Zhongde LYF2.0/300-0.7
Composite boiler (oil-fired and exhaust gas)
The Zhongde LYF2.0/300-0.7 is a vertical composite boiler: an oil-fired section with a SAACKE SKVJ-15 rotary cup burner and an exhaust gas section heated by main engine exhaust. It can run oil-fired, combined or on exhaust gas only, producing saturated steam at 0.7 MPa. Feed is on/off controlled by a float level transmitter, and surplus exhaust-gas steam is dumped to a condenser by a pneumatic dump valve. The manual covers design data, erection and supports, reflex water level gauges, feed and boiler water treatment limits, safety valves, level transmitter testing, accessories (salinometer, oil detector, sample cooler, dosing pump, test cabinet), CR2 feed pumps, steam dump adjustment, spare parts, and the start-up, operation and daily maintenance instructions with alarm and trip set points.
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Процедуры обслуживания
Light-up and raising steam (oil-fired)
- Check the isolating valve is open and the pressure gauge reads zero. стр. 91
- Fill to between low and medium water level; test both water level gauges by opening and closing the upper and lower cocks alternately. стр. 91
- Open the air vent on top and keep it open until steam comes out. стр. 91
- Raise temperature slowly: about 1.5 hours to working pressure. стр. 91Fast firing damages the heating surfaces
- Near 0.7 MPa blow down all blowdown valves and gauge cocks to clear dirt. стр. 92
- Drain and warm the steam lines with a small flow, then open line valves fully. стр. 92
Blowing down the water level gauge
- Water side: shut cock S, open cock W, open drain cock D briefly; repeat so the level rises and falls. стр. 13
- Steam side: shut cock W, open cock S and blow through drain D for 1–2 seconds only. стр. 14Longer steam blowing shortens glass life
- Return both cocks to the operating position and check the level settles. стр. 14
Replacing the reflex gauge glass
- Shut cocks S and W and open drain D until the glass is empty. стр. 14
- Remove nuts and lift off the gauge body; remove screws, cover plate, glass and gaskets. стр. 14
- Clean sealing faces and check for scars; fit sealing gasket, new reflex glass and cushion gasket, then the cover plate. стр. 15
- Tighten screws evenly from the centre outwards to 60 Nm. стр. 15
Daily level transmitter function test
- With the boiler steaming, slowly close the upper shut-off valve: the level rises and the feed pumps must stop at high level. стр. 24
- Close the lower shut-off valve and open the drain slowly: the stand-by pump start and low level alarms must operate in turn. стр. 24
- Reopen both shut-off valves and close the drain. стр. 24
Emergency: water below the gauge glass
- Stop the burner at once through the burner control. стр. 92Do not feed cold water into an overheated boiler before it is checked
- Close the steam valve gradually and only restart after the boiler has cooled and been inspected. стр. 92
Интервалы технического обслуживания
| Что | Когда | Что делать | Мануал |
|---|---|---|---|
| Feed and boiler water | Daily | Analyse with the test cabinet and adjust chemical dosing | стр. 19 |
| Level transmitter | Daily | Function test of high level, stand-by pump start and low level alarms | стр. 24 |
| Water level gauge | Every hour in service / before light-up and shut-down | Blow through and check reading; renew a cracked glass at once | стр. 92 |
| Bottom blowdown | Every morning, then every 8 h (at least weekly 1 min per valve) | Blow down until clean water, then refill | стр. 92 |
| Scum (surface) blowdown | Every 4–8 h (at least weekly 2 min) | Skim; immediately if oil contamination (brown water) is seen | стр. 92 |
| Exhaust gas tubes | Weekly | Blow ash off with compressed air or steam through the smoke box door | стр. 93 |
| Furnace and oil-fired smoke tubes | Monthly | Inspect furnace and refractory for coke; clean smoke tubes | стр. 93 |
| Salinity and oil detection | Monthly | Check function | стр. 19 |
| Water side, hotwell and dosing pump | Yearly | Inspect for corrosion and scale, check injection pump | стр. 19 |
Неисправности и что делать
Water level below the lowest visible part of the gaugeFeed failure or level control faultBrown water in the gauge glass / primingOil or dirt in the boiler waterSafety valve does not lift at set pressureSticking or wrongly set valveHeating surface red-hot or deformedOverheating, low water or scaleCoke or smoke in the furnaceBurner out of adjustmentWater level gauge leaksLoose nuts or worn cock packing
Технические характеристики
| Steam output, oil-fired section | 2000 kg/h | стр. 4 |
|---|---|---|
| Steam output, exhaust gas section (85 % MCR) | 1500 kg/h | стр. 4 |
| Working / design / test pressure | 0.7 / 0.8 / 1.2 MPa | стр. 4 |
| Feed water temperature | 60 °C | стр. 4 |
| Steam temperature at working pressure | 170 °C | стр. 5 |
| Exhaust gas inlet temperature | 280 °C | стр. 5 |
| Diameter / height | 2956 mm / 6340 mm (excl. insulation and mountings) | стр. 4 |
| Burner | SAACKE SKVJ-15 rotary cup, fuel about 160 kg/h | стр. 88 |
| Feed water pumps | Grundfos CR2-150, 3 m³/h, 130 m, 3 kW, 440 V 60 Hz | стр. 54 |
| Water level set points | +90 mm high alarm, +50 mm feed pump stop, −50 mm feed pump start, −110 mm low-low level burner stop | стр. 94 |
| Burner pressure switch | stop at 0.74 MPa, start at 0.55 MPa | стр. 94 |
| Safety valve | opens 0.77 MPa, reseats 0.67–0.69 MPa | стр. 94 |
| Steam dump valve | SAUTER V6G DN40 with XSP 31 positioner; opens 0.2–0.5 bar above working pressure, 1.2 bar control air | стр. 64 |
| Water level gauge bolts | 60 Nm, cold or hot | стр. 13 |
| Boiler water pH / P-alkalinity / phosphate | pH 10.5–11.5, P-alkalinity 100–150 ppm CaCO3, phosphate 20–50 ppm | стр. 18 |
| Boiler water chloride / conductivity | < 100 ppm Cl, < 2000 µS/cm | стр. 18 |
| Feed water | hardness 0–0.5 ppm CaCO3, chloride < 15 ppm, pH 8.5–9.5, no oil | стр. 18 |
| Hydrazine excess (or sulphite) | 0.1–0.2 ppm N2H4 (sodium sulphite 30–60 ppm) | стр. 18 |
Запчасти и номера по каталогу
| Деталь | Номер | Кол. | Мануал |
|---|---|---|---|
| Safety valve spring | 25.912 | 1 | стр. 81 |
| Reflex glass (water level gauge) | KD 8 - IX | 2 | стр. 81 |
| Gasket set, water level gauge | KD 8 - IX | 4 | стр. 81 |
| Gland ring, water level gauge | KD 8 | 6 | стр. 81 |
| Pressure gauge 0–1.6 MPa | K.1180 | 1 | стр. 81 |
| Tube plug, boiler tube | 10–15 | стр. 81 | |
| Manhole gasket 296 x 396 x 3 | 4 | стр. 81 | |
| Handhole gasket 86 x 100 x 3 | 12 | стр. 81 | |
| Pressure transmitter EMP 2 | B.3045 | 1 | стр. 85 |
| Pressure switch RT 116 | B.3001 | 3 | стр. 85 |
| Self-monitoring low level electrode NRG 16-11S | 1 | стр. 60 | |
| Level switch NRS 1-7b | 1 | стр. 61 | |
| Conductivity electrode ERL 16-1 | 1 | стр. 40 |
Источник: мануал производителя «EM-3 ZHONGDE BOILER», 96 стр. Номера страниц указаны по оригиналу. Перед работой сверяйтесь с мануалом на судне.
Страница переведена автоматически. Номера деталей, коды и страницы — как в оригинале.