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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保养规程
Light-up and raising steam (oil-fired)
- Check the isolating valve is open and the pressure gauge reads zero. 第 91 页
- Fill to between low and medium water level; test both water level gauges by opening and closing the upper and lower cocks alternately. 第 91 页
- Open the air vent on top and keep it open until steam comes out. 第 91 页
- Raise temperature slowly: about 1.5 hours to working pressure. 第 91 页Fast firing damages the heating surfaces
- Near 0.7 MPa blow down all blowdown valves and gauge cocks to clear dirt. 第 92 页
- Drain and warm the steam lines with a small flow, then open line valves fully. 第 92 页
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. 第 13 页
- Steam side: shut cock W, open cock S and blow through drain D for 1–2 seconds only. 第 14 页Longer steam blowing shortens glass life
- Return both cocks to the operating position and check the level settles. 第 14 页
Replacing the reflex gauge glass
- Shut cocks S and W and open drain D until the glass is empty. 第 14 页
- Remove nuts and lift off the gauge body; remove screws, cover plate, glass and gaskets. 第 14 页
- Clean sealing faces and check for scars; fit sealing gasket, new reflex glass and cushion gasket, then the cover plate. 第 15 页
- Tighten screws evenly from the centre outwards to 60 Nm. 第 15 页
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. 第 24 页
- Close the lower shut-off valve and open the drain slowly: the stand-by pump start and low level alarms must operate in turn. 第 24 页
- Reopen both shut-off valves and close the drain. 第 24 页
Emergency: water below the gauge glass
- Stop the burner at once through the burner control. 第 92 页Do 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. 第 92 页
保养周期
| 项目 | 周期 | 操作 | 说明书 |
|---|---|---|---|
| Feed and boiler water | Daily | Analyse with the test cabinet and adjust chemical dosing | 第 19 页 |
| Level transmitter | Daily | Function test of high level, stand-by pump start and low level alarms | 第 24 页 |
| Water level gauge | Every hour in service / before light-up and shut-down | Blow through and check reading; renew a cracked glass at once | 第 92 页 |
| Bottom blowdown | Every morning, then every 8 h (at least weekly 1 min per valve) | Blow down until clean water, then refill | 第 92 页 |
| Scum (surface) blowdown | Every 4–8 h (at least weekly 2 min) | Skim; immediately if oil contamination (brown water) is seen | 第 92 页 |
| Exhaust gas tubes | Weekly | Blow ash off with compressed air or steam through the smoke box door | 第 93 页 |
| Furnace and oil-fired smoke tubes | Monthly | Inspect furnace and refractory for coke; clean smoke tubes | 第 93 页 |
| Salinity and oil detection | Monthly | Check function | 第 19 页 |
| Water side, hotwell and dosing pump | Yearly | Inspect for corrosion and scale, check injection pump | 第 19 页 |
故障及处理方法
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
技术参数
| Steam output, oil-fired section | 2000 kg/h | 第 4 页 |
|---|---|---|
| Steam output, exhaust gas section (85 % MCR) | 1500 kg/h | 第 4 页 |
| Working / design / test pressure | 0.7 / 0.8 / 1.2 MPa | 第 4 页 |
| Feed water temperature | 60 °C | 第 4 页 |
| Steam temperature at working pressure | 170 °C | 第 5 页 |
| Exhaust gas inlet temperature | 280 °C | 第 5 页 |
| Diameter / height | 2956 mm / 6340 mm (excl. insulation and mountings) | 第 4 页 |
| Burner | SAACKE SKVJ-15 rotary cup, fuel about 160 kg/h | 第 88 页 |
| Feed water pumps | Grundfos CR2-150, 3 m³/h, 130 m, 3 kW, 440 V 60 Hz | 第 54 页 |
| 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 | 第 94 页 |
| Burner pressure switch | stop at 0.74 MPa, start at 0.55 MPa | 第 94 页 |
| Safety valve | opens 0.77 MPa, reseats 0.67–0.69 MPa | 第 94 页 |
| Steam dump valve | SAUTER V6G DN40 with XSP 31 positioner; opens 0.2–0.5 bar above working pressure, 1.2 bar control air | 第 64 页 |
| Water level gauge bolts | 60 Nm, cold or hot | 第 13 页 |
| Boiler water pH / P-alkalinity / phosphate | pH 10.5–11.5, P-alkalinity 100–150 ppm CaCO3, phosphate 20–50 ppm | 第 18 页 |
| Boiler water chloride / conductivity | < 100 ppm Cl, < 2000 µS/cm | 第 18 页 |
| Feed water | hardness 0–0.5 ppm CaCO3, chloride < 15 ppm, pH 8.5–9.5, no oil | 第 18 页 |
| Hydrazine excess (or sulphite) | 0.1–0.2 ppm N2H4 (sodium sulphite 30–60 ppm) | 第 18 页 |
备件与目录号
| 零件 | 编号 | 数量 | 说明书 |
|---|---|---|---|
| Safety valve spring | 25.912 | 1 | 第 81 页 |
| Reflex glass (water level gauge) | KD 8 - IX | 2 | 第 81 页 |
| Gasket set, water level gauge | KD 8 - IX | 4 | 第 81 页 |
| Gland ring, water level gauge | KD 8 | 6 | 第 81 页 |
| Pressure gauge 0–1.6 MPa | K.1180 | 1 | 第 81 页 |
| Tube plug, boiler tube | 10–15 | 第 81 页 | |
| Manhole gasket 296 x 396 x 3 | 4 | 第 81 页 | |
| Handhole gasket 86 x 100 x 3 | 12 | 第 81 页 | |
| Pressure transmitter EMP 2 | B.3045 | 1 | 第 85 页 |
| Pressure switch RT 116 | B.3001 | 3 | 第 85 页 |
| Self-monitoring low level electrode NRG 16-11S | 1 | 第 60 页 | |
| Level switch NRS 1-7b | 1 | 第 61 页 | |
| Conductivity electrode ERL 16-1 | 1 | 第 40 页 |
来源：制造商说明书《EM-3 ZHONGDE BOILER》，共 96 页。页码以原文为准。作业前请核对船上的说明书。
本页为自动翻译。零件号、代码和页码与原文一致。