Equipment for boiler rooms: additional devices. Schemes of boiler plants
DEVICE OF THE MAIN AND AUXILIARY EQUIPMENT OF THE BOILER ROOM AND ITS OPERATION
FOREWORD
“Gas is safe only with technically competent operation
gas boiler room equipment.
The operator's training manual provides basic information about a hot water boiler house operating on gaseous (liquid) fuel, and considers the schematic diagrams of boiler houses and heat supply systems for industrial facilities. Also in the guide:
- basic information from heat engineering, hydraulics, aerodynamics is presented;
- provides information about energy fuel and the organization of their combustion;
- issues of water treatment for hot water boilers and heating networks are covered;
- the device of hot water boilers and auxiliary equipment of gasified boiler houses is considered;
- the schemes of gas supply of boiler houses are presented;
- a description of a number of control and measuring instruments and schemes of automatic control and safety automation is given;
- great attention was paid to the operation of boiler units and auxiliary equipment;
- issues on preventing accidents of boilers and auxiliary equipment, on providing first aid to victims of an accident;
- the basic information on the organization of the effective use of heat and power resources is given.
This manual for the operator is intended for retraining, training in a related profession and advanced training for operators of gas boilers, and can also be useful: for students and students in the specialty "Heat and Gas Supply" and for operational dispatch personnel when organizing a dispatch service for the operation of automated boilers. AT more The material is presented for water-heating boiler houses with a capacity of up to 5 Gcal with gas-tube boilers of the Turbotherm type.
Foreword |
2 |
Introduction |
5 |
CHAPTER 1. Schematic diagrams boiler rooms and heat supply systems |
8 |
1.3. Ways to connect consumers to the heating network 1.4. Temperature chart for quality control of the heating load 1.5. Piezometric graph |
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CHAPTER 2. Basic information from heat engineering, hydraulics and aerodynamics |
18 |
2.1. The concept of the coolant and its parameters 2.2. Water, water vapor and their properties 2.3. The main methods of heat transfer: radiation, thermal conductivity, convection. Heat transfer coefficient, factors affecting it |
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CHAPTER 3. Properties energy fuel and its combustion |
24 |
3.1. general characteristics energy fuel 3.2. Combustion of gaseous and liquid (diesel) fuels 3.3. Gas burner devices 3.4. Conditions for stable operation of burners 3.5. Requirements of the Rules for the Design and Safe Operation of Steam and Hot Water Boilers for burners |
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CHAPTER 4. Water treatment and water-chemical regimes of the boiler unit and heating networks |
39 |
4.1. Quality standards for feed, make-up and network water 4.2. Physical and chemical characteristics of natural water 4.3. Corrosion of boiler heating surfaces 4.4. Water treatment methods and schemes 4.5. Soft water deaeration 4.6. Complex metric (trilonometric) method for determining water hardness 4.7. Malfunctions in the operation of water treatment equipment and methods for their elimination 4.8. Graphical interpretation of the sodium cationization process |
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CHAPTER 5. Construction of steam and hot water boilers. Auxiliary equipment of the boiler room |
49 |
5.1. The device and principle of operation of steam and hot water boilers 5.2. Steel water-heating fire-tube-smoke boilers for burning gaseous fuels 5.3. Schemes of air supply and removal of combustion products 5.4. Boiler fittings (shut-off, control, safety) 5.5. Auxiliary equipment for steam and hot water boilers 5.6. Headset for steam and hot water boilers 5.7. Internal and external cleaning of heating surfaces of steam and hot water boilers, water economizers 5.8. Boiler safety instrumentation and automation |
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CHAPTER 6. Gas pipelines and gas equipment of boiler houses |
69 |
6.1. Classification of gas pipelines by purpose and pressure 6.2. Gas supply schemes for boiler houses 6.3. Gas control points of hydraulic fracturing (GRU), purpose and main elements 6.4. Operation of gas control points of hydraulic fracturing (GRU) boiler houses 6.5. Requirements of the "Safety Rules in the gas industry" |
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CHAPTER 7. Automation of boiler rooms |
85 |
7.1. Automatic measurements and control 7.2. Automatic (technological) signaling 7.3. Automatic control 7.4. Automatic regulation of hot water boilers 7.5. Automatic protection 7.6. Set of controls KSU-1-G |
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CHAPTER 8. Operation of boiler plants |
103 |
8.1. Organization of the operator's work 8.2. Operational piping diagram of a transportable boiler house 8.3. Regime map of the operation of a hot water boiler of the "Turboterm" type equipped with a burner of the Weishaupt type 8.4. Operating instructions for a transportable boiler house (TK) with boilers of the "Turboterm" type 8.5. The requirement of the "Rules for the design and safe operation of steam and hot water boilers" |
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CHAPTER 9. Accidents in boiler rooms. Personnel action to prevent boiler accidents |
124 |
9.1. General provisions. Causes of accidents in boiler rooms 9.2. Operator action in emergency situations 9.3. Gas hazardous work. Works according to the permit and according to the approved instructions 9.4. Fire safety requirement 9.5. Individual protection means 9.6. Providing first aid to victims of an accident |
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CHAPTER 10. Organization of efficient use of heat and power resources |
140 |
10.1. Heat balance and boiler efficiency. Mode map of the boiler 10.2. Fuel consumption rationing 10.3. Determination of the cost of generated (released) heat |
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Bibliography |
144 |
INTRODUCTION
Modern boiler technology of small and medium productivity is developing in the following areas:
- increase of energy efficiency by all possible reduction of heat losses and the most complete use of the energy potential of the fuel;
- reduction in the dimensions of the boiler unit due to the intensification of the process of fuel combustion and heat exchange in the furnace and heating surfaces;
- reduction of harmful toxic emissions (СО, NOx, SOv);
- improving the reliability of the boiler unit.
The new combustion technology is implemented, for example, in pulsed combustion boilers. The combustion chamber of such a boiler is an acoustic system with a high degree of flue gas turbulence. In the combustion chamber of boilers with pulsating combustion, there are no burners, and therefore no torch. The supply of gas and air is carried out intermittently at a frequency of about 50 times per second through special pulsating valves, and the combustion process occurs in the entire furnace volume. When fuel is burned in the furnace, pressure rises, the speed of combustion products increases, which leads to a significant intensification of the heat exchange process, the possibility of reducing the size and weight of the boiler, and the absence of the need for bulky and expensive chimneys. The operation of such boilers is characterized by low emissions of CO and N0 x . The efficiency of such boilers reaches 96 %.
The vacuum hot water boiler of the Japanese company Takuma is a sealed container filled with a certain amount of well-purified water. The boiler furnace is a flame tube located below the liquid level. Above the water level in the steam space, two heat exchangers are installed, one of which is included in the heating circuit, and the other works in the hot water supply system. Thanks to a small vacuum, automatically maintained inside the boiler, the water boils in it at a temperature below 100 ° C. Having evaporated, it condenses on the heat exchangers and then flows back. Purified water is not discharged anywhere from the unit, and it is not difficult to provide the required amount. Thus, the problem of chemical treatment of boiler water, the quality of which is an indispensable condition for reliable and long-term operation of the boiler unit, was removed.
Heating boilers of the American company Teledyne Laars are water-tube installations with a horizontal heat exchanger made of finned copper pipes. A feature of such boilers, called hydronic, is the possibility of using them on unprepared network water. These boilers provide for a high water flow rate through the heat exchanger (more than 2 m/s). Thus, if water causes corrosion of equipment, the resulting particles will be deposited anywhere but in the boiler heat exchanger. In the case of hard water, a fast flow will reduce or prevent scale formation. The need for high speed led the developers to the decision to minimize the volume of the water part of the boiler. Otherwise, you need an overly powerful circulation pump that consumes a large amount of electricity. AT recent times The products of a large number of foreign firms and joint foreign and Russian enterprises that develop a wide variety of boiler equipment appeared on the Russian market.
Fig.1. Hot water boiler of the Unitat brand of the international company LOOS
1 - burner; 2 - door; 3 - peeper; four - thermal insulation; 5 – gas-tube heating surface; 6 - a hatch into the water space of the boiler; 7- flame tube (furnace); 8 - branch pipe for supplying water to the boiler; 9 - outlet pipe hot water; 10 - flue of exhaust gases; 11 - viewing window; 12 - drainage pipeline; 13 - support frame
Modern water-heating and steam boilers of small and medium power are often fire-tube or fire-gas-tube. These boilers are characterized by high efficiency, low emissions of toxic gases, compactness, high degree of automation, ease of operation and reliability. On fig. 1 shows a combined fire and gas tube hot water boiler of the Unimat brand of the international company LOOS. The boiler has a furnace made in the form of a flame tube 7, washed from the sides with water. At the front end of the flame tube there is a hinged door 2 with two-layer thermal insulation 4. A burner 1 is installed in the door. Combustion products from the flame tube enter the convective gas-tube surface 5, in which they perform a two-way movement, and then leave the boiler through the gas duct 10. Water is supplied to the boiler through pipe 8, and hot water is discharged through pipe 9. The outer surfaces of the boiler are thermally insulated 4. To monitor the torch, a peeper 3 is installed in the door. the end part of the body - through the viewing window 11. To drain the water from the boiler, a drainage pipeline 12 is provided. The boiler is installed on the support frame 13.
In order to assess the efficient use of energy resources and reduce the costs of consumers for fuel and energy supply, the Law “On Energy Saving” provides for energy audits. Based on the results of these surveys, measures are being developed to improve the heat and power facilities of the enterprise. These activities are as follows:
- replacement of heat and power equipment (boilers) with more modern ones;
- hydraulic calculation of the heat network;
- adjustment of hydraulic regimes of heat consumption facilities;
- regulation of heat consumption;
- elimination of defects in enclosing structures and the introduction of energy-efficient structures;
- retraining, advanced training and material incentives for personnel for the effective use of fuel and energy resources.
For enterprises with their own heat sources, training of qualified boiler house operators is necessary. Persons trained, certified and having a certificate for the right to service boilers may be allowed to service boilers. This operator's manual serves exactly to solve these problems.
CHAPTER 1. PRINCIPAL DIAGRAM OF BOILER AND HEAT SUPPLY
1.1. principled thermal scheme hot water boiler house running on gas fuel
On fig. 1.1 shows a schematic thermal diagram of a hot water boiler house operating on a closed hot water supply system. The main advantage of such a scheme is the relatively low productivity of the water treatment plant and make-up pumps, the disadvantage is the increase in the cost of equipment for hot water supply subscriber units (the need to install heat exchangers in which heat is transferred from network water to water used for hot water supply). Hot water boilers operate reliably only when maintaining a constant flow of water passing through them, regardless of fluctuations in the heat load of the consumer. Therefore, in the thermal schemes of hot water boilers, they provide for the regulation of the supply of thermal energy to the network according to a qualitative schedule, i.e. change in water temperature at the outlet of the boiler.
To ensure the calculated temperature of the water at the inlet to the heating network, the scheme provides for the possibility of mixing the required amount of return network water (G per) to the water leaving the boilers through the bypass line. To eliminate low-temperature corrosion of the tail heating surfaces of the boiler to the return network water at a temperature of less than 60 ° C when operating on natural gas and less than 70-90 ° C when operating on low and high sulfur fuel oil, using a recirculation pump, hot water leaving the boiler is mixed to return network water.
Fig 1.1. Schematic diagram of the boiler room. Single-circuit, dependent with recirculation pumps
1 - hot water boiler; 2-5 - pumps for network, recirculation, raw and make-up water; 6- make-up water tank; 7, 8 - heaters of raw and chemically treated water; 9, 11 – make-up water and steam coolers; 10 - deaerator; 12 - installation of chemical water treatment.
Fig.1.2. Schematic diagram of the boiler room. Double-circuit, dependent with hydraulic adapter
1 - hot water boiler; 2-circulation pump of the boiler; 3- network heating pump; 4- network ventilation pump; 5-pump DHW internal circuit; 6- DHW circulation pump; 7-water-water DHW heater; 8-filter-sump; 9-reagent water treatment; 10-hydraulic adapter; 11-membrane tank.
1.2. Schematic diagrams of thermal networks. open and closed heating network
Water heating systems are divided into closed and open. AT closed systems ah, the water circulating in the heating network is used only as a heat carrier, but is not taken from the network. AT open systems ah, the water circulating in the heating network is used as a heat carrier and partially or completely taken from the network for hot water supply and technological purposes.
The main advantages and disadvantages of closed water heating systems:
- stable quality of hot water supplied to subscriber units, which does not differ from the quality of tap water;
- ease of sanitary control of local hot water installations and control of the density of the heating system;
- the complexity of the equipment and operation of subscriber inputs of hot water supply;
- corrosion of local hot water installations due to non-deaerated tap water entering them;
- scale deposition in water-water heaters and pipelines of local hot water supply installations with tap water with increased carbonate (temporary) hardness (W c ≥ 5 mg-eq / kg);
- with a certain quality of tap water, it is necessary, with closed heat supply systems, to take measures to increase the corrosion resistance of local hot water supply installations or to install special devices at subscriber inputs for deoxygenation or stabilization of tap water and for protection against sludge.
The main advantages and disadvantages of open water heating systems:
- the possibility of using low-potential (at temperatures below 30-40 ° C) industrial thermal resources for hot water supply;
- simplification and reduction in the cost of subscriber inputs and increase in the durability of local hot water installations;
- the possibility of using single-pipe lines for transit heat;
- complication and rise in the cost of station equipment due to the need to build water treatment plants and make-up devices designed to compensate for water consumption for hot water supply;
- water treatment should provide clarification, softening, deaeration and bacteriological treatment of water;
- instability of water entering the water intake, according to sanitary indicators;
- complication of sanitary control over the heat supply system;
- complication of control of tightness of the heat supply system.
1.3. Temperature chart for quality control of the heating load
There are four methods for regulating the heating load: qualitative, quantitative, qualitative-quantitative and intermittent (gap). Qualitative regulation consists in the regulation of heat supply by changing the temperature of hot water while maintaining a constant amount (flow) of water; quantitative - in the regulation of heat supply by changing the flow of water at its constant temperature at the inlet to the controlled installation; qualitative-quantitative - in the regulation of heat supply by a simultaneous change in water flow and temperature; intermittent, or, as it is commonly called, gap regulation - in the regulation of heat supply by periodically disconnecting heating installations from the heating network. Temperature curve with high-quality regulation of heat supply for heating systems equipped with heating devices convective-radiating action and connected to the heating network according to the elevator scheme, is calculated on the basis of the formulas:
T 3 \u003d t int.r + 0.5 (T 3r - T 2r) * (t int.r - t n) / (t int.r - t n.r) + 0.5 * (T 3r + T 2p -2 * t int.r) * [(t int.r - t n) / (t int.r - t n.r)] 0.8. T 2 \u003d T 3 - (T 3r - T 2r) * (t int.r - t n) / (t int.r - t n.r). T 1 \u003d (1 + u) * T 3 - u * T 2
where T 1 is the temperature of the network water in the supply line (hot water), o C; T 2 - temperature of water entering the heating network from the heating system (return water), o C; T 3 - the temperature of the water entering the heating system, o C; t n - outdoor air temperature, o C; t vn - temperature of the internal air, o C; u is the mixing ratio; the same designations with the index "p" refer to the design conditions. For heating systems equipped with convective-radiant heating devices and connected directly to the heating network, without an elevator, u \u003d 0 and T 3 \u003d T 1 should be taken. The temperature chart for the qualitative regulation of the heat load for the city of Tomsk is shown in Fig. 1.3.
Regardless of the adopted method of central control, the temperature of the water in the supply pipeline of the heating network must not be lower than the level determined by the conditions of hot water supply: for closed heat supply systems - not lower than 70 ° C, for open heat supply systems - not lower than 60 ° C. Water temperature in the supply pipeline on the graph looks like a broken line. At low temperatures t n< t н.и (где t н.и – наружная температура, соответствующая излому температурного графика) Т 1 определяется по законам принятого метода центрального регулирования. При t н >t n. and the temperature of the water in the supply pipeline is constant (T 1 \u003d T 1i \u003d const), and the regulation of heating installations can be carried out both quantitatively and intermittently (local passes) method. The number of hours of daily operation of heating installations (systems) in this range of outdoor temperatures is determined by the formula:
n \u003d 24 * (t int.r - t n) / (t int.r - t n.i)
Example: Determination of temperatures T 1 and T 2 for plotting a temperature graph
T 1 \u003d T 3 \u003d 20 + 0.5 (95-70) * (20 - (-11) / (20 - (-40) + 0.5 (95 + 70 -2 * 20) * [(20 - (-11) / (20 - (-40)] 0.8 \u003d 63.1 o C. T 2 \u003d 63.1 - (95-70) * (95-70) * (20 - (-11) \u003d 49.7 about C
Example: Determining the number of hours of daily operation of heating installations (systems) in the range of outdoor temperatures t n > t n.i. The outdoor temperature is t n \u003d -5 ° C. In this case, the heating installation should work per day
n \u003d 24 * (20 - (-5) / (20 - (-11) \u003d 19.4 hours / day.
1.4. Piezometric graph of the heat network
Pressures at various points of the heat supply system are determined using water pressure graphs (piezometric graphs), which take into account the mutual influence of various factors:
- geodetic profile of the heating main;
- pressure losses in the network;
- height of the heat consumption system, etc.
The hydraulic modes of operation of the heating network are divided into dynamic (during the circulation of the coolant) and static (when the coolant is at rest). In static mode, the pressure in the system is set to 5 m above the mark of the highest water position in it and is depicted as a horizontal line. The static pressure line for the supply and return pipelines is one. The pressures in both pipelines are equalized, since the pipelines communicate with the help of heat consumption systems and mixing jumpers in elevator nodes. The pressure lines in dynamic mode for the supply and return pipelines are different. The slopes of the pressure lines are always directed along the coolant and characterize the pressure loss in the pipelines, determined for each section according to hydraulic calculation pipelines of the heating network. The choice of the position of the piezometric graph is made on the basis of the following conditions:
- the pressure at any point in the return line must not exceed the permissible operating pressure in local systems. (no more than 6 kgf / cm 2);
- pressure in return pipeline should ensure the flooding of the upper appliances of local heating systems;
- the pressure in the return line in order to avoid the formation of a vacuum should not be lower than 5-10 m.
- the pressure on the suction side of the network pump must not be lower than 5 m.a.c.;
- the pressure at any point of the supply pipeline must be higher than the flashing pressure at the maximum (calculated) temperature of the heat carrier;
- The available pressure at the end point of the network must be equal to or greater than the calculated pressure loss at the subscriber input with the calculated coolant flow.
In most cases, when moving the piezometer up or down, it is not possible to set such a hydraulic regime in which all connected local heating systems could be connected in the simplest way. dependent scheme. In this case, you should focus on installing on the inputs at the consumers, first of all, backwater regulators, pumps on the jumper, on the return or supply lines of the input, or choose the connection according to an independent scheme with the installation of heating water-water heaters (boilers) at the consumers. The piezometric graph of the heat network is shown in Fig. 1.4 CONTROL QUESTIONS AND TASKS:
- Name the main measures to improve the thermal power economy. What are you doing in this direction?
- List the main elements of the heat supply system. Give a definition of an open and closed heating network, name the advantages and disadvantages of these networks.
- Write on a separate sheet the main equipment of your boiler room and its characteristics.
- What kind of device do you know thermal networks. What is the temperature schedule for your heating network?
- What purpose does it serve temperature chart? What determines the temperature of the break in the temperature graph?
- What purpose does it serve piezometric graph? What role do elevators, if you have, play in thermal nodes?
- On a separate sheet, list the features of each element of the heat supply system (boiler, heat network, heat consumer). Always consider these features in your work! The operator's manual, together with a set of test tasks, should become a reference book for an operator who respects his work.
Gas boiler operator training manual 350 rubles,it was tested in training centers during preparation, the reviews are the best, both from students and teachers of special technology.
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Auxiliary equipment of boiler plants is:
- electrical filters;
- air heaters;
- chimneys.
These elements are the main parts among the auxiliary equipment. Their installation takes place above the boiler. The main and auxiliary equipment of the boiler room should be designed according to such technical schemes that will automate control.
Boiler system installation and safety
During construction own house, everyone carefully plans the interior, tries to carry out all the work and repairs with high quality, and, of course, the installation of the boiler. The equipment of the boiler plant is the most important step in achieving complete comfort in your own home. The installation of this system must be treated responsibly so that in the future you do not pay fines and do not redo anything.
Work must be carried out under strict supervision by a specialist in order to avoid both fires and explosions.
In order to avoid repair of boiler equipment and serious consequences, a serious list of services from installation and organization is provided. It all starts with the collection of documents and ends with the launch of the heating system for use. In order for the operation of the boiler and the entire system to run smoothly, reliably and economically, all services for the use of the installation and commissioning of boiler equipment must be carried out by a highly qualified specialist. He must have a license and permission to carry out such work.
- The entire heating system is pre-piped.
- Checking for the correct operation of the entire system, in order to avoid repair of boiler equipment and accidents.
- Carrying out the final adjustment of equipment for the boiler room.
- Getting coaching from experts.
System Maintenance
If the installation, adjustment of the boiler equipment and the boiler was carried out in accordance with all the rules and regulations, during use, situations may still arise that require additional repair of the auxiliary equipment of the boiler installation. The most common cause of such breakdowns is poor-quality water, which does not meet the standards of equipment for the boiler. Boiler adjustment, repair, related work is quite a consumable business.
Rice. oneTo reduce the cost of repairing boiler rooms and boiler equipment in the future, the construction of a heating system should be carried out by companies that have a wide range of services:
- Post-warranty maintenance of the constructed facility.
- Reconstruction.
- Necessary repairs and adjustments.
The main task of the owner is to carry out timely maintenance of the premises for the boiler room.
The main (Fig. 1) and auxiliary elements of the heating system
A boiler room is a set of devices that is completely ready to convert the chemical energy of the fuel into thermal hot energy, or a couple of the necessary parameters.
The manufacturer of boiler equipment offers the following main components:
- water economizer;
- air heater;
- frame with ladders and service shelves;
- frame;
- thermal insulation;
- sheathing;
- fittings;
- headset;
- flues.
Equipment for the boiler room (needs adjustment) has additional settings any manufacturer:
- fans;
- smoke exhausters;
- nutritional, nourishing and circulation pumps;
- water treatment plants;
- fuel transfer systems;
- ash collection plant;
- vacuum ash remover.
Manufacturers of boiler equipment have developed the main installation in the oil industry during the combustion of gas gas control station or gas control installation.
Rice. 2Adjustment of the entire heating system, commissioning process is the key to uninterrupted operation and comfort for everyone.
- Steam boiler installation. This is a device that consists of a firebox, evaporation surfaces. Its main job is to evaporate the steam that was used outside of this device. Incorrect adjustment of the process provokes, under pressure, which is higher than the atmospheric heat count and is released during the combustion of the fuel, the steam exits the boiler.
- Water heating boiler. This heat exchange device, in which the main source of thermal energy is water.
- Furnace device. The operation of this unit is to burn fuel, converting its energy into heat.
- Boiler lining. This system is provided by manufacturers to perform work to reduce heat loss, ensure gas density.
- Kazan. This is a metal structure. Its main work is to hold the boiler and individual loads, to ensure the desired mutual placement of the elements of the boiler.
- Steam superheater. This device increases the temperature of the steam above the saturation temperature of the pressure in the boiler. The manufacturer has provided for the operation of this system of coils, where the complete adjustment of the boiler equipment implies the connection of saturated steam to the boiler drum at the inlet, and to the superheated steam chamber at the outlet.
- Water economizer. The essence of the operation of this device lies in its heating by the products of combustion of fuel, which, in turn, partially heats up or completely evaporates the water in the boiler.
- Air heater. Its main job is to heat the air with the products of fuel combustion before the fuel enters the boiler furnace.
The need for repair within the warranty period
Parts for the boiler may be needed even while the unit is still under warranty.
Repair of boiler equipment is possible:
- the work on the installation of the boiler was carried out incorrectly;
- the use of the unit is not correct;
- Maintenance carried out at the wrong time;
- voltage drops (you can purchase a stabilizer that will eliminate this problem);
- low-quality coolant (on the inlet pipeline, it can be installed as a filter for the boiler).
To avoid repair of boiler equipment, all the nuances should be considered in advance, rather than urgently solving the problem.
Breaking? Don't panic
Of course, if repair of boiler equipment is needed before heating season, then this is not so bad, and if in the midst of cold weather, the main thing is not to panic. But you also need to take the problem seriously, because the adjustment of the boiler and the entire system can go astray. If the breakdown of the installation is not serious, repairs can be made independently. But if there are doubts about the causes and consequences, the repair should be entrusted to a professional.
The successful operation of the installation depends not only on the manufacturer, but also on the choice of model in the store. It depends on the choice whether the unit will cope with the tasks and the amount of work - the entire commissioning process. It is better if the company that made the sale had service center somewhere nearby. In order to help with the commissioning process at any time, she carried out an inspection and repair of the boiler (Fig. 2).
Of course, the manufacturer of boiler equipment is responsible for its product, but the owner must operate according to the instructions and rules so that there are no failures in setting up the installation and wasting money on repairs. Statistics of companies repairing boilers and heating systems claim that almost 70% of the causes of breakdowns are due to improper use and operation of appliances, violation of requirements and norms. Therefore, the repair of boiler equipment happens, mainly through the fault of the consumer, not the manufacturer.
Rice. fourDevice setup and repair
If a person does not understand repair issues, then it will be difficult for him to understand this process with boilers and appliances for it.
Here is a list of the most common problems:
- Electronic board. The manufacturer gave this device responsibility for all processes. It regulates the device, turns it on and off, controls, affects the commissioning process. A slight malfunction will lead to an explosion. In order to avoid breakdowns, it is better to mount such an element as a voltage stabilizer.
- (Figure 3). If the sale of boiler equipment was carried out with a defect from the manufacturer, not one commissioning process will help. The problem with the operation of the installations occurs in the first months of operation. To eliminate the deficiency, it is necessary to completely replace the heat exchanger. But much more common is the problem of clogging the passage with various deposits and salts. The coolant flow begins to decrease, and one day the boiler boils. In order to avoid repairs and commissioning, attention must be paid to water quality. And also, during the sale of the unit, pay attention to its quality, whether there is a marriage from the manufacturer.
- (Figure 4). The commissioning process of the installation implies the continuous operation of this pump. But if it turns off, the boiler will boil. The unit will shut down thanks to the safety thermostat (commercially available). But the problem will not disappear and the repair is provided. The fault in the breakdown is the coolant - liquid for heating boilers. The pump can stop for two reasons: the appearance of scale; an increase in debris in the middle of the case. To avoid this trouble, there is a special filter on sale, which is installed on the inlet pipe.
- Gas automation. Repair of this boiler element is practically impossible. Usually, this component is completely changed. In order to avoid another adjustment of the boiler, this breakdown is better to prevent than to solve. Low quality fuel is found on sale. Therefore, in order to prevent breakdown of gas automation, it is worth buying high-quality fuel and using clean water for the coolant.
Today, there are many outlets that offer accessories for boilers. It is worth noting that well-known branded, popular firms parts are always recommended by professionals. They are of high quality, have an uncomplicated commissioning process, the boiler is adjusted quite quickly.
A steam boiler is a heat exchanger in which, when burning organic fuel, water is converted into steam used for the needs of the ship. In ship installations, energy can be supplied by direct combustion of fuel in the boiler furnace and by supplying exhaust gases from an internal combustion engine or gas turbine. In the latter case, the boilers are called waste.
On ships with main steam engines, which are the main consumers of steam, the boilers serving them are called the main ones. The main boilers provide steam simultaneously to all other auxiliary consumers. On ships with main diesel or gas turbine engines, auxiliary boiler plants are used, which, as a rule, include auxiliary and waste boilers. Auxiliary, as well as the main boilers, operate on fuel burned in the furnace and provide auxiliary consumers with steam. Such consumers, regardless of the type of the main engine, can be: steam auxiliary mechanisms and apparatus (turbine generators, turbopumps, evaporators); steam deck mechanisms (spires, windlasses, winches); steam heaters for water, fuel, oil, air, liquid cargo, fuel and water in tanks, water in the tank washing system; a system for steaming tanks, blowing through seastone grates, etc.; equipment that serves to meet household needs in steam (heating systems, baths, laundries).
Boilers that produce steam based on the heat released during the combustion of fuel in the furnace are a unit that includes: the boiler itself with steam-generating elements, a furnace, a furnace device, boiler fittings and instrumentation (I&C). Together with the boiler unit, they form a boiler plant.
Scheme of the boiler plant
The boiler plant can perform both independent functions and be one of the main elements of power plants. Thus, industrial boiler plants provide steam and heat supply at industrial facilities, and heating boiler plants provide both hot water supply and heating. Depending on what functions the boiler plant performs, it consists of a hot water or steam boiler and the corresponding additional equipment that ensures the operation of the boiler room.
A hot water or steam boiler is a device that is used to produce hot water or steam using the heat released during the combustion of exhaust gases or fossil fuels. Boilers that use the heat of waste gases to heat water are called heat recovery boilers.
Auxiliary equipment of boiler plants
In order for any boiler, regardless of its type, power and purpose, to work normally, it is necessary to ensure such processes as the preparation and combustion of fuel in the boiler furnace, the supply of a sufficient amount of oxidizer, and the removal of gases and other products formed as a result of fuel combustion. combustion (slag and ash formed during the combustion of solid fuels). All this provides additional auxiliary equipment.
Raw fuel feeders, coal mills, fuel containers and bunkers provide continuous supply of fuel of the required consistency to the boiler furnace in automatic mode.
Smoke exhausters and blowers, installed in the boilers, provide a continuous supply of air to the furnace and blow out the products of combustion. However, some models of boilers provide for the combustion of fuel in the ambient air, as a rule, these are gas boilers.
Water treatment plants are a whole set of various devices that remove various contaminants from the feed water, the presence of which can clog and damage the entire system.
Ash and ash collectors and ash collectors devices are installed in chimneys and serve to remove ash, slag and other suspended particles that pollute the atmosphere from flue gases.
Control and measuring equipment, various sensors, signaling devices and devices for preventive cleaning of boiler pipes from various contaminants.
Principal thermal diagram of a hot water boiler house
According to the conditions for preventing metal corrosion, the temperature of the water at the inlet to the boiler when operating on gas fuel must be at least 60 ° C in order to avoid condensation of water vapor contained in the exhaust gases. Since the return water temperature is almost always below this value, in boiler rooms with steel boilers, part of the hot water is supplied to the return line by a recirculation pump.
Make-up water enters the collector of the network pump from the tank (a pump that compensates for the consumption of water by consumers). The initial water supplied by the pump passes through the heater, chemical water treatment filters and, after softening, through the second heater, where it is heated to 75-80 °C. Next, the water enters the vacuum deaerator column. The vacuum in the deaerator is maintained by suction of the vapor-air mixture from the deaerator column using a water-jet ejector. The working fluid of the ejector is water supplied by a pump from the tank of the ejector installation. The steam-water mixture removed from the deaerator head passes through a heat exchanger - a vapor cooler. In this heat exchanger, water vapor condenses, and the condensate flows back into the deaerator column. The deaerated water flows by gravity to the make-up pump, which delivers it to the suction manifold of network pumps or to the make-up water tank.
Heating in the heat exchangers of chemically treated and source water is carried out by water coming from the boilers. In many cases, the pump installed on this pipeline (shown by a dashed line) is also used as a recirculation pump.
If the heating boiler is equipped steam boilers, then hot water for the heat supply system is obtained in surface steam-water heaters. Steam water heaters are most often free-standing, but in some cases heaters are used that are included in the boiler circulation circuit, as well as built on top of the boilers or built into the boilers.
A schematic thermal diagram of a production and heating boiler house with steam boilers supplying steam and hot water closed two-pipe water and steam systems heat supply. One deaerator is provided for the preparation of feed water of boilers and make-up water of the heating network. The scheme provides for heating the source and chemically treated water in steam-water heaters. Blowdown water from all boilers enters the continuous blowdown steam separator, which is maintained at the same pressure as the deaerator. The steam from the separator is discharged into the steam space of the deaerator, and hot water enters the water-to-water heater for preliminary heating of the source water. Next, the purge water is discharged into the sewer or enters the make-up water tank.
Steam network condensate returned from consumers is pumped from the condensate tank to the deaerator. The deaerator receives chemically purified water and condensate from the steam-water heater of chemically purified water. Network water is heated sequentially in the condensate cooler of the steam-water heater and in the steam-water heater.
In many cases, hot water boilers are also installed in steam boilers for the preparation of hot water, which fully meet the demand for hot water or are peak. The boilers are installed behind the steam-water heater along the water course as the second stage of heating. If the steam boiler house serves open water networks, the thermal scheme provides for the installation of two deaerators - for feed and make-up water. To equalize the mode of preparation of hot water, as well as to limit and equalize pressure in hot and cold water supply systems in heating boilers, installation of storage tanks is provided.
Schematic diagram of a steam boiler house with closed networks.
Draft installations according to the application scheme are: general - for all boilers of the boiler house; group - for separate groups of boilers; individual - for individual boilers. General and group installations must have two smoke exhausters and two draft fans. Individual installations according to the conditions of regulation of their work when the boiler capacity changes are the most desirable.
Methodology for designing boiler plants
Boilers for the home
Boiler equipment is one of the mandatory constituent parts life support engineering networks. And this is not only the most difficult and serious, but also the most expensive part. However, these costs will still have to be borne, because you cannot live without heat in the cold season. And in modern conditions in a civilized country, this indicator should be at a fairly high level.
Add to this the cost of design and installation, which take up half of all costs. That is why this part of building a house is one of the most profitable. Of course, much will depend on certain indicators. For example, on the size of the heated area, the number of storeys of the building, the size of window and door openings, the thickness of the walls and the presence of thermal insulation.
Although you can save a little. After all, saving at all stages of construction today is one of the most important tasks facing the developer. First of all, it is determined on what fuel the system will operate. If it is gas, then the gain is obvious due to the cheapness of fuel and inexpensive gas equipment. We add here the simplicity and ease of use, as well as safety. There are also few problems with electricity, but you will have to pay decently for it, which not everyone can afford. With solid and liquid fuels, everything is not so simple, because here strict fire-fighting measures come into force, which in any case will have to be observed. And this comes with additional costs.
Therefore, before embarking on the implementation of your own plans, we advise you to make a project not only at home, but also of all engineering networks, especially heating. The specialist, having understood all the intricacies of future construction, will select the best option, the piping layout, the heating boiler model, radiators and pipes. Here it is important not to rely on chance, as is often the case. A slight inaccuracy may result in big problems in winter. So everything needs to be done to the smallest detail.
It is the equipment for your boiler room that can become a stumbling block when choosing. Imagine a situation where the fuel is known, but the boiler power is not chosen correctly. If it is less, then the house will always be cool. If more, then the boiler will not work at full capacity. It turns out that you invested money in such equipment in vain, because a more powerful boiler costs more. But that's not all. If your house is heated with gas, then gas service, which gives permission to connect to the central pipe, will not talk to you without a project.
The choice of boiler equipment requires certain knowledge of the market. But there are a few tips to make your search easier:
- First, all attention to the brand. If the company is on everyone's lips, the experience of its stay in the market is quite long, and there are no complaints about the quality of the products, then this is what you need. In this case, you should not pay attention to the price, because quality cannot be cheap. Although today it is possible to find equipment with an optimal price-quality ratio on the market.
- Secondly, there are reviews. They can be viewed on the Internet, but you cannot trust them 100%. Therefore, there is only one way out - ask your friends, relatives, colleagues and neighbors. Among such a large number of people, there will always be those who have already dealt with a similar problem. Their feedback and recommendation will be the most objective.
Pay attention to whether the brand you have chosen has a network after-sales service in your region. Why is it so important? Any malfunction of the equipment, any breakdown should be corrected only by specialists. Home craftsmen may not know much, so you should not trust them with complex and expensive equipment. Keep this in mind.
Technical nuances of choice
Boiler room in the basement
The capacity of the purchased boiler equipment has already been mentioned. This is one of the most important indicators of the technical condition of the boiler. But there are others. Today they offer various modifications of both the boilers themselves and auxiliary units, instruments and fixtures:
- Let's start with the possibility of organizing, on the basis of one boiler, both a heating system and a hot water supply system for the household needs of the guests. For this, a special two-circuit model was developed. The essence of its design lies in the fact that both the heat exchanger of the heating system and the heat exchanger of hot water supply are heated by one burner. Both of these devices are located separately, and there is no connection between them. This is a good boiler, requiring a little more fuel consumption. There is also an option with a single-circuit boiler, to which an additional container is attached - a boiler. It is difficult to advise unambiguously what to choose, because both options are equally in demand.
- In second place is the choice of fuel. Unfortunately, not all regions have gas. This is especially true for areas located far from large cities. But there is a wide variety of choices here as well. Electric, solid fuel, liquid fuel boilers are represented by a large model range. And you will have to choose based on what kind of fuel is available in your region. Its availability and low cost are the selection criteria.
- Please note that in specifications includes ease and safety of operation. So, a boiler that you can start and forget about its existence is preferable. True, this is an expensive option, because its design necessarily contains complex electronic devices responsible for controlling and guiding the entire device as a whole. Yes, and its maintenance will be expensive.
- Deleting from the list electric boilers heating, let's focus on the remaining ones. In them, one of the main roles will be played by a chimney - with natural draft or with forced draft. The first device is simple and cheap, but less efficient. The second is more difficult, more expensive, but more effective. As always, the chimney is chosen considering the operating conditions, which sometimes depend on the availability of AC power.
Installation of boiler equipment
Wiring diagram
So, almost everything is ready. You have received the project and selected the necessary equipment. It remains to carry out the installation. And here again the question arises of who will do all this.
Note! If in heating system gas is selected as the fuel, then all installation work will be carried out only by specialists. This process is simple, but requires a certain qualification, confirmed by certificates and tolerances.
All other types of equipment can be mounted with your own hands, if you have the time and desire for this. In addition, manufacturers of electric boilers offer compact wall-mounted options that are even easier to install. Under them, you do not need to arrange a solid and reliable foundation - a few fixed brackets will solve the problem.
One piece of advice will help you save some money. Try to find an organization that will be both a project developer, an equipment seller, an installer, and a service provider in one person. If you find it, consider yourself lucky. Such offices always quickly resolve all problems and questions, and you will definitely receive a 10–15% discount for the wholesale services provided.
Conclusion on the topic
So choosing boiler equipment, you will need to take into account several important nuances. But note that in this case, not only technical aspects are important, but also social living conditions.