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GB/T 16508.7-2013 English PDF (GBT16508.7-2013)

GB/T 16508.7-2013 English PDF (GBT16508.7-2013)

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GB/T 16508.7-2013: Shell boilers -- Part 7: Installation

This Part of GB/T 16508 specifies the installation requirements of stationary shell boiler. This Part is applicable to the shell boilers defined within the scope of GB/T 16508.1.
GB/T 16508.7-2013
NATIONAL STANDARD OF THE
PEOPLE REPUBLIC OF CHINA
ICS 27.060.30
J 98
Shell Boilers -- Part 7: Installation
ISSUED ON: DECEMBER 31, 2013
IMPLEMENTED ON: JULY 1, 2014
Issued by: General Administration of Quality Supervision, Inspection and Quarantine of the PRC;
Standardization Administration of the PRC.
Table of Contents
Foreword ... 3
1 Scope ... 4
2 Normative References ... 4
3 Terms and Definitions ... 5
4 Basic Requirements ... 5
5 Foundation Inspection and Marking Out ... 6
6 Steel Frame Installation ... 6
7 Shell, Header and Heating Surface Tube ... 7
8 Tubular Air Preheater Installation ... 13
9 Instrument and Valve ... 13
10 Combustion Equipment ... 16
11 Boiler Setting Construction and Heat Insulating Layer ... 18
12 Installation of Integrative and Shop-assembled Boilers ... 19
13 Installation of Such Auxiliary Machine as Fan and Pump ... 20
14 Drying-out, Boiling-out, Tightness Test and Test Run ... 22
15 Acceptance ... 25
Shell Boilers -- Part 7: Installation
1 Scope
This Part of GB/T 16508 specifies the installation requirements of stationary shell boiler. This Part is applicable to the shell boilers defined within the scope of GB/T 16508.1. 2 Normative References
The following documents for the application of this document are essential. Any dated reference, just dated edition applies to this document. For undated references, the latest edition (including any amendments) applies to this document.
GB/T 1576 Water Quality for Industrial Boilers
GB/T 2900.48 Electrotechnical Terminology of Boilers
GB/T 10180 Thermal Performance Test Code for Industrial Boilers
GB/T 16508.1 Shell Boilers - Part 1: General Requirements
GB/T 16508.4 Shell Boilers - Part 4: Fabrication, Inspection and Acceptance GB/T 16508.5 Shell Boilers - Part 5: Safety Appurtenances and Instruments GB 50211 Code for Construction and Acceptance of Industrial Furnaces
Building
GB 50231 General Code for Construction and Acceptance of Mechanical
Equipment Installation Engineering
GB 50264 Design Code for Insulation Engineering of Industrial Equipment and Pipe
GB 50273 Code for Construction and Acceptance of Boiler Installation
Engineering
TSG G0001 Boiler Safety Technical Supervision Administration Regulation Supervision Administration Regulation (TSG G3001).
4.2 Prior to construction, the installation and construction organizations may carry out construction only after informing the special equipment safety supervision department of the boiler equipment installation condition.
4.3 The boiler installation work shall meet those specified in Boiler Safety Technical Supervision Administration Regulation (TSG G0001), and the installation process shall be subjected to the supervision and inspection of national special equipment safety supervision and inspection organization; the boiler failing to pass the supervision and inspection shall not be put into service.
4.4 Qualifications of operating personnel for welding or non-destructive testing shall meet those specified in GB/T 16508.1.
4.5 During the installation of boiler, in case of quality problems (pressure component influences safe application), the installation shall be stopped.
4.6 After the completion of boiler installation, the installation organization shall hand over the relevant technical data to the using organization within 30 days after acceptance.
4.7 Boiler using organization shall establish safety technical file of boiler equipment. 5 Foundation Inspection and Marking Out
5.1 Before boiler and its auxiliary equipment are put in place, the foundation dimension and position shall be inspected, and the permissible deviation shall meet those specified in boiler equipment technical document; if there is no requirement, the permissible deviation shall meet those specified in GB 50273.
5.2 Before shell boiler installation, vertical and transversal installation reference lines as well as elevation reference point shall be marked.
6 Steel Frame Installation
6.1 Before steel frame installation, the quantity of members shall be checked against construction drawing and such primary members as upright column, girder, etc. shall be inspected, and the permissible deviation shall meet those specified in boiler equipment technical document; if there is no requirement, it shall meet those specified in GB 50273.
in GB/T 16508.4.
7.1.2 Before installing the support and suspension device of shell and header, the following contents shall be inspected:
a) The arcs of the contact parts shall be fit and meet the requirements of design document;
b) The contact between support and steel beam shall be in good condition; c) Suspension device shall be firm, and the installation of spring suspension device shall meet the requirements of design document.
7.2 Installation requirements
7.2.1 After the steel frame is installed and fixed, the shell may be hoisted and put in place; as for shell not directly supported by steel beam, firm temporary support shall be installed, and the temporary support shall be removed before feeding water for boiler hydrostatic test.
7.2.2 As for putting shell and header in place, expansion clearance of support shall be reserved in their expansion direction, and they shall be temporarily fixed. 7.2.3 As for the installation of devices in the shell, the following contents shall be inspected:
a) The quantity of parts shall not be short;
b) The connection of steam or water supply connection clapboard shall meet the requirements of design document;
c) The flange joint surface shall be tight;
d) Connection of the connecting pieces shall be firm and the looseness preventing device shall be arranged.
7.3 Installation acceptance requirements
After the installation of shell and header is completed, the center lines of shell and header shall be measured according to vertical and transversal installation reference lines as well as elevation reference line, and the permissible deviation shall meet those specified in boiler equipment technical document; if there is no requirement, the permissible deviation shall meet those specified in GB 50273.
b) The non-destructive testing shall meet those specified in GB/T 16508.4; c) In case the result of non-destructive testing is unqualified, the unqualified welds shall be repaired, and re-inspection shall be carried out for the welded joints of the same kind welded by the corresponding welder with double quantity of the unqualified welds; in case there is still unqualified weld in re-inspection, flaw inspection shall be carried out for all the welded joints of the same kind welded by the corresponding welder;
d) In case undesirable defect is found in welded joints through radiographic inspection, the reason shall be found out, feasible repair scheme shall be made and then the welded joint may be repaired; the number of times for repairing on the same part shall not exceed 2, otherwise, the repair shall be approved by the technical director of the organization, and the repaired part, the number of times and the repair condition shall be recorded in the technical files of the boiler product.
7.4.8 All the auxiliary welding parts on the tube shall be welded before hydrostatic test.
7.4.9 The arrangement of tube bank after installation shall be trim and shall not influence brickwork (brick hanging).
7.4.10 In case heat treatment is necessary after welding, it shall be carried out after all the welding works are completed and pass the inspection, and generally partial heat treatment is adopted. Before heat treatment, the heat treatment process shall be compiled according to corresponding standard and drawing; the heat treatment equipment shall be inspected and shall meet the requirements of the heat treatment process; all the indexes of post-weld heat treatment shall meet the requirements of heat treatment process.
7.4.11 The weld and the heating width at its both sides shall not be less than 3 times of wall thickness of the tubes at both sides of the welded joint (the larger value prevails) or not be less than 200mm. In partial heat treatment, sufficient insulation materials shall be provided to cover the zone adjacent to parts outside the hot zone so that no harmful temperature gradients will generate.
7.5 Expansion connection of heating surface tube
7.5.1 Before the expansion connection installation of heating surface tube, the following requirements shall be met:
a) The tube surface shall be free from such defects as double-skin, crack, flattening and severe corrosion;
be carried out immediately;
b) After the reference tube is fixed, the expansion connection should be carried out from center to both sides;
c) Expanding efficiency shall be calculated according to the change value of tube inside diameter before and after expansion connection (hereinafter referred to as inside diameter control method), or calculated according to the outside diameter of tube adjacent to shell outer wall after expansion connection (hereinafter referred to as outside diameter control method).
7.5.8 In order to ensure the normal operation of tube expansion work, during production, the operating personnel of each shift shall carry out trial expansion for once. 7.6 Hydrostatic test
7.6.1 As for the pressure-bearing steam and water systems of boiler as well as their accessory devices, after the installation is completed, they shall be subjected to hydrostatic test. Before installation of cast-iron economizer, they should be subjected to hydrostatic test piece by piece (or set by set).
7.6.2 Main steam valve, outlet valve, blowdown valve and feedwater stop valve shall be subjected to hydrostatic test together with boiler; the safety valve shall be subjected to hydrostatic test separately.
7.6.3 The inspection before hydrostatic test shall meet the following requirements: a) Such pressure components (parts) as shell and header shall be subjected to internal cleaning and surface inspection;
b) Water-cooled wall, convection tube bank and other tubes shall be inspected and shall be unblocked;
c) The quantity of installed pressure gage shall not be less than 2; as for boiler with the rated working pressure less than 2.5MPa, its accuracy grade shall not be lower than Grade 2.5; as for boiler with the rated working pressure larger than or equal to 2.5MPa, its accuracy grade shall not be lower than Grade 1.6. The pressure gage shall be calibrated and qualified, its dial measuring range shall be 1.5~3 times of the test pressure, and twice of test pressure should be selected;
d) Drainage pipeline shall be installed at the lowest point of the system and air release valve shall be installed at the highest point of the system.
9.1.4 The installation of temperature measuring device shall meet the following requirements:
a) The installation position of the temperature measuring part shall meet the requirements of design document;
b) The material of the thermometer socket shall be the same as that of the main piping.
9.1.5 The installation of the pressure measuring device shall meet the following requirements:
a) The pressure measuring point shall meet the requirements of design document; b) In case local pressure gauge is used to measure remarkably fluctuated pressure, buffer device shall be installed behind the secondary valve;
c) The shell pressure gage shall be marked with red line indicating the operating pressure of shell.
9.1.6 The pressure-obtaining device installed on boiler setting and flue shall be inclined and upward and shall not stretch into the inner wall of the boiler setting and the flue.
9.1.7 The installation of the water gauge shall meet the following requirements: a) The water gauge of glass tube (plate) type shall be indicated with "maximum water level", "minimum water level" and "normal water level";
b) Electric contact water gauge shall be installed vertically, and its design zero point shall coincide with the normal water level of the shell;
c) Before installation of shell water level balancing vessel, the manufacturing dimension and the tightness of the internal pipeline shall be checked; it shall be installed vertically; positive and negative pressure tubes shall be led out horizontally and let the design zero position of the balancer coincide with the normal water line.
9.1.8 The action of signal device shall be sensitive and reliable, its action value shall be set according to the requirements, and it shall be subjected to simulation test. 9.1.9 Thermal process protection and interlocking devices shall be subjected to subitem and complete set of linkage test by system, and the action shall be correct and reliable.
a) The safety valves shall be subjected to tightness test one by one;
b) The set pressure of boiler safety valve shall meet those specified in GB/T 16508.5;
c) The safety valve shall be vertically installed and equipped with dribble pipe; the dribble pipe shall be directly led to safe place and possess sufficient sectional area and be taken with anti-freezing measures so that the discharge is
unblocked;
d) The safety valve, after being adjusted and passing the inspection, shall be marked.
9.2.4 The installation of fixed tube type soot blower shall meet those specified in design document and product instruction. The soot blower pipeline shall be with gradient and enable the condensed water to pass through the drain valve to flow out; the thermal insulation of the pipeline shall be in good condition.
10 Combustion Equipment
10.1 Requirements for grate plate installation
10.1.1 The inspection of chain grate before installation shall meet those specified in GB 50273.
10.1.2 During chain grate installation, the permissible deviation shall meet those specified in GB 50273.
10.1.3 The scale type chain grate or bar and key grate shall be measured in its tightened state, and the relative length difference of each chain shall meet those specified in GB 50273.
10.1.4 Grate plate assembling shall be free from over tightness or over looseness; after assembly, the grate plate shall be wrenched with hand and it should rotate flexibly. 10.1.5 There shall be expansion clearance between grate bar at edge part and wallboard.
10.1.6 As for installation of reciprocating grate, the permissible deviation shall meet those specified in GB 50273.
10.1.7 The test run of grate in cold state shall be carried out before boiler construction and shall meet the following requirements:
b) The coaxiality of air register throat and oil gun shall meet those specified in design document and product instruction;
c) The inside of oil gun, nozzle and mixer shall be clean without blocking; the oil gun shall be free from bending deformation.
10.2.2 As for combustor installation, the air register shall be able to be adjusted flexibly; the permissible installation deviation of combustor shall meet those specified in design document and product instruction.
11 Boiler Setting Construction and Heat Insulating Layer
11.1 Requirements for boiler setting construction
11.1.1 Boiler setting construction and heat insulating layer construction shall comply with those specified in this Part as well as the relevant requirements of GB 50211 and GB 50264.
11.1.2 As for the boiler setting construction, it shall be carried out after the boiler hydrostatic test is passed and the installation quality of supporting and lifting devices for parts, water tubes and boiler tops to be built in wall is regarded to meet the design requirements.
11.1.3 Brick processed surface and defective surface should not face towards furnace or internal surface of boiler passage.
11.1.4 After the clay brick of boiler setting reaches certain height, the red brick shall be built at external wall; guy brick shall be laid where the heights of inner and outer layers of the boiler wall are basically equivalent.
11.1.5 As for external wall construction with red brick, steel tube with short section shall be buried at proper part or temporarily reserve a gap for a header brick as exhaust steam hole for drying-out; the hole shall be blocked after drying-out is completed. 11.1.6 As for combustor hole construction, central position, elevation and inclination angle of the hole shall meet the design requirements.
11.1.7 Type and preparation ratio of refractory castable shall meet the design requirements; casting body surface shall be free from such defects as peeling, crack or hole.
11.1.8 As for the upright column, girder, door frame, peephole, tube and header built in the boiler setting, their surfaces contacting the fire-resistant masonry shall be paved no requirement, the permissible deviation shall meet those specified in GB 50273. 12.2 Boiler equipment acceptance
After the boilers arrive, the parts and components shall be checked, the equipment integrity shall be re-checked and whether the large parts of the boiler are damaged or deformed during transportation shall be inspected within specified time according to manufacturer's data accompanying the boiler; in case of missing part or damaged part, the boiler manufacturer shall be contacted at appointed time.
12.3 Unloading of integrative boiler (or large part of shop-assembled boiler) As for unloading of integrative boiler (or large part of shop-assembled boiler), it shall be moved by pulling or lifting according to the requirements of data accompanying the boiler. In case it is moved by pulling, several steel tubes may be used at the bottom of the support for moving the boiler large part and pull with steel wire rope; during pulling, attention shall be paid to the position for putting the steel wire rope, which shall not damage any part of the boiler large part; in case it is moved by lifting, the capacity of the arranged lifting equipment shall meet the requirements for lifting the boiler large part, the lifting point shall be at the appointed location of boiler large part, and the boiler large part shall not be lifted at any other locations.
12.4 Boiler overall installation
12.4.1 Before putting the integrative boiler (or large part of shop-assembled boiler) in place, the parts and components stored in advance shall be put at appointed locations according to the requirements of boiler installation.
12.4.2 After the boiler large part is put in place, its level shall be corrected, and the permissible deviation shall meet those specified in boiler equipment technical document; if there is no requirement, the permissible deviation shall meet those specified in GB 50273; in case the permissible deviation is exceeded, iron gasket may be used for correction.
12.4.3 The shop-assembled boiler shall be assembled according to the requirements of data accompanying the boiler, the dimension of assembly position as well as the longitudinal center deviation and the slope deviation and the like of each large part shall meet those specified in boiler equipment technical document; the contact surface of each large part shall be fixed and filled with filler for sealing as required. 13 Installation of Such Auxiliary Machine as Fan and Pump
13.1 Fan installation
13.2.4 Piping installation shall meet those specified in GB 50231 as well as the following requirements:
a) The tube inside and tube end shall be washed and cleaned, and the sundries shall be removed; the sealing surface and the thread shall not be damaged; b) Suction line and output line shall have their su...

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