燃气锅炉维护检修规程

燃气锅炉维护检修规程

二○○七

目 录

1

总则 ························································································································· 739

2 完好标准 ················································································································ 741 3 燃气锅炉的维护 ···································································································· 742

3.1 维护 ················································································································ 742 3.2 常见故障和处理方法 ···················································································· 743

4 燃气锅炉的检验 ···································································································· 747

4.1 外部检查 ········································································································ 747 4.2 内外部检查 ···································································································· 748 4.3 压力试验 ········································································································ 748 4.4 定期检验 ········································································································ 750

5 燃气锅炉的修理 ···································································································· 750

5.1 检修周期 ········································································································ 750 5.2 检修内容 ········································································································ 751

5.3 检修方法及质量标准 ···················································································· 752 6 试车与验收 ············································································································ 764 7 维护检修安全注意事项 ························································································ 765 8

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附件 燃气锅炉的化学监督与管理 ····································································· 766

1 1.1

总则 适用范围

根据山西太原锅炉集团有限公司所提供的《TG－40/3.82/350－Q锅炉产品说明书》、《TG－35/3.82－Qg型锅炉安装使用说明书》和原化学工业部制订的《化工厂工业锅炉运行和检修规程》以及其它有关资料，编制本规程。

本规程适用于TG－40/3.82/350－Q燃气锅炉(以下简称为“锅炉”)的维护与检修。锅炉的附属设备如引风机、送风机等的检修按各自维修规程执行。

本规程与国家或上级有关部门的规定相抵触时，应遵循国家和上级有关部门制定的一切规定。 1.2

结构简述

TG－40/3.82/350－Q燃气锅炉由炉膛、上锅筒及汽液分离器、燃烧器、空气预热器、过热器、省煤器、炉墙、钢架平台、安全阀等附件组成。 1.2.1

炉膛：炉膛断面为437034370(宽3深)，采用全膜式水冷壁结构，前、后及两侧

冷水壁各有43根管子(管径为￠5135)，采用悬吊结构。炉膛结构具有密封性能和传热效果好的特点，可预防煤气泄漏而导致人员中毒事故的发生。 1.2.2

上锅筒(汽包)：采用单锅筒横向布置，由20g钢板卷制而成，内径￠1400mm，壁

厚42mm，筒身直段长度7300mm，通过锅筒座支在锅炉大梁上。上锅筒上设有压力表、安全阀、水位表、平衡容器管座等附件；为保证蒸汽品质，锅筒 内装有汽水分离设备、给水、加药及连续排污等装置。 1.2.3

汽液分离器：一次汽液分

离器为14个￠290的旋风分离器；二次分离器为多孔板加钢丝网的组合分离装置。 1.2.4

燃烧器(如图1)：

在锅炉的侧墙布置四台多管式燃烧器。燃烧器由煤气管系、煤气

７３９

喷嘴、空气管、空气调节系统、空气压力信号管和旋风叶片等零件组成。 1.2.5

空气预热器：空气预热器为管式双回程结构，由￠4031.5的有缝钢管及管板、

框架等组成，空气 经过预热后进入燃烧器与煤气一起送入炉膛燃烧。 1.2.6

.过热器：在炉膛后水平烟道内布置高、低两级过热器，高温过热器在前，低温

过热器在后，两者之间有面式减温器；过热器由￠3833.5的20#无缝钢管弯制而成。 1.2.7 1.2.8

省煤器：由￠3233的20#无缝钢管制作，三级布置，整个省煤器由尾部钢架支撑。 炉墙：炉膛膜式壁部分为敷管炉墙；中部及尾部炉墙采用轻型炉墙，由托架支撑，

炉墙外围全部用蒙皮包装。炉墙材料由耐火砖、硅酸铝纤维毡、岩棉等组成。 1.2.9

钢架平台：钢架由8根型钢组合柱、梁和顶板组成一个整体，用来承受锅炉的全

部负荷，构架按8级地震区室外布置设计。该炉设有6层平台，两层平台之间有扶梯相连，平台的承载能力为200Kg/m2。 1.3

主要性能

燃气锅炉的主要技术指标如下： 锅炉型号 额定蒸发量 额定蒸汽压力 额定蒸汽温度 给水温度 锅炉热效率 排烟温度 燃烧方式

锅炉烟尘排放浓度 烟气黑度

TG－40/3.82/350－Q 40吨/小时 3.82MPa 350℃ 104℃ 92.42% 143℃ 室燃 ＜50mg/m3 ＜1级

锅炉在70%～100%额定负荷范围内运行时，过热蒸汽温度能达到额定值，偏差不超过＋5/－15℃(即过热蒸汽温度为335℃～355℃)。

燃气组成(设计值，体积%) ⑴

PSA装置解吸气

H2 12.5%； CO 51.5%； CH4 0.86%； N2＋Ar 15.21%； CO2 16.02%； 气量 4612.6Nm3/h； 热值Qydw 8510KJ/Nm3； 煤气压力(炉前) 2500～3500Pa。

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⑵ 城市煤气

H2 65.6%； CO 5.4%； CH4 23.4%； O2 0.3%； CmCn 1.8%； N2 2.0%； CO2 1.6%； H2S ＜20mg/m3； NH3 ＜50mg/m3； 热值Qydw 17280KJ/Nm3； 煤气压力(炉前) 2500～3500Pa。 两种燃料气在气柜中混合后供锅炉使用。 2 2.1 2.1.1

完好标准 零、部件

燃气锅炉的零、部件及附件完整齐全，安全附件如安全阀、压力表完好、齐全并

按规定定期校验。 2.1.2

仪表、计量器具和各种安全装置齐全，完整，灵敏，准确、可靠，并按规定定期

进行校验。 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7 2.2 2.2.1 2.2.2 2.2.3 2.3 2.3.1 2.3.1.1 2.3.1.2

基础无倾斜、下沉、裂纹等现象。

各部连接螺栓、地脚螺栓紧固齐整，无锈蚀，符合技术要求。

管道、管件、阀门、管架等安装合理，牢固完整，标志分明，符合要求。 燃气锅炉汽水管路焊接质量均符合技术要求。 防腐、保温设施完整有效，符合技术要求。 运行性能

燃气锅炉各部温度、压力、流量等参数符合技术要求。 燃气锅炉各部位阀门开关正常。 工作能力达到铭牌出力或查定能力。 技术资料

燃气锅炉的设备档案齐全，各项记录填写及时、准确；设备档案内容如下： 设计单位提供的设计图样和设计、安装(使用)说明书；

燃气锅炉的设备卡片及运行、缺陷、检修、事故记录；运行时间和累计运行时间

有统计记录；燃气锅炉的密封点统计准确并有消除泄漏的记录； 2.3.1.3

燃气锅炉的设备图纸齐全，包括制造厂提供的竣工图(如在原蓝图上修改，则必

须有修改人、技术审核人的确认标记)、产品质量证明书、产品安全质量监督检验证书； 2.3.1.4 料；

燃气锅炉的安装检验记录；运行中的检验、检测记录，以及有关的技术文件和资

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