, or pressure from mica plates. The use of viewing plates without mica protection is allowed if their material is resistant to the corrosive effects of water and steam on it at the appropriate temperature and pressure.

16. Water-indicating devices must be equipped with shut-off valves (valves or gate valves) to disconnect them from the boiler and purge fittings. To drain water when purging water-indicating devices, there must be funnels with a protective device and a drain pipe for free draining. At a pressure of more than 45 kgf / cm2, two shut-off devices must be installed on water-indicating devices to disconnect from the boiler. The use of plug valves as shut-off devices is allowed in this case only for boilers with a working pressure of up to 13 kgf / cm2.

Pressure gauges

1. Each steam boiler must be equipped with a pressure gauge showing the steam pressure. On boilers with a steam capacity of more than 10 t/h and hot water boilers with a heat capacity of more than 5 Gcal/h, a recording pressure gauge must be installed. The pressure gauge must be installed on the boiler drum, and if the boiler has a superheater, also behind the superheater, up to the main valve. On once-through boilers, the pressure gauge must be installed downstream of the superheater in front of the shut-off valve. The installation of a pressure gauge on superheaters of locomotive, locomobile, fire-tube boilers and vertical-type boilers is not required.

2. Each steam boiler must have a pressure gauge installed on the feed line upstream of the boiler water supply regulator. If several boilers with a steam capacity of less than 2 t / h each are installed in the boiler room, it is allowed to install one pressure gauge on a common feed line.

3. When using a water supply network instead of the second feed pump, a pressure gauge must be installed on this water supply network in the immediate vicinity of the boiler.

4. On a water-switched economizer, pressure gauges must be installed at the water inlet to the shut-off body and safety valve and at the water outlet to the shut-off body and safety valve. If there are pressure gauges on the common supply lines up to the economizers, it is not necessary to install them at the water inlet to each economizer.

5. On hot water boilers, pressure gauges are installed: at the water inlet to the boiler and at the outlet of heated water from the boiler to the shut-off valve, on the suction and discharge lines circulation pumps with the location at the same level in height, as well as on the power lines of the boiler or feeding the heating system.

6. Pressure gauges installed on boilers, superheaters, economizers and feed lines must have an accuracy class of at least:

2.5 - for working pressure up to 23 kgf/cm2;

1.6 - for working pressure over 23, up to 140 kgf/cm2 inclusive;

1.0 - for working pressure over 140 kgf/cm2.

7. The pressure gauge must be with such a scale that, at operating pressure, its arrow is in the middle third of the scale.

8. On the scale of the pressure gauge, a red line should be drawn according to the division corresponding to the highest allowable working pressure in the boiler, and for reduced pressure gauges - taking into account the additional pressure from the weight (mass) of the liquid column. Instead of a red line, it is allowed to attach a metal plate to the pressure gauge case, painted red and tightly adjacent to the pressure gauge glass.

9. The manometer must be installed so that its readings are clearly visible to the maintenance personnel, while its scale must be in a vertical plane or tilted forward up to 30 ° C. The nominal diameter of pressure gauges installed at a height of up to 2 m from the level of the pressure gauge observation site must be at least 100 mm, at a height of 2 to 5 m - at least 150 mm and at a height of more than 5 m - at least 250 mm.

10. Between the pressure gauge and the steam boiler there must be a connecting siphon pipe with a diameter of at least 10 mm with a three-way cock or other similar device with a hydraulic seal. On boilers with a pressure above 39 kgf / cm2, with the exception of boilers of power trains, valves should be installed on the siphon tube instead of a three-way valve, allowing the pressure gauge to be disconnected from the boiler, communicate it with the atmosphere and blow through the siphon tubes.

11. Pressure gauges are not allowed to be used in cases where:

a) there is no seal or stamp on the pressure gauge with a mark on the test;

b) the period for checking the pressure gauge has expired;

in) the arrow of the pressure gauge, when it is turned off, does not return to the zero reading of the scale by an amount exceeding half of the permissible error for this pressure gauge;

G) the glass is broken or there is other damage to the pressure gauge, which may affect the correctness of its readings.

Instruments for measuring the temperature of steam, water and liquid fuels

1. On the superheated steam pipelines in the section from the boiler to the main steam valve, devices for measuring the temperature of the superheated steam must be installed. For boilers with natural circulation with a steam capacity of more than 20 t/h, and for once-through boilers with a steam capacity of more than 1 t/h, in addition, it is mandatory to install a device that records the steam temperature.

2. On superheaters with several parallel sections, in addition to devices for measuring the steam temperature installed on the common steam pipelines of superheated steam, devices must be installed to periodically measure the temperature of the steam at the outlet of each section, and for boilers with a steam temperature above 500 ° C - at the outlet superheater coils, one thermocouple (sensor) for each meter of flue width. For boilers with a steam capacity of more than 400 t/h, instruments for measuring the steam temperature at the outlet of the superheater coils must be of continuous operation with a recording device.

3. If there is an intermediate superheater, devices for measuring the steam temperature must be installed at its outlet in accordance with Art. 2.

4. If there is a desuperheater on the boiler to control the temperature of superheated steam, devices for measuring the temperature of the steam must be installed before and after the desuperheater.

5. Sleeves must be installed at the water inlet to and outlet from the economizer, as well as on the feed pipes of steam boilers without an economizer, to enable the temperature of the feed water to be measured.

6. For hot water boilers, instruments for measuring the water temperature must be installed at the water inlet to the boiler and at the outlet of it. At the hot water outlet, the device must be located between the boiler and the shut-off valve. For a boiler with a heat output of more than 1 Gcal / h, a temperature measuring device installed at the outlet of water from the boiler must be recording.

7. When operating boilers on liquid fuel, a thermometer must be installed on the fuel line in the immediate vicinity of the boiler to measure the temperature of the fuel in front of the nozzles.

Fittings of the boiler and its pipelines

1. Fittings installed on the boiler or pipelines must be clearly marked, which must indicate:

a) the name or trademark of the manufacturer; b) conditional pass; c) conditional pressure or working pressure and temperature of the medium; d) the direction of the flow of the medium.

2. Valves with a nominal bore over 20 mm, made of alloy steel, must have a passport (certificate), which indicates the grades of materials used for the manufacture of the main parts (body, cover, fasteners), nominal bore, nominal pressure or operating pressure and temperature environment.

3. Valve handwheels must be marked with signs indicating the direction of rotation when opening and closing the valve.

4. On all pipelines of boilers, superheaters and economizers, fittings must be connected by flanges or by welding. In boilers with a steam capacity of not more than 1 t / h, it is allowed to attach fittings on a thread with a conditional passage of not more than 25 mm and a working pressure of saturated steam not higher than 8 kgf / cm2.

5. A shut-off valve or gate valve must be installed between the boiler and the steam pipeline or turbine connected to it. If there is a superheater, shut-off valves must be installed downstream of the superheater. If necessary, it is allowed to install a check valve between the shut-off valves and the boiler, which prevents the flow of steam into the boiler from the common steam pipeline of the boiler room. On the steam pipelines of mobile steam generators (SPU), the installation of a check valve is mandatory. For boilers with a pressure of more than 39 kgf / cm2, at least two shut-off devices with a drainage device between them with a passage of at least 20 mm communicating with the atmosphere must be installed on each steam pipeline from the boiler to the common steam pipeline of the boiler room or to the turbine shut-off valve. On steam pipelines of monoblocks (boiler-turbine), shut-off valves behind the boiler can be omitted, provided that the need for it is not determined by the scheme for kindling, stopping or adjusting the operation of the boiler.

6. If there is an intermediate superheater in the boiler, one shut-off valve must be installed at the inlet and outlet of the steam. For monoblocks, the installation of valves is not required. If steam is directed from the turbine to the reheaters of two or more boilers, then at the inlet to the reheater of each boiler, in addition to a shut-off valve, a regulating body must be installed for proportional distribution of steam among the superheaters of individual boilers.

7. Shut-off devices on steam pipelines should be located as close as possible to the boiler (superheater). For once-through boilers, as well as for monoblocks and double blocks (two turbine boilers) with drum boilers, it is allowed to install stop valves anywhere in the steam pipeline connecting the boiler to the common steam pipeline of the boiler room or to the turbine shut-off valve.

8. For each boiler with a steam capacity of 4 t/h or more, the control of the main steam locking body must be carried out from the workplace of the boiler driver (fireman).

9. A shut-off valve or gate valve must be installed on the supply pipe and check valve, preventing the exit of water from the boiler into the feed pipe. On boilers with pressure up to 39 kgf / cm2, a shut-off element is installed between the boiler and the check valve. For steam boilers with centralized power supply, at least two shut-off valves or gate valves must be installed on each supply pipeline when using flangeless fittings, between which there must be a drainage device with a passage of at least 20 mm, connected to the atmosphere. If the boiler has an economizer that cannot be switched off by water, then a shut-off valve and a check valve are installed on the feed pipelines in front of the economizer. For an economizer that is switched off by water, a shut-off element and a check valve must also be installed at the water outlet of the economizer.

10. On the feed lines of each steam boiler, control fittings (valves, gates) must be installed. With automatic regulation of the boiler feed, there must be a remote drive to control the control feed fittings from the workplace of the boiler driver (fireman).

11. When installing several feed pumps with common suction and discharge pipelines, shut-off devices must be installed for each pump on the suction side and on the discharge side. A non-return valve must be installed on the discharge connection of each centrifugal pump up to the shut-off element.

12. A safety valve must be installed on the supply pipeline between the piston pump (which does not have a safety valve) and the shut-off device, which excludes the possibility of exceeding the design pressure of the supply pipeline. The inner diameter of the pipeline (pipe) connected to the safety valve must be at least 1/3 of the inner diameter of the supply pipeline and at least 25 mm.

13. The supply pipeline must have vents to release air from the upper points of the pipeline and drains to drain water from the lower points of the pipeline.

14. Each boiler (superheater, economizer) must have pipelines for:

a) purging the boiler and draining the water when the boiler stops; b) removal of air from the boiler during kindling; c) removal of condensate from steam pipelines; d) sampling water and steam and introducing additives into boiler water; e) release of superheated steam from drum boilers and water or steam from once-through boilers during ignition or shutdown.

For boilers with a capacity of not more than 1 t / h, the installation of pipelines specified in paragraphs "b" and "d" is not required.

15. The system of purge and drain pipelines must ensure the possibility of removing water and sediments from the lowest parts of the boiler (superheater, economizer). The conditional passage of the drain pipelines must be at least 50 mm. For water-tube boilers that do not have lower drums, the nominal diameter of the drain pipelines connected to the lower chambers must be at least 20 mm. For boilers with pressure above 60 kgf/cm2, it is necessary to install two shut-off bodies on each drain pipeline. Shut-off devices should be installed as close as possible to the drum or chamber. There should be no detachable connections in the section of the pipeline between the boiler and the shut-off device, except for the flange connections necessary for connecting this pipeline to the boiler or the shut-off body.

16. On boilers with a pressure of 39 kg/cm2 or more, there must be devices controlled from the workplace of the boiler operator to discharge water from the upper drum in case of dangerous overflow of it above the upper permissible level. This device must exclude the possibility of draining water below the lowest permissible level.

17. Blowdown pipes must be connected at the lowest points of the respective drums, chambers and boiler bodies. For boilers with a pressure of more than 8 kgf / cm2, two shut-off bodies or one shut-off and one regulating must be installed on each purge line. In boilers with a pressure of more than 100 kgf / cm2, in addition, the installation of throttle washers is allowed on these pipelines. To purge the chambers of superheaters, it is allowed to install one shut-off element. The conditional passage of the purge pipelines and fittings installed on them must be at least 20 mm for boilers with a pressure of up to 140 kgf/cm2 and at least 10 mm for boilers with a pressure of 140 kgf/cm2 or more.

18. Each intermittent blowdown boiler must have its own blowdown line connected to a common line directed to the atmosphere or to a pressureless blowdown tank. A pressurized purge tank may be used, provided that the tank is equipped with at least two safety valves. Devices for continuous purge boiler and steam collectors (chambers) purge must have separate purge lines. The installation of shut-off valves on common purge or drain lines is prohibited. It is allowed to install an additional shut-off device on a common drain or purge line that combines several drain or purge lines of one boiler. The arrangement of purge and drain lines must exclude the possibility of burns to people.

19. On drain and purge pipelines, the use of cast iron fittings (with the exception of fittings made of ductile iron), fittings, as well as cork specks, gas welded and cast iron pipes is not allowed.

20. In places where air can accumulate in the boiler and economizer, devices must be installed to remove it. If it is possible to remove the air accumulated in the economizer through the drainage pipes, then the installation of an air venting device is not necessary. It is not allowed to install an air venting device on the steam outlet.

21. In all sections of the steam pipeline that can be turned off by shut-off devices, drainage must be provided to ensure the removal of condensate. A shut-off valve must be installed on each drainage pipeline, and at a pressure of more than 8 kgf / cm2 - two shut-off valves or one shut-off valve and one control valve. For boilers with a pressure of more than 100 kgf / cm2, in addition to shut-off devices, it is allowed to install throttle washers.

22. Each hot water boiler connected to a common hot water main must have one shut-off device (valve or gate valve) installed on the inlet and outlet pipelines.

23. The hot water boiler in the upper part of the drum must have a device for removing air when filling the boiler (system) with water.

24. On hot water boilers with forced circulation, in order to prevent a sharp increase in pressure and water temperature in the boiler in the event of an accidental stop of the circulation pumps, a drain device with an internal diameter of at least 50 mm with a shut-off valve ( valve) to divert water into the drain. On boilers with a capacity of 4 Gcal / h and more, the installation of a drain device is not required.

Safety devices

1. Boilers with a steam capacity of 0.7 t/h and above with chamber combustion of fuel must be equipped with devices that automatically stop the supply of fuel to the burners when the water level drops below the permissible limit.

2. Steam and hot water boilers operating on gaseous fuels, when air is supplied to the burners from draft fans, must be equipped with devices that automatically stop the gas supply to the burners when the air pressure drops below the permissible value.

3. Water-heating boilers with multiple circulation and chamber combustion of fuel must be equipped with devices that automatically stop the supply of fuel to the burners, and with layered fuel combustion - with devices that turn off draft devices when the water pressure in the system drops to a value at which a risk of hydraulic shocks is created, and when rise in water temperature above the set value.

4. Once-through water-heating boilers with chamber combustion of fuel must be equipped with automatic devices that stop the supply of fuel to the boiler furnace, and in the case of layered fuel combustion, shut off the draft devices and fuel supply mechanisms of the furnace in the following cases:

a) increasing the water pressure in the boiler outlet manifold to 1.05 of the design pressure on the strength of the heating network pipeline and the boiler itself; b) lowering the water pressure in the boiler outlet manifold to a value corresponding to the saturation pressure at the maximum operating water temperature at the boiler outlet; c) increasing the temperature of the water at the outlet of the boiler to a value of 20°C below the saturation temperature corresponding to the operating pressure of the water in the outlet collector of the boiler; d) reduction of water flow through the boiler, at which water subcooling to boiling at the outlet of the boiler at maximum load and operating pressure in the outlet manifold reaches 20°C.

The definition of this flow should be determined by the formula

where Gmin is the minimum allowable water flow through the boiler, kg/h; Qmax - maximum heat output of the boiler, kcal/h; ts - boiling point of water at operating pressure at the outlet of the boiler, °С; tin - water temperature at the boiler inlet, °С.

To prevent water from boiling average speed it in separate pipes heated by radiation from the furnace must be at least 1 m / s.

5. Boilers with a steam capacity of 0.7 t/h and above must be equipped with automatic sound alarms for the upper and lower limit positions of water levels.

6. Boilers with a steam capacity of 2 t/h or more must be equipped with automatic power regulators; this requirement does not apply to boilers, in which the steam extraction to the side, in addition to the boiler, does not exceed 2 t/h.

7. Boilers with a steam superheat temperature above 400°C must be equipped with automatic superheated steam temperature controllers. In those cases where it is possible to increase the temperature of the walls of the pipes of the intermediate superheater in excess of the permissible value, it must be equipped with protective device to prevent such an increase in steam temperature.

8. Safety devices must be protected from impact on them by persons not related to their maintenance and repair, and have devices for checking the correctness of their operation.

Boiler water regime

General requirements

1. The choice of water treatment method for feeding boilers should be made by a specialized (design, commissioning) organization.

2. The water regime must ensure the operation of the boiler and the feed path without damage to their elements due to scale and sludge deposits, the excess of the relative alkalinity of the boiler water to dangerous limits or as a result of metal corrosion, and also ensure the production of steam of the proper quality. All boilers with a steam capacity of 0.7 t/h or more must be equipped with pre-boiler water treatment plants. It is also possible to use other effective ways water treatment, guaranteeing the fulfillment of the requirements of this article.

3. For boilers with a steam capacity of 0.7 t/h or more, taking into account their design, a specialized (adjustment) organization must develop an instruction (regime cards) approved by the administration of the enterprise, indicating the procedure for performing analyzes of boiler and feed water, the quality standards for feed and boiler water, the mode of continuous and periodic blowdowns, the procedure for servicing equipment in water treatment, the timing of stopping the boiler for cleaning and flushing, and the procedure for inspecting stopped boilers. If necessary, a check of the aggressiveness of the boiler water must be provided.

4. The boiler room should have a log (sheet) for water treatment to record the results of water analyzes, the performance of the boiler purging mode and maintenance operations for water treatment equipment. At each shutdown of the boiler to clean the internal surfaces of its elements, the type and thickness of scale and sludge, the presence of corrosion, as well as signs of leaks (vapor, external salt buildup) in rivet and rolling joints should be recorded in the water treatment journal.

5. For boilers with a steam capacity of less than 0.7 t / h, the period between cleanings should be such that the thickness of deposits on the most heat-stressed areas of the heating surface of the boiler does not exceed 0.5 mm by the time it is stopped for cleaning.

6. On reserve raw water lines connected to lines of softened feed water or condensate, as well as to feed tanks, two shut-off bodies and a control valve between them must be installed. The locking elements must be in the closed position and be sealed, the control valve is open. Each case of raw water supply should be recorded in the water treatment log.

Feed water requirements

1. The quality of feed water for natural circulation boilers with a steam capacity of 0.7 t/h and above with an operating pressure of up to 39 kgf/cm2 must comply with the following standards:

a) total hardness (no more):

for gas-tube and fire-tube boilers operating on solid fuel - 500 mcg-eq / kg;

for gas-tube and fire-tube boilers operating on gaseous or liquid fuels - 30 mcg-eq / kg;

for water-tube boilers with operating pressure up to 13 kgf/cm2 - 20 mcg-eq/kg;

for water-tube boilers with operating pressure above 13 to 39 kgf/cm2 - 15 mcg-eq/kg;

b) dissolved oxygen content (no more): for boilers with operating pressure up to 39 kgf/cm2 and steam capacity of 2 t/h or more, without economizers, and boilers with cast iron economizers - 100 µg/kg; for boilers with operating pressure up to 39 kgf/cm2 and steam capacity of 2 t/h or more with steel economizers - 30 µg/kg;

in) oil content (no more):

for boilers with working pressure up to 13 kgf/cm2 - 5 mg/kg;

for boilers with operating pressure above 13 kgf/cm2 up to 39 kgf/cm2 - 3 mg/kg.

2. The quality of feed water for steam boilers with natural circulation with an operating pressure of more than 39 kgf / cm2, as well as for once-through boilers, regardless of pressure, must meet the requirements of the Rules technical operation power stations and networks.

3. Salinity and alkalinity standards for boiler water are set on the basis of relevant tests. The relative alkalinity of boiler water for steam boilers must not exceed 20%. In steam boilers with welded drums, an increase in the relative alkalinity of boiler water in excess of the permissible norm may be allowed, provided that measures are taken to prevent intergranular corrosion of the metal.

4. The quality of make-up water for hot water boilers must comply with the following standards:

a) carbonate hardness - no more than 700 mcg-eq / kg; b) content of dissolved oxygen - no more than 50 mcg/kg; c) the content of suspended solids - no more than 5 mg/kg; d) the content of free carbon dioxide is not allowed; e) pH value not less than 7.

Nutrient Devices

General requirements

1. To feed the boiler with water, the following feeders can be used;

a) centrifugal and piston pumps with electric drive;

b) piston and centrifugal pumps with steam drive; c) steam injectors; d) pumps with manual drive.

2. Each feed pump and injector must be affixed to the housing with the following information:

a) the name of the manufacturer; b) year of manufacture and serial number; c) nominal flow at nominal water temperature in m3/h (l/min); d) RPM for centrifugal pumps or strokes per minute for reciprocating pumps; e) maximum head at nominal flow, m of water. Art. (kgf/cm2); f) nominal water temperature in front of the pump, °С.

In the absence of a factory passport, a pump test must be carried out to determine its flow and pressure. This test must be carried out after each overhaul pump.

3. The pump head must be selected taking into account the supply of water to the boiler at a pressure corresponding to the full opening of the working safety valves installed on the steam boiler, as well as taking into account the pressure loss in the discharge network.

4. To supply boilers with a working pressure of not more than 4 kgf / cm2 and a steam capacity of not more than 1 t / h, it is allowed to use a water supply system as a backup source of power if the water pressure in the latter directly at the boiler exceeds the permitted pressure in the boiler by at least 1.5 kgf / cm2.

5. For boilers with a working pressure of not more than 4 kgf / cm2 and a steam capacity of not more than 150 kg / h with periodic feeding, manual feeding pumps are allowed.

6. Steam boilers with different operating pressures must be fed from independent feeding devices. It is allowed to supply such boilers from one feeding device, if the difference in the working pressures of the boilers does not exceed 15%. Feed pumps connected to a common line must have characteristics that allow parallel operation of the pumps.

7. As feeding devices, instead of steam-driven pumps, it is allowed to use injectors in the same quantity and the same capacity.

8. In block installations (boiler-turbine or two boiler-turbines), the power supply of the boilers must be individual for each block.

9. Each once-through boiler must have an independent feeder (with electric or steam drive), independent of the feeders of boilers of other designs.

10. When using feed pumps with only a steam drive, there must be an additional feed device to power the steam boiler during its kindling or supply steam to the steam drive from the side.

11. When using pumps with only electric drive, automatic switching from one independent power supply to another must be provided.

Number and performance of nutrient devices

1. The number and supply of pumps with electric drive to power the steam boilers of stationary power plants are selected so that in the event of a shutdown of any of the pumps, the remaining ones ensure the operation of all working boilers (without a backup boiler) at their nominal steam output, taking into account the flow of water for blowing and other losses. In addition to the indicated feed pumps, standby steam driven feed pumps must be installed:

a) at power plants that are not included in the common power system or are not connected by parallel operation with another permanently operating power plant; b) for feeding steam boilers with chamber combustion of fuel, in which the drums are heated by hot gases; c) for feeding steam boilers with stratified fuel combustion.

The total supply of standby feed pumps must provide at least 50% of the nominal steam output of all working boilers. It is allowed to use steam-driven pumps as the main constantly operating feeding devices, while the installation of standby pumps is not necessary. The number and supply of pumps for supplying once-through boilers with a steam capacity of 450 t/h or more for supercritical parameters are selected so that in the event of a shutdown of the most powerful pump, the remaining ones, including the standby pump, ensure the operation of the boiler with a steam capacity of at least 50% of the nominal one.

2. To feed steam boilers (with the exception of boilers of power plants and power trains), at least two independently driven feed pumps must be installed, of which one or more must be steam driven. The total supply of pumps with an electric drive must be at least 110%, and with a steam drive - at least 50% of the rated steam output of all operating boilers. It is allowed to install all feed pumps only with a steam drive, and in the presence of two or more independent power supplies - only with an electric drive. Pumps for steam boilers with a pressure of not more than 4 kgf / cm2 can only be electrically driven with one power supply. In these cases, the number and flow of pumps are chosen so that when the most powerful pump stops, the total flow of the remaining pumps is at least 110% of the nominal steam output of all working boilers. It is allowed to operate boilers with a steam capacity of not more than 1 t / h with one feed pump with an electric drive, if the boilers are equipped with an automatic safety device that excludes the possibility of lowering the water level and increasing the pressure above the permissible level.

3. To feed boilers in the absence of steam extraction, in addition to the boiler, at least two pumps must be installed with a total supply of at least 50% of the steam output of the most powerful boiler. If there is a steam extraction in addition to the boiler, the total flow of the pumps must be increased to take into account the actual steam extraction.

4. To feed hot water boilers with natural circulation, at least two pumps must be installed, and for hot water boilers with forced circulation, there must be at least two make-up pumps and at least two circulation pumps. The pressure and flow of the pumps must be selected so that in the event of the failure of the most powerful pump, the remaining ones can ensure the normal operation of the boilers (system). Pumps for hot water boilers with a heat output of 4 Gcal/h or more must have two independent power supplies for the electric drive. To feed hot water boilers, instead of one of the total number of pumps, it is allowed to use a water pipe if the pressure in the water pipe directly at the place of its connection to the boiler or system exceeds the sum of the static and dynamic pressures of the system by at least 1.5 kgf / cm2.

5. The pressure created by the circulation and make-up pumps must exclude the possibility of boiling water in the boiler and system.

6. The number and supply of feed pumps for powering steam boilers of power trains must comply with the following standards:

a) with individual power supply, each boiler is equipped with one working pump with a steam or electric drive and one standby pump with a steam drive. The flow of each pump must be at least 120% of the nominal steam output of the boiler;

b) in case of centralized supply of boilers, two pumps with a steam or electric drive must be installed and each pump must supply at least 120% of the total rated steam output of all working boilers. In addition, each boiler must have one standby steam pump supplying at least 120% of the boiler's rated steam output.

7. When the feeding devices are located outside the boiler room, a direct telephone or other connection must be established between the driver (fireman) and the personnel servicing the feeding devices.

8. The supply line must be sized for the maximum pressure generated by the pumps connected to it. The supply of boilers with a steam capacity of 4 t / h and more with a layered method of fuel combustion, and with any other method of fuel combustion in the presence of drums heated by hot gases, should be carried out through two feed pipelines independent of each other. One feed line is allowed between the power regulator and the boiler. The capacity of each supply and suction pipeline must provide the nominal steam output of the boiler, taking into account the water flow for blowdown.

Boiler rooms

General requirements

1. Stationary boilers must be installed in separate buildings (closed-type boiler rooms). It is allowed to install boilers in boiler rooms:

a) semi-open type - in areas with an estimated outdoor air temperature below minus 20 ° C to minus 30 ° C; b) open type - in areas with an estimated outdoor temperature of minus 20 ° C and above.

In areas of dust storms and heavy precipitation, regardless of the calculated outdoor temperature, boilers should be placed in closed-type boiler rooms. Waste-heat boilers and tower-type steel once-through water-heating boilers can be installed in open-type boiler houses in areas with an estimated outdoor air temperature of at least minus 35 ° С. When boilers are placed in semi-open and open boiler rooms, measures must be taken to prevent the impact of precipitation on the lining of boilers, freezing of water in pipelines, fittings and elements of boilers during their operation and shutdown. All measuring devices, devices for regulating and controlling the operation of boilers, feeders, water treatment equipment (with the exception of deaerators) and workplaces of maintenance personnel must be located in warm rooms. Boilers must be protected from access by unauthorized persons.

Note. The estimated outdoor temperature is the average air temperature of the coldest five-day period of the year in the area where the boiler house is located.

2. Boiler rooms should not be adjacent to residential buildings and public premises (theaters, clubs, hospitals, children's institutions, educational institutions, changing rooms and soap rooms of baths, shops), as well as located inside these buildings. It is allowed to adjoin boiler rooms to industrial premises, provided that they are separated by a fire wall with a fire resistance limit of at least 4 hours. doorways doors should open towards the boiler room. The arrangement of any premises directly above the boilers is not allowed.

3. Inside industrial premises, as well as above and below them, installation is allowed:

a) once-through boilers with a steam capacity of not more than 4 t/h each; b) boilers that meet the condition (t - 100)V<= 100 (для каждого котла), где t - температура насыщенного пара при рабочем давлении, °С; V - водяной объем котла, м3; в) водогрейных котлов теплопроизводительностью каждый не более 2,5 Гкал/ч, не имеющих барабанов; г) котлов-утилизаторов без ограничений.

4. The installation site of the boilers inside the production premises, above and below them must be separated from the rest of the premises by fireproof partitions along the entire height of the boiler, but not lower than 2 m, with doors for access to the boiler. Waste-heat boilers can be separated from the rest of the production area along with furnaces or units with which they are connected by a technological process.

5. In industrial premises adjacent to residential premises, but separated from them by capital walls, it is allowed to install steam boilers, in which (t - 100) V<= 5, где t - температура жидкости при рабочем давлении, °С; V - водяной объем котла, м3.

6. In the buildings of the boiler house, it is allowed to place household, service premises and workshops intended for the repair of boiler room equipment, provided that they are separated by walls and ceilings made of fireproof materials and that normal conditions are provided for people working in them.

7. If it is necessary to install an ash room in the boiler house building, it must be isolated from other rooms to prevent the penetration of gas and dust into them.

8. It is allowed to use the frame of boilers as load-bearing elements of the building structure, if it is provided for by the project.

9. For service personnel in the building of the boiler house, amenity rooms must be equipped in accordance with sanitary standards.

10. All elements of boilers, pipelines, superheaters, economizers and auxiliary equipment with an outer surface wall temperature above 45°C, located in places accessible to service personnel, must be covered with thermal insulation, the outer surface temperature of which should not exceed 45°C.

11. Ventilation and heating of the boiler room must ensure the removal of excess moisture, harmful gases and dust and the maintenance of the following temperature conditions:

a) in the zone of permanent residence of service personnel, the air temperature in winter should not be lower than 12 ° C, and in summer it should not exceed the outside air temperature by more than 5 °; b) in other places of possible stay of service personnel, the air temperature should not exceed by more than 15 ° C the temperature in the main zone.

12. In the boiler room, attic floors above the boilers are not allowed.

13. The floor level of the lower floor of the boiler house should not be lower than the level of the area adjacent to the boiler house building.

Arrangement of doors and vestibules

1. Each floor of the boiler room must have at least two exits located on opposite sides of the room. A single exit is allowed if the floor area is less than 200 m2 and there is an emergency exit to the external fire escape, and in single-storey boiler rooms - if the length of the room along the front of the boilers is not more than 12 m. The exit from the boiler room is considered to be both a direct exit to the outside and an exit through stairwell or vestibule.

2. Exit doors from the boiler room must open outwards when pressed by hand and must not have locks from the boiler room. All exit doors of the boiler room must not be locked during operation of the boilers. Exit doors from the boiler room to service, domestic, and auxiliary production rooms must be equipped with springs and open towards the boiler room.

3. The gates of the boiler room, through which fuel is supplied and ash and slag are removed, must have a vestibule or an air thermal curtain. The dimensions of the vestibule must ensure safety and ease of maintenance for supplying fuel or removing ash and slag. In areas with an average air temperature of the coldest five-day trip not lower than minus 5 ° C, the installation of vestibules and thermal curtains is not necessary.

Lighting

1. The boiler rooms must be provided with sufficient daylight, and at night - with electric lighting. Places that, for technical reasons, cannot be provided with daylight, must have electric lighting. The illumination of the main workplaces should not be lower than the following standards:

2. In addition to working lighting, boiler rooms should have emergency electric lighting from power sources independent of the general electrical lighting network of the boiler room. The following places are subject to mandatory emergency lighting:

a) the front of the boilers, as well as passages between the boilers, behind the boilers and above the boilers; b) heat shields and control panels; c) water-indicating and measuring instruments; d) ash rooms; e) fan area; f) smoke exhaust site; g) rooms for tanks and deaerators; h) platforms and ladders of boilers; i) pump room.

For boiler rooms with a floor area of ​​up to 250 m2, it is allowed to use portable electric lights as emergency lighting.

3. Electrical equipment, lamps, current conductor, grounding and their installation must comply with the requirements of the Rules for Electrical Installations.

4. For electric lamps of general and local lighting, suspended at a height of less than 2.5 m above the floor or platforms, the voltage should not exceed 36 V. Voltage 127-220 V is allowed, provided that the arrangement of lighting fixtures will not allow the replacement of lamps by persons on which this is not assigned by the instructions for the personnel of the boiler rooms, and the lamps will be protected from accidental contact with them by the maintenance personnel.

Placement of boilers and auxiliary equipment

1. The distance from the front of the boilers or protruding parts of the furnaces to the opposite wall of the boiler room must be at least 3 m, while for boilers operating on gaseous or liquid fuels, the distance from the protruding parts of the burner devices to the wall of the boiler room must be at least 1 m, and for boilers equipped with mechanized furnaces, the distance from protruding parts of the furnaces must be at least 2 m. For boilers with a steam capacity of not more than 2 t / h, the distance from the front of the boilers or protruding parts of the furnaces to the wall of the boiler room can be reduced to 2 m in the following cases:

a) if the manual solid fuel firebox is serviced from the front and has a length of not more than 1 m; b) when there is no need to service the furnace from the front; c) if the boilers are fired with gaseous or liquid fuels (while maintaining a distance from the burners to the wall of the boiler room of at least 1 m).

2. The distance between the front of the boilers and the protruding parts of the furnaces located opposite each other should be:

a) for boilers equipped with mechanized furnaces - at least 4 m; b) for boilers operating on gaseous and liquid fuels - at least 4 m, while the distance between the burners must be at least 2 m; c) for boilers with manual fireboxes, at least 5 m.

3. In front of the front of the boilers, it is allowed to install pumps, fans and heat shields, as well as to store a stock of solid fuel for no more than one shift of boiler operation. The width of free passages along the front must be at least 1.5 m. The installed equipment and fuel must not interfere with the maintenance of the boilers.

4. When installing boilers that require lateral maintenance of the furnace or boiler (shoveling, blowing, cleaning of gas ducts, drums and headers, excavation of economizer and superheater packages, excavation of pipes, maintenance of burner devices), the width of the side passage should be sufficient for maintenance and repair, but at least 1.5 m for boilers with a steam capacity of up to 4 t/h and at least 2 m for boilers with a steam capacity of 4 t/h or more. Between the outer boiler and the wall of the boiler house, regardless of the boiler capacity, it is allowed to reduce the width of the side passage to 1.3 m.

5. In the absence of lateral maintenance of furnaces and boilers, it is obligatory to arrange at least one passage between the boilers or between the outermost boiler and the wall of the boiler room. The width of this side passage, as well as the width between the boilers and the rear wall of the boiler room, must be at least 1 m. protruding parts of the building (columns), stairs, work platforms, etc. should be at least 0.7 m. If there is no passage between the wall of the boiler lining and the wall of the boiler room building, the lining should not closely adjoin the wall of the building and should be at least 70 mm away from it.

6. The distance from the upper mark (platform) for servicing the boiler to the lower structural parts of the boiler room cover located above it must be at least 2 m. .7 m

7. It is forbidden to install machines and devices in the same room with boilers and economizers that are not directly related to their maintenance, repair of boiler equipment or steam generation technology. It is allowed to install steam engines, water heaters, pumps and reserve thermal power engines, provided that these installations do not impede the maintenance of boilers and economizers. Boiler units and turbine units of power plants can be installed in a common room or in adjacent rooms without the construction of dividing walls between the boiler room and the machine room.

8. The placement of boilers, superheaters and economizers in power trains, on cranes and other mobile vehicles is determined by the design organization based on the maximum ease of maintenance and safety of work.

Platforms and stairs

1. For convenient and safe maintenance of boilers, superheaters and economizers, permanent platforms and stairs with railings at least 0.9 m high with a continuous railing sheathing at the bottom of at least 100 mm should be installed. Transition platforms and stairs should be with railings on both sides. Platforms longer than 5 m must have at least two ladders (exits) located at opposite ends. It is allowed to arrange dead-end platforms with a length of more than 5 m with one exit intended only for repair work.

2. Platforms and steps can be made:

a) from expanded metal; b) from corrugated sheet steel or from sheets with a non-smooth surface obtained by welding or in another way; c) from sectional or strip (on edge) steel with a clearance of no more than 30x30 mm.

The use of smooth platforms and steps of stairs, as well as their execution from bar (round) steel is prohibited. Platforms and steps of stairs in boiler rooms of semi-open and open types must be made of expanded metal, sectional or strip steel.

3. Stairs must have a width of at least 600 mm, a height between steps of no more than 200 mm, a width of steps of at least 80 mm and every 3-4 m in height - platforms. Ladders with a height of more than 1.5 m must have an angle of inclination to the horizontal of not more than 50 ° C. For maintenance of deaerator tanks and other equipment that does not require frequent monitoring, as well as for access to hatches and manholes and for short stairs with a height of not more than 1.5 m, stairs with an angle of inclination to the horizontal of not more than 75 ° are allowed. Ladders with a height of no more than 3 m, intended for use during the repair of the boiler, can be vertical.

4. The width of the free passage of platforms for servicing valves, instrumentation, etc. must be at least 800 mm, for other platforms - at least 600 mm. The free height above the walkways and stairs must be at least 2 m.

5. The vertical distance from the platform for servicing water-indicating devices to the middle of the water-indicating glass must be at least 1 m and not more than 1.5 m. 6 to 2 m.

6. In cases where the distance from the working platform of the driver (fireman) to the upper platform of the boilers exceeds 20 m, a passenger-and-freight elevator must be installed.

Fuel supply and ash removal

1. For boilers with a steam capacity of 2 t/h and above, operating on solid fuel, the fuel supply to the boiler room and to the boiler furnace must be mechanized, and for boiler rooms with a total output of slag and ash from all boilers in the amount of 200 kg/h or more (regardless of performance of boilers), the removal of ash and slag must be mechanized.

2. When equipping boiler rooms with mechanized ash removal, it is allowed to place mechanisms below the level of the territory directly adjacent to the boiler house building, in impassable channels and recesses, provided that access for inspection and repair of these mechanisms is secured. When constructing a passage corridor for periodic inspection and repair of ash removal mechanisms, it must have dimensions in height to the lower parts of the protruding structures of at least 1.9 m and a width of at least 1 m. The corridor must have two exits to the outside.

3. In case of manual ash removal, slag and ash removal bunkers must be equipped with devices for filling ash and slag with water in bunkers or trolleys. In the latter case, isolated chambers should be arranged under the bunker for the installation of trolleys before lowering ash and slag into them. Cells should have tight-closing doors with glazed peepers and be equipped with ventilation and lighting. The control of the bunker shutter and the filling of the slag must be moved outside the chamber to a safe place for maintenance. The lower parts of the ash bins for manual transportation of ash: in trolleys should be at such a distance from the floor level that under the bunker gate the height of the passage was at least 1.9 m from the floor; for mechanized transportation, this distance should be 0.5 m more than the height of the trolley. The width of the passage of the ash room must be at least the width of the trolley, increased by 0.7 m on each side. Reducing the width is allowed only in the passages between the columns of the foundation of the boilers.

4. If ash and slag are raked out of the furnace to the working site, then exhaust ventilation must be arranged in the boiler room above the place of raking and pouring of focal residues.

5. In case of hand-loaded shaft furnaces for wood fuel or peat, loading hoppers with a lid and a folding bottom must be arranged.

6. When burning liquid fuel, a drain of the fuel flowing from the nozzles should be provided, excluding the possibility of it getting on the floor of the boiler room.

7. Shut-off valves must be installed on the liquid fuel pipelines to be able to stop the supply of fuel to the boilers.

8. The gas equipment of boiler rooms should not impede the maintenance of boilers; all locking devices and measuring devices must be convenient for maintenance.

9. It is not allowed to transfer boilers to burning liquefied gas in operating boiler houses, the floor level of which is below the level of the territory adjacent to the boiler room.

General requirements

1. The administration of the enterprise must ensure the maintenance of boilers, superheaters and economizers in good condition, as well as ensure safe working conditions for their work by organizing repair and supervision services in full compliance with the requirements of these Rules.

2. The administration of the enterprise is obliged to appoint the required number of engineering and technical workers and maintenance personnel to the boiler room. Responsible for the safe operation of boilers, superheaters and economizers - the head (manager) of the boiler house. In the absence of a head of the boiler house, responsibility for the safety of the operation of boilers, superheaters and economizers should be assigned to one of the engineering and technical workers with experience in operating boilers, superheaters and economizers and who have passed the knowledge test in the prescribed manner.

3. Engineering and technical workers who are directly related to the operation of boilers, superheaters and economizers must be subjected to a knowledge test of these Rules before being appointed to a position and periodically, at least once every three years, in the commission of the enterprise, and in the absence of relevant specialists at the enterprise - in commission of a higher organization.

4. Persons not younger than 18 years of age who have passed a medical examination, trained according to the appropriate program and have a certificate from the qualification commission for the right to service the boiler may be allowed to service the boiler. Programs for training personnel servicing boilers should be drawn up on the basis of standard programs approved in the manner established by the State Committee of the Council of Ministers of the USSR for vocational education. Training and certification of personnel servicing boilers of power plants, which are subject to the Rules for the technical operation of power plants and networks, must be carried out in the manner prescribed by these Rules.

5. Certification of drivers (stokers) of boilers and water inspections should be carried out in permanent qualification commissions organized at specialized vocational schools, training complexes and other educational institutions. Certification is also allowed at enterprises and organizations that have the necessary conditions and specialists in agreement with the local bodies of Gosgortekhnadzor. The participation of a representative of the local Gosgortekhnadzor in the work of qualification commissions for the certification of drivers (stokers) of boilers and water inspections is mandatory. The local authority of Gosgortekhnadzor must be notified of the day of the examinations no later than 10 days in advance.

6. Re-testing the knowledge of the operating personnel of the boiler room should be carried out periodically, at least once every 12 months, as well as when transferring to another enterprise and in cases of transferring boilers of another type to servicing or transferring boilers serviced by them from solid fuel to liquid fuel in commissions directly at enterprises or in organizations without the participation of a boiler supervision inspector. When transferring personnel to service boilers operating on gaseous fuels, their knowledge must be checked in the manner prescribed by the Safety Rules in the gas industry

7. The results of examinations and periodic testing of the knowledge of the service personnel must be drawn up in a protocol signed by the chairman of the commission and its members and indicated in a special journal. Persons who have passed the exams are issued certificates signed by the chairman of the “commission and the inspector of boiler supervision.

Boiler service requirements

1. It is forbidden to entrust the boiler driver (fireman) and the water inspection, who are on duty, to perform any other duties during the operation of the boiler that are not provided for in the instructions.

2. It is forbidden to leave the boiler without constant supervision by the maintenance personnel until the combustion stops, the fuel is removed from the furnace and the pressure in it is completely reduced to atmospheric pressure, with the exception of boilers that do not have brickwork, in which pressure reduction to zero after removing the fuel from the furnace is not necessary, if the boiler room is locked.

3. The operation of the boiler during chamber combustion of fuel can be allowed without constant supervision of the driver (fireman) if the boiler has automation that ensures its normal operation from the monitoring and control panel, as well as stopping the boiler in case of violations of the operating mode that can cause damage to the boiler, while simultaneously signaling this to the control panel. In this case, it should be possible to stop the boiler at any time from the control panel.

4. It is allowed to operate drum boilers, in which the water level in the drums is at a height of more than 6 m from the boiler service platform, without water inspections, provided that the requirements provided for in paragraph 4 (“Water level gauges”) are met. In this case, one of the remote indicators must be with a recording device.

5. The administration of the enterprise, on the basis of the “Standard Instruction for Boiler Room Personnel”, taking into account the characteristics of this boiler plant, must develop and approve in the prescribed manner a production instruction for boiler room personnel. The production instruction must be posted in a conspicuous place in the boiler room and given to the operating personnel. In boiler power plants, which are subject to the "Rules for the technical operation of power plants and networks", instructions may not be hung out. For boiler elements with a steam superheat temperature of 450°C and above, in addition, there should be instructions for monitoring creep and structural changes in the metal.

6. The boiler room must have a clock, a telephone or an audible alarm to call representatives of the enterprise administration in emergency cases and connect the boiler room with steam consumption places, and the waste heat boiler also for communication with the heat source installation site.

7. Persons not related to the operation of boilers and boiler room equipment should not be allowed into the boiler room. In necessary cases, unauthorized persons may be allowed into the boiler room only with the consolation of the administration and accompanied by its representative. It is forbidden to store any materials and objects in the boiler room. The boiler room must be kept clean.

8. The boiler room should keep a removable journal of the form established by the administration to record the results of checking boilers and boiler equipment, water-indicating instruments, limit water level alarms, pressure gauges, safety valves, feeders, automation equipment, time and duration of boiler blowdown, as well as other data as directed by the administration . Delivery and acceptance of boilers, superheaters, economizers and auxiliary equipment must be recorded in this journal with the signatures of persons responsible for shifts. The shift log also records the orders of the head of the boiler room or the person replacing him, on kindling or stopping the boiler (except in cases of emergency shutdown). Entries in the log must be checked daily by an employee responsible for the safe operation of boilers, with a receipt in the log.

9. When working in a boiler and gas ducts for portable electric lighting, a voltage of no higher than 12 V should be used; It is forbidden to use kerosene and other lamps with flammable materials.

Checking safety devices, gauges, fittings and feed pumps

1. Checking pressure gauges with their sealing (branding) must be carried out at least once every 12 months in the manner prescribed by the rules of the Committee for Standards, Measures and Measuring Instruments of the USSR. In addition, at least once every six months, the enterprise should check the working pressure gauges with a control pressure gauge or a tested working pressure gauge that have the same scale and accuracy class as the pressure gauge being checked, with the results recorded in the log of control checks. Checking the correct operation of the pressure gauge using three-way valves or shut-off valves replacing them should be carried out at least once per shift. Checking the serviceability of pressure gauges on boilers, superheaters and economizers with an operating pressure of 100 kgf / cm2 and above of thermal power plants can be carried out within the time limits stipulated by the instructions of the USSR Ministry of Energy and Electrification.

2. Checking water-indicating devices by purging should be carried out for boilers with a working pressure of up to 24 kgf / cm2 inclusive at least once a shift, for boilers with a working pressure of 24 to 39 kgf / cm2 inclusive at least once a day, and for boilers with a working pressure over 39 kgf/cm2 within the terms established by the production instruction. Reconciliation of the readings of reduced water level indicators with direct-acting water-indicating instruments should be carried out at least once per shift.

3. Checking the correct operation of the safety valves by blowing down should be carried out at each start-up of the boiler, superheater and economizer, as well as during their operation in the following periods: for boilers, superheaters and economizers with a pressure of up to 24 kgf/cm2 times a day, with a pressure of 24 to 39 kgf/cm2 inclusive, one valve of each boiler, superheater and economizer is checked in turn - at least once a day, with a pressure above 39 kgf/cm2 (including safety valves of intermediate superheaters) - in the terms established by the instructions of the Ministry of Energy and Electrification of the USSR. Checking the correct operation of the safety valves of boilers, superheaters and economizers with a pressure of more than 24 kgf / cm2 is carried out in the presence of the person responsible for the shift.

4. The serviceability of all feed pumps or injectors should be checked by briefly putting each of them into operation: for boilers with a working pressure of up to 24 kgf / cm2 - at least once a shift, for boilers with a working pressure of more than 24 kgf / cm2 - within the time limits established production instruction.

Boiler emergency stop

1. The boiler must be stopped immediately in cases stipulated by the production instructions, and in particular: a) if more than 50% of the safety valves or other safety devices replacing them cease to operate; b) if the pressure has risen above the permitted by more than 10% and continues to grow, despite the interruption of the fuel supply, the reduction of draft and blast and the increased supply of water to the boiler; c) when water is lost; feeding the boiler with water is strictly prohibited; d) if the water level drops rapidly, despite the increased supply of water to the boiler; e) if the water level has risen above the upper visible edge and the water-indicating device (overfeeding) and it is not possible to lower it by blowing the boiler; f) upon termination of all nutritional devices; g) upon termination of all water-indicating devices; h) if cracks, bulges, gaps in their welds, breaks in two or more adjacent connections ; i) in boiler houses operating on gas fuel, in addition, in cases provided for by the rules and instructions for safety in the gas industry; j) in the event of an explosion of gases in gas ducts, a power outage due to artificial draft, as well as damage to the elements of the boiler and its lining, creating a danger to the operating personnel or a threat of destruction of the boiler; k) in the event of a fire in the boiler room or ignition of soot and fuel particles in gas ducts that threaten the operating personnel or the boiler.

2. Possible causes and procedure for emergency shutdown of the boiler must be specified in the production instructions. The reasons for the emergency shutdown of the boiler must be recorded in the shift log.

Repair of boilers, superheaters and economizers

1. The administration of the enterprise (organization) must ensure the timely repair of boilers, superheaters and economizers according to the approved preventive maintenance schedule. Repairs must be carried out according to the technical specifications and in accordance with the requirements of these Rules.

2. Each boiler room must have a repair log, in which, signed by the head of the boiler room or the person responsible for the safe operation of the boiler, information must be entered on the repair work performed that does not require an early survey, and on boiler shutdowns for cleaning or flushing. Replacement of pipes, rivets and rolling of pipe connections with drums and chambers should be noted on the layout of pipes (rivets) in the repair log. The repair log also reflects the results of the inspection of the boiler before cleaning, indicating the thickness of scale and sludge deposits and all defects identified during the repair period.

3. Information about repair work that necessitates early inspection of boilers, superheaters and economizers, as well as data on materials and welding used in the repair, and information about the welder must be entered in the boiler passport.

4. Before starting any work inside the chamber drum or boiler header connected to other operating boilers by common pipelines (steam, feed, drain and drain lines, etc.), as well as before inspection or repair of pressure elements, when if there is a danger of people being burned by steam or water, the boiler must be separated from all pipelines with plugs or disconnected; disconnected pipelines must also be plugged. It is allowed to shut off boilers with a pressure above 39 kgf / cm2 by two shut-off devices if there is a drainage device between them with a nominal diameter of at least 32 mm, which has a direct connection to the atmosphere. In this case, the drives of the gate valves, as well as the valves of open drains, must be locked so that there is no possibility of weakening their tightness when the lock is locked. The key to the lock must be kept by the head of the boiler room. With gas heating, the boiler must be reliably disconnected from the common gas pipeline in accordance with the instructions of the boiler maintenance company.

5. The plugs used to turn off the boiler, installed between the flanges of the pipelines, must be of adequate strength and have a protruding part (tail), which determines the presence of the supplied plug. When installing gaskets between the flanges and the plug, they must be without shanks.

6. The admission of people into the boiler and the opening of the shut-off valves after removing people from the boiler should be carried out at a temperature not exceeding 60 ° C only with a written permission (alongside the admission) of the head of the boiler room, issued in each individual case after an appropriate check.

7. The work of people in gas ducts can be carried out at a temperature not exceeding 60 ° C only after the place of work is ventilated and reliably protected from the ingress of gases and dust from operating boilers by closing and sealing the dampers with locking them to the lock or placing temporary brick walls. The time spent by people in the furnace (gas duct) at a temperature of 50-60 °C should not exceed 20 minutes. When operating on gaseous or pulverized fuel, the boiler must, in addition, be reliably separated from the general gas or dust pipeline in accordance with the production instructions.

8. When shutting off the relevant sections of the pipeline, steam pipelines, gas pipelines and gas ducts, as well as on the starters of smoke exhausters, blowers and fuel feeders, posters “Do not turn on, people are working” should be posted on valves, gate valves and dampers, while at the starters of smoke exhausters, blowers fusible links must be removed from fans and fuel feeders.

Registration, certification and operating permit

Registration

1. Boilers, independent superheaters, individual and group economizers must be registered with the local authorities of Gosgortekhnadzor before being put into operation. Boilers with: (t - 100) V<= 5, где t - температура насыщенного пара при рабочем давлении, °С; V - водяной объем котла, м3.

2. Registration of the boiler, superheater and economizer is carried out on the basis of a written application, the administration of the enterprise - the owner of the boiler or the organization renting them, with the submission of the following documents:

a) passports of the established form with drawings of the actual execution of the combustion device; b) an act on the serviceability of the boiler, if it arrived from the manufacturer in an assembled form (or moved from one place to another); c) certificates of the quality of installation, indicating the allowed changes to the project; d) drawings of the boiler room (plan, longitudinal and transverse sections); e) certificates of compliance of water treatment with the project; f) information about the availability and characteristics of nutritional devices.

The listed documents, except for the passport, must be signed by the head of the enterprise and bound together with the passport.

3. In the absence of a factory passport, it can be compiled by the enterprise - the owner of the boiler, superheater and economizer or an appropriate organization based on the manufacturer's documentation or according to full-scale measurement, mechanical tests, chemical and metallographic studies of the metal, its main elements and testing of welded joints by non-destructive methods of flaw detection in accordance with the requirements of these Rules. The passport of the boiler, superheater and economizer must include the results of studies of the quality of the material and welded joints, as well as a strength calculation performed in accordance with the requirements of these Rules.

4. The installation quality certificate is issued by the organization that performed the installation. The certificate must be signed by the head of this organization, as well as the head of the enterprise that owns the superheater boiler and economizer, and sealed. The certificate must contain the following data: the name of the installation organization; enterprises - the owner of the boiler, superheater and economizer; manufacturer of the boiler, superheater and economizer and their serial numbers; information about the materials used by the installation organization in addition to those indicated in the passports; on welding, including the type of welding, type and brand of Electrodes, names of welders and numbers of their certificates, test results of control joints (samples); information on checking the piping system by passing the ball and flushing the boiler, superheater and economizer; on steeloscopy of boiler elements, superheater, operating at a wall temperature above 450°C; a general conclusion on the compliance of the production installation work with these Rules, the project, technical conditions and installation instructions for the boiler, superheater and economizer and their suitability for operation with the parameters specified in the passport.

5. Boilers, superheaters and economizers after dismantling and installation in a new location must be re-registered.

6. Boilers of power trains after arriving at a new place of work must be registered with the local Gosgortekhnadzor authority.

7. If the documentation complies with the requirements of these Rules, the local Gosgortekhnadzor body registers the boiler, superheater and economizer with the assignment of registration numbers to them and returns the passport to the owner of the boiler.

8. The answer to the application for registration of the boiler, superheater and economizer must be given by the supervisory authority no later than five days from the date of receipt of the documents. In case of refusal to register the boiler, the owner must be informed of this in writing, indicating the reasons for the refusal with reference to the relevant articles of the Rules.

9. Each boiler and group economizer must have a label affixed in a conspicuous place, not less than 300x200 mm, indicating the following data: a) registration number; b) permitted working pressure; c) dates (year, month) of the next internal inspection and hydraulic test.

Technical certification

1. Each boiler, superheater, economizer must be subject to technical inspection before commissioning, periodically during operation and, if necessary, ahead of schedule. Superheaters and economizers, constituting one unit with the boiler, are surveyed simultaneously with the boiler.

2. The administration of the enterprise is obliged to prepare and present the boiler, superheater and economizer for examination within the time specified in the passport, and provide the technical means necessary for the examination.

3. On the day of readiness of the boiler, superheater and economizer for primary, periodic or early inspection, the administration of the enterprise must notify the inspector of boiler supervision no later than 10 days in advance.

4. If it is impossible to send and arrive at the enterprise a boiler supervision inspector to inspect the boiler, superheater, economizer within the prescribed period, the administration of the enterprise - owner of the boiler can carry out an examination only with the permission of the local Gosgortekhnadzor body under its own responsibility. To do this, by order of the head of the enterprise, a commission of competent engineering and technical workers should be created. The boiler approved by the commission for operation is subject to mandatory examination by the boiler supervision inspector at the time appointed by the commission, but no later than 12 months later.

5. The technical examination of the boiler, superheater, economizer must be carried out by the boiler supervision inspector in the presence of the head (manager) of the boiler house or the person responsible for the safe operation of the boiler, superheater and economizer.

6. The technical examination of the boiler, superheater and economizer consists of an internal inspection and a hydraulic test.

7. The internal inspection is aimed at: a) during the initial survey, to establish that the boiler, superheater and economizer are built, installed and equipped in accordance with these Rules and documents submitted during registration, and that the boiler and its elements are in good condition; b) during periodic and early surveys, establish the serviceability of the boiler and its elements and the reliability of its further safe operation.

8. During an internal inspection of the boiler and its elements, attention should be paid to identifying possible cracks, tears, vents, bulges and corrosion on the inner and outer surfaces of the walls, violations of the density and strength of welded, riveted and rolling joints, as well as damage to the lining, which can cause a risk of overheating metal elements of the boiler.

9. The hydraulic test aims to check the strength of the elements of the boiler, superheater and economizer and the tightness of their connections. The value of the test hydraulic pressure in this handbook is not given. During a hydraulic test, certain requirements of paragraph 4 must be observed. The boiler, superheater and economizer must be submitted for a hydraulic test with fittings installed on them.

10. The primary technical examination of newly installed boilers, superheaters, economizers is carried out by the boiler supervision inspector after their installation and registration. Boilers to be bricked may be inspected by the Boiler Inspector prior to registration.

11. Boilers that were subjected to internal inspection and hydraulic testing at the factory and arrived at the installation site assembled, as well as boilers that are not registered with the supervisory authorities, are subject to an initial technical examination at the installation site by a person responsible for the safe operation of boilers, superheaters and economizers .

12. Boilers registered with the local bodies of Gosgortekhnadzor, which were not subjected to internal inspection and hydraulic testing in assembled form at the manufacturer's plant, as well as boilers, the installation of which was carried out using welding, rolling or riveting of their elements, are subject to initial technical examination by the inspector of boiler supervision.

13. Periodic technical examination of boilers, superheaters and economizers registered with local supervisory authorities that are in operation is carried out by the boiler supervision inspector within the following periods:

a) internal inspection - at least once every four years; b) hydraulic test - at least once every eight years. Before a hydraulic test, an internal inspection must be carried out without fail.

14. The administration of the enterprise is obliged to independently inspect boilers, superheaters and economizers in the following cases: a) internal inspection - after each cleaning of internal surfaces or repair of elements, but at least every 12 months; this inspection may be combined with an internal inspection conducted by a boiler supervisor, provided that the gap between inspection periods does not exceed three months; at thermal power plants, it is allowed to conduct internal inspections of boiler units during their overhaul, but at least once every three years; b) internal inspection - immediately before presenting the boiler for inspection to the boiler inspection inspector; c) hydraulic test with operating pressure - each time after cleaning the internal surfaces or repairing the elements of the boiler, superheater and economizer, if the nature and extent of the repair do not necessitate an early survey.

15. Periodic inspection of boilers that are not subject to registration with the local authorities of Gosgortekhnadzor is carried out by a person responsible for the safe operation of boilers, superheaters and economizers.

16. The day of inspection of the boiler, superheater and economizer is set by the administration of the enterprise, while the boiler must be stopped no later than the period specified in the passport.

17. The local authority of Gosgortekhnadzor grants the right, in exceptional cases, to extend the established periods for the inspection of boilers up to three months upon a justified written request from the administration of the enterprise with the provision of data confirming the satisfactory condition of the boiler, and with positive results of the inspection of the boiler in working condition by the inspector of boiler supervision.

18. Before internal inspection and hydraulic testing, the boiler, superheater and economizer must be cooled down and thoroughly cleaned of scale, soot and ash. Internal devices in the drum must be removed if they interfere with inspection. If there is doubt about the good condition of the walls or seams, the person who conducts the survey has the right to demand the opening of the brickwork or the removal of insulation in whole or in part, and when conducting an internal inspection of the boiler with fire tubes, the complete or partial removal of pipes. When surveying once-through boilers, as well as other systems with tube bundles inaccessible for internal inspection, if necessary, it should be required to cut samples from the pipes of the heating surfaces in order to control the condition of their internal surface.

19. Early technical inspection of the boiler, superheater or economizer should be carried out in the following cases: a) the boiler has been inactive for more than one year; b) the boiler has been dismantled and re-installed; c) at least part of the sheet has been replaced or welding of the boiler elements has been applied, with the exception of welding of single fittings, pipes and plugs; d) the bulges and dents of the main elements of the boiler were corrected; e) more than 25% of the total number of rivets in any seam is riveted; f) more than 15% of the bonds of any wall have been changed; g) after replacing the screen chamber, superheater or economizer; h) more than 50% of the total number of screen and boiler tubes or 100% of superheater, economizer, fire tubes were changed simultaneously; i) according to the state of the boiler, the administration of the enterprise or the inspector of the boiler supervision consider such an examination necessary.

20. Early inspection of boilers registered with the local bodies of Gosgortekhnadzor is carried out by the inspector of boiler supervision, and boilers that are not subject to registration - by the person responsible for the safe operation of boilers, superheaters and economizers.

21. If during the technical examination of the boiler, superheater and economizer no defects are found that reduce their strength, they are allowed to operate at nominal parameters until the next examination.

22. If defects are detected, in which only temporary operation of the boiler, superheater and economizer is possible, the person who carried out the survey may allow the operation of the boiler with a reduced period of the next survey.

23. If, during the examination of the boiler, superheater and economizer, defects are found that reduce the strength of its elements (thinning of the walls, wear of connections, etc.), then until the replacement of defective elements, further operation of the boiler can be allowed at reduced parameters (pressure and temperature). The possibility of operating the boiler at reduced parameters must be confirmed by a strength calculation submitted by the administration of the enterprise.

24. If, during the examination of the boiler, superheater and economizer, defects are revealed, the cause of which is difficult to establish, the boiler supervision inspector is given the right to demand from the administration to conduct special studies, and, if necessary, present the conclusion of specialized organizations or relevant specialists on the causes of defects, the possibility and conditions for further operation of the boiler .

25. Depending on the condition of the elements of the boiler, superheater and economizer in the presence of defects (films, metal delamination, cracks, ruptures and swelling of pipes, etc.) that raise doubts about the quality or grade of the metal, the boiler supervision inspector is given the right to demand a mechanical tests of metallographic examination and chemical analysis. In these cases, the boiler passport should indicate the reasons why metal testing is required, as well as the places from which samples should be taken.

26. If during the examination of the boiler, mechanical tests of the metal of drums or other main elements of the boiler were carried out and the results obtained for carbon steel turn out to be lower than the values ​​\u200b\u200bspecified in the table, then further operation of the boiler should be prohibited. Permissible values ​​​​of the mechanical properties of the metal of the boiler elements under pressure of 39 kgf / cm2 or more, made of carbon and alloy steel, are established by the local authorities of the State Technical Supervision Service in each specific case at the conclusion of the manufacturer or a specialized organization.

27. If, during the examination of the boiler, leaks (leaks, traces of steam, salt build-up) are found in the places of rolling or riveting joints, then further operation of the boiler can be allowed only after examining defective joints for the absence of intergranular corrosion. If cracks are found, the boiler must be repaired. Chasing, welding and rolling of loose joints without research is not allowed.

28. If, during the examination of the boiler, superheater and economizer, it turns out that it is in an emergency condition or has serious defects that cast doubt on its strength, further operation of the boiler should be prohibited.

29. If during the analysis of defects identified during the inspection of boilers, superheaters and economizers, it is established that their occurrence is associated with the mode of operation of boilers at a given enterprise or is characteristic of boilers of this design, then the person who conducted the survey should require an extraordinary survey of all installed at this enterprise boilers, the operation of which was carried out according to the same regime, or, accordingly, all boilers of this design with notification of the local authority of Gosgortekhnadzor.

30. The results of the survey and the conclusion on the possibility of operation of the boiler, superheater and economizer, indicating the permitted pressure and the timing of the next survey, must be recorded in the boiler certificate. In case of an early survey, the reason for the need for such an survey must be indicated. If during the survey additional tests and studies were carried out, then the types and results of these tests and studies should be recorded in the boiler passport, indicating the sampling sites or areas subjected to tests, as well as the reasons that necessitated additional tests.

31. If, as a result of the survey, further operation of the boiler, superheater and economizer is prohibited, the operating pressure is reduced, or the period for the next survey is shortened, then an appropriate substantiated entry must be made in the boiler passport. The record of the survey is signed by the person who carried out the survey. If the examination was carried out by the commission in accordance with paragraph 4, the entry is signed by all members of the commission, and a copy of this entry is sent to the local Gosgortekhnadzor body no later than five days after the examination.

Permission to start up the newly installed boilers

1. Each newly installed boiler, superheater and economizer can be put into operation on the basis of a written order from the administration of the enterprise after acceptance by the acceptance committee of the boiler, superheater and economizer from the installation company and with the permission of the boiler supervisor.

2. Permission to operate the boiler, superheater and economizer is issued on the basis of the results of the initial technical examination and inspection during the steam test, which checks:

a) the presence and serviceability of the fittings, instrumentation and safety devices required by these Rules; b) serviceability of nutritional devices and their compliance with the requirements of these Rules; c) compliance of the water regime of the boiler with the requirements of these Rules; d) correct connection of the boiler to the common steam pipeline, as well as connection of feed and purge lines; e) the presence of certified service personnel, as well as engineering and technical workers who have passed the knowledge test; f) the availability of production instructions for the personnel of the boiler room, shift and repair magazines; g) compliance of the boiler room with the requirements of these Rules. The permit for the operation of the boiler, superheater and economizer, subject to registration with the local bodies of Gosgortekhnadzor, is recorded in the passport of the boiler, superheater and economizer by the inspector of boiler supervision, and not subject to registration - by the person responsible for their safe operation.

Monitoring compliance with these rules

1. Control over compliance with these Rules is carried out by local bodies of Gosgortekhnadzor by conducting periodic inspections of enterprises operating boiler plants and manufacturing plants in accordance with methodological guidelines, instructions and other guidance materials of Gosgortekhnadzor.

2. If, during the inspection of the manufacturing plant, it is established that violations of these Rules are allowed during the manufacture of boilers, superheaters, economizers and their individual elements, then, depending on the nature of the violation, the terms for their elimination are set or further manufacture is prohibited.

3. If during the examination of boilers, superheaters and economizers in operation, defects in their elements or violations of the Rules are revealed that threaten safety during further operation, and also if the period for their next examination has expired or the maintenance personnel have not been trained, then the operation of the boiler, superheater and economizer must be prohibited. The reason for the prohibition with reference to the relevant articles of these Rules must be recorded in the passport.

Investigation of accidents and accidents

1. About every accident and every serious or fatal case associated with an accident or maintenance of the boiler, superheater and economizer, the administration of the enterprise - the owner of them is obliged to immediately notify the local Gosgortekhnadzor body.

2. Prior to the arrival of a representative of Gosgortekhnadzor at the enterprise to investigate the circumstances and causes of the accident or accident, the administration of the enterprise is obliged to ensure the safety of the entire situation of the accident (accident), if this does not pose a danger to people's lives and does not cause further development of the accident. Investigation of accidents and accidents should be carried out in accordance with the procedure established by Gosgortekhnadzor.

Final provisions

1. The necessity and terms for bringing the existing boilers, superheaters and economizers into compliance with these Rules, as well as those manufactured or in the process of manufacture, installation or reconstruction at the time these Rules come into force, are established in each individual case by the Gosgortekhnadzor district administration.

2. With the entry into force of these Rules, the “Rules for the Design and Safe Operation of Steam Boilers”, approved by the USSR Gosgortekhnadzor on March 19, 1957, lose their force.

All boilers are operated in accordance with the requirements specified by the Gosgortekhnadzor inspection. Failure to do so may result in fires and explosions in boilers. Causes of explosions include:

· malfunction of control and measuring and (or) safety devices for controlling the operating modes of the boiler (safety valves, pressure gauges, water-indicating devices);

Violation of the process of preparing a combustible mixture, for example, due to a malfunction of the nozzle, an emergency stop of the fan, etc.);

Reducing the strength of the boiler walls as a result of corrosion, overheating, etc.;

operation of the boiler without supervision;

untimely technical examination of the boiler;

a large layer of scale on the walls;

maintenance of boilers by untrained personnel.

Boilers with excess steam pressure over 0.07 MPa and hot water boilers with water temperature over 115 °C must be registered with the Gosgortekhnadzor. For registration, the following documents are submitted to the inspection: an application, a boiler passport, an act on the serviceability of the boiler, if it arrived assembled; a certificate of installation quality, a drawing of the boiler room, a certificate of compliance of water treatment with the project, a certificate of the availability of feeding devices and their characteristics.

Steam boilers with excess pressure less than or equal to 0.07 MPa, and hot water boilers with a water heating temperature not exceeding 115 ° C, must be located in separate buildings or rooms, separated from production by a firewall (fire wall). Boilers must not be installed under premises where a large number of people can be located, under warehouses of combustible materials (except for those that serve as fuel for the boiler room) and in adjacent premises.

Floors in boiler rooms should be made of non-combustible non-slip materials (concrete).

The distance from the front of the boilers to the opposite wall must be at least 3 m, for liquid and gas fuel boilers - at least 2 m. The width of the passages between the boilers, as well as between the boilers and the wall must be at least 1 m.

In boiler rooms with an area of ​​\u200b\u200bless than 200 m2, one entrance door is arranged that opens outward, with a larger area - at least two in opposite parts of the room. Doors from the boiler room to other rooms should open towards the boiler room, have devices for self-closing and be upholstered with sheet metal from the side of the boiler room.

The boiler room is equipped with natural and artificial ventilation and an emergency lighting system (for a room area of ​​​​less than 250 m2, it is envisaged to use lights, including rechargeable ones, and for an area of ​​\u200b\u200bmore than 250 m2, an autonomous power supply and electric lamps).

Shut-off valves are installed on liquid fuel pipelines in case of an accident or fire, but at least two: one is at the burner, and the other is outside the boiler house building. A fuel tank with a capacity of not more than 0.5 m3 may be installed in the same room as the boilers, but no closer than 3 m from them. Liquid fuel tanks are located at a distance of at least 12 m from the boiler room and are equipped with a lightning protection device.

The boiler room should have: an instruction on labor protection for operators posted in a conspicuous place; fire-fighting equipment, including two foam fire extinguishers, a box with sand with a capacity of at least 0.5 m3, a shovel, a bucket and a hook.

On the body of the boiler there must be a plate with passport data printed on it: the name of the manufacturer, serial number, year of manufacture, the values ​​​​of the working and test pressure, the permissible heating temperature of the boiler walls.

The person responsible for the safe operation of boilers is the head of the boiler house. In the absence of this position, by order of the enterprise, one of the engineering and technical workers is appointed responsible, who at least once every three years must pass a knowledge test in the relevant commission of the enterprise.

Boiler servicing is allowed to persons not younger than 18 years old who have passed a medical examination, have been trained according to the relevant program and have a certificate issued by the qualification commission of the enterprise where the training was conducted. Re-testing the knowledge of operators is carried out at least once a year, as well as when switching to maintenance of boilers of other types.

In the boiler room, a watch log should be kept, in which the shift supervisor signs for the acceptance and delivery of the shift, notes the start and stop times of the boilers, and the observed malfunctions. It is forbidden to leave the boiler unattended after the combustion has stopped until the pressure in it drops to atmospheric pressure.

During operation:

check water-indicating devices by blowing at least once per shift (usually 2 ... 3 times);

· control the serviceability of the operation of the safety valves at each start-up of the boiler, but in any case at least once per shift (safety valves of steam boilers with overpressure up to 1.3 MPa should operate when the operating pressure increases by 0.03 MPa);

Check and seal pressure gauges at least once a year.

The dial of the pressure gauge should have a red line corresponding to the maximum working pressure. It is forbidden to put such a line on the pressure gauge glass, as it may turn and the mark of the maximum allowed pressure will shift. When the pressure is released, the pointer should stop at the zero division of the scale. During operation, it should be within the middle third of the scale. At the same time, pressure gauges are installed not lower than accuracy class 2.5. The diameter of pressure gauges must be at least 100 mm at a height of up to 2 m and at least 150 mm -2 ... 5 m from the floor level. These devices are installed on the boiler vertically or with a forward inclination of up to 30 °.

It is not allowed to use pressure gauges if there is no seal or brand, the check period is overdue, the pressure gauge needle does not return to the zero scale mark when it is turned off, the glass is broken or there are other damages that may affect the correctness of the pressure gauge readings.

The boiler is immediately stopped:

upon termination of the operation of water-indicating instruments or safety valves in an amount greater than 50% of their total number;

if the water temperature or steam pressure has risen above the permitted by more than 10% and continues to grow, despite the measures taken (stopping the fuel supply, reducing draft or blast, increasing water replenishment, etc.);

· when the water level drops below the minimum mark on the gauge glass (in this case, make-up is prohibited in order to avoid an explosion) or its level drops rapidly, despite increased make-up;

· if cracks, bulges, cavities or gaps in welds are found in the main elements of the boiler (drum, header, firebox);

in case of gas explosion in gas ducts, combustion of fuel particles and soot in them;

if there was a power outage (for boilers with artificial draft);

in case of damage to the lining, threatening collapse, or red-hot elements of the boiler;

in case of detection of malfunctions that are dangerous for the boiler or maintenance personnel (in the event of knocks, vibration, noise in gas ducts, etc.);

in case of fire.

During the technical examination, the boilers are subjected to:

· internal inspection and hydraulic testing by test pressure during commissioning, after rearrangement or repair of the main elements;

internal inspection and hydraulic testing by operating pressure at least once a year, as well as after cleaning or minor repairs that did not affect the main structures;

· hydraulic testing by test pressure at least once every six years.

The test pressure must be at least 150% of the working pressure, but at the same time be equal to or more than 0.2 MPa. The boiler is maintained at a certain pressure value, usually for 10 ... 15 minutes (but not less than 5 minutes). If signs of leakage, rupture, "tears", sweating of welded joints or base metal, residual deformations are not found, then the boiler is recognized as serviceable. The examination is carried out by a commission consisting of the head of the production unit, a labor protection specialist and a person responsible for the operation of pressure vessels, or the head of the boiler house. The test results are recorded in the boiler passport indicating the date of the next test. Inspection of high-pressure boilers is carried out by an inspector of Gosgortekhnadzor in the presence of a person responsible for safe operation.

General provisions for the operation of boiler plants

The operation of steam and hot water boilers is carried out in accordance with the Rules for the Design and Safe Operation of Steam and Hot Water Boilers of Rostekhnadzor, the Rules for the Technical Operation of Power Plants and Networks (PTE), the Safety Rules for Gas Distribution and Gas Consumption Systems, instructions from manufacturers, local instructions: official, defining rights and responsibilities of staff; technical, which determine the conditions for the safe and economical operation of boilers and their individual elements in different periods of operation; on safety measures, which indicate the necessary measures to ensure the conditions for the safe work of personnel; emergency, which indicate measures to prevent the development and elimination of accidents; other regulatory and technical documents.

The rules for the design and safe operation of steam and hot water boilers apply to steam boiler units with a pressure of more than 0.07 MPa and hot water boiler units with a water temperature of at least 115 ° C. They define the requirements for the design, manufacture, repair and material of the specified equipment, indicate the range and quantity of fittings, measuring equipment, protection, automation devices, and also provide requirements for service equipment.

The boiler plant is a very dangerous production facility and therefore it is subject to the requirements of Federal Laws No. 116-FZ of July 21, 1997 (as amended by Federal Laws No. 122-FZ of August 7, 2000, No. 15-FZ of January 10, 2003, No. 122 of August 22, 2004) -FZ, 09.05.2005 No. 45-FZ, 18.12.2006 No. 232-FZ) "On industrial safety of production facilities" and dated 27.12.2002 No. 184-FZ "On technical regulation".

The Federal Law "On industrial safety of production facilities" defines the legal and economic foundations for ensuring the safe operation of hazardous arbitrariness; critical facilities and is aimed at preventing accidents at hazardous production facilities and ensuring the readiness of the organization operating hazardous production facilities to localize and eliminate the consequences of these possible accidents.

The Federal Law "On Technical Regulation" regulates relations arising from the development, adoption, application and implementation of mandatory requirements for products, production processes, operation, storage, transportation, sale and disposal. The law sets out the requirements for the content and application of technical regulations, the principles of standardization, the rules for the development and approval of standards, the organization of mandatory certification, the accreditation of certification bodies and the implementation of state control over compliance with technical regulations.

In accordance with the Federal Law "On industrial safety of production facilities", the basis of industrial safety is the licensing of activities (design, construction, operation, reconstruction, manufacture, installation, adjustment, repair, etc.) in the field of industrial safety; certification of technical devices used at a hazardous production facility; examination of industrial safety of technical devices; industrial safety requirements for the operation of a hazardous production facility (ensuring the staffing of employees of a hazardous production facility that meets the relevant qualification requirements; the presence of regulatory legal acts and regulatory technical documents at the hazardous production facility establishing the rules for conducting work at a hazardous production facility; organizing and exercising production control over compliance with industrial safety requirements, ensuring the availability and operation of the necessary instruments and systems for monitoring production processes, ensuring the examination of industrial safety of buildings, diagnostics and testing of technical devices in a timely manner, etc.).

The operation of steam and hot water boilers and boiler equipment consists in servicing boiler units, auxiliary equipment (smoke exhausters, fans, pumps, flues and chimneys).

In accordance with the PTE, the boiler room personnel must ensure the reliable operation of all main and auxiliary equipment, the possibility of achieving the rated output, steam and water parameters. The PTE sets out the basic requirements for the operation of boilers and auxiliary equipment (kindling, shutdowns, basic operating modes, conditions for the immediate shutdown of equipment).

The instructions provide technical characteristics and a detailed description of the equipment, the procedure and terms of maintenance, control, repairs; limit values ​​and deviations of parameters, recommendations for safe maintenance and rules for the safe work of maintenance personnel are given.

The complexity of the equipment makes high demands on the maintenance personnel of the boiler room. All newly hired workers who do not have a production specialty or change it are required to undergo vocational training in the scope of the qualification requirements in accordance with the Unified Tariff and Qualification Handbook (ETKS). The training of workers is carried out, as a rule, in training complexes and other institutions of initial vocational maintenance, control, and repairs; limiting values ​​of nic formation are given.

Persons who have received theoretical and industrial training undergo internships and knowledge testing at the enterprises where they will work. During the internship, the equipment of the boiler room, production instructions and operating schemes, safety and fire safety rules, Rostekhnadzor rules, job descriptions are studied. After that, the trainee may be allowed to perform duplicate duties at the workplace under the supervision and guidance of an experienced employee for a period of duplication of at least 10 work shifts. Particular attention is paid to the problems of professional suitability, physiological, psychological preparedness of the employee. People who have reached the age of 18 and have a positive medical report are hired. Thereafter, a medical examination is carried out once every two years.

Maintenance personnel need to constantly deepen and improve their knowledge and improve their skills. To do this, work should be organized to improve the skills of staff. For operators, an annual test of knowledge of safe labor methods and work performance methods is carried out, and once every two years - according to the PTE, Fire Safety Rules, production and job descriptions.

1.2. Preparation of the boiler unit and auxiliary equipment for start-up

Putting the boiler into operation is a complex process that is carried out after the installation of the boiler during its commissioning, as well as after reconstruction, repair, scheduled and unscheduled shutdowns of the boiler. Carrying out the start-up process is associated with the precise execution strictly according to the instructions of a large number of various actions, while observing the strict distribution of duties of the personnel, coordination of their actions in conditions of high efficiency and technical discipline. The most qualified personnel are allowed to start the boiler. The shift manager or senior operator supervises the boiler start-up operations.

The start-up of the boiler is associated with its kindling, which is preceded by a detailed inspection of the unit in order to check its serviceability and readiness for operation. The furnace, radiant and convective heating surfaces, superheater, water economizer, air heater, lining, explosion valves, lining, collectors, pipelines and fittings, gas and fuel oil pipelines, burners, suspensions, supports, protective and spacer elements are subject to inspection. When examining the heating surfaces in the boiler, attention is drawn to the presence of cracks, fistulas, bulges, traces of corrosion and contamination of pipes. All foreign objects and debris from the furnace and gas ducts must be removed, and the manholes of the gas-air path must be tightly closed.

The removal of plugs on the gas pipeline, steam, water, purge and drainage lines is checked; serviceability of drives and ease of movement of gate valves, axial guide vanes of smoke exhausters and fans; their controllability from the main shield; grounding of electric motors; the presence of oil in the bearings; water supply for their cooling; the presence of enclosing covers on rotating mechanisms and the freedom of their rotation. After inspecting the auxiliary equipment, their mechanisms should be turned on idle, while there should be no knocking, vibration, excessive heating of bearings, electric motors.

The serviceability of all water and steam fittings of the boiler, water-indicating devices, and the serviceability of the operation of remote drives are being checked. The operation of ignition and protective devices, the serviceability of safety valves, as well as the serviceability and readiness for switching on instrumentation, automatic regulators, interlocks, protections, operational communications, lighting, and fire extinguishing equipment are checked.

The malfunctions revealed during the check must be eliminated before the boiler is started. In the event of a malfunction of the protections that act to stop the boiler, its start-up is prohibited.

After checking the equipment, preparations begin for the launch of the gas-air and water-steam paths, kindling, steam and gas-oil facilities, blowing the boiler, etc. Shut-off common and individual dampers (on air ducts, burners, nozzles) open, guide vanes of fans, smoke exhausters, regulating air dampers are closed .

Before filling the boiler with water, the closing of the main steam shut-off valve, all drain and purge valves is checked; air vents of the drum and water economizer open; water-indicating glasses, water valves and a pair of lowered level indicators are included in the working position; the pressure gauge on the drum must be in working order; shut-off devices are opened on the supply pipelines in front of the water economizer; adjusting devices are checked - they must be tightly closed.

For boilers with a cast-iron economizer, a direct-running damper opens to allow the SG to pass by the economizer. In the absence of a bypass gas duct, water must be continuously pumped through the economizer and sent through the slip line to the deaerator. For boilers with a steel economizer, the valve in the recirculation line opens.

To supply water to the boiler, it is necessary to open the supply valve and fill the water economizer with water; when water appears, close the air vent on the economizer outlet manifold. The boiler is filled with water up to the ignition level.

In order to avoid violation of the density of rolling joints and thermal deformations from uneven heating, it is not allowed to fill the boiler with water with a temperature above 90 °C in summer and 50...60 °C in winter.

After filling the boiler with water, it is necessary to verify the tightness of the fittings by probing the drain pipes. If within 0.5 hours after filling the boiler with water with the feed valve closed, there is no decrease or increase in the water level in the boiler drum, you can continue the operations to prepare the boiler for start-up. If there is a device for steam heating of the lower drum, the steam supply from the operating boilers is opened and the water in the boiler is heated to a temperature of 90 ... 100 °C.

Before firing up a gas-fired boiler from a cold state, a pre-start check of the tightness of the shut-off devices in front of the burners and safety shut-off valves (control pressure testing) is carried out. The order and methods of the pre-launch check are established by the production instruction. On automatic and block gas burners, which are currently equipped with many boiler units, devices are installed for automatic tightness testing.

When preparing to fire up a gas-fired boiler, the gas pipeline to the shut-off devices on the burners must be purged with gas through the purge candles. To do this, it is necessary to open the slam-shut valve on the passage and slightly open the locking device on the descent, and within the time specified in the production instructions, blow the gas pipeline through the purge candle.

The end of the purge is determined using a gas analyzer by the oxygen content in the gas pipeline. In a purged gas pipeline, the oxygen content should not exceed 1%.

Before turning on the gas burners or oil-fired pilot burners, it is necessary to ventilate the furnace and gas ducts, first using natural draft, and then forced. With natural ventilation, the gas path dampers and dampers that regulate the air supply to the burners are fully opened. For forced ventilation, the smoke exhauster is put into operation, and then the fan, and for 10 ... 15 minutes, when they work together, they ventilate the smoke path of the boiler unit.

6.3. Starting the steam boiler unit

The steam boiler unit can be put into operation only by written order of the head of the boiler house. The sequence of operations during the start-up of boilers is determined by their thermal state after a corresponding downtime (in repair or in reserve). Depending on the degree of cooling of the boiler unit after the previous shutdown, starts are distinguished from cold, not cooled down, hot states and from a hot reserve. Each type of start-up is characterized by a certain technology. Starting from a cold state is carried out 3–4 days or more after a shutdown with complete cooling of the boiler unit and the absence of pressure in it. In this case, the start-up, starting from the lowest level of temperatures and pressures in the boiler unit, has the longest duration.

Reliability ignition of gas burners with forced air supply depends mainly on the density of the dampers that regulate the air supply to the burner. The ignition of each of the installed burners must be carried out from an individual igniter installed in the pilot hole. The stability of the igniter flame depends on the rarefaction in the furnace and the density of the damper that regulates the air supply to the burner. Therefore, before introducing the igniter into the furnace, it is necessary to make sure that the damper that regulates the air supply is closed and adjust the vacuum in the upper part of the furnace in accordance with the recommended for kindling by value. The igniter flame should be located on the side and in the immediate vicinity of the loophole or above it.

With stable operation of the igniter, the gas supply to the burner is carried out smoothly so that the gas pressure does not exceed 10 ... 15% of the pump pressure. Ignition of the gas coming out of the burner must take place immediately. If the gas leaving the burner does not immediately ignite, it is necessary to quickly stop its supply to the burner and igniter and ventilate it for 10-15 minutes to remove gas from the furnace. Re-ignition of the burner is allowed only after the elimination of the reasons preventing its normal start-up.

After ignition of the gas leaving the burner, the air supply is regulated so that the torch luminosity decreases, but it does not come off the burner. To improve the performance of the burner, first increase the gas pressure by 10 ... 15%, and then, respectively, the air pressure, after which the set vacuum value in the furnace is restored. With stable operation of the first burner, the remaining burners are sequentially ignited.

For ignition of oil-fired boilers after the ventilation of the furnace and gas ducts is completed (during the operation of the smoke exhauster and fans), the fuel oil nozzles are ignited in turn. So, for example, before igniting a nozzle with steam spraying of fuel oil, it is necessary to close the hatches and peepers completely, stop the air supply to the nozzle, adjust the vacuum in the upper part of the furnace, setting it to 10 ... 20 Pa, and make sure that the required fuel oil heating temperature has been established . Then you should insert a fuel oil kindling torch into the ignition hole. With a steady burning of the torch, a little air and steam are first supplied to the nozzle, and then fuel oil by gradually opening the control valve. When fuel oil ignites, it is necessary to adjust its combustion by changing the supply of fuel oil, steam and air. With stable combustion of fuel oil, the kindling torch is removed.

When starting the boiler, special attention is paid to maintaining the specified temperature of the metal of thick-walled parts (drum, collectors, steam pipelines, fittings) and the rate of their heating. The choice of heating technology depends on their initial state. To ensure uniform temperatures around the perimeter of the drum, especially its upper and lower parts, steam heating is used, for which appropriate steam lines are installed in the drum in the lower part.

When kindling the boiler, the water level in the drum is monitored by water-indicating columns on the drum and by lowered level indicators. On boilers with a pressure of up to 4 MPa, water-indicating columns are purged at a pressure of 0.1 MPa and again before the boiler is connected to a common steam pipeline. As the pressure rises, the water level in the drum rises. If the water level exceeds the permissible limit, it is necessary to drain part of the water from the boiler through the periodic blowdown line. When the water level drops due to the purging of the boiler unit and the superheater, it is necessary to replenish the boiler with water.

In the process of kindling the boiler from a cold state, it is necessary to monitor the thermal expansion of the screens, drum, collectors and pipelines along the benchmarks installed on them. If there is a delay in the heating of any screen, it should be blown through the drains of the lower collectors for 25 s.

When the steam pressure in the boiler unit rises above atmospheric, steam will begin to escape from the air vents, after which it is necessary to close the air vent valves and blow out the boiler pressure gauges. The connecting steam pipelines from the boiler to the main steam pipeline are warmed up simultaneously with the boiler kindling. During the heating of the steam pipeline, hydraulic shocks should not be allowed, and if they occur, it is necessary to suspend heating, find out the cause of hydraulic shocks and eliminate it.

The boiler unit is connected to a common steam pipeline at a temperature close to the calculated one, and when it reaches a pressure of 0.05 ... 0.10 MPa less than the pressure in the common steam pipeline. The locking devices on the steam line open very slowly to avoid water hammer. If, however, during the inclusion of the boiler unit in the common steam pipeline, shocks and hydraulic shocks occur, the switching on procedure is immediately suspended, the combustion in the furnace is reduced by opening the valve, the superheater is blown through and the drainage of the steam pipeline is increased.

6.4. Maintenance of the boiler plant during operation

Maintenance of a boiler installation is a process that includes monitoring the operation of the installation, managing its organs and auxiliary mechanisms in order to regulate the working process in the boiler.

To control the operation, the boiler is equipped with instrumentation located on the unit itself and on the heat shield. To regulate the operation, the boiler unit has controls with drives directly at the place of their installation or with remote drives. So, remote control by means of electric drives is carried out from the boiler control panel.

Critical Maintenance Tasks steam boiler units are maintaining the specified steam pressure and productivity (load) of the boiler in accordance with the instructions of the regime map, an approximate example of which is given in Table. 6.1, as well as maintaining the set temperature of superheated steam, uniform supply of the boiler unit with water, maintaining a normal water level in the drum, ensuring the normal purity of saturated steam, and taking care of all equipment of the boiler unit.

Table 6.1

Approximate regime map of the operation of the steam boiler unit DKVr-10-13

"Approve" Chief engineer of the enterprise

	Parameter	measurements	Steam capacity, t/h
	Steam pressure in the boiler drum
	Number of burners in operation
	Gas pressure in front of the burners
	Primary air pressure before burners
	Secondary air pressure before burners
	Vacuum in the boiler furnace
	Feed water temperature
	Feed water pressure
	Excess air coefficient behind the boiler unit
	Flue gas temperature
	Heat loss with flue gases
	Heat loss from chemical incomplete combustion
	Heat loss through external fences
	Boiler unit gross efficiency
	Heat consumption for own needs
	Boiler unit net efficiency
	Fuel consumption

Note. Type of burners - gas-oil type GMG-2.5.

The regime map was compiled

Position of the worker of the adjustment organization

At work hot water boiler unit it is necessary to ensure the temperature schedule for the release of thermal energy (Table 6.2), which is guided by the operator in his work when setting the operating parameters of the installation.

Maintenance of steam pressure and productivity of the boiler unit. Depending on the mode of operation of the boiler house, the main equipment can work more or less for a long time at a constant (basic) mode. Violation of the stationary regime can be caused by a change in heat release in the furnace and water supply, as well as by transferring the load from one boiler unit to another.

The main task of the personnel servicing the boiler is to maintain the most economical modes of fuel combustion, which mainly determines the thermal efficiency of the boiler. Thus, the maximum efficiency of a boiler unit operating on gaseous and liquid fuels is achieved with minimal total heat losses with flue gases and from chemical incompleteness of combustion. Heat losses with exhaust gases depend on the coefficient of excess air in the furnace, the level of air suction through the boiler gas ducts and the temperature of the flue gases, and heat losses from chemical incompleteness of combustion depend on the coefficient of excess air at at the furnace outlet and on the distribution of air and gas over the burners .

Thus, when servicing the boiler unit, the operator must monitor the temperature and excess air coefficient aug in the flue gases at the outlet of the boiler unit (according to the content of O2 or CO2), gas and air pressure in front of the burners. To obtain the greatest efficiency of the boiler unit, it is necessary to maintain the combustion mode in accordance with the regime map, which is compiled according to the results of special tests of the boiler, when the highest efficiency is determined for each of the loads under study.

Maintaining normal steam pressure in the boiler is carried out by regulating the operation of the furnace.

Table 6.2 Approximate temperature schedule for heat supply

An increase in steam pressure above the norm indicates an excessive steam capacity of the boiler unit, and in order to reduce it, it is necessary to reduce the supply of gas and air to the furnace. On the contrary, a decrease in steam pressure indicates an insufficient steam capacity of the boiler unit, and in order to increase it, it is necessary to increase the supply of gas and air. Steam pressure deviations are caused by changes in the steam flow at the consumer, the amount of gas supplied to the furnace and the temperature of the feed water. Therefore, the regulation of steam pressure in the boiler unit is directly related to the regulation of steam production and is carried out by changing the flow rate of fuel and air supplied to the furnace and establishing the proper draft.

During the operation of the boiler unit, it is necessary to visually monitor the combustion process in the furnace through peepers. According to the results of the observation of the torch, certain decisions are made in order to achieve a good and correct combustion. Signs of good combustion: the torch evenly fills the combustion chamber; a certain color of the torch and its length (depending on the type of burners); combustion must end in the combustion chamber, the end of the torch must be clean.

Maintain normal steam temperature. When the boiler is operating with a time-constant load, the temperature deviations of the superheated steam from the average value are small and its temperature control is practically not required.

The need to control the temperature of the superheated steam arises when the optimal combustion mode is established or the boiler load changes. An increase in the temperature of the superheated steam may occur due to an increase in the load of the boiler; excess air in the furnace; lowering the temperature of the feed water; reducing the flow of cooling water through the desuperheater. If the capacity of the desuperheater is already completely exhausted, and the temperature of the superheated steam is above the norm, then it is necessary to reduce the excess air in the furnace to an acceptable limit; reduce the selection of saturated steam; reduce the load on the boiler.

Feeding the boiler unit with water. During the operation of the boiler unit, it is necessary to maintain its normal supply of water, i.e. ensure the material balance of water and steam. The supply of the boiler with water is regulated automatically or manually. With automatic regulation, a uniform supply of water to the boiler is ensured in accordance with the steam flow rate and a predetermined water level in the drum is maintained.

The operator controls the correct operation of the regulators for feeding the boiler with water using instruments that indicate the level of water in the drum (water gauges, lowered level indicators). The water in the water-indicating columns must fluctuate slightly constantly around the normal level (at the middle of the glass height). A perfectly calm water level in the columns can be a sign of clogging of the gauge glass tubes. The level should not be allowed to approach the limit (upper and lower) positions in order to avoid missing the level from the visible zone of the gauge glass.

Water regime of the boiler unit. The operation of the boiler unit without damage to its elements due to deposits of scale, sludge and an increase in the alkalinity of boiler water to dangerous limits is ensured by the water regime. Maintaining the specified salt content of the boiler water is achieved by continuous blowing. To remove sludge from low points, the unit is periodically blown down (boiler water drain).

With continuous blowing, a significant amount of heat is lost. At a steam pressure of 1 ... 1.3 MPa, each 1% of blowdown, the heat of which is not used, increases fuel consumption by about 0.3%. The use of continuous blowdown heat is possible in specially installed separators for obtaining secondary steam. Needle valves are used to control the amount of continuous blowdown. From the common collector of continuous blowdown, water enters the separator, where, as a result of pressure reduction, part of it boils. The resulting steam is sent to the deaerator, and the water is sent to heat the raw water supplied to the chemical water treatment site.

The timing and duration of periodic purges are set by the production instructions. Before such a purge, make sure that the feed pumps are working properly, that there is water in the feed tanks, and feed the boiler to the upper level on the water indicator glass. The purge is carried out in the following order: first, the second in the course, and then the first valve on the purge pipe is opened, and after the purge pipeline has warmed up, the actual purge is carried out, during which the water level in the boiler drum is continuously monitored using a water gauge glass. In case of hydraulic shocks in the pipeline, the purge valve is immediately closed until the knocking in the pipeline stops, then the valve is gradually opened again. At the end of the purge, the valves are closed - first the first along the water course, and then the second.

Maintenance of boiler equipment. During the operation of the boiler unit, it is necessary to monitor the condition of the shut-off and control valves, tighten the glands in case of their weakening and the passage of water or steam. If the gaskets are faulty and the fittings are leaking, it is repaired. The serviceability of the safety valves is checked every shift by carefully opening them (“undermining”).

The serviceability of the pressure gauge is checked every shift by setting its pointer to “zero” (“setting to zero”) by slowly closing the three-way valve of the pressure gauge and connecting it to the atmosphere. After making sure that the pressure gauge needle has gone to “zero”, carefully return the three-way valve to its working position, trying not to let water out of the siphon tube in order to avoid overheating of the spring and damage to the pressure gauge. To check the pressure gauge, periodically (at least once every 6 months) its readings are compared with the readings of the control pressure gauge.

The serviceability of the operation of the water-indicating columns on the drum is checked by blowing them in the following order: the purge valve is opened, the water gauge glass, water and steam pipes are simultaneously blown; the water tap is closed and the steam pipe and gauge glass are blown; the water tap opens and the steam tap closes - the water tube and water gauge glass are blown; the steam valve is opened and the purge valve is closed, i.e. the water level in the gauge glass is set to the operating position and the water level in the drum is checked.

All purge actions should be carried out slowly, with eye protection goggles and always with gloves on.

During operation of the boiler, it is necessary to carefully monitor the density of gas fittings and gas pipelines. Periodically, at least once per shift, check for gas leakage by the methane content in the room; if there is more than 1% methane in the air, identify leaks and take measures to eliminate them.

It is necessary to monitor the condition of the boiler lining, the density of manholes and hatches, inspecting them during the bypass, and also, according to the readings of the oxygen meter, control the possibility of suction along the tract. You should also, when opening the hatches, listen to the sounds in the furnace and gas ducts to identify possible damage to the pipes, which are accompanied by increased noise.

Periodically it is necessary to check the operation of smoke exhausters, fans, boiler pumps. The temperature of the stators of electric motors and bearings is checked by touch; the noise of rotating machines should be monotonous, without sharp shocks indicating rubbing, and without vibrations, which are also checked by touch at the base of the bearings and base plates; the nuts of the foundation bolts of electric motors, pumps, smoke exhausters and fans must be tightly tightened.

Every 2 hours, it is necessary to record the readings of instrumentation in a shift log.

Features of maintenance of hot water boilers. When the boiler is in operation, the temperature of the water entering the boiler must be above the dew point temperature, i.e. at least 60 °C. This is achieved by mixing the water leaving the boiler with the return network water, i.e. by recirculating hot water, which is provided for by the scheme for connecting the boiler to the network.

Hot water from the outlet header of the boiler is supplied by a recirculation pump to the inlet header and, mixing with the return network water, heats it up. The specified temperature of the water and the heating system is achieved by directing the return flow into it along the jumper. When regulating the flow of water supplied for recirculation, it is necessary to ensure that the flow of water through the boiler is always higher than the minimum allowable for boiling conditions.

6.5. Planned shutdown of the boiler unit

The planned shutdown of the boiler unit is carried out according to the written order of the head of the boiler house. Shutdown technology, volume and sequence of operations are determined by the type of boiler unit, the fuel used and the type of shutdown. According to the final thermal state of the boiler unit, two types of shutdowns are distinguished - without cooling down the equipment and with its cooling down. Shutdown without cooldown It is carried out when the boiler is taken into the hot reserve and for small work, as a rule, outside the boiler. Cooldown shutdown is carried out in order to carry out repair work of increased duration, and the completeness of cooling depends on the type of proposed repair.

At boiler in hot standby it is necessary to take measures to maintain the pressure in it for a longer time and to maximize the accumulation of heat in the equipment. To do this, after ventilation of the furnace and gas ducts, the gas-air path is sealed by closing the dampers and guide vanes of smoke exhausters and draft fans. It is forbidden to keep the boiler unit in a hot standby without disconnecting it from the steam pipeline. To maintain the pressure in the boiler, periodic heating is allowed. When the boiler is in the hot reserve, its duty personnel must be at their workplaces.

At boiler stop it is necessary to reduce the supply of fuel and blast, maintaining a vacuum in the furnace; at the same time, it is necessary to monitor the water level in the drum using the water-indicating columns. To reduce the supply of gaseous or liquid fuel, the air pressure is gradually reduced, and then gas or fuel oil in front of the burners, maintaining the required vacuum at the outlet of the furnace. When the limiting minimum values ​​of fuel pressure are reached, the burners are extinguished in turn.

After the fuel supply to the boiler is stopped, the main steam valve is closed, i.e. the boiler is disconnected from the steam line, and the superheater purge is opened. For a certain time, in accordance with the production instructions, the furnace and gas ducts are ventilated, after which the fans are stopped, and then the smoke exhauster, the smoke gates and blades of the axial guide vanes of the smoke exhausters and fans are closed.

Fill the boiler drum with water up to the upper mark in the water column and maintain this level until the water is drained. Descent of water from the stopped drum boiler is allowed after the pressure in it is reduced to atmospheric. After stopping the boiler, it is not allowed to open hatches and manholes until it cools down.

In winter, in a boiler filled with water, in order to avoid defrosting, careful monitoring of the density of the gas-air path, heating surfaces and their purge and drainage lines, heaters, impulse lines and sensors of instrumentation and automation should be established. The temperature inside the furnace and gas ducts must be above 0 ° C, for which the furnace and gas ducts are periodically heated by turning on oil burners or supplying hot air from neighboring boilers, monitoring the density of gates, manholes and hatches. On hot water boilers, the circulation of water through the boiler must be ensured.

6.6. Emergency stop of the boiler unit

During the operation of the boiler unit, damage can occur in it, malfunctions can occur that create dangerous situations, fraught with failure of the equipment or the boiler unit as a whole, destruction with large material losses and human casualties. Elimination of detected violations and defects is possible, taking into account damage, without stopping the boiler unit or with its obligatory immediate stop.

The basis for the correct conduct of emergency response operations is the preservation of equipment and the prevention of major damage to it (due to incorrect actions of personnel or delay in the elimination of an accident), as well as the exclusion of the possibility of injury to personnel. Any equipment showing defects that pose a threat to the life of personnel must be immediately stopped. If an accident occurred at the junction of two shifts, the operating personnel of the receiving shift are involved in the liquidation of the accident and carry out the orders of the personnel of the shift liquidating the accident. Repair personnel and personnel of other workshops may be involved in the liquidation of the accident.

The technology of emergency shutdown of the boiler unit is determined by the type of accident and the moment of establishing its causes. Initially, until the cause of the accident is established, but not more than within 10 minutes, the shutdown is carried out with the minimum possible cooldown of the equipment (with maintaining the operating pressure and sealing the gas-air path). If the cause of the accident is identified and eliminated within 10 minutes, then the boiler unit is then started from the hot standby state. If during this period the cause of the accident is not identified, then, as in the case of equipment breakdown, the boiler unit is stopped.

Mandatory immediate shutdown of the boiler unit personnel spends with an unacceptable increase or decrease in the water level in the drum, as well as failure of indicating devices (caused by malfunctions of power regulators, damage to control valves, thermal control devices, protection, automation, power failure, etc.); failures of all feed water meters; shutdowns of all feed pumps; unacceptable increase in pressure in the steam-water path and failure of at least one safety valve; rupture of pipes of the steam-water path or the appearance of cracks, swellings, gaps in the welds of the main elements of the boiler, in steam pipelines, fittings.

In addition, the boilers must be stopped when combustion stops and an unacceptable decrease or increase in gas pressure and a decrease in fuel oil pressure behind the control valve; in case of an unacceptable decrease in air flow in front of the burners and vacuum in the boiler furnace, caused by the shutdown of all fans and smoke exhausters, respectively; explosions in the furnace, in gas ducts; warming up the load-bearing beams of the frame and collapses of the lining; fire that threatens personnel, equipment, power supply of the remote control system of the shutdown valves and the corresponding protection systems; loss of voltage in the lines of remote and automatic control and instrumentation.

Hot water boilers must also be stopped when the water flow and pressure in front of the boiler drop below the minimum allowable value.

6.7. Malfunctions and accidents in the boiler room. Damage to the elements of the boiler unit

Accidents and malfunctions of boiler equipment cause downtime of the unit, which leads to undersupply of electricity and thermal energy (steam and hot water) to consumers. All cases of emergencies, serious malfunctions in the operation of the boiler and its equipment must be dealt with, identifying the causes and considering the actions of the personnel. In order to prevent possible accidents, in boiler rooms and to develop confident actions of personnel in emergency situations, emergency response training is regularly held for maintenance personnel, during which various types of accidents are conditionally created and the work of personnel is controlled. After such training, an analysis of the work carried out is carried out and an assessment is made of the efficiency and correctness of the actions of the shift personnel.

Accidents due to overfeeding and leakage of water in the boiler. With a significant overfeeding of the drum, boiler water, together with steam, is thrown into the superheater, from there it (if it does not have time to evaporate) can be carried out into the steam pipeline. Moving along with steam at very high speeds, water causes water hammer, which is sometimes so strong that it can cause damage to steam lines.

With a deep leakage of water in the boiler below the permissible level, the metal of the boiler and screen pipes and parts of the drums heated by hot gases overheats, as a result of which it loses its strength, deforms, and sometimes breaks, and the boiler drum explodes. An explosion is usually accompanied by great destruction with severe consequences. It should be borne in mind that clogging of the connecting pipes of the drum with water-indicating columns causes a distortion of the water level in the water gauge glasses, it does not correspond to the actual position of the water level in the boiler drum. At the same time, clogging of the steam valve or connecting pipe from the drum to this valve leads to a rapid increase in the water level in the gauge glass, and clogging of the connecting water pipe or water valve is accompanied by a slower increase in level due to the gradual condensation of steam in the water indicator column.

In the event of a significant decrease in the water level in the boiler, i.e. “leaving” the level below the lowest allowed at normal pressure of water in the supply line and steam, it is necessary to purge the water-indicating columns and make sure that their readings are correct; check the operation of the power regulator and, if the defect is difficult to eliminate, switch to manual regulation, increase the power supply to the boiler; check the serviceability of the feed pumps and, in case of damage, turn on the backup ones; close the continuous blowdown valve and check the tightness of all boiler blowdown valves; check visually and aurally for leaks in the seams, pipes, hatches (by noise). If the water level continues to decrease and is already 25 mm above the lower edge of the gauge glass, then an emergency stop of the boiler unit must be carried out.

When refeeding the boiler, when the water level has risen to the highest permissible level at normal pressure in the boiler and in the feed line, it is necessary to blow out the water-indicating columns and make sure that their readings are correct; check the operation of the automatic power regulator and, if it is faulty, switch to manual regulation, reduce the power supply to the boiler. If, despite the measures taken, the water level continues to rise, further reduce the boiler feed and increase the continuous blowdown; carefully open the intermittent purge, but as soon as the water level begins to decrease, stop the purge.

If the water level "left" beyond the upper edge of the water gauge glass, it is necessary to carry out an emergency shutdown of the boiler unit.

Damage to boiler and screen pipes, feed and steam pipelines. Operating experience of steam boilers shows that damage to boiler and screen pipes most often occurs due to violations of the water regime caused by unsatisfactory operation of chemical water treatment, failure of the correct phosphating regime, etc. Excessive pressure, violation of temperature conditions can also be the causes of pipe ruptures. their work, corrosion or wear of pipes, poor quality of their manufacture and installation, inconsistency of the materials used, etc.

Sometimes, ring cracks are observed at the ends of boiler and screen pipes rolled into drums or collectors. The reason for such damage is the aggressiveness of boiler water and significant local additional stresses due to the impossibility of free thermal expansion of pipes or collectors due to their clamping at the points of passage through the lining, etc. Breaks in feed pipelines and main steam lines are observed much less frequently than breaks in pipes of heating surfaces, however, in terms of their destructive consequences, these damages are much more dangerous.

Given the increased risk of destructive actions during breaks, it is necessary to regularly check the condition of pipelines. The inspection is carried out in accordance with the Instructions for Monitoring and Controlling the Metal of Pipelines and Boilers. During these inspections, timely selection of damaged sections of pipelines and their subsequent replacement should be carried out. Mostly violations occur in the areas of bends, near the installation of reinforcement, in places of transitions from one thickness to another, in places of welded joints.

External signs of rupture of the boiler or screen rough are a rapid decrease in the water level in the boiler drums, despite their increased water supply: a significant discrepancy between the mass of feed water entering the boiler and the mass of steam generated by the boiler, which is determined by instrument readings; strong steam noise in the furnace or boiler flues; an increase in pressure in the furnace and knocking out gases from the loose lining and hatches of peepers.

Accidents and malfunctions of superheaters. The superheater is one of the least reliable elements of the boiler unit. The main type of accidents in it is the burnout of coils due to an excessive increase in the temperature of the pipe wall relative to the calculated value. An increase in the wall temperature of the coils is possible due to the uneven distribution of SG temperatures along the width of the gas duct, in which the superheater is located; uneven distribution of steam over the coils; drift of the superheater tubes with salts, which leads to a deterioration in the transfer of heat from the tube walls to the steam.

Often in the operation of the superheater there are malfunctions, expressed in an excessive increase in the temperature of the superheated steam. The reasons for this are the change in the grade and quality of the fuel; increase in boiler load; SG temperature increase in front of the superheater; decrease in feed water temperature.

Accidents and malfunctions of water economizers. Damage to steel coil economizers occurs mainly due to internal and external pipe corrosion. In addition, fistulas and ruptures are often observed in the places of welding of coils, indicating the unsatisfactory quality of welding work.

Internal corrosion of pipes usually occurs when the economizer is fed with non-deaerated water with a high content of oxygen or CO2. External corrosion of the economizer is more common when operating boilers on sour fuels. The causes of external corrosion are cooling and condensation on the walls of pipes of water vapor and sulfur dioxide present in the products of fuel combustion.

Damage to cast iron ribbed economizers occurs due to rupture of pipes and connecting joints, as well as damage to gaskets in flange connections. Such damage can be caused by water hammer in the economizer, improper gasket installation, overtightening of flanges, etc.

The first signs of an accident in water economizers (pipe rupture, leakage, etc.) are a sharp drop in the water level in the boiler drum during normal operation and noise in the economizer area.

Explosions and pops in the furnace and gas ducts. In gas-fired boilers, explosions in the furnace are caused by gas leaks, poor ventilation of the furnace and gas ducts before kindling and incomplete purging of gas pipelines to the burners (through candles), as well as re-ignition of gas after a flame break without sufficient re-ventilation of the furnace. These explosions usually have dire consequences.

When burning liquid fuel, fires and explosions in the furnace and gas ducts occur when it is sprayed with poor quality nozzles, accompanied by leakage of fuel oil into the loopholes and on the walls of the furnace with its accumulation in significant quantities, as well as increased soot removal into the gas ducts, which appears when air is poorly mixed with fuel oil and its incomplete combustion. In the latter case, accumulation occurs, and under certain conditions, ignition of deposits on the heating surfaces. At the same time, an increase in the temperature of gases, unusual for this surface, is noted, thrust decreases, the skin heats up, and sometimes a flame is knocked out.

If a fire is detected, immediately stop the fuel supply, localize the fire (by turning off the blowers and smoke exhausters and tightly closing the gas and air dampers) and turn on local fire extinguishing (supply of steam or water to the flue). Explosions and pops can cause destruction of the lining and elements of the boiler unit.

PB 10-574-03 Rules for the design and safe operation of steam and hot water boilers	establish requirements for the design, construction, materials, manufacture, installation, commissioning, repair and operation of steam boilers, autonomous superheaters and economizers with an operating pressure of more than 0.07 MPa (0.7 kgf / cm2), hot water boilers and autonomous economizers with water temperature above 115 °C.
PB 10-575-03 Rules for the design and safe operation of electric boilers and electric boilers	establish requirements for the design, manufacture, installation, repair and operation of electric boilers and apply to steam boilers with an operating pressure of more than 0.07 MPa (0.7 kgf / cm2) and hot water boilers with a water temperature above 115 ° C
GOST 20995-75 Stationary steam boilers with pressure up to 3.9 MPa. Feed water and steam quality indicators.	sets the values ​​of quality indicators for feed water and steam for stationary steam boilers in accordance with GOST 3619 with an absolute pressure of up to 3.9 MPa (40 kgf / cm2), including for boilers with a built-in boiler. The standard does not apply to steam boilers with an absolute pressure of 0.9 MPa (9 kgf / cm2) with a steam output of up to 0.7 t / h, operating on solid fuel, as well as electrode boilers.
RTM 108.030.114-77 Low and medium pressure steam boilers. Organization of the water-chemical regime	applies to stationary steam boilers with natural circulation according to GOST 3619-76, pressure up to 4 MPa (40 kgf/cm2) and steam capacity from 0.7 t/h
RTM 108.030.130-79 Stationary high-pressure steam boilers with natural circulation. Feed water and steam quality standards.	applies to the quality standards of feed water and steam stationary high-pressure boilers with natural circulation and staged evaporation at a pressure of 100 and 140 kgf / cm2
RD 24.031.120-91 Guidelines. Standards for the quality of network and make-up water for hot water boilers, organization of the water-chemical regime and chemical control.	These guidelines (MU) apply to stationary once-through hot water boilers with a heat output of 2.33 MW (2 Gcal / h) to 209 MW (180 Gcal / h) with a network water temperature at the outlet of the boiler not more than 200 C
RD 24.032.01-91 Guidelines. Feed water and steam quality standards, organization of water-chemical regime and chemical control of steam stationary waste-heat boilers and power-technological boilers.	establish quality standards for feed water and steam, requirements and recommendations for the organization of the water-chemical regime and chemical control for steam stationary waste heat boilers and power-technological boilers with a working steam pressure of up to 4 MPa (40 kgf / cm2), for operating boilers - up to 5 MPa (50 kgf / cm2), as well as for boilers with a working steam pressure of 11 MPa (110 kgf / cm2).
RD 34.37.506-88 Guidelines for water treatment and water-chemical regime of water-heating equipment and heating networks	apply to water-heating equipment with a capacity of more than 58 MW and heat networks included in the system of RAO "UES of Russia", and establish requirements for the choice of water treatment schemes, water chemistry, ensuring reliable operation of the main and auxiliary equipment of heat supply systems with the necessary composition of water and heat treatment equipment.

Back to Boiler water treatment

Extract from PB 10-574-03 RULES FOR THE DEVICE AND SAFE OPERATION OF STEAM AND WATER BOILERS

VIII. WATER CHEMICAL MODE OF BOILERS

8.1. General requirements
8.1.1. The water chemistry regime must ensure the operation of the boiler and the feed path without damage to their elements due to scale and sludge deposits, an increase in the relative alkalinity of the boiler water to dangerous limits, or as a result of metal corrosion.
All steam boilers with natural and multiple forced circulation with a steam output of 0.7 t/h or more, all once-through steam boilers, regardless of steam output, and all hot water boilers must be equipped with pre-boiler water treatment plants. It is also allowed to use other effective methods of water treatment that guarantee the fulfillment of the requirements of this article.
8.1.2. The choice of water treatment method for feeding boilers should be carried out by a specialized organization.
8.1.3. For boilers with a steam capacity of less than 0.7 t/h, the period between cleanings should be such that the thickness of deposits on the most heat-stressed areas of the heating surface of the boiler by the time it is stopped for cleaning does not exceed 0.5 mm.
8.1.4. Raw water make-up of boilers equipped with devices for pre-boiler water treatment is not allowed.
In cases where the project provides for the boiler to be fed with raw water in emergency situations, on the raw water lines connected to the lines of softened additional water or condensate, as well as to the feed tanks, two shut-off bodies and a control valve between them should be installed. During normal operation, the shut-off elements must be in the closed position and be sealed, and the control valve must be open.
Each case of feeding the boilers with raw water must be recorded in the water treatment log (water-chemical regime), indicating the duration of the feeding and the quality of the feed water during this period.
8.1.5. For steam and hot water boilers, commissioning organizations should develop instructions and regime charts for maintaining the water chemistry regime, taking into account these Rules, instructions from manufacturers, guidelines for developing instructions and regime charts for operating pre-boiler water treatment plants and for maintaining the water chemistry regime of steam boilers. and hot water boilers approved by Gosgortekhnadzor of Russia. Operating instructions for pre-boiler water treatment plants should be developed by the plant manufacturers.
8.1.6. Instructions and regime cards must be approved by the head of the organization that owns the boiler and be at the workplaces of the personnel.
8.2. Feed water quality requirements
8.2.1. Feed water quality indicators for natural and multiple forced circulation boilers with a steam capacity of 0.7 t/h or more should not exceed the values ​​specified:
a) for steam gas-tube boilers - in table. 3;

Table 3. Feedwater quality standards for gas-fired steam boilers

Indicator	For boilers operating
	liquid fuel	on other types of fuel
General hardness, mcg×eq/kg
	50 8
8 For boilers without economizers and boilers with cast iron economizers, the content of dissolved oxygen is allowed from 100 µg/kg.

b) for water-tube boilers with natural circulation (including boilers) and operating steam pressure up to 4 MPa (40 kgf/cm2) - in Table. 4;

Table 4. Feed water quality standards for water-tube boilers with natural circulation and operating steam pressure up to 4 MPa (40 kgf / cm2)

Indicator
	0,9 (9)	1,4 (14)	2,4 (24)	4 (40)
Font transparency, cm, not less than
General hardness, mcg×eq/kg	30 9	15 14	10 14	5 14
	Not standardized	300 14 Not standardized	100 14	50 14
	Not standardized			10 14 Not standardized
	50 14	30 14	20 14	20 14
pH value at 25 °C 11	8,5 - 10,5
9 The numerator indicates the values ​​for boilers operating on liquid fuel, the denominator - for other types of fuel. 10 For boilers without economizers and for boilers with cast iron economizers, the content of dissolved oxygen is allowed up to 100 µg/kg when burning any type of fuel. 11 In some cases, justified by a specialized organization, a decrease in the pH value to 7.0 may be allowed.

c) for water-tube boilers with natural circulation and a working steam pressure of 10 MPa (100 kgf / cm2) - in table. 5.

Table 5. Feed water quality standards for water-tube boilers with natural circulation and operating steam pressure of 10 MPa (100 kgf/cm2)

Indicator	For boilers operating
	liquid fuel	on other types of fuel
General hardness, mcg×eq/kg
pH value at 25 °C 12	9.1±0.1	9.1±0.1
Note . For gas-tube waste-heat boilers of vertical type with an operating steam pressure of more than 0.9 MPa (9 kgf / cm 2), as well as for soda recovery boilers, the feed water quality indicators are normalized according to the values ​​of the last column of Table. . In addition, for soda recovery boilers, the salt content of feed water is standardized, which should not exceed 50 mg/kg. 12 When replenishing the loss of steam and condensate with chemically purified water, it is allowed to increase the pH value to 10.5.

d) for power-technological boilers and waste heat boilers with a working steam pressure of up to 5 MPa (50 kgf / cm2) - in table. 6;
e) for power-technological boilers and waste heat boilers with a working steam pressure of 11 MPa (110 kgf / cm2) - in table. 7;

Table 6. Feed water quality standards for power-technological boilers and waste heat boilers with operating steam pressure up to 5 MPa (50 kgf/cm2)

Indicator	Working pressure, MPa (kgf / cm 2)
	0,9 (9)	1,4 (14)		4 (40) and 5 (50)
	Heating gas temperature (calculated), °C
	Up to 1200 inclusive	Up to 1200 inclusive	Over 1200	Up to 1200 inclusive	Over 1200
Font transparency, cm, not less than	30 13	40 18
General hardness, mcg×eq/kg	40 18	20 14
	Not standardized				50 15
a) for boilers with cast-iron economizer or without economizer, mcg/kg
b) for boilers with a steel economizer, mcg/kg
pH value at 25 °C	Not less than 8.5 16
13 The numerator indicates the value for water-tube boilers, the denominator - for gas-tube boilers. 14 For water-tube boilers with a working steam pressure of 1.8 MPa (18 kgf / cm 2), the hardness should not be more than 15 μg × equiv / kg. 15 It is allowed to increase the content of iron compounds up to 100 µg/kg, provided that reagent water treatment methods are used that reduce the intensity of scale formation by transferring iron compounds into solution, while the standards agreed with the Gosgortekhnadzor of Russia on the permissible amount of deposits on the inner surface of steam generating pipes must be observed. The conclusion about the possibility of the indicated increase in the content of iron compounds in the feed water is given by a specialized research organization. 16 The upper pH value is set to no more than 9.5 depending on the materials used in the equipment of the steam condensate path.

Table 7. Feed water quality standards for power-technological boilers, waste heat boilers with an operating steam pressure of 11 MPa (110 kgf / cm2)

Indicator	Meaning
General hardness, mcg×eq/kg
pH value at 25 °C	9.1 ± 0.1 17
Conditional salt content (in terms of NaCl), mcg/kg
Specific electrical conductivity at 25 °С, µS/cm 18
17 The upper pH value is set to no more than 9.5 depending on the materials used in the equipment of the steam condensate path. 18 Conditional salinity should be determined by a conductometric salt meter with preliminary degassing and concentration of the sample, and specific electrical conductivity - by a conductometer with preliminary hydrogen cationization of the sample; one of these indicators is controlled.

f) for high-pressure boilers of combined-cycle plants - in table. eight.

Table 8. Feed water quality standards for high-pressure boilers of combined cycle plants

Indicator	Working pressure, MPa (kgf / cm 2)
General hardness, mcg×eq/kg
	50 19	30 24	20 24
pH value at 25 °C	9.1±0.2	9.1±0.1	9.1±0.1
Conditional salt content (in terms of NaCl), mcg/kg 20	Not standardized
Specific electrical conductivity at 25 °C, µOhm/cm 25	Not standardized
19 It is allowed to exceed the norms for iron content by 50% when the steam generator is operating on natural gas. 20 Conditional salt content should be determined by a conductometric salt meter with preliminary degassing and concentration of the sample, and specific electrical conductivity - by a conductometer with preliminary hydrogen cationization of the sample; one of these indicators is controlled.

8.2.2. The quality indicators of feed water for water-tube boilers with natural circulation and a working steam pressure of 14 MPa (140 kgf / cm2) and for all power once-through boilers must meet the requirements of the RD in force in the electric power industry and agreed with the Gosgortekhnadzor of Russia.
8.2.3. The quality of make-up and network water for hot water boilers must meet the requirements specified in Table. nine.

Table 9. Quality standards for make-up and network water for hot water boilers

Indicator	Heating system
	open			Closed
	Temperature of network water, °C
Font transparency, cm, not less than
Carbonate hardness, mcg×eq/kg:	800 21	750 26	375 26	800 26	750 26	375 26
at pH not more than 8.5				700 30
		300 26	250 26	600 26	500 26	375 26
pH value at 25 °C	7.0 to 8.5			7.0 to 11.0 22
Note . These standards do not apply to hot water boilers installed at thermal power plants, thermal power plants and heating boilers, for which the water quality must comply with the requirements of the rules for the technical operation of power plants and networks approved in the prescribed manner. 21 The numerator shows the values ​​for solid fuel boilers, the denominator - for liquid and gaseous fuels. 22 For heating networks in which hot water boilers operate in parallel with boilers having brass tubes, the upper pH value of the heating water must not exceed 9.5.

8.3. Boiler water quality requirements
Boiler water quality standards, the necessary mode of its corrective treatment, modes of continuous and periodic blowdowns are adopted on the basis of the instructions of the boiler manufacturer, standard instructions for maintaining a water-chemical regime and other departmental regulatory documents or based on the results of thermal chemical tests.
At the same time, for steam boilers with pressure up to 4 MPa (40 kgf / cm2) inclusive, having riveted joints, the relative alkalinity of boiler water should not exceed 20%; for boilers with welded drums and pipe fastening using the rolling method (or rolling with sealing welding), the relative alkalinity of boiler water is allowed up to 50%, for boilers with welded drums and welded pipes, the relative alkalinity of boiler water is not standardized.
For steam boilers with pressure over 4 MPa (40 kgf/cm2) up to 10 MPa (100 kgf/cm2) inclusive, the relative alkalinity of boiler water should not exceed 50%, for boilers with pressures over 10 MPa (100 kgf/cm2) up to 14 MPa (140 kgf/cm2) inclusive should not exceed 30%.