GB/T 16508.7-2022 English PDF (GBT16508.7-2022)
GB/T 16508.7-2022 English PDF (GBT16508.7-2022)
GB/T 16508.7-2022: Shell boilers - Part 7: Installation
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
CCS J 98
Replacing GB/T 16508.7-2013
Shell boilers - Part 7: Installation
ISSUED ON: MARCH 09, 2022
IMPLEMENTED ON: NOVEMBER 01, 2022
Issued by: State Administration for Market Regulation;
Standardization Administration of the People's Republic of China.
Table of Contents
Foreword ... 3
Introduction ... 6
1 Scope ... 8
2 Normative references ... 8
3 Terms, definitions and symbols ... 9
4 Basic requirements ... 9
5 Installation base ... 10
6 Steel structure installation ... 11
7 Boiler shell, header and heating surface installation ... 12
8 Instrument and valve installation ... 20
9 Combustion equipment installation ... 23
10 Furnace wall masonry and insulation layer construction ... 25
11 Packaged boiler and assembled boiler installation ... 25
12 Auxiliary equipment installation ... 26
13 Boiler baking, boiler boiling, tightness test and commissioning... 28 14 Acceptance ... 31
Bibliography ... 33
Shell boilers - Part 7: Installation
This document specifies the requirements for installation, commissioning and acceptance of shell boilers.
This document applies to shell boilers defined in GB/T 16508.1.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. GB/T 1576, Water quality for industrial boilers
GB/T 2900.48, Electrotechnical terminology of boilers
GB/T 12145, Quality criterion of water and steam for power plant and steam- generating equipment
GB/T 16508.1, Shell boilers - Part 1: General requirements
GB/T 16508.4, Shell boilers - Part 4: Fabrication, inspection and acceptance GB/T 16508.6, Shell boilers - Part 6: Combustion systems
GB 50126, Code for construction of industrial equipment and pipeline insulation engineering
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, Code for design of industrial equipment and pipeline insulation engineering
GB 50273, Standard for construction and acceptance of boiler installation engineering
GB 50275, Code for construction and acceptance of fan, compressor and pump a) There shall be no mechanical damage to the boiler shell, header surface and welded short pipe. Welds shall have no obvious defects such as cracks.
b) The position marks of the horizontal centerlines at both ends of the boiler shell and header shall not exceed the standard.
c) According to the requirements of the technical documents, spot check the surface roughness Ra value of 5%~10% of the expansion pipe holes. If there is no regulation, it shall meet the requirements of GB/T 16508.4.
d) The allowable deviation of the expansion pipe hole shall meet the requirements of GB/T 16508.4.
7.1.2 The following inspections shall be carried out before installation of the boiler shell, the support of the header and the hanging device:
a) The arc contact parts shall match and meet the requirements of technical documents.
b) The contact surface between the support and the steel beam shall be flat. c) The hanging device shall be firm. The installation of the spring suspension device complies with the requirements of the technical documents.
7.2 Installation of boiler shell, header and rear heating surface
7.2.1 The boiler shell shall be installed and fixed in the steel structure before it can be hoisted into place. For boiler shells directly supported by non-steel beams, firm temporary supports shall be installed. Temporary supports shall be removed before water is fed for the boiler hydrostatic test.
7.2.2 When the boiler shell and header are in place, the expansion gap of the support shall be reserved according to the expansion direction. It shall be temporarily fixed. 7.2.3 Carry out the following inspections when installing the internal devices of the boiler shell:
a) The number of parts shall not be missing.
b) The connection of steam and water supply connection partitions shall meet the requirements of technical documents.
c) The flange joint surface shall be tight.
d) The connection of the connectors shall be firm. There shall be an anti-loosening device.
7.2.4 After the boiler shell and header are installed, the center line of the boiler shell 7.4.1 Before expansion joint installation, the heating surface pipe meets the following requirements:
a) There shall be no defects such as heavy skin, cracks, flattening and severe corrosion on the surface of the pipe.
b) Alloy steel pipes shall be inspected one by one.
c) Heating surface pipes shall be inspected and corrected for shape.
d) The heating surface pipes shall be arranged neatly. The deviation between the local pipe section and the designed installation position shall meet the requirements of the drawing.
e) The inclination of the end face of the expansion joint shall comply with the design drawings and technical documents.
7.4.2 Pipe expansion operators shall understand the pipe expansion process and expansion rate parameters. The expansion test shall be carried out again when the operator is replaced.
7.4.3 When the hardness of the expansion joint end of the unannealed pipe is greater than or equal to the hardness of the boiler shell pipe plate, the pipe end of the expansion joint pipe shall be annealed. When the hardness of the expansion joint pipe end is less than the hardness of the pipe hole wall of the boiler shell pipe plate, the pipe end may not be annealed (except for the special material expansion process).
7.4.4 Before expansion, the surface oil at the end of the pipe shall be removed. Polish to a metallic sheen. Lubricating grease shall be applied inside the pipe end and on the rollers and expansion rods of the expander. Grease shall not seep into the interface between the hole and the pipe.
7.4.5 During expansion, the ambient temperature shall be 0°C or above. When the ambient temperature is below 0°C or in other bad weather, protective measures shall be taken.
7.4.6 Test expansion shall be carried out before formal expansion. The specimen shall be inspected. Expansion shall be free of cracks. The transition part of the expansion joint shall be even and smooth. There shall be no defects such as peeling, wrinkles, and cuts in the joint state of the root of the expansion pipe and the pipe hole. The contact marks and meshing conditions between the pipe hole wall and the pipe outer wall, pipe wall thinning, and pipe hole deformation shall be checked, so as to determine the pipe expansion rate.
7.4.7 The expansion joint shall be selected according to the measured data of the pipe hole directly and the outer diameter of the pipe end after grinding. The maximum gap between the expansion pipe hole and the pipe end shall meet the requirements of design drawings and process documents.
7.4.8 Expand the pipe according to the requirements of GB/T 16508.4, and meet the following requirements:
a) After the pipe end is installed in the pipe hole, it shall be expanded immediately. b) After the reference pipe is fixed, it shall be expanded from the middle to both sides.
c) Calculate the pipe expansion rate according to the inner diameter control method or the outer diameter control method. When using the inner diameter control method, the pipe expansion rate shall not exceed the range of 1.0%~2.1%. When using the outer diameter control method, the pipe expansion rate shall not exceed the range of 1.0%~1.8%.
7.5 Hydrostatic test
7.5.1 During boiler installation, the pressure elements shall undergo hydrostatic test after non-destructive testing and heat treatment.
7.5.2 After the installation of the pressurized steam and water system of the boiler and its accessories is completed, a hydraulic test shall be carried out. Before installation of cast iron economizers, it is advisable to carry out hydrostatic test one by one (or group). 7.5.3 The main steam valve, water outlet valve, blowdown valve and feed water shut- off valve shall be subjected to hydrostatic test together with the boiler. The safety valve shall be subjected to pressure test independently.
7.5.4 Carry out the following checks before the hydrostatic test.
a) Internal cleaning and surface inspection shall be carried out for pressure components (elements) such as boiler shells and headers.
b) Water cooling walls, convection pipe bundles and other pipes shall be kept unblocked.
c) There shall be no less than 2 pressure gauges installed. For boilers with rated working pressure less than 2.5 MPa, the accuracy level of the pressure gauge shall not be lower than 2.5. For boilers with a rated working pressure of not less than 2.5 MPa, the accuracy level of the pressure gauge shall not be lower than 1.6. The pressure gauge shall be calibrated as qualified. The range of the dial shall be 1.5 to 3 times the test pressure, preferably 2 times.
d) Install drainage pipes at the lowest point of the system. Install a vent valve at the highest point of the system.
7.5.5 During the installation process of the boiler, the hydraulic pressure test of the requirements:
a) The materials, elements and manufacture of pressure piping shall meet the requirements of relevant manufacturing supervision and inspection of boiler components.
b) The opening of pressure piping and equipment shall meet the requirements of design drawings and process documents.
c) When the pressure taking device and the temperature measuring element are installed on the same pipe section, the pressure taking device shall be installed upstream of the temperature measuring element.
d) The installation of the flowmeter shall be in accordance with the requirements of the technical documents. Determine the installation location according to the length requirements of the front and rear pipelines of the flowmeter to ensure the correctness of the flowmeter measurement.
8.1.3 The installation of the temperature measuring device complies with the following requirements:
a) The installation position of the temperature measuring element shall meet the requirements of the technical documents.
b) The material of the thermometer socket shall be the same as that of the main piping. 8.1.4 The installation of the pressure measuring device complies with the following requirements:
a) Pressure measuring points shall meet the requirements of technical documents. b) When the local pressure gauge fluctuates violently, a buffer device shall be installed behind the secondary door.
c) The indicator red line of the working pressure of the boiler shell shall be marked on the boiler shell pressure gauge.
8.1.5 The pressure-taking device installed on the furnace wall and flue shall be inclined upward. It shall not extend into the inner wall of the furnace wall and flue. 8.1.6 The installation of the water level gauge meets the following requirements: a) The glass pipe (plate) water level gauge shall be marked with the words "maximum water level", "minimum water level" and "normal water level".
b) The electric contact water level gauge shall be installed vertically. Its design zero point shall coincide with the normal water level of the boiler shell.
9.1.3 The grate shall not be too tight or too loose when assembling. After assembly, inspection shall be carried out according to the requirements of technical documents. There shall be an expansion gap between the grate and the wall around the grate. There shall be an adjustment margin for the grate tensioning device.
9.1.4 The cold test run of the grate shall be carried out before the furnace is built. The following requirements shall be met:
a) Cold test run time: for chain grate, it shall not be less than 8 h; for reciprocating grate, it shall not be less than 4 h.
b) When the grate is running at an accelerated speed, check the action of the safety mechanism of the transmission device.
c) When the grate rotates smoothly, there shall be no abnormal sound, jamming, vibration and deviation. The grate shall be able to turn over freely without protrusions.
d) The roller rotation shall be flexible. The meshing with the sprocket shall be stable without jamming. The temperature of lubricating oil and bearing shall be normal. 9.1.5 Coal gates and grate bearing cooling devices shall be hydraulically inspected in accordance with the requirements of technical documents and product instructions. 9.1.6 Coal gate lift shall be flexible. The opening and the distance deviation between the lower edge of the coal gate and the grate surface shall meet the requirements of technical documents and product instructions.
9.1.7 The damper, the grate air pipe and its flange joints, the air chambers of each section, and the ash-falling door shall be flat and sealed. The slag-stop iron shall fit neatly on the grate surface. When the grate is running, there shall be no resistance or overturning. The gap between the side sealing block and the fire grate shall meet the requirements of the technical documents.
9.2 Burner installation
9.2.1 Matching burners shall meet the requirements of technical documents. Product technology, quality, and environmental certification materials shall be complete. 9.2.2 The reserved burner installation position shall be correct. Prevent the flame from directly scouring the surrounding heating surface.
9.2.3 Before the burner is installed, the overall dimensions of the burner shall be checked. The installation of the burner shall meet the requirements of technical documents, product instructions and GB/T 16508.6.
10 Furnace wall masonry and insulation layer construction
10.1 Furnace wall masonry shall pass the boiler water pressure test. The installation quality of all the parts built into the wall, the water pipes and the supporting and hanging devices of the furnace top meet the design requirements.
10.2 The construction of furnace wall masonry and insulation layer shall comply with the relevant regulations of GB 50211, GB 50126 and GB 50264.
10.3 The type of insulation layer, the location of expansion joints, and the strength, bulk density, thermal conductivity, and specification of insulation materials shall meet the requirements of the technical documents.
10.4 Before the construction of the heat insulation layer, the oil stains and rust on the surface of the heat insulation parts such as the boiler shell, header, metal flue, air duct, and pipe shall be removed. Apply corrosion-resistant paint according to the requirements of technical documents.
10.5 The construction of the heat insulation layer shall be carried out after the strength test or tightness test of the metal flue, air duct, pipe and other insulated parts have been passed. When the thermal insulation material is made of molded products, the seams shall be staggered, and the inner and outer layers shall be seamed. The allowable deviation of the heat insulation layer shall meet the requirements of the technical documents.
11 Packaged boiler and assembled boiler installation
11.1 Before installation, the boiler or parts shall be counted according to the boiler exit- factory data. Review the integrity of boiler equipment. Check whether there is any damage or deformation during transportation.
11.2 Before the boiler or components and parts are put in place, the foundation size and position shall be checked. The allowable deviation shall comply with the technical documents or the requirements of Chapter 5.
11.3 Before the boiler or components and parts are in place, the components and parts shall be placed in the designated place according to the requirements of the boiler installation technical data. Carry out boiler or components and parts in place according to the requirements of technical documents. In-place movement can be done in the following ways:
a) When pulling to move, place multiple steel pipes under the moving support of the boiler part. Pull with a wire rope. Pay attention to the position where the wire rope is placed. Do not damage the boiler or its components or parts.
requirements of technical documents and product instructions.
12.2.2 Before the pump is installed, unpacking and acceptance shall be carried out according to the following requirements:
a) The pump and supporting parts shall be free from missing parts, damage and corrosion, etc. Inlet and outlet protection shall be intact.
b) The main installation dimensions of the pump shall comply with the requirements of technical documents and product instructions.
12.2.3 The installation of the pump shall comply with the requirements of technical documents and product instructions. When the requirements are not clear, it shall comply with the requirements of GB 50275.
12.2.4 In addition to complying with the provisions of GB 50231, the installation of piping shall also meet the following requirements:
a) The inside of the pipe and the end of the pipe shall be cleaned and cleared of debris. The sealing surface and thread shall not be damaged.
b) Suction piping and output piping shall have separate brackets. The pump shall not bear the weight of the piping directly.
12.2.5 The test run of the pump shall be carried out after the separate test run of its subsidiary systems is normal. The test run shall be carried out in the presence of medium. The medium or substitute medium for trial operation shall meet the requirements of technical documents and product instructions.
12.3 Installation acceptance
12.3.1 Fans and pumps shall pass the test run before going through the project acceptance procedures.
12.3.2 The following information shall be available for project acceptance: a) Exit-factory technical documents of the equipment;
b) Unpacking inspection records;
c) Basic review records;
d) Relevant information on design changes;
e) Various actual measurement records and concealed process records during the installation process;
f) Completion data such as test run records.
13 Boiler baking, boiler boiling, tightness test and commissioning
13.1 Boiler baking
13.1.1 Before baking the boiler, a boiler baking plan shall be formulated and the following requirements shall be met:
a) The boiler and its water treatment, steam water, sewage discharge, material conveying, slag removal, air supply, dust removal, lighting, circulating cooling water and other systems have been installed and passed the test run.
b) After the furnace body masonry and insulation layer construction is completed, the furnace body air leakage test is qualified.
c) The thermal and electrical instruments (such as water level gauges, pressure gauges, temperature measuring instruments, etc.) required for boiler baking shall be installed and debugged.
d) Boiler feed water shall meet the requirements of GB/T 1576 or GB/T 12145. e) After the expansion indicators on the boiler shell and header are installed, they shall be adjusted according to the requirements of the technical documents in the cold state.
f) Temperature measurement points or mortar sampling points on the furnace wall shall be set.
g) There shall be an oven temperature rise curve.
h) Piping, air ducts, flue ducts, gray ducts, valves and baffles shall be marked with medium flow direction, opening direction and opening degree indication. i) The inside and outside of the boiler and all passages shall be cleaned. 13.1.2 According to the site conditions, flame, steam and other methods can be used for boiler baking. Shell boilers with water cooling walls shall use steam to bake. 13.1.3 Boiler baking with flame shall meet the following requirements:
a) The flame shall be concentrated in the center of the hearth. It is suitable to bake with slow fire at the beginning. The fire shall be uniform and increase slowly. b) The mechanical grate shall be rotated regularly during the baking process to prevent the grate from burning.
c) For the furnace wall of refractory castables, the temperature rise of the furnace shall be started after the curing period expires. It shall be measured according to 13.2.3 The medicine shall be dissolved into a liquid and added to the boiler. There shall be safety measures when configuring and adding liquid medicine.
13.2.4 The boiler water shall be at a low level when dosing. When boiling the boiler, the liquid medicine shall not be carried into the superheater.
13.2.5 The boiling time shall be 48 h ~ 72 h. It is advisable to keep the pressure at 75% of the rated working pressure in the last 24 h of boiling. When boiling at a lower pressure, the boiling time shall be extended.
13.2.6 Water samples shall be regularly taken from the boiler and the lower header of the water cooling wall for water quality analysis during the boiler boiling period. When the alkalinity of boiler water is lower than 45 mol/L, supplementary dosing shall be made.
13.2.7 After the boiler is boiled, water supply and sewage discharge shall be carried out alternately until the water quality meets the requirements of GB/T 1576 or GB/T 12145. Then stop the boiler and drain. Flush the inside of the boiler and the valves in contact with the liquid medicine, etc. Remove the sediment inside the boiler shell and header. Ensure that the blowdown valve is not blocked.
13.2.8 After the boiler is boiled, the oil dirt on the inner wall of the boiler shell and the header shall be removed. Ensure that there is no rust on the metal surface. 13.3 Tightness test and commissioning
13.3.1 After the boiler is baked and boiled, the tightness pressure test shall be carried out according to the requirements of the technical documents. Follow the requirements below:
a) After the pressure is increased to 0.3 MPa ~ 0.4 MPa, the bolts of flanges, manholes, handholes and other connecting parts within the boiler pressure test range shall be fastened once in a hot state.
b) After continuing to increase the pressure to the rated working pressure, check the tightness of manholes, hand holes, valves, flanges and cushions within the pressure test range. At the same time, observe the thermal expansion of the boiler shell, header, pipeline and support.
13.3.2 After the tightness pressure test is qualified, the safety valve shall be finally adjusted. The adjusted safety valve shall be locked or sealed immediately. 13.3.3 After the safety valve is adjusted, the boiler shall be commissioned in the cold state of the system and the hot state of the overall startup.
13.3.4 During the startup process of the boiler, the pressure shall be increased slowly according to the requirements of the pressure increase curve provided by the boiler manufacturer.
13.3.5 After commissioning, the assembled boiler shall be continuously tested for 48 h under a certain load. It is advisable to conduct a continuous test run of 4 h ~ 24 h for the packaged boiler.
14.1 After the boiler has passed continuous test runs, the project acceptance can be carried out. Unaccepted boilers shall not be put into use.
14.2 The acceptance of the installation project of the assembled boiler shall at least have the following information:
a) Commencement report;
b) Inventory records of boiler technical documents (including related documents of design modification);
c) Equipment defect list and repair records;
d) Installation foundation inspection records;
e) Steel structure installation records;
f) Quality inspection records of pad iron and grouting layer under the bottom plate of steel structure column;
g) Passing ball test records of heating surface pipes of boiler proper; h) Valve hydraulic test records;
i) Installation records of boiler shell, header, economizer, superheater and air preheater;
j) Pipe end annealing records;
k) Actual measurement records of expansion pipe holes and pipe ends;
l) Boiler expansion records;
m) Inspection records and inspection reports for welding quality of heating surface pipes;
n) Hydrostatic test records and visas;
o) Boiler shell sealing inspection record;