I.V. Plygun, chief designer,
V.S. Okhremenko, design engineer of the department for the development of new equipment,
JSC Biysk Boiler Plant, Biysk

The reliability and safety of boiler houses, as well as the longevity of their service, are laid down not only by the features of the structures, their components, the presence of security systems, compliance with regulated building codes and skilled installation, but also by competent operation and timely service.

The opinion that the boiler, being the heart of the heat supply system, with proper manufacture, installation and commissioning, can work out the estimated period without a set of works to maintain the rest of the systems involved in the boiler room in good condition is undoubtedly wrong.

Qualified maintenance of boiler equipment during operation is a necessary and obligatory condition for its long-term operation without accidents, the elimination of the consequences of which will require more funds than timely service.

Causes of accidents in theory and practice

Emergencies may arise from different reasons, but the main ones are:

■ operation of counterfeit and falsified boiler equipment;

■ poor-quality installation or repair of equipment;

■ incorrect commissioning;

■ wear or poor quality of the material from which the individual components are made;

■ incorrect actions of the boiler room attendants.

Work experience shows that most of the accidents of boiler equipment (80%) occur due to improper operation. In many cases, unqualified boiler room personnel are not able to prevent or quickly eliminate malfunctions and accidents of boiler units, which is their main task as maintenance personnel. Here are just a few cases that serve as examples of the above, without mentioning the names of companies that violated the operating instructions for boiler equipment.

Example No. 1. The DKVr-20-13S boiler, equipped with automation based on a modern controller, was put into operation in January 2010 on the territory of the Republic of Belarus. In March 2010, the company operating the boiler sent a letter to the manufacturer, informing him that an accident had occurred. When the boiler was kindled, the pipes of the side screens of the front furnace block and the rear screen were deformed, and subsequently the pipe of the left side screen ruptured.

According to the results of the inspection, it was revealed that the accident occurred due to the fault of the operating organization. The immediate reason is that during the firing up of the boiler, the valve connecting the level gauge column and the drum was closed, and the drain valve of the lower drum was ajar (or not completely closed), as a result of which the actual water level in the boiler dropped below the permissible value. The signal from the level gauge, at the same time, showed the working level of water in the drum, as a result of which the automatic protection and blocking did not work when it dropped beyond the minimum level.

Example No. 2. In 2008, 3 water-heating boilers of the KVE-0.7-115GM series were put into operation, and in September 2010, the operating company sent a letter to the manufacturer, which stated that when carrying out maintenance on In preparation for the heating season, the left walls of two boilers burned out. Photos of broken equipment were also sent.

Based on the results of a more detailed study of the burnout of the left walls of the boilers, it was revealed that the burnout occurred in the same place on all boilers, namely in the area of ​​the first turn of the flue gases. The cause of burnout of enclosing walls made of thermal insulation materials, was the fact that unburned fuel particles were present in the flue gas stream. These particles were deposited and burnt out at the place where the gases turned, namely on the left wall of the boiler. The presence of unburned particles in the flue gas flow indicates incomplete combustion of the fuel.

The main causes of the accident: incorrect commissioning and incorrectly selected nominal mode, which led to burnout of the boiler walls and incomplete combustion of fuel.

Example No. 3. E-1-0.9GM boiler installed in Krasnodar Territory in 2014, failed due to the formation of multiple fistulas on the screen and convective surfaces of the boiler.

At the request of the operating company, a representative of the manufacturer was sent to the facility to investigate the reasons for the failure of the boiler. During the inspection, it was revealed that during the period of repair and restoration work on the boiler, about 10% of the total number of evaporator pipes was cut off. Also, the presence of dense deposits on the inner surface of the pipes and the boiler feed line was noted, the salt deposits of which blocked about 20% of the pipe flow area, in connection with which a control cutting of samples was made for further study of the nature of the deposits and the microstructure of the metal.

According to the results of the study, the causes of the fistulas were under-sludge corrosion caused by insufficient water treatment for normal operation, which is confirmed by dense black deposits up to 12 mm thick on a pipe sample cut from the boiler feed line. On the remaining samples, the boundaries of the vapor cushion were clearly visible, where there is an intensive concentration of substances that cause corrosion, as well as foci of oxygen corrosion, which are distinguished by a darker color.

This phenomenon is caused by a violation of the water-chemical regime by the operating personnel - the supply of non-deaerated boiler water with a low pH level of 7.1 units to the boiler.

Example No. 4. According to the operating organization about the impossibility of reaching the nominal parameters for the steam output of the DE-16-14-225GM boiler (in operation since 2015) due to increased vibration on the burner device, leading to the destruction of the burner loophole, a survey was carried out boiler room equipment.

As a result, it was determined that increased vibration to the burner device is transmitted from the pressure boxes of the blower fan designed in-house. At the same time, the design of the air ducts does not meet the requirements for the design of air ducts, and besides, they were made in violation of the recommendations of the aerodynamic calculation standards. In addition, there are no flow meters for feed water and superheated steam to determine the actual load on the boiler, as well as a gas analyzer, the absence of which makes it difficult to determine the recommended fuel-air ratio. In addition, the level of automation of the boiler does not meet the requirements of SP 89.13330.2012.

It was revealed that the reasons for the failure of the boiler to reach the nominal parameters were unfulfilled in full installation work, non-compliance of the project with a number of regulatory documents, as well as the implementation of commissioning works not in accordance with RD 34.70.110-92.

Example No. 5. In 2014, after one month of operation of the BVES-1-2 economizer, a coil leak was detected in the boiler room. During the inspection of the equipment of the boiler room by a representative of the manufacturer, it was noted that the DA-15 deaerator works only as storage tank due to the inoperability of the deaeration column. A control cutting of metal samples was made for further study of the nature of the deposits.

It was determined that the destruction of the pipes of the economizer coils followed due to the violation by the operating personnel of the water-chemical regime - the supply of non-deaerated boiler water to the economizer and boiler.

Errors - consequences - elimination

The most common errors in the operation of boilers are associated with a violation of the water treatment system, a decrease in the water level, contamination of the boiler water, violation of the blowing technology, non-compliance with the heating technology, fuel explosion and other malfunctions. The table provides a list of the most common errors in the operation of boiler equipment and recommendations for eliminating their consequences.

Table. Errors in the operation of boiler plants, their consequences and recommendations for elimination.

Errors in the operation of boiler plants		Consequences of misuse	Troubleshooting Tips
Violations water treatment.	The quality of the water does not meet the standards (most often water with increased hardness is used to feed the boilers).	Scale formation, burning of heating surfaces, excessive fuel consumption.	Boiler water must comply with the standards for boiler operating parameters. It is necessary to constantly monitor the quality of boiler and make-up water in accordance with the requirements of the Industrial Safety Rules for Hazardous Production Facilities Using Equipment Operating Under Excessive Pressure.
	There is no preparation of the water circuit before starting the boiler house.	Accumulation of sludge in the bottom zones.
	The internal surfaces of the boiler (on the water side) are not checked.	Signs of scale deposits.
	There is no continuous monitoring of the quality of the return condensate.	Pollution of boiler water, which causes corrosion of the internal surfaces of the boiler, accumulation of sludge in the lower points of the boiler.	Constant and continuous monitoring of the condition of the condensate is required.
Lowering of the water level.	Violation of the water regime, namely, when the water level drops below the permissible level.	Overheating of the metal, causing deformation of the pipe system. Boiler explosion.	Variable differential pressure sensors must be used to prevent the water level from falling below the allowable level.
Non-compliance with the warm-up schedule.	The boiler fires up too fast.	Damage to the lining of the boiler, deformation of the drum is possible.	Follow the boiler firing schedule according to the manufacturer's recommendations (operating instructions).
Incorrect operation of the burner.		Nozzle clogging, combustion instability or flame separation. Explosion in the furnace.	Before kindling the boiler, check the operability of the explosive valves, nozzles, clean the nozzles of the furnace.
Operation is carried out with faulty or unadjusted safety equipment and instrumentation.		The increase in pressure in the boiler is higher than the permissible one. Boiler explosion.	Checking the health of the action safety valves must be carried out on time in accordance with the "Industrial Safety Rules for Hazardous Production Facilities Using Equipment Operating Under Excessive Pressure". It is necessary to timely hand over pressure gauges for verification, operate the equipment only with serviceable and verified devices.
Use of off-design fuel.		The boiler does not reach the set parameters.	When switching to off-design fuel, it is necessary to carry out commissioning work.

Undoubtedly boiler equipment needs not only proper operation, but also constant preventive maintenance, and often repair. For high-quality maintenance of boiler rooms, qualified personnel are needed who can identify the malfunction in time and take appropriate measures.

The operating personnel of the boiler room must:

■ know the relationship between the processes occurring inside the systems that form the boiler room;

■ follow service instructions and “ manufacturing instructions maintenance of boiler room equipment”, other service instructions;

■ carry out constant monitoring of the operation of all equipment of the boiler house and carry out timely troubleshooting;

■ keep technical records, provide reports and work plans.

Conclusion

The boiler room is a complex system requiring close attention and care. In order for the boiler equipment to work out its service life without emergency situations, operating organizations need to pay special attention to the training and education of personnel in the process of servicing boiler rooms, which would clearly adhere to the technical recommendations of boiler equipment manufacturers.

Thousands of people around the world are involved in repairs every day. When it is done, everyone begins to think about the subtleties that accompany the repair: what color scheme to choose wallpaper, how to choose curtains in the color of the wallpaper, and arrange the furniture correctly to obtain a unified style of the room. But few people think about the most important thing, and this main thing is the replacement of electrical wiring in the apartment. After all, if something happens to the old wiring, the apartment will lose all its attractiveness and become completely unsuitable for life.

Any electrician knows how to replace the wiring in an apartment, but any ordinary citizen can do it, however, when performing this type of work, he should choose quality materials to get safe electrical network in room.

The first action to be taken plan future wiring. On the this stage you need to determine exactly where the wires will be laid. Also at this stage, you can make any adjustments to the existing network, which will allow you to place the fixtures and fixtures as comfortably as possible in accordance with the needs of the owners.

12.12.2019

Narrow-industry devices of the knitting sub-industry and their maintenance

To determine the extensibility of hosiery, a device is used, the scheme of which is shown in fig. one.

The design of the device is based on the principle of automatic balancing of the rocker by the elastic forces of the product under test, acting at a constant speed.

The weight beam is an equal-armed round steel rod 6, which has an axis of rotation 7. On its right end, paws or a sliding form of the trace 9 are attached with a bayonet lock, on which the product is put on. On the left shoulder, a suspension for loads 4 is hinged, and its end ends with an arrow 5, showing the equilibrium state of the rocker arm. Before testing the product, the rocker arm is balanced by a movable weight 8.

Rice. 1. Scheme of a device for measuring the extensibility of hosiery: 1 - guide, 2 - left ruler, 3 - engine, 4 - suspension for loads; 5, 10 - arrows, 6 - rod, 7 - axis of rotation, 8 - weight, 9 - trace shape, 11 - stretching lever,

12 - carriage, 13 - lead screw, 14 - right ruler; 15, 16 - helical gears, 17 - worm gear, 18 - coupling, 19 - electric motor

To move the carriage 12 with a stretching lever 11, a lead screw 13 is used, at the lower end of which a helical gear 15 is fixed; through it, the rotational movement is transmitted to the lead screw. The change in the direction of rotation of the screw depends on the change in rotation 19, which is connected to the worm gear 17 with the help of a coupling 18. A helical gear 16 is mounted on the gear shaft, directly communicating the movement of the gear 15.

11.12.2019

In pneumatic actuators, the displacement force is created by the action of compressed air on the membrane, or piston. Accordingly, there are membrane, piston and bellows mechanisms. They are designed to set and move the valve of the regulating body in accordance with the pneumatic command signal. The full working stroke of the output element of the mechanisms is carried out when the command signal changes from 0.02 MPa (0.2 kg / cm 2) to 0.1 MPa (1 kg / cm 2). Ultimate pressure compressed air in the working cavity - 0.25 MPa (2.5 kg / cm 2).

In membrane linear mechanisms, the stem performs a reciprocating motion. Depending on the direction of movement of the output element, they are divided into mechanisms of direct action (with an increase in membrane pressure) and reverse action.

Rice. 1. Membrane design executive mechanism direct action: 1, 3 - caps, 2 - membrane, 4 - support disk, 5 - bracket, 6 - spring, 7 - stem, 8 - support ring, 9 - adjusting nut, 10 - connecting nut

The main structural elements of the membrane actuator are a membrane pneumatic chamber with a bracket and a moving part.

The membrane pneumatic chamber of the direct action mechanism (Fig. 1) consists of covers 3 and 1 and membrane 2. Cover 3 and membrane 2 form a hermetic working cavity, cover 1 is attached to bracket 5. The movable part includes support disk 4, to which the membrane is attached 2, rod 7 with connecting nut 10 and spring 6. The spring rests at one end against the support disk 4, and at the other end through the support ring 8 into the adjusting nut 9, which serves to change the initial tension of the spring and the direction of movement of the rod.

08.12.2019

To date, there are several types of lamps for. Each of them has its pros and cons. Consider the types of lamps that are most often used for lighting in a residential building or apartment.

The first type of lamps - incandescent lamp. This is the cheapest type of lamps. The advantages of such lamps include its cost, simplicity of the device. The light from such lamps is the best for the eyes. The disadvantages of such lamps include a short service life and a large number of consumed electricity.

The next type of lamps - energy-saving lamps. Such lamps can be found absolutely for any type of socles. They are an elongated tube in which a special gas is located. It is the gas that creates the visible glow. In modern energy-saving lamps, the tube can have a wide variety of shapes. The advantages of such lamps: low power consumption compared to incandescent lamps, daylight glow, a large selection of socles. The disadvantages of such lamps include the complexity of the design and flicker. The flicker is usually imperceptible, but the eyes will get tired from the light.

28.11.2019

cable assembly- a kind of assembly unit. The cable assembly consists of several local ones, terminated on both sides in the electrical installation shop and tied into a bundle. Installation of the cable route is carried out by laying the cable assembly in the cable route fastening devices (Fig. 1).

Ship cable route- an electric line mounted on a ship from cables (cable bundles), cable route fastening devices, sealing devices, etc. (Fig. 2).

On the ship, the cable route is located in hard-to-reach places (along the sides, ceiling and bulkheads); they have up to six turns in three planes (Fig. 3). On large ships, the maximum cable length reaches 300 m, and the maximum cross-sectional area of ​​​​the cable route is 780 cm 2. On individual ships with a total cable length of more than 400 km, cable corridors are provided to accommodate the cable route.

Cable routes and cables passing through them are divided into local and trunk, depending on the absence (presence) of sealing devices.

Main cable routes are divided into routes with end and through boxes, depending on the type of application of the cable box. This makes sense for the choice of technological equipment and cable route installation technology.

21.11.2019

In the field of development and production of instrumentation and instrumentation, the American company Fluke Corporation occupies one of the leading positions in the world. It was founded in 1948 and since that time has been constantly developing and improving technologies in the field of diagnostics, testing, and analysis.

Innovation from an American developer

Professional measuring equipment from a multinational corporation is used in the maintenance of heating, air conditioning and ventilation systems, refrigeration systems, air quality testing, electrical parameter calibration. The Fluke branded store offers certified equipment from an American developer. Full the lineup includes:

• thermal imagers, insulation resistance testers;
• digital multimeters;
• power quality analyzers;
• rangefinders, vibration meters, oscilloscopes;
• temperature and pressure calibrators and multifunctional devices;
• visual pyrometers and thermometers.

07.11.2019

Use a level gauge to determine the level different types liquids in open and closed storages, vessels. It is used to measure the level of a substance or the distance to it.
To measure the liquid level, sensors are used that differ in type: radar level gauge, microwave (or waveguide), radiation, electrical (or capacitive), mechanical, hydrostatic, acoustic.

Principles and features of operation of radar level gauges

Standard instruments cannot determine the level of chemically aggressive liquids. Only a radar level transmitter is able to measure it, since it does not come into contact with the liquid during operation. In addition, radar level transmitters are more accurate than, for example, ultrasonic or capacitive level transmitters.

Description of the boiler TP-10

Purpose, design and operational characteristics of the boiler.

The TP-10 boiler is single-drum, manufactured by the Taganrog Boiler Plant Krasny Kotelshchik, and operates in a unit with a PT-60–90/13 turbine.

The workshop has two such boilers, station No. 1 and 2, with a capacity of 220 tons / hour, working pressure in the drum 110 kgf / cm 2, temperature of superheated steam 540 ° C. Minimum productivity 130 tons / hour, efficiency - 91.6%.

The boiler furnace is a chamber furnace for burning fuel in a pulverized state. Fuel oil grade M - 40 or M - 100 is used as starting fuel. The boiler is equipped with four fuel oil nozzles of the MFPR - 3 type, mounted under burners No. 5,6,7,8. Fuel oil is sprayed with steam 14 kgf/cm. Boilers No. 1,2 additionally have tie-ins from air distribution to fuel oil spray. For combustion, coals of the Cheremkhovskoye deposit of grade "D" and Azeya grade "B - 3" are used. The composition and characteristics of these coals will be described below.

The boiler is equipped individual system pulverization with an intermediate bunker of coal dust. To clean flue gases from ash, wet ash collectors are installed on the boiler unit. Each unit is equipped with smoke exhaust, fan installations.

The frame of the boiler weighing 290 tons consists of metal columns connected by horizontal trusses and braces and serves to absorb the load from the drum, heating surfaces, lining, gas-air boxes, insulation and boiler maintenance platforms. Beams, to which screen contours with lining are suspended, are attached to the upper frame of the frame. The frame is welded from profile rolled metal and steel sheets. The vertical columns rest on a reinforced concrete foundation. To increase the rigidity of the frame in case of seismic impact, stiffening brackets made of pipes with a diameter of 150 mm are installed on the side walls of the boiler.

Brickwork - lightweight type. The walls of the combustion chamber and the cold funnel have a hairpin-type pipe lining, consisting of the following layers:

a) refractory concrete 20 mm thick, applied along the grid on the screen pipes;

b) mats from mineral wool, reinforced with studs to the pipes of the screen;

c) sealing lining 40 mm thick, applied over the mesh over the wool;

d) gas-tight coating.

The ceiling of the combustion chamber and the horizontal flue is insulated in the same way as the furnace, along the ceiling pipes.

The lining of the ceiling, together with the pipes, is attached to the frame beams with the help of hangers. The walls of the turning chamber and the convection shaft are lined with fireclay or diatomite bricks.

Drum and intra-drum device

A welded unheated drum with a diameter of 1778x89 mm, steel 22K, is mounted above the combustion chamber. Connection of all pipes is carried out by electric welding to the factory welded fittings. Feed water after the economizer through 8 pipes with a diameter of 108 x 8 mm. Through steam jackets it enters the drum to the feed trough located in the clean compartment, and from there it overflows to the surface of the boiler water. Two end pipes are brought into the space of the salt compartments to wash the wet steam from the salts dissolved in it.

Steam separation in the drum is mechanical and gravitational without flushing with feed water (except for salt compartments).

Steam-water mixture from panels of screen heating surfaces through 36 pipes with a diameter of 130 x 10 mm. is introduced into the boiler drum under the baffles located above each pipe along the clean compartment on both sides.

After passing through the shutters, the steam enters the steam space of the drum, where gravity separation takes place. Moisture flows to the surface of the water mirror. In the upper part of the drum, steam through a perforated sheet, where the second separation stage takes place, is directed through 32 pipes with a diameter of 60 x 5 mm to the ceiling superheater.

The steam-water mixture enters the salt compartments through 6 pipes (3 from each panel) under the fenders. Steam from the salt compartments to the clean one enters through vertical blinds, which, together with the vertical wall at the ends of the drum, form the volume of salt compartments. The salt content of the boiler water of the saline compartments reaches up to 500 mg/dm 3 . To prevent the removal of salts, before the steam exits, a flushing device (shower) of steam with feed water is installed in the vertical blinds. it transverse pipes with plugged ends and a large number of holes directed to the bottom through which feed water is sprayed.

Each compartment - two salty and one clean - has its own water meter to control the water level in the compartments. Separate lines with regulators are made from salt compartments continuous purge and brought into the barbater.

Superheater

Saturated steam from the drum is sent through 32 pipes with a diameter of 60 x 5 mm to 4 inlet chambers of the ceiling superheater (material steel 20), with a diameter of 60 x 5 mm. The ceiling superheater consists of 4x38=152 pipes (material steel 20), 4 outlet chambers of the ceiling superheater with a diameter of 219x25 mm (material steel 15XM).

Each outlet chamber of the ceiling superheater is welded with 4 chambers of a screen superheater (4x4 = 16 in total) with a diameter of 168x16 mm (material st. 15XM). Inside each chamber, one partition is installed, which contributes to the sequential flow of steam from the first strip into the second strip of the screen superheater. The outlet coils of the second SHPP tape are welded to short outlet chambers made of 12KhMF steel, which are welded in 4 pieces to four common, transversely located outlet chambers (15KhM steel). The same chambers are the input for the second part of the ceiling superheater.

Thus, across the width of the boiler in front of the entrance to the revolving chamber there are 16 two strip screens ShPP. The first screen strips (along the gases) are made of pipes Ø 32x4 mm, steel 20; allowable wall temperature is not more than 430 ° C.

The second screen strips are made of pipes Ø 42x4.5 mm, steel 12KhMF. The first tape consists of 14, the second - of 10 coils; along the gas flow they form 14×2+10×2=48 rows of SHPP. 216 coils Ø 42x4.5 mm (steel 12KhMF) of a ceiling superheater with steam transfer from the outer coil packs to the coils of the middle part of the gas duct and, conversely, from the middle ones to the outer parts, come out of 4 common outlet chambers of the SHPP. The ceiling superheater (second part) is located above the rotary chamber and the convection shaft; then its coils pass into the loops of the first stage of a convective superheater, made according to the principle of mixed current with a predominance of countercurrent (2 countercurrent loops and 1 direct-flow loop). The hinges are made of pipes Ø 42x5.5 mm (steel 12XMF). From the first stage of the convective superheater, steam enters 4 chambers Ø 273x35 mm (steel 15 XM), then through 4 pipes Ø 133x10 mm from two right chambers it enters the right desuperheater and from two left chambers through 4 pipes Ø 133 × 10 mm into the left one. The diameter of the desuperheaters is 273x35 mm.

From the right desuperheater, through 4 pipes Ø 233 × 10 mm, steam enters two inlet chambers of the second stage of the convective superheater located on the left side, and from the left desuperheater - into two chambers right sides s; diameter of all 4 chambers 273×10 mm, steel 15XM. Such transfer of steam provides for the equalization of temperatures in the coils along the width of the gas flow and eliminates the effect of gas distortions along the width of the rotary chamber.

The second stage of the convective superheater consists of 108 pipes Ø 42×5.5 mm steel 12KhMF and is connected according to the cocurrent principle.

Having passed the coils of the second stage of the superheater, the steam exits into 4 outlet chambers with a diameter of 325 × 45 mm, steel 12KhMF. From the outlet chambers, steam is discharged through 3×4=12 pipes with a diameter of 133×13 mm into a steam-collecting chamber Ø 325×58 mm, steel 12KhMF.

The main safety valves are located on the steam collecting chamber. Having passed the main steam valve with a bypass, located on the boiler ceiling, steam from the steam collecting chamber is directed to the turbine through a steam pipeline Ø 273 × 28 mm, steel 12KhMF. In front of the valve PP-2, a branch is made from the steam pipeline to the BROU located in the turbine compartment.

Desuperheater

To regulate the superheated steam temperature, the boiler is equipped with a mixed-type desuperheater located in the gap between the I and II stages of the convective superheater. The desuperheater consists of 2 vertical chambers Ø 273×35 mm located on the left and right sides of the boiler. Steam enters the upper parts of the chambers, spray nozzles are located below the steam supply, the latter are located along the steam path. Feed water is supplied to the nozzles through a special line from the feed unit.

Economizer

The economizer is located in the convection shaft of the boiler and consists of two stages. The first stage of the economizer (along the water flow) is located between the I and II stages of the air heater. Feed water is supplied to 4 inlet chambers Ø 219x16 mm, steel 20 (two on each side), of which 136 coils Ø 32x3.5 mm, steel 20, after passing through 8 (4 outlet and 4 inlet) intermediate chambers, water exits on 4 outlets chambers with a diameter of 219x16 mm, steel20. Thus, the first stage of the economizer consists of two sections in terms of the depth of the flue and two parts in terms of height.

In terms of width, I and II stages of the economizer consist of two parts: left and right. Moreover, the coils run along the entire width of the flue. The location of the coils is staggered, the movement of water along them is counter. Intermediate chambers (4 outlets and 4 inlets) are connected by pipes Ø 60x5 mm, 10 pieces (5x20) on each side of the flue. From the outlet chambers of the 1st stage, water is transferred through 8 pipes Ø 60x5 mm (4 pipes on each side) to the 2nd stage of the economizer; moreover, water from packages located at rear wall of the convective shaft is sent to the packages of the II stage, located at the front wall of the convective shaft.

Air heater

A two-stage air heater is mounted on the boiler from small-sized tubes with a diameter of 40x1.5 mm, steel 20. The first stage of the air heater (along the air flow) is located at the end of the convective shaft in front of the flue going to the ash collectors, and consists of 16 cubes (4 in width, 2 in depth and 2 in height). Heating surface - 9740 m 2. The second stage of the air heater is located between the stages I and II of the economizer and consists of 8 cubes (4 in width and 2 in depth). Heating surface - 4870m 2 .

Purpose of operation of boiler houses. The operation of boiler plants includes a set of measures aimed at ensuring safe, reliable and economical operation of all equipment and uninterrupted supply of consumers with steam and hot water given costs and parameters.

In connection with the explosion and fire hazard of boiler plants, the Federal Law "On industrial safety of hazardous production facilities"(No. 116 dated February 21, 1997) refers boiler plants to the category of production facilities dangerous for the personnel of boiler houses, the population of adjacent territories and the natural environment. According to the law, control over the manufacture, installation and safe operation of steam boilers with an operating pressure of more than 0.07 MPa (0.7 kgf / cm 2) and hot water boilers with a water temperature above 115 0 С is carried out by the federal state executive body called " federal Service for Environmental, Technological and Nuclear Supervision (abbreviated as Rostekhnadzor) and its territorial bodies.

Basic requirements for the personnel of boiler plants. In view of the complexity of the device and maintenance of modern boilers and boiler rooms, specially trained personnel are allowed to operate them, recruited from competent persons not younger than 18 years of age who have passed medical examination, training and certification.

According to the "Regulations on the procedure for training and certification of employees of organizations engaged in activities in the field of industrial safety of hazardous production facilities controlled by the Gosgortekhnadzor of Russia" (RD 03-444-02 dated 11.01.99), boiler room personnel are divided into operational management, duty and operational - repair.

The operational management personnel of boiler houses include: the head of the boiler room, the shift supervisor, the shift foreman, the dispatcher on duty and other specialists in accordance with the staffing table. From among the management personnel with a thermal engineering education, the administration of the enterprise appoints a person responsible for the good condition and safe operation boilers, which is recorded in the boiler passport.

Only the Responsible has the right to give an order (mandatory in writing) to start the boiler and stop it. Certification of Responsible and leading specialists is carried out in the bodies of Rostekhnadzor at least once every three years. Certification of senior personnel in the field of industrial safety is carried out according to the schedule approved by the head of the enterprise.

Duty personnel are operators, boiler operators, stokers, HVO apparatchiks and other workers servicing boilers and auxiliary equipment of boiler rooms in accordance with the approved duty schedule;

Operational and repair personnel include workers engaged in repairs and having the right to maintain and perform operational switching in boiler rooms.

According to the requirements of the "Rules for the Design and Safe Operation of Steam and Hot Water Boilers" (PB-10-574-03), training and certification of operators, machinists and firemen of the boiler room should be carried out in educational institutions, as well as at courses specially created by enterprises and licensed by Rostekhnadzor for this type of activity. must be drawn up on Individual training of personnel is not allowed.

Based on the results of the final exam (with the participation of an inspector from Rostekhnadzor), the trainee is awarded a qualification and a certificate is issued for the right to service boilers, signed by the chairman of the attestation commission and the inspector of Rostekhnadzor. Specialists are allowed to service boilers by order of the organization.

Periodic (repeated) testing of the knowledge of the maintenance personnel is carried out at least once every 12 months by a commission appointed by order for the organization (participation in its work of an inspector from Rostekhnadzor is not necessary).

An extraordinary examination of the knowledge of the service personnel is carried out by the commission of the organization in the following cases:

When moving to another organization;

When transferring to service boilers of other types;

When transferring the boiler to burning another type of fuel;

At the request of the inspector of Rostekhnadzor or the administration.

Responsibilities of the staff on duty.

According to the "Typical instructions for safe work for boiler room personnel" (RD 10-319-99), personnel servicing boilers must:

Know their duties, to whom they are subordinate, whose instructions they must follow, whom to notify about malfunctions, accidents, fires and accidents;

Know the structure and operation of the boilers he serves and all auxiliary equipment, piping schemes, fuel oil pipelines and gas pipelines, the design of gas and oil burners and the limits of their regulation;

To be able to timely identify malfunctions in the operation of boilers and auxiliary equipment and pipelines, fittings, headsets, and if malfunctions are detected, immediately eliminate them;

To be able to check the serviceability of the operation of water indicating devices, pressure gauges, safety devices, signaling devices, check valves etc.;

Work trouble-free and economically, uninterruptedly supply consumers with steam or hot water in the required quantity and of the established quality with minimal fuel consumption;

Monitor the condition of the fittings, tighten the leaking glands;

Keep track of the density flange connections and for the condition of pipelines (coloring, inscriptions, plates, etc.);

Check the density of manholes, hatches, the absence of leaks, as well as the absence of air leaks into the furnace, gas ducts, etc.;

Timely check the serviceability of the operation of automatic control, safety and signaling devices in accordance with the requirements of the instructions for their operation.

The main duties of the person responsible for the good condition and safe operation of boilers defines the "Standard instruction for those responsible for the good condition and safe operation of boilers" (RD 10-304-99).

The person in charge must have a special heat engineering education and pass a knowledge test in accordance with the requirements of RD 03-444-02 "Regulations on the procedure for training and certification of employees of organizations operating in the field of industrial safety of hazardous production facilities controlled by the Gosgortekhnadzor of Russia"

In some cases, the Responsible may be a specialist who does not have a thermal engineering education, but who has been trained under the “Program for advanced training of managers and specialists who do not have a thermal engineering education, who are appointed responsible for the good condition and safe operation of steam and hot water boilers” (RD 10-60-94 ) in educational institutions licensed by Rostekhnadzor for personnel training. In addition, the Responsible must be certified by a commission with the participation of an inspector from Rostekhnadzor.

According to the requirements of the Rules and the Standard Instruction, the Responsible is obliged to:

Allow trained and certified personnel to service;

Provide maintenance personnel with production instructions developed on the basis of the manufacturer's instructions for installation and operation, taking into account the layout of the equipment. Instructions are issued to personnel against receipt and are constantly at the workplace;

Ensure that service personnel undergo periodic medical examinations;

Ensure the maintenance and storage of technical documentation for the operation and repair of boilers (passports, shift and repair logs, a water treatment log, repair cards, a log of control checks of pressure gauges, etc.);

Provide each boiler put into operation with a plate indicating the registration number, the permitted pressure and the timing of the next internal inspection and hydraulic test;

Regularly inspect boilers in working order;

Every day on working days, inspect the boilers in working order and check the entries in the shift log with a list in it;

Issue a written order to put the boiler into operation after checking the readiness of the boiler room equipment for operation;

Work with staff to improve their skills;

Carry out technical inspection of boilers;

Keep passports of boilers and instructions of manufacturers for installation and operation;

Conduct emergency drills with boiler room personnel;

Participate in surveys and technical examinations;

Participate in the commission for certification and periodic testing of knowledge of engineers and maintenance personnel;

Timely comply with the instructions issued by the bodies of Rostekhnadzor.

The person in charge is given the right to remove personnel from service in case of violation of instructions or personnel who have shown unsatisfactory knowledge. He has the right to submit proposals to the management on bringing to responsibility engineering and technical workers and persons on duty who violate the rules and instructions, as well as submit proposals to the management on eliminating the causes that give rise to violations of the requirements of the rules and instructions.

Organization of emergency service. In connection with the continuous long-term operation of the equipment of boiler rooms, their operation is organized through constant duty (shifts) of maintenance personnel. Duty is carried out in shifts with a duration of shifts of no more than 8 hours. The composition of the shift is determined by the staffing table. The procedure for the entry of personnel on duty and leaving the duty is determined by the Internal Regulations.

The order of acceptance-delivery of the shift (duty). Before going on duty (approximately 20 minutes in advance), the shift supervisor (shift foreman) checks the availability of service personnel, the possibility of them being on duty, as well as their knowledge of their duties.

After that, the shift supervisor conducts a staff briefing, during which:

Indicates to each person what special attention should be paid during the reception, carrying and delivery of the shift;

Familiarizes the personnel with the switched on and off equipment and heat consumers;

Draws attention to malfunctions and malfunctions in the equipment;

Reminds about the need to comply with the rules and measures of safety and fire safety, etc.

After the briefing, the staff takes the shift at their posts and reports to the shift supervisor on the condition and malfunctions of the equipment within their workplace.

The operator on duty (driver, fireman) must:

Obtain from the shift operator information about the operation of the equipment, operating modes, malfunctions, about the task for the shift and the comments of the management;

Check the availability of water and fuel supplies;

Find out the condition of the heating surfaces of the boiler and economizer, lining, furnace devices, auxiliary equipment, instrumentation and get acquainted with their readings;

Check the operability of automatic control, safety and signaling;

Specify the time of the last purge and the time of the next purge;

Check to the touch the tightness of the purge, drain valves and check valves;

Make sure that there are no gas leaks and the position of the shut-off and control valves on the gas pipeline near boilers, etc.

The shift supervisor, in turn, gets acquainted with the state, scheme and mode of operation of the boiler room equipment, with all entries in the shift log, receives information about the operation of the boiler room from the shift supervisor being replaced. The shift supervisor, having received the report, signs the shift acceptance in the shift log.

It is prohibited to accept and hand over a shift during the period of liquidation of an accident, fire and during critical switching.

Technical documentation of the boiler room.

Technical documentation includes:

Technical passports for boilers and pressure vessels (continuous blowdown expander and heat exchangers), forms for auxiliary equipment, drawings, descriptions and instructions from manufacturers of boilers and auxiliary equipment and structures;

Executive technological schemes boiler room systems (feed and network pipelines, steam pipelines, blowdowns and drainages, fire pipelines, electrical cables and connections, automation, etc.), acts and protocols for installation, testing and commissioning;

Technical (production) instructions for maintenance, scheduled preventive inspections (PPO) and repairs (PPR) of boilers and auxiliary equipment;

job descriptions;

HSE and fire safety instructions;

Instructions for using the gas analyzer;

Regime maps, load schedules (heat supply);

Replaceable magazine;

Repair log;

Journal of instrumentation and automation;

Journal of Water Treatment;

Journal of accounting for briefings;

Journal of accounting for periodic inspections and control tests of protective equipment;

Journal and schedule of emergency drills;

Plan for localization and liquidation of emergency situations;

Journal of controlling persons of the enterprise;

Journal of bypassing the route of external gas pipelines and a route map;

List of works with increased danger.

Forms and drawings, technological schemes, factory and project documentation are transferred by installation, construction and commissioning organizations to the personnel of the boiler house when it is put into operation. The instructions are developed by the management personnel of the boiler house on the basis of the manufacturer's documentation and standard instructions.

The removable log is used to record data on the operation of boilers and auxiliary equipment, switching on and switching operations, malfunctions and accidents, orders received, inspections and repairs. (Details of repairs are recorded in the repair log). In particular, in accordance with the Rules, the shift log should reflect: the start time of firing up and stopping the boiler, inspection of the boiler before accepting the shift, blowing the boiler, checking the serviceability of boiler pressure gauges and water-indicating devices, safety valves and feed pumps.

A repair log is entered for each boiler, in which the Responsible enters information about the completed repair work, the materials used, the welder and welding, shutdowns of the boilers for cleaning or flushing. The replacement of pipes and the rolling of pipe connections with drums and headers are noted on the pipe layout attached to the magazine. Also, the repair log reflects the results of the inspection of the boiler before cleaning, indicating the thickness of scale and sludge and all defects identified during the repair period.

Information about repair work that necessitates an early inspection of the boiler, as well as repair work to replace boiler elements using welding or rolling, is recorded in the repair log and entered in the boiler passport.

Replacement and repair magazines must be numbered, laced and sealed.