【Haichuan Anhuan Cup】--0011+Safety Technical Regulations for Boiler Operators+*anpangpang

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This post was last edited by zhaolijun on 2015-8-9 at 16:02. Safety Technical Regulations for Boiler Operators 1 Scope: These standards specify the procedures for starting up and shutting down boilers in the power plant’s boiler operator positions； Some precautions during operation and maintenance, routine tasks, load adjustment, and equipment repair are necessary to ensure the safe operation of the boiler as well as the safety of the operators ； This standard applies to the boiler positions in power workshops. 2 Standard reference documents: “Interim Regulations on the Safety Supervision of Boilers and Pressure Vessels” and “Operating Procedures for the Power Workshop of Shaanxi Weihe Coal Chemical Group Co., Ltd.” 3 Safety regulations 3.1 Boiler operators must receive technical training, pass relevant examinations, and hold a “Boiler Operator Certificate” before they are allowed to operate boilers; they must also undergo regular safety training and examinations ； Apprentices and trainees are strictly not allowed to operate independently ； 3.2 Boiler operators must comply with the Power Workshop’s “Shift Handover Management System” and “Routine Inspection System” ； 3.2 Boiler operators must comply with the relevant provisions specified in the \"Power Workshop Operating Procedures\". 4 Boiler Chemical Cleaning Procedures 4.1 For boilers that have been newly installed or repaired, it is necessary to remove rust, grease, and dirt from inside the boiler through chemical cleaning before they are put into operation ； 4.2 All cleaning workers must receive pre-job training and work with valid certificates ； 4.3 Cleaning workers must strictly abide by the factory’s relevant safety regulations and various systems ； During operations, operators must strictly follow the operating procedures to avoid any illegal practices ； 4.4 The raw materials and chemicals used for cleaning should all be transported in sealed packaging ； Isolate areas such as raw material storage and cleaning operations at the cleaning site using colored strips of fabric or similar ； 4.5 During cleaning operations, operators must be equipped with a full set of protective gear, such as acid-resistant suits, gloves, goggles, face shields, and safety helmets ； A water source must be available near acid pumps, sampling points, testing stations, etc., and should be connected by hoses for use in flushing in case of valve or pipeline leaks. 5? Boiler water filling procedure? 5.1 Opening the drum vent valve ； 5.2 The inlet water temperature should not be too high; the temperature difference between the water temperature and the wall temperature of the boiler drum should not exceed 50℃ ； ?5.3 During the water injection process, inspections should be intensified; any leaks detected must be addressed promptly. Additionally, the automatic water level control system and the high/low water level alarms should be checked to ensure their reliable operation ； ?5.4 When the feed water level rises to the lowest level, suspend feeding and observe whether there is any change in the water level; if there is a change, identify the cause immediately. No abnormalities detected; water supply can be resumed to raise the water level to normal levels. Only then can the furnace be started. 6 Ignition procedures? 6.1 Checks and preparations before igniting the boiler ； 6.1.1 Boiler operators must be familiar with the boiler they operate, the location of the piping systems and major auxiliary equipment, their functions, and the methods of operating them ； 6.1.2 After starting work, check whether there are any foreign objects in the flue and furnace, and verify that the furnace walls are airtight and there is no air leakage. Inspect all parts of the boiler and flue; open the dampers and use natural ventilation for 10–15 minutes or mechanical ventilation for 5–10 minutes to remove any remaining combustible gases from the flue and furnace. All accessories must be properly installed to ensure safety and reliability ； 6.1.3 The water level in the boiler should reach the lowest allowable level. When filling the boiler with water, the vent valve should be opened to allow air to escape from the boiler drum. Water should not be added too quickly. During water filling, it is necessary to carefully check whether there is any leakage from the hole covers and valves; if leakage is detected, it must be repaired immediately ； 6.2 Boiler ignition ； 6.2.1 Open the flue damper and start the fan for mechanical ventilation for 5–10 minutes ； ?6.2.2 Use an ignition gun to ignite; ensure that the oil gun nozzles are unobstructed and provide good atomization. Open the supply and return valves, then ignite carefully. 6.2.3 Adjust the throttle, fuel supply, and air supply according to the combustion conditions to ensure stable combustion. 6.2.4 Once the flame is stable, combustion is normal, and the furnace temperature has increased, the oil injector can be switched on ； 6.2.5 The ignition speed should not be too rapid, especially in boilers with a large water capacity and poor water circulation; the furnace temperature should rise more slowly in such cases ； 6.2.6 In the event of a fire extinguishing incident, the cause should be analyzed and the fault resolved. After forced ventilation for 5–10 minutes, ignite the material; take great care to prevent deflagration accidents ； 6.2.7 Closely monitor changes in water level. Appropriately enhance ventilation and combustion, and start increasing pressure or temperature ； ?6.2.8 If ignition does not occur, the fuel supply should be cut off immediately, forced ventilation should be applied for 5–10 minutes again, and then ignition attempted once more. ?6.3 Boiler pressure/temperature rise operation ； ?6.3.1 When the pressure of the steam boiler rises to 0.05–1 MPa gauge pressure, flush the water level gauge ； 6.3.2 When the pressure rises to 0.1–0.15 MPa gauge pressure, flush the pressure gauge’s trap to prevent malfunction due to blockage by dirt ； 6.3.3 When the pressure rises to 0.15–0.2 MPa gauge pressure, close the vent on the upper drum ； 6.3.4 When the steam pressure rises to 0.2–0.3 MPa gauge pressure, check that there are no leaks, and tighten any loose screws on access holes, manholes, and flange connections. When operating, turn sideways, and the length of the wrench used should not exceed 20 times the diameter of the screw ； 6.3.5 When the steam pressure rises to 0.3–0.4 MPa gauge pressure, perform a lower-level water discharge; when the water level drops as a result of this discharge, the feed water valve should be opened to replenish water ； ?6.3.6 When the temperature rise of the hot water boiler reaches 20°C, a drain and water mixing operation should be carried out, and the pressure gauge should be flushed. The normal heating process for account opening must be no less than 4 hours. ?7 Boiler gas supply and steam connection 7.1 Preparations before boiler steam supply ； 7.1.1 When preparing to supply gas for boiler pressure increase, the main steam valve must be slowly opened slightly in order to warm the pipes and remove any condensation water from the various pipelines ； 7.1.2 When warming the pipes, it is necessary to check the condition of each pipe valve. Warm-up operation of steam boilers ； 7.1.3 Once the vapor pressure reaches the operating pressure of the boiler, slowly open the main valve and supply a small amount of steam to each pipe over 10–15 minutes; after checking all parts, resume normal steam supply. 7.2 Boiler steam connection ； 7.2.1 Parallel operation should be carried out when the boiler steam pressure is 0.05–0.1 MPa lower than that of the steam pipe ； 7.2.2 Slowly open the main steam valve; once no abnormal noises are heard in the steam pipes, then open the valve further. If there is a knocking sound in the pipeline, increase the opening of the pipeline drain valve; once all the condensate has been drained, reopen the main steam valve to supply steam ； 7.2.3 When connecting to the steam system, attention should be paid to water level and steam pressure changes; if any abnormalities occur, the connection to the steam system should be stopped. 8 Normal operation of the boiler and precautions 8.1 The water level indicated by the gauge must remain around the normal level; slight fluctuations are acceptable. The gauge should be cleaned at least once per shift, and it is necessary to ensure that it remains clear, tidy, and free from leaks of water or air ； 8.2 The pressure gauge should be monitored regularly to maintain normal pressure; it is not allowed to exceed the operating pressure ； 8.4 The system should be drained at least once or twice per shift, and this drainage should be carried out at a lower load (or pressure) ； 8.5 It is necessary to check the tightness of the boiler and its water wall on both sides, as well as other components and steam traps, in each shift ； 8.6 The load should be adjusted slowly and smoothly while maintaining stable steam pressure and water level in the boiler ； 8.7 During operation, the boiler itself, its auxiliary equipment, and the surrounding environment should be kept clean. 9 Operation of steam boiler blowdown? 9.1 First, slightly open the slow-opening valve to preheat the pipeline between the two valves; once there is no sound of shock, open it fully. Then open the quick-opening valve a little to preheat the blowdown pipeline. Without any sound of shock, close the quick-opening valve completely several times to carry out blowdown. After the blowdown is complete, first close the quick-opening valve, and then close the slow-opening valve ； 9.2 When two or more boilers share a single blowdown main, it is strictly prohibited to blow down both boilers simultaneously. Also pay attention to leakage. 10 Handling of water shortage incidents? 10.1 If the water level indicated by the gauge is below the lowest safe water level line, but the water level can still be seen, the gauge should be flushed to determine the actual water level ； ?10.2, Manually increase the water supply volume ； 10.3 After the above treatments, if the water level continues to drop, the furnace should be shut down immediately. Close the main steam valve and continue to feed water to the boiler ； 10.4 If there is a severe water shortage, water should not be supplied to the boiler. It should be handled in accordance with the emergency shutdown procedures. And report it promptly to the relevant leadership. 11 Handling of full-water accidents? 11.1 Immediately close the feedwater valve, and open the economizer recirculation valve or the bypass flue ； ?11.2 Open the sewage valve and increase water discharge, but pay attention to the water level indicated by the gauge to prevent water shortage due to excessive discharge ； ?11.3. Close the air dampers to reduce the amount of oil (gas) and air supplied ； 11.4. Open the drain valves on the main steam valve, steam headers, and steam manifolds ； ?11.5. Once the water level returns to normal, resume normal combustion. ?12 Handling of steam and water boiling together accidents?12.1 Fully open the surface blowdown valves on the upper boiler drum; at the same time, carry out bottom blowdown as appropriate, increase the feedwater supply to maintain a normal water level, in order to reduce the salt content in the boiler ； ?12.2 Open the drain valves on the superheater, steam pipelines, and steam distribution cylinders ； ?12.3 Effective measures should be taken to improve the quality of boiler water, and the frequency of analyses of boiler water should be increased. The boiler load shall not be increased until the quality of boiler water improves. 13 Handling of steam boiler tube rupture accidents? 13.1 In the case of a minor rupture in the boiler tubes, as long as the water level in the boiler can be maintained at normal levels and the crack is not likely to expand rapidly, it is necessary to increase the water supply, operate the boiler at reduced load, and immediately activate the backup boiler. Once the backup boiler is started up and operating normally, the boiler can then be shut down in the usual manner. If several boilers are operating in parallel to supply heat, this boiler should be isolated from the steam main before being shut down normally ； 13.2 In the event of a furnace tube explosion and a rapid drop in water level and steam pressure, the furnace should be shut down urgently. If the water level is below the minimum level or is not visible, be sure to supply water into the furnace; however, keep the exhaust fan running until all smoke and steam have been removed before stopping it ； ?13.3 After shutting down the furnace, close the main steam valve immediately. ?14 Handling of secondary combustion accidents in flue ducts?14.1 Immediately stop feeding fuel to the furnace and shut it down urgently ； ?14.2 Close the flue air supply dampers and all access doors; ventilation is strictly prohibited ； ?14.3 Use steam injection into the flue for fire extinguishing or CO2 fire extinguishers for fire suppression ； ?14.4 After the accident is resolved, carefully inspect the equipment; if nothing is abnormal, ventilate it for about 5–10 minutes first, then ignite it according to the operating procedures, restart it, and put it back into operation. ?15 Handling of power outage incidents?15.1 Immediately shut down the burner and open the economizer recirculation valve ； 15.2 Immediately close the main valve of the steam header and clean the oil system ； ?15.3 Determine the cause of the power outage and the time required for restoration, and prepare to restart the furnace. ?16 Handling of Boiler Fire Extinguishment Incidents?16.1 Upon detecting a fire, immediately stop the fuel supply and proceed with an emergency shutdown (make sure this does not affect normal operation of the boiler) ； ?16.2 After the fan has been running for 5–10 minutes, stop it and close the smoke and air dampers. ； ?16.3 Pay close attention to the boiler water level ； ?16.4 Analyze the causes of the fire and take corresponding measures. ?17 Operation for emergency shutdown of the furnace?17.1 When operating a single furnace and an emergency shutdown is required, increase the flow rate of the circulation valve, close the oil (gas) supply valves, and immediately shut off the heat supply ； ?17.2 If other furnaces are operating in parallel, the operating furnace should be subject to enhanced adjustment and monitoring ； ?17.3 If there is a backup furnace, it should be started immediately to ensure heat supply and brought into operation. 18 Emergency Shutdown Procedures 18.1 When the boiler is in operation, it should be shut down immediately if one of the following situations occurs ； 18.1.1 When the boiler’s steam pressure exceeds the allowable operating pressure, the safety valve does not operate, the exhaust valve to the atmosphere cannot be opened, and the pressure continues to rise ； 18.1.2 When the water level cannot be seen on the gauge ； 18.1.3 When the boiler water level has risen to the highest visible level (i.e., full water) ； 18.1.4 When all water supply equipment fails ； 18.1.5 When all water level gauges fail ； 18.1.6 When all pressure gauges fail ； 18.1.7 When all safety valves fail ； 18.1.8 When cracks appear in the furnace wall posing a risk of collapse, or when the furnace frame beams become red hot ； 18.1.9 When boiler components are damaged, posing a threat to human safety and equipment safety ； 18.1.10 When the safety of boiler equipment is at risk due to other events ； 18.2 The operating procedures for emergency shutdown are as follows: 18.2.1 Stop the fuel supply ； 18.2.2 Isolate the boiler from the main steam pipe ； 18.2.3 If there is no shortage of water or no excess water, water can be supplied to the boiler or sludge can be discharged in order to reduce the pressure inside the boiler ； 18.2.4 In the event of a water shortage in the boiler, it is strictly prohibited to supply water to the boiler ； 18.2.5 Close the fan dampers; if the furnace tubes burst, keep the exhaust fan running to draw out the steam from the furnace and maintain a negative pressure in the furnace chamber.