Basic requirements for the operation of boiler installations. Basic provisions for organizing the operation of boiler houses. Boiler room operation services from third party companies

15.03.2020

Read also

Boy at Christ's Christmas tree (Dostoevsky)

How does the Holy Trinity icon help and what is its meaning?

Operation of a boiler unit consists of the following: lighting and stopping the unit, monitoring and controlling the operation of the boiler unit, choosing optimal operating modes and the most favorable load distribution, observing the rules of technical and safe operation, organizing repairs, preventing accidents, etc. A modern boiler unit requires the most careful monitoring and error-free control. The task of monitoring and control is to ensure at every moment the required steam output or heat output and the specified parameters of steam and water with reliable and economical operation of the unit. Productivity is the main indicator of the operation of a boiler installation.

Preparing the boiler for operation. Before lighting, check the serviceability of the boiler and its readiness for start-up, for which a thorough internal (if the boiler is open) and external inspection of the unit is carried out. They check the serviceability of all fittings, explosion valves, the tightness of closing manholes and hatches, the readiness to start smoke exhausters and fans by testing their operation, etc. After this, open the air valves on the boiler and economizer or lift the safety valve to release air. Next, the feed valve is opened and the boiler is filled with water. The boiler is filled with water through the economizer (if equipped), while the air valve or safety valve on the economizer must be open; When water appears in them, they are closed.

The boiler is filled with water of proper quality at a temperature in the range of 50–90°C. Uneven heating or cooling of the boiler can cause thermal deformations. Fill the boiler slowly (1–2 hours) to the lowest level of the water indicator glass, taking into account that the water level will rise when it is heated. Then they begin to light the boiler: burn a layer of fuel on the grate , fuel oil nozzles or gas burners. At the same time, they monitor the density of the boiler and the absence of leaks based on the water level in the water indicator glass. The boiler is first fired up with the gate behind the boiler slightly open (without a smoke exhauster) without a fan, then the fan is turned on and the draft is increased.

Before lighting the boiler flues, it is necessary to ventilate them with natural draft or by turning on the smoke exhauster for 5–15 minutes, longer – with gaseous fuel and fuel oil.

When installing a non-boiling and group economizer, gases are passed in addition to it through a bypass chimney; in the absence of the latter, water is continuously pumped through the economizer; the water temperature leaving the economizer should not exceed 60 °C. To prevent corrosion of the air heater, the fans are turned on when the gas temperature behind the air heater reaches at least 120°C or air is passed in addition to it. Rapid heating of the boiler during firing causes uneven expansion of the heating surfaces, which is often the main reason for the destruction of rolling and other joints. Therefore, kindling is carried out within 2–4 hours.

When the pressure in the boiler is 0.02–0.05 MPa below the pressure in the common steam line (main), slowly and carefully open the steam valve (gate) on the boiler drum or on the steam superheater (if any) and connect the boiler to the steam line; After connecting the boiler to the steam line, the condition of the entire unit and its fittings is carefully checked again. Then close the superheater drain valve. When the water level in the boiler decreases, they begin to feed it with water. The bypass chimney is closed and the gases are directed through an economizer or air heater. Thus, the boiler unit is transferred to operating mode.

Maintenance of the boiler during operation is reduced to maintaining normal mode, which ensures the highest steam production of the specified parameters at the lowest fuel consumption under conditions of safe and reliable operation of the boiler unit.

Boiler shutdown may be planned , short-term and emergency. Planned(complete) shutdown of the boiler is carried out according to a schedule in a certain sequence. The fuel supply stops, the remaining fuel on the grate is burned in the layered firebox, the air supply stops (the fan stops), the flue ducts are ventilated for 10 minutes; then the smoke exhausters stop and the gate behind the boiler closes. After combustion in the furnace has stopped and steam has been produced, the boiler is disconnected from the steam line and the superheater purge is opened for 30–50 minutes to cool it. Then the furnace is cleaned of residual fuel, ash and slag, and the ash bunkers are unloaded. During the boiler shutdown, the water level in the boiler and its power supply are continuously monitored. After disconnecting the boiler from the steam main, it is recharged to the permissible upper limit. Over the course of 4–6 hours, the boiler slowly cools down, while the combustion doors and gate behind the boiler must be closed.

Short term stopping the boiler unit may be caused by a disruption in its normal operation due to equipment malfunction or for other reasons that may cause an accident. The sequence of operations in these cases is the same , as during a planned boiler shutdown. After disconnecting the boiler from the steam line and opening the superheater purge, monitor the pressure gauge, water indicating device and the general condition of the firebox and boiler.

Emergency The boiler unit may stop in the following cases:

When the steam pressure in the boiler increases above the permissible level (despite the reduction in fuel supply, blast and draft and increased water supply);

If there is a water leak or the boiler is overfilled with water;

If both safety valves fail;

Due to a malfunction of the pressure gauge and all water indicating devices;

If all feed pumps fail and the water supply to the boiler stops;

If there is significant damage to the boiler elements (pipe rupture, cracks, bulges, leaks, etc.);

If abnormalities are detected in the operation of the boiler (shocks, knocks, noise, vibration);

When the masonry is destroyed, the frame and casing of the boiler are heated until red;

If a fire occurs that threatens the boiler.

In the event of an emergency stop, the boiler is immediately disconnected from the main steam line, the supply of fuel and air is stopped, and the draft is sharply reduced; Burning fuel in layered fireboxes is immediately removed or carefully filled with water.

Adjustment of boiler equipment is carried out in order to extend the life of the device, maintain uninterrupted operation of the heating and hot water supply system, and also in the event of breakdowns. Boiler room repairs and maintenance are carried out by specialists from organizations that monitor life safety procedures related to heating equipment.

Regime adjustment of boilers

Operational and adjustment tests are a set of calculations and adjustment work, which is carried out to increase energy saving by setting up equipment in specific conditions in accordance with the resource consumption standards specified in the project documentation. Wherein technical compliance with the parameters of all operating modes is recorded boiler rooms in accordance with load standards.

Upon completion of operational and adjustment tests, the specialist must issue a operational card, which indicates the technical parameters of the boiler, power and efficiency indicators, calculations of fuel consumption in different performance modes, automation parameters of controlled processes, safety level and compliance with equipment standards.

Over time, the technical data recorded in the card begins to change, therefore, according to the instructions, performance testing should be carried out once every 3-5 years (for boilers on solid and - at least once every 5 years, for gas - at least once every 3 years). These instructions are legally approved in the set of “Rules for the technical operation of thermal power plants.”

Operational testing is necessary when it is required:

Identify and eliminate breakdowns;
Increase fuel economy;
Reduce the formation of combustion and heating by-products;
Coordinate the operation of the boiler and increase efficiency;
Extend the service life of the thermal unit;
Test new equipment;
Calculate the thermal power.

Maintenance

Maintenance requirements for heating boilers are aimed at checking the safety and performance of the equipment. Maintenance helps maintain the operating condition of all components of the boiler room, promptly monitoring their serviceability. This type of work is carried out by specialized organizations. Calculating the cost of services is simple: the greater the power of the equipment, the higher the cost of its maintenance.

Repair

Repair work is carried out if violations or non-compliance with standards are discovered during the inspection.

Date: 10/20/2014

How safe its operation will be depends on the clear and coordinated operation of all its systems and units of such a complex heating system as a boiler room. A sudden shutdown of the boiler room can mean disruption of the production process, cold in residential or industrial premises and in educational institutions. Therefore, it is so important to comply with all established rules and regulations aimed at promptly detecting faults, eliminating them and ensuring the supply of heat to consumers. In addition, identifying possible breakdowns at an early stage can mean significant savings on equipment repairs.

Component stages of boiler room operation

commissioning;
routine maintenance of boiler room equipment;
planned preventive maintenance;
scheduled work to clean the interior of boilers and units from combustion products;
prevention of parking corrosion;
boiler room operation;
obtaining an opinion on the technical condition of the equipment.

It should be remembered that a boiler room is a very serious facility and does not tolerate neglect. The consequences can be severe - even an accident. It is extremely important to exercise proper control over the operation and technical condition of boiler equipment. Reliable and uninterrupted operation of the boiler room is largely ensured thanks to preventive measures.

The process of producing thermal energy is regulated in detail. Standards have been established for water treatment, water level and pressure in the system, technical condition of pipes, heating and boosting procedures. Failure to follow the instructions may result in the entire system stopping.

What do the boiler room operating rules require?

proper qualifications of maintenance personnel
availability of production and service instructions directly at the workplace
constant technical inspection of equipment
economical use of equipment
planned preventative and major repairs of equipment
monitoring the operation of equipment and its timely repair.

Rosgortekhnadzor of Russia has adopted a number of documents that regulate the operation of hot water and steam boiler plants, power plants and networks, gas distribution and gas consumption systems.

Based on the regulations of the Gosgortekhnadzor of Russia, instructions from factories that produce boiler equipment, the administration in charge of the boiler room is obliged to develop, approve and bring to the attention of personnel a number of instructions. Safety rules for the economical and safe operation of all boiler room equipment as a whole and each element separately are mandatory. In addition, each employee must be familiarized with his responsibilities and rights.

The operation of boiler houses is a dangerous production, during which it is necessary to comply with the norms of the Federal Law “On Industrial Safety of Hazardous Production Facilities” dated July 21, 1997 No. 116-F3. The purpose of this law is to ensure safety at all stages of production, to determine the economic and legal foundations of industrial safety.

You may also be interested in

Construction of mini-boiler houses

What to do if installing a boiler room in a house is impossible, and building a full-fledged one is not cost-effective? The optimal solution is a mini-boiler room, which has all the equipment required for heating the facility, is quickly installed and has a fairly low cost.

Basic provisions for organizing the operation of boiler houses

Operation of boiler plants

Purpose of operation of boiler rooms. Operation of boiler plants includes a set of measures aimed at ensuring safe, reliable and economical operation of all equipment and uninterrupted supply of steam and hot water to consumers at specified costs and parameters.

In connection with the explosion and fire hazard of boiler installations, Federal Law ʼʼOn industrial safety of hazardous production facilitiesʼʼ(No. 116 dated 02.21.97ᴦ.) classifies boiler installations as industrial facilities hazardous to boiler plant personnel, the population of adjacent territories and the natural environment. Based law control over the manufacture, installation and safe operation of steam boilers with a working pressure of more than 0.07 MPa (0.7 kgf/cm 2) and hot water boilers with water temperatures above 115 0 C is carried out by the federal state executive body called the Federal Environmental Service, Technological and Nuclear Supervision (abbreviated as Rostechnadzor) and its territorial bodies.

Basic requirements for boiler plant personnel. Due to the complexity of the design and maintenance of modern boilers and boiler rooms, specially trained personnel recruited from literate persons at least 18 years of age who have undergone a medical examination, training and certification are allowed to operate them.

According to the “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 State Mining and Technical Supervision of Russia” (RD 03–444–02 dated 11.01.99 ᴦ.), boiler house personnel are divided into operational management, duty and operational repair.

The operational management personnel of boiler houses include: boiler house manager, shift supervisor, shift foreman, duty dispatcher and other specialists in accordance with the staffing schedule. From among the management personnel with thermal engineering education, the enterprise administration appoints someone responsible for the good condition and safe operation of the boilers, which is recorded in the boiler passport. Only the Responsible Person has the right to give orders (must be written) to start the boiler and stop it. Certification of Responsible and Managing Specialists is carried out by Rostechnadzor bodies at least once every three years. Certification of management personnel in the field of industrial safety is carried out according to a schedule approved by the head of the enterprise.

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

Operational repair personnel include workers involved in repairs and who have the right to perform operational maintenance and make operational switches 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 boiler room operators, machinists and stokers must be carried out in educational institutions, as well as in courses specially created by enterprises and licensed by Rostechnadzor authorities for this Kind of activity. must be prepared for Individual training of personnel is not allowed. Based on the results of the final exam (with the participation of a Rostechnadzor inspector), the trainee is awarded a qualification and issued a certificate for the right to service boilers, signed by the chairman of the certification commission and the Rostechnadzor inspector. Specialists are allowed to service boilers by order of the organization.

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

An extraordinary test of the knowledge of service personnel is carried out by a 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 burn another type of fuel;

At the request of a Rostechnadzor inspector or administration.

Responsibilities of duty personnel. According to the “Standard Instructions for Safe Work Practices for Boiler House Personnel” (RD 10–319–99), boiler maintenance personnel must:

Know your responsibilities, to whom you are subordinate, whose instructions you must follow, who to notify about malfunctions, accidents, fires and accidents;

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

Be able to promptly identify problems in the operation of boilers and auxiliary equipment and pipelines, fittings, fittings, and if problems are detected, immediately eliminate them;

Be able to check the proper operation of water indicating devices, pressure gauges, safety devices, alarms, check valves, etc.;

Operate trouble-free and economically, uninterruptedly supply consumers with steam or hot water in extremely important quantity and specified quality with minimal fuel consumption;

Monitor the condition of the fittings, tighten leaking seals;

Monitor the tightness of the flange connections and the condition of the pipelines (painting, inscriptions, plates, etc.);

Check the tightness of manholes, hatches, the absence of leaks, as well as the absence of air leaks into the firebox, flues, etc.;

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

Main responsibilities of the person responsible for the good condition and safe operation of boilers defines “Standard instructions for those responsible for the good condition and safe operation of boilers” (RD 10-304-99).

The person in charge must have a special thermal 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 State Mining and Technical Supervision of Russia.”

In some cases, the Responsible Person should be a specialist who does not have a thermal engineering education, but 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 Person must undergo certification by a commission with the participation of an inspector from Rostechnadzor.

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

Allow trained and certified personnel to perform maintenance;

Provide maintenance personnel with production instructions developed on the basis of manufacturers' instructions for installation and operation, taking into account the layout of the equipment. Instructions are issued to personnel against signature and are constantly located at their workplaces;

Ensure that service personnel undergo periodic medical examinations;

Ensure the maintenance and storage of technical documentation for the operation and repair of boilers (passports, replacement and repair logs, water treatment logs, repair cards, pressure gauge control logs, etc.);

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

Regularly inspect boilers in working condition;

Every day on weekdays, inspect the boilers in working condition and check the entries in the shift log with signatures 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 qualifications;

Conduct technical inspection of boilers;

Keep boiler passports and instructions from 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 service personnel;

Timely comply with instructions issued by Rostechnadzor authorities.

The person in charge is given the right to remove personnel from service if they violate instructions or personnel who show unsatisfactory knowledge. He has the right to present to management proposals for bringing to justice engineering and technical workers and persons on duty who violate rules and instructions, as well as to submit proposals to management for eliminating the reasons that give rise to violations of the requirements of rules and instructions.

Organization of duty service. Due to the continuous long-term operation of boiler room equipment, their operation is organized through constant duty (watches) of maintenance personnel. Duties are carried out in shifts with a shift duration of no more than 8 hours. The composition of the shift is determined by the staffing schedule. The procedure for personnel joining and leaving duty is determined by the Internal Regulations.

The procedure for accepting and handing over a shift (duty). Before going on duty (approximately 20 minutes before), the shift supervisor (shift foreman) checks the availability of service personnel, their ability to be on duty, and their knowledge of their duties. After this, the shift manager briefs the staff, during which:

Indicates to each person what special attention needs to be paid when receiving, carrying and turning over a shift;

Introduces personnel to switched on and off equipment and heat consumers;

Draws attention to malfunctions and malfunctions in the operation of equipment;

Reminds us of the extreme importance of following safety rules and measures, fire safety, etc.

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

The operator (driver, fireman) taking over duty must:

– obtain information from the operator being replaced about the operation of the equipment, operating modes, operational problems, assignments for the shift and comments from management;

read the journal with all the instructions of the management;

– check the availability of water and fuel reserves;

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

check the functionality of automatic control, security and alarm systems;

– specify the time of the last purge and the time of the next purge;

– check by touch the tightness of the purge, drain valves and check valves;

– make sure there are no gas leaks and the position of shut-off and control valves on the gas pipeline at boilers, etc.

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

It is prohibited to accept or hand over shifts during the period of liquidation of an accident, fire, or during critical switching operations.

Technical documentation of the boiler room. Technical documentation includes:

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

Executive technological diagrams of boiler room systems (supply and network pipelines, steam pipelines, blowdowns and drains, 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 (RPR) of boilers and auxiliary equipment;

Job descriptions;

Instructions for safety and fire safety;

Instructions for using the gas analyzer;

Regime maps, load (heat supply) schedules;

Shift magazine;

Repair log;

Journal on instrumentation and automation;

Journal of water treatment;

Logbook for conducting briefings;

Logbook for periodic inspections and control tests of protective equipment;

Emergency training log and schedule;

Emergency containment and response plan;

Journal of the controlling persons of the enterprise;

Logbook for inspecting the route of external gas pipelines and route map;

List of works with increased danger.

Forms and drawings, technological diagrams, factory and design documentation are transferred by installation, construction and commissioning organizations to the boiler room personnel upon commissioning. Instructions are developed by boiler house management personnel based on documentation from manufacturers and standard instructions.

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

A repair log is kept for each boiler, in which the Responsible Person enters information about the repair work performed, the materials used, the welder and welding, and about boiler shutdowns for cleaning or flushing. Replacement of pipes and beading of connections of pipes with drums and collectors are noted on the pipe layout diagram 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 makes it extremely important to carry out 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 into the boiler passport.

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

Basic provisions for organizing the operation of boiler houses - concept and types. Classification and features of the category "Basic provisions for organizing the operation of boiler houses" 2017, 2018.