GB/T 16508.7-2022 English PDF (GB/T16508.7-2022)

GB/T 16508.7-2022: Shell boilers - Part 7: Installation
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GB/T 16508.7-2022
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 27.060.30
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
1 Scope
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 bui...