DZH Installation and Operation Manual

Installation & Operation Manual Henan Province Sitong Boiler Co,.
Ltd
DZH series horizontal fired biomass boiler
Installation & Operation Manual
Henan Province Sitong Boiler Co.,Ltd.

Installation & Operation Manual Henan Province Sitong Boiler Co,.Ltd
Catalogue
Chapter One Brief introduction of boiler structure
1、Structure intro ………………………………………………………………………………… 2
2、System design overview ……….………………………………………………………………… 2
3、Energy saving use and management …… …………………………………………………… 4
4、Technical features …………………………………………………………………………… ...5
5、Delivery from factory …………………………………………………………………………… .6
Chapter Two Installation introduction
1、Prepare for Installing ……… ..………………………………………………………………… 7
2、Boiler & Auxiliary equipments lifting ……… ………………………………………………… 8
3、Boiler installation .…….. ………………………………………………………………………… 8
4、Auxiliary equipments installation ……. ……………………………………………………………9
5、Boiler pipeline & Instrument Installation …. …..…………………………………………………9
6、Control introduction ……..……………………………………………………………………10
7、Hydrostatic test …..……………………………………………………………………………. …11
Chapter Three Operation manual
1、Drying boiler …………………………………………………………………………………… 13
2、Boiling boiler……………………………………………………………………………………… 15
3、Verify safety valve and pressure gage ……. ……………………………………………… .16
4、Fire up ……………………………………………………………………………………… 17
5、Steam supply ………………………………………………………………………………… 18
6、Heating tube & steam combine ……. …………………………………………………… 19
7、Normal economical operation guide …….…………………………………………………… 20
8、Pollution discharge …….………………………………………………………………… 27
9、Blowing out …….…………………………………………………………………………… 27
10、Maintaining ……. …………………………………………………………………………… 29
11、Pressure part testing & water pressure test .………..……………………………………… 30
12、Safety precautions …………………………………………………………………… 30
13、Others …...…………………………………………………………………………… 32
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Chapter One Brief introduction of boiler structure

The wide variety of sources of biomass fuel is renewable green energy, it is almost no sulfur,
low ash content, the growth process can absorb CO2 from combustion processes realizing
CO2 zero emission. Biomass energy will gradually replace coal and become one of the main
energy sources.
1、Structure introduction
The new steam boiler of DZH series is a kind of horizontal composite boiler with three-pass
fire-and-water tubes. Combustion equipment is designed as moving grate and increase
forced draft feeding device. According to the special feature of the biomass fuel , we set a
unique combustion chamber to strengthen the combustion efficiency. We also adopt domestic
advanced arched tube plate, set a group of threaded pipe bundles inside the drum and
welding water wall tube on both sides of furnace. Gas flues on the each side enlarge boiler
heating areas. The heat preservation system of boiler adopts refractory fiber felts of
Silicate-rock which help to reduce heat losses of boiler , and to improve thermal efficiency of
boiler.
2、System design overview
Boiler and its system should accord with the law、rules、 safety technical manual about energy
saving as well as others relevant standard. The combustion equipment and furnace of boiler
has reasonable structure design, matched with fuel types, making sure it can burning more
safe、stable、efficient. Reasonable heating surface arrange. Select rational economic velocity of
smoke to decrease the resistance of beside smoke. Reasonable set access door (hole) and
peephole, using seal structure in the taphole, it guarantee boiler’s air leakage factor in design
requirements.
Before designing of boiler room, should fully improve efficiency of energy use, reduce the
consumption of water、electric、heat and others consume under the premise of safety, to
promote heat recycle and utilizing it stepwise. While decorating boiler room, designer should be
try to reduce the length of tube、air flue and elbow quantity, thus decreasing the flow resistance.
Primary air duct suitable use prototype structure, and consider it’s expansion and hang support.
When fluctuation of heat load is big and frequently, user should balance the load, making
efficient adjust. Several boilers systems suit for central control device, to make sure balance of
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boiler running and in economic running status. The medium and parameter of boiler should be
satisfied with request of usage, can’t let the rated outlet pressure and actual working pressure、
temperature discrepancy too large.
In order to rational utilizing heat of continuous water-polluter, user should install continuous
blowdown extender according to gross of continuous blowdown. Escaping、emiting、dropping、
leaking is prohibited in boiler and boiler system, taking full advantage of condensate water、
flash steam、heat of continuous blowdown water, and taking step to increase use ratio of
recoverable condensate water.
Boiler system as follows:
(1)、Boiler circuit
Softened water →water tank→ feed pump →economizer →distribution pipe→ boiler →
down comer → header→ water wall tube→ drum→ steam separator→ steam outlet pipe→ user
(2)、Smoke system
High temperature flue gas generated from furnace pass through middle wall, then goes into
back of furnace by bottom of both wings flue, after heat transfer in both wings flue, rushed
forward to front smoke box, enter into thread flue to fulfill heat transfer, after goes into dust filter,
discharged into atmosphere through chimney by induced draft fan.
(3)、Ash system
Ash generated by fuel after burning was discharged into ash pool by handle boiler’s fire
grate, the worker use tool fish out the ash from ash removal door, a part of ash among smoke
settle down burn out furnace after-combustion, then pushed out by back ash removal door, the
rest part was processed in dust filter, dropped down dust vehicle.
(4)、Blast blower system
Air goes into head air flue by blast blower, enter into air room through air distributor, come
into furnace passed by handle fire grate coal seam.
(5)、Blast feeding system
Biomass fuel (rice husk) goes into feed hopper by belt transport device, come into furnace
through air blower.

3、Energy saving use management
（1）The user have responsibility to boiler and boiler system’s energy saving. The technical
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workers must know of boiler specialized knowledge, are familiar with relevant nation laws、
rules、safety technical manual and others standard.
（2）The user of boiler should set up perfecting energy saving management regime and carry
out. Energy saving management regime at least include several items as follows:
1）Energy saving target-oriented responsibility system and manage work post responsibility.
2）Boiler system everyday censorship, doing inspection recorder and saving.
3）Fuel quality testing management system, selecting correct fuel according to design
requirements
4）Metering device adjust and management system
5）Boiler maintaining system
6）Boiler water quality management system.
7）Boiler operator、water treatment workers training and check system, training boiler workers
about economic running knowledge, work plan checking and recording.
（3）Boiler user should set up working mechanism about energy efficiency check and rewards
& punishment, try to promote energy management based on practical situation, check out
energy efficiency regularly, reforming those inconformity in time.
（4）Boiler user should regularly maintain boiler and relevant device、meter、tube and valve,
Any special situation , the operator must dispose in time and recording.
（5）Boiler user should inspect and supervise the function of all boiler parts usually. Key
inspection include: whether use fuel suit for the design fuel, fuel consumption , temperature and
pressure of medium output, water supply quantity and temperature, exhaust gas temperature
and furnace wall surface temperature, besides, whether system have situation like escaping,
emitting, dropping, leaking.
（6）Boiler user should strengthen work at energy detection、measure and statistic. Advanced
users should evaluate the function of boiler regularly, method refer to 《Industry boiler efficiency
test & evaluation rules》（TSG G0003)
（7）Boiler user should test the boiler efficiency every two years, test work should together with
boiler external inspection, the testing organization should be authorized by National Bureau of
Quality Inspection (AQSIQ).
（8）Boiler workers should according to the change of thermal load, to adjust quantity of
running boilers and boiler energy output, advanced boiler rooms can install boiler automatic
load regulation device.
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（9）Industry boiler normal blowdown rate should according to the following requirements:
1）Industry boilers based on softened water as supply water or adulterant processing less
than 10%.
2) Boilers based on demineralized water as supply water less than 2%.
（10）Boiler water conditioning must accord with boiler water processing technical manual and
relevant requirements.
（11）Boiler users should observe 《high energy consumption special equipment energy saving
supervision and management method》, to build special equipment technical files. Advanced
users should unified manage the files such as boiler energy efficiency technique, quality of
products and using. Boiler energy efficiency technical file at least including the following:
1) Boiler delivery attached documents (include energy efficiency test report)
2）Evidentiary material about Boiler auxiliaries、accessory equipment and so on;
3）Boiler installation testing report、energy saving improvement information;
4）An evaluation about boiler installing、improving、maintaining or efficiency test report
5）Energy efficiency test report regularly and year running efficiency report;
6）Inspection record about boiler and system energy saving.
7）Certificate of measurement 、instrumentation;
8）A report about water conditioning;
9）Fuel analysis report.
4、Technique features
（1）Boiler drum consist of arch form tube plate and thread smoke tube, making drum from
rigidity changed into elastomer structure, canceled the tension part, reduce the strength.
Smoke tube from double return trip changed into single return, solve the problem of tube plate
flaw.
（2）Rise pipe bank was fixed under the drum, eliminate the dead water zone in the bottom of
drum, thus sludge doesn’t deposit, high-temperature region of drum get cool enough,
preventing the swelling under the boiler shell.
（3）With high efficiency heat transfer thread smoke tube, effect of heat transfer was enhanced,
so that boiler get high-temperature、boosting rapidly, improved the boiler efficiency.
（4）Compact structure, compared with similar boiler, advantage at smaller in dimension, saved
the boiler room cost.
（5）Running stable, safety and reliable, operating mechanization , reduced the labor cost.
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（6）An great innovation at water cycle aspect, that is the usage of fluidics, return water was
ripped into downcomer by injection water, then increased the cycling flow velocity of the rise
pipe.
（7）With thread smoke tube strengthen heat transfer, improved heat transfer coefficient,
because of the disturbance caused by pipe smoke, smoke pipe is not easy to deposit dust, it
can cleaning naturally.
（8）Boiler middle brickwork, import bend of both wings pipes both have the function of
dedusting , making discharged dust consistence under the control standard, making sure that
dust emission reach the standard of nation environmental protection.
（9）Particular design of combustor, inside of the furnace, energy-efficient brickwork consist of
refractory bricks, improved fire condition, independent plenum making blowing more
reasonable, thus an aerodynamic field which to the benefit of burning was formed in the
furnace, improving burning temperature and efficiency.
Chapter 2 Installation introduction

In order to safeguard your rights and interests, before installation and use of the boiler, please
hold the attached relevant documents to the local department of boiler safety supervise
organization to go through the registration formalities of the installation。
1、Prepare for Installing

(1) Appoint the installation company. The company must have corresponding qualifications
of boiler installation!
（ 2) go through the notification procedures. before installation, please go to the local
department of boiler & pressure vessel safety supervise organization to do the notification of
installation procedures!
（3）Subsection examination and hydraulic pressure test of boiler installation，shall be
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completed commonly by both of client and installation contractor. The representatives of
department of boiler & pressure vessel safety supervise organization must attend to the site
total examination of boiler!
（4）After the acceptance of installation, the boiler can be put into use upon the certifications
obtained by the company handing relevant materials to complete the registration in the local
department of boiler and pressure vessel safety supervise organization!
（5）The boiler must be operated by the qualified stoker operator who has passed the
examination of department of boiler & pressure vessel safety supervise organization!
（6）Organization staff to learn installation technology measures, safety technical measures,
"TSG G0001-2012 boiler safety technology supervision regulation" and be familiar with boiler
drawings and relevant technical documents.
（7）before installing the boiler, please carefully check, inspect, count and record the boiler
proper, auxiliary equipments, accessories according to the technical documents. If any parts
are not conforming to the relevant standards , please notify the manufacturer(us) as soon as
possible.
2、 Boiler & Auxiliary equipments lifting

（1）The boiler proper, auxiliary equipments, packing wooden case for the accessories and
meters should be lifted as designated position specified by the manufacturer. The result of
damage by random pothook and operation without conforming to the requirements of the
manufacturer shall be the responsibility of the user.
（2）Load-carrying vehicles, lifting equipments,steel wire rope for binding, winch and other
equipments must enough to load the boiler and should comply with technical specifications.
（3）Please choose lifting equipments according to the biggest size and the heaviest products
as technical specifications before lifting and develop the corresponding safety precautions.
3、Boiler installation
(1) the foundation of boiler must be determined by the local soil and refer to the foundation
drawing that is provided by the manufacturer and should be redesigned by the department of
civil engineering.
（2）When the foundation of boiler is reaching the required strength, the relevant person must
inspect and accept the boiler conforming to the drawing and draw up the three datum lines of
the whole boiler.
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a、 Vertical datum line - center of drum.
b、 Horizontal datum line – load-bearing centerline of the base front and back.
c、 Elevation datum line - the user can mark several positions respectively around the
foundation, and the relative offsets of marks must not beyond 1 millimetre.
(3)The boiler proper should be set up in accordance with the positioning centerline in the
drawing，and sealed leakage point by concrete.
（4） Dimensional deviation of installation location and acceptance of boiler follow the <Test
Standard for Construction and Acceptance of Industrial Boiler Installation Project,
GB50273> .
（5）Pipeline’s welding and acceptance should obey the Test Standard for Construction and
Acceptance of Filed Equipments and industrial pipeline welding project.
4、Auxiliary equipments installation

(1) the economizer, dust collector, induced draft fan and blast blower must be installed after
passing the inspection of air shutter, blocking valve of dust collector and transmission part.
Defects such as sticking and leakage should be checked. after installation. Finally plug into an
electric power supply to check the motor to make sure the right motor steering，without friction
and vibration, the normal dynamo temperature. In order to ensure good lubrication performance
of the bearing of induced draft fan at high temperature, bearing block should be taken effective
cooling measures, and add lubricating oil regularly. When induced draft fan start in cold state,
the flue gas damper should be closed to prevent burn out motor in case of oversize start
electricity. The time of cold-conditional operation not exceed 5 minutes.
（2）Smoke duct connected with blast blower and induced draft fan, if not complied with the
designed drawings, and the length, elbow and sectional area change larger, should be
recalculated the resistance of smoke wind and proofed the flow rate and pressure head of blast
blower and induced draft fan to meet the practical requirements of boiler.
（3）Auxiliary equipments of boiler should install reduced voltage starter of motor power
exceeding 15 kw.
（4）The economizer should be installed conforming to the drawing of smoke duct and proceed
the hydrostatic test in accordance with the relevant regulations and rules.
5、 Boiler pipeline & Instrument Installation

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(1) the water gauge and water level controller:
⑴．The deviation of water gauge and normal water level elevation of drum is about +2mm.
The highest, the lowest and the normal water level should be accurately marked. The water
gauge should have drain valve (or drain cock) and draining tube of drum which connected to
safe place. Run-off pipe at the bottom of water gauge must be connected to a safe place. The
water gauge must be flexible rotation without leakage and attached lighting equipment for
convenient observation.
⑵．Water level alarm alarm and water level controller of water-supply system , as a kind of
electrode automatic controlling device should be connected with machine conforming to the
drawing.
(2) the instrument for measuring pressure and temperature.
⑴．At the water inlet and gas outlet of a boiler the instrument must be installed for
measuring temperature, and able to correctly reflect temperature of the medium as well as
conveniently observe temperature.
a、Pressure gauge should be installed in a location for easy observation and purging, and
prevent influence by high temperature, frozen and vibration.
b、Among pressure gauge and trap bend, it should be equipped with a cock so as to purge
pipeline and change pressure gauge when necessary .
c、The dial of pressure gauge should be marked with red line to indicate boiler working
pressure.
d、The safety valve should be installed exhaust pipe which can discharge exhaust steam to a
safe place with sufficient sectional area to ensure smooth exhausting. The bottom of valve's
exhaust pipe shall be equipped with a drain pipe to a safe place. Prohibit install valve on the
exhaust pipe and drain pipe.
e、Each boilers should be installed an independent blow-off pipe which should avoid too
much elbows to ensure smooth drainage and be connected to a safe place of outdoor or a
drainage expansion tank. If several boilers need share a main blow-off pipe to proceed
periodic drainage, which can be realized by taking appropriate security measure. When a boiler
adopts a drainage expansion tank with certain pressure, safety valve should be installed on
drainage tank.
f、The blowoff valve and drainage pipe of boiler is not allowed to connect with thread.
6、The Instructions of Control system

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（1）Main control parameters:
⑴. The pressure control: This series of boilers are installed with two full-opening spring
safety valve to ensure safe operation of a boiler. when the operate pressure reaches to the
lower setting value, the first safety valve will automatic start to discharge pressure; if the
pressure continues to increase to the more higher pressure setting value, the second safety
valve starts to operation. The safety valve start pressure are shown in table 1
Table 1 The start pressure of safety valve
The start pressure of safety valve
1.04 times the working pressure
1.06 times the working pressure
⑵. Water level control:

Water level controller UDG - 32 (electrode water level alarm)
a. When the normal water level up +30mm, the control switch of water pump cuts off
contact point and stops working.
b. When the normal water level down -30mm, the control switch of water pump starts to
touch the contact point and begins to work.
c. When the normal water level up +40mm, the first group of electromagnet high water
level contact point will combine with extreme high water level alarm to send out alarm signal.
d. When the normal water level down -30mm, the second group of electromagnet low
water level contact point will combine with extremely low water level alarm to send out alarm
signal.
e. When the normal water level down -40mm, the low water level interlock protect device of
water pump and the blower will start.
⑶. The fuel gas temperature control:
When the fuel gas temperature is higher than 170 ℃, stokers should adjust the combustion
condition and adjust exhaust gas temperature.
（2）The indicate status:
⑴.The "automatic" signal light is bright when the water pump is under the automatic work
situation; the "manual" signal light shows green when it is under the manual work situation.
⑵. High water level status is indicated with yellow light.
⑶.Red light is used for indicating various situations like low water level, extremely low water
level, overpressure and when burner out of order.
(3) Alarm protection:
Under unforeseen circumstances, such as, when the water level of boiler is lower than the
lowest water level, the interlock protect device of low water level start to work, at the same time
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the switch interlock of water pump and blast blower begin to shut down and the induced draft
fan should be opened to take emergency measures for shutdown the boiler.
7、hydrostatic test
（1） After the completed installation of boiler or overhaul of the boiler pressure parts, boiler
should process hydrostatic test.
The test pressure shall conform to Table 2
Table 2. Test pressure of the steam boiler

name work pressure of Drum (shell) P test pressure
1.5P, not less than 0.2

The boiler proper ＜0.8 Mpa
Mpa
The boiler proper 0.8～1.6 Mpa P+0.4 Mpa

The boiler proper ＞1.6 Mpa 1.25P
（2）Preparation work before Hydrostatic test：

a、Do the internal cleaning and surface inspection of boiler.
b、Check to ensure that no clogging pipes.
c、Install calibrated qualified pressure gauges (more than 2 pieces)
（3）Hydrostatic test should meet the following requirements：
a、Metal surface condensation phenomenon should be eliminated after boiler filling with
water.
b、Water pressure should be risen and fallen slowly. When the pressure rises to the
working pressure, should pause increase pressure, check whether there are water leakage or
abnormal phenomenon，and then Increase pressure to the test pressure. Boiler shall be under
the test pressure for 20 minutes, and then reduce to working pressure and check again, during
the period the pressure should remain unchanged.
c、Hydrostatic test should be performed when the surrounding temperature is higher than
5 ℃, there must be anti-freezing measures below 5 ℃. Water used for hydrostatic test should
be kept above the dew point temperature to prevent condensation on the boiler surface, and
should not be too hot, prevent vaporization and overlarge metal temperature difference stress,
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generally 20-70 ℃.
（4）Boiler Hydrostatic test is qualified when meet the following conditions:
⑴.There is no water and water mist on metal pressure parts and metal welds.
⑵. After Hydrostatic test, there is no residual deformation
The Third Chapter Operation Instruction
Warning: the method of baking boiler, which is not as the regulation, it will make the
furnace wall cracking, deformation, collapse, and affect the safe operation of the
boiler！
1、 Furnace drying
Newly installed、removal installed 、overhaul or long-term Outage boilers，the furnace and the
gas flue wall are very wet , so if it contact with the high temperature flue gas, Internal moisture
will evaporate rapidly and the furnace wall and arch will appear cracks 、deformation ，even
collapse. So before putting into operation the boiler furnace wall and arches must be baked
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slowly and dry, Make the moisture inside the furnace wall and the arch evaporate slowly. This
slow drying method is Furnace drying.
（1）Before Furnace drying should meet the following conditions:
① boiler and its attached devices assembled and hydrostatic test is qualified.
② anti-corrosion and insulation work end and examine whether the gas flue is clean.
③ boiler ’s thermal instrumentation should be checked and up to standard.
④ boiler auxiliary equipments commissioning is completed, all parts of the boiler meet the
safe start conditions.
（2）The method of Furnace drying:
You should fire wood to bake the boiler at the first three days. Wood should be stacked in the
middle of the grate and cover about 1/2 area . Ignite wood and use a small fire to bake at the
beginning，open The flue damper about 1/6 ~1/5, proceed natural ventilation，make the flue gas
flow slowly, maintain the water temperature at 70 ~ 80 ℃. After three days, you can add a small
amount of coal to gradually replace wood. At this time appropriate to open flue damper larger
and start to enhance ventilate by induced draft fan, then the water can be slight boiling.
In the process of baking boiler the temperature rising speed should control by flue gas
temperature after super heater. If the boiler has no super heater, the temperature rising speed
should control by flue gas temperature between the first and second compartment firewall. For
heavy furnace wall, the first day the temperature rise should not exceed 50 ℃, after that the
temperature rise should not exceed 20 ℃ each day, the maximum temperature of the flue gas
should not exceed 220 ℃. For light brick furnace wall, the first day the temperature rise should
not exceed 80 ℃, after that the temperature rise should not exceed 25 ℃ each day, the
maximum temperature of the flue gas should not exceed 160 ℃. For heat-resistant concrete
wall, the temperature rise should not exceed 10℃ per hour, the maximum temperature of the
flue gas should not exceed 160 ℃, at the highest temperature range, duration should not be
less than one day and night.
（3）Eligibility criteria of baking boiler：
Furnace wall, furnace arch should not appear crack, deformation and at the same time meet
one of the following requirements will be qualified.
1) Take refractory bricks and red bricks’ T-shaped cross joints mortar sample 50g from
both sides wall’s middle part, furnace grate above the 1.5 ~ 2.0m position and both sides of
the super heater Central wall, if the moisture content less than 2.5%, Furnace drying is
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qualified. When the refractory mortar moisture content is 7%, moisture content of brick
mortar is 7% to 10%, it is unnecessary to bake furnace separately, and then start boiling out,
because during the boiling out period the heat from combustion also can bake the furnace.
2）At both sides wall’s middle part, at the furnace grate above 1.5 ~ 2.0m, check the red
brick wall where from surface to inner 100mm if temperature can reach to 50℃, if yes, keep it
within 48h, at the same time, start to boiling the boiler.
（4）Furnace drying considerations as follows：
1）according furnace structure and Installation instructions，formulate furnace drying
operating procedures and do well organization work.
2）During Furnace drying process, check the furnace wall and other parts regular, detect
cracks, deformation and bump defects timely.
3）At the beginning of furnace drying, furnace wall and the arch should be uniformly baked
at low temperature, and then slowly increase the baking temperature, Impatience to increase
the fire is prohibited. Rise the furnace temperature According to the operating procedures, not
allow the temperature fluctuation and interrupt. Flame should be distributed evenly to prevent
the furnace wall local heating up too fast.
4）Maintain a normal water level during Furnace drying. It is allowed the boiler water a
slight boiling in the later period .If the water is boiling violently, should open the exhaust valve,
and then filling water in time.
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(Light Brick furnace wall drying chart）

2、Boiling Out
CAUTION: if boiling out does not meet the requirements, will cause steam quality
deterioration or priming, corroding pipe、header and other components, harming
safe and economic operation of the boiler ，influence use life of the boiler!
(1) Boiling out purpose is adding NaOH and Na3Po4 into the feed water, because alkaline water
can remove the greasy dirt, rust, to ensure that the boiler heated evenly, operating normally.
(2) The dosage should comply with equipment technical document, if no rules, shall comply
with the table below:
Dosage(kg/m³water)
Drug name
Thin rust Thick rust
NaOH 2~3 3~4
Na3Po4 2~3 2~3
Attentions:
⑴ .the drug is calculated by 100% purity.
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⑵ .The Na3Po4 (Trisodium phosphate) could be replaced by Sodium Bicarbonate, the quantity of
the Sodium Bicarbonate dosage is 1.5 times of the Na3Po4
⑶ .The Na2CO3 could be exclusive used boiling the boiler by feeding 6kg/m3water.
(3)The boiler water should be low water level when adding the drug into the boiler
(4) Keep the boiler pressure retain about 75% when boiling the boiler. The time of cooking
boiler is 2~3 days in general.
(5)Take boiler water to analysis when boiling the boiler in regular, if the water alkalinity in the
boiler lower 45mmoI/L, it should be added drug.
(6)After boiling the boiler, clean the boiler drum and deposits in the container, wash the inner of
the boiler and the valve which touched with the liquid medicine, inspect the drain outlet whether
jammed.
(7)The boiler should accord with following standard:
(A) Boiler drum, the inner of the container have no oil pollution
(B) The surface of the metal has no rust after wiped the attachment.
(8) Proceed the boiling out work after furnace drying or in later period of furnace drying.
3、Verify the safety valve and the pressure gage.

(1) the safety valve should be adjusted and verified before firing accord with the set pressure
which stated in the <<safety technique supervise regulation of steam boiler >> chart 7-2 ,article
143,Chapter 7.
Caution: the boiler will explode if you don not adjust the safety valve according to the
rule.
Rated steam pressure(Mpa) Set-pressure of the safety valve
≤0.8 Working pressure +0.03Mpa
Working pressure +0.05Mpa
0.8<P≤5.9 1.04 times of the working pressure

1.06 times of the working pressure
>5.9 1.05 times of the working pressure
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1.08 times of the working pressure
About the safety valve set-pressure parameters of the boiler, please refer to the pipeline
valve instrument diagram.
Note:
1) At least one safety valve on the boiler which must be adjusted according to the lower
set-pressure.
2) The working pressure in the diagram is means the working pressure of the safety valve
which located.
3) The safety valve should not be has gas (air) leakage and impact.
4) The safety valve set-pressure of the economizer should 1.1times of the installation site.
5) After above mentioned up to standard ,the boiler should test run 4~24 hours continuously
with full load, pay attention to whether the boiler up to standard based on all the parts and
accessory equipment run normal.
(2) method of adjustment
(the safety valve adjustment should execute by who has acquired the relevant
qualification ) take down the cotter pin ,remove the head cover ,unscrew the hexagon jam
nut ,then screw the adjustment screw rod ,let the spring loosen or tightening, in order to reach
the exhaust pressure of the safety valve, screw the jam nut after adjustment and then install
other parts ,finally add lead sealing ,the user should not open without permission .All the
safety valve should not adjust randomly.
(3) Be sure not to knock any parts of the safety valve, only the joystick could be used
when open the safety valve.
(4) The pressure gauge could be used after examined in metrological service
organization.
4、 Fire up
The boiler should be examined thoroughly before fire (include the attachment ,pipeline)，then
feed water into the boiler, the procedure of the fire as follows:
(1) close the blow-down valve, open one safely valve and make the air in the boiler could be
exhaust, run alone and don not put the boiler link with the steam pipe system. The air in the
boiler could be exhaust by open water escape valve of steam header and main steam vale.
(2) Put the softened water into the boiler, then promise the water in the boiler up to the lowest
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water level of the water gauge .Finally, close the feed water valve, watch the water level
whether dropped after the water level became stable.
(3) Put the wood or ignition material on the fire grate, turn on induced draft fan before
fire(turn down smoke damper).then begin use blast blower feeding device after the ignition
material burn fully ,meanwhile, turn on air blower and adjust induced draft fan in order to make
the fire burn normally.
(4) To avoid every part of the boiler produce too much pressure to bear which would influence
the boiler life because of the temperature of the fire uneven heating, so it should not adjust the
fire too high quickly. Keep in mind that 3~4 hours is perfect time from cold furnace to
working pressure when fire the boiler in the first time, the cold furnace should not less than
2 hours, the heat furnace should not less than 1 hour except the special situation occurred that
in need of steam.
(5) Pay attention to the water level after firing, the water level would rise because the heat,
proceed drain contamination if the water level exceeded the highest level.
(6) Close the safety valve when steam come out and wash the pressure gauge bent pipe and
water gauge, examine whether the manhole cover and the handhole cover seepage after the
air pressure up to 0.2Mpa, if seepage, it should screw down the bolt of the manhole cover 、
handhole cover and flange screws again ,in the same time ,check the blow down valve has no
leakage situation.
(7) When the pressure in the boiler rise high gradually, pay attention that whether the boiler
occurred special voice, if this happened, should examine quickly, stop the boiler
working when it is needed ,the boiler only could go on working after the trouble was
solved.
(8) Examine the economizer outlet water temperature ,the temperature should lower 40C than
saturation temperature of the working pressure, if surpass this temperature, close the
recirculation valve of the economizer which lead to the water tank, then supply water to
economizer alone.
(9) When ignition the boiler at first time, not less than one hour when the furnace is cold, not
less than half an hour when the furnace is heat.
5 Supply steam
When the boiler pressure closed to the working pressure and ready to supply steam, the fire
should be slowly, the water level should not exceed the normal level before supply steam.
18
Open the main steam valve a little, let a little steam to heat the pipe and open the drain valve
at the same time, drain the condensate water, the time of heating pipe is depend on the
length ,diameter ,steam temperature of the pipeline ,in general, at least need half an hour. Pay
attention to the piping support’s situation when heating pipe, stop heating if occurred
abnormality situation. The main steam valve could open slowly after the trouble and defect is
solved, fully-open the valve when the pipe became hot and the condensate water on the
pipeline has reduced step by step, meanwhile, examine the boiler if there is some special
noise occurred. Adjust half-turn of the main steam valve handwheel when the valve
fully-open in order to keep running after heating. Examine attachment parts ,valve and gauge
again after supply steam to keep everything is normal.
6 、warm pipe and combine supply steam (feed the steam to main steam header)
1) Warm pipe
Warm pipe means that heating the steam pipeline, valve, flange in atmospheric temperature
with steam, make the temperature rise evenly, drain the condensate water to avoid damage
pipeline, valve and flange when supply steam. Warm pipe should begin when the boiler
pressure rise up to two-thirds of the rated working pressure and the time depends on the
pipeline length, diameter, steam temperature, season temperature. The time should not less
than 30 minutes if the working pressure under 0.8Mpa in general.
① Operate procedure
The warm pipe range is from the main steam valve outlet to the pipeline before steam-using
equipment for a single boiler. First, open all the steam trap of the main steam pipeline ,drain the
condensate water which stored in the pipeline then close them until the normal supply steam,
then open slowly the bypass-valve about half-turn on the main air valve ,let a little steam into
the pipeline, fully-open the main steam valve after the pipeline is fully preheat,.
The warm pipe range is the pipeline and pipeline parts between the main steam valve and main
steam header when some boilers use a main steam header in the same time .If the new boiler
connected the main steam valve and the isolating valve of the main steam header, the warm
pipe also apply to the pipeline between the isolating valve and boiler.
Before warm pipe, first, open all the steam trap valve before the main steam valve and main
steam header, drain the condensate water ,open the main steam valve slowly ,use the steam
which produced from boiler pressure rising to preheat, the pipeline would rise pressure and
19
temperature followed the boiler, it is safe, convenience and save-time. Close the steam trap
valve on the pipeline, then could supply steam to the main steam header.
② Warm pipe attentions
If the pipeline expansion, support is abnormal or happened shock or water attack when warm
pipe, it means that the pipeline temperature rise quickly, so it should slow the supply steam,
that is turn down the throughput of the main steam valve, extend the pipeline time. Stop the
warm pipe and close the main steam valve and turn up steam trap valve if the shock noise is
too high. Keep warm pipe after solve the trouble.
(2) Feed steam to the main steam header
Feed steam to the main steam header means that when more than two boilers working at the
same time, the new operate boiler can supply steam to the main steam header which supplying
steam to equipments. After the boiler finished warm pipe through steam header before isolating
valve, it could be ready supply steam when the boiler working without problem and the firing is
stable.
①Before merge the generated steam into the main pipe, the boiler pressure should be slightly
lower than the steam header pressure, avoid boiler water rapid evaporation caused by air
pressure fall suddenly.
②Before merge the generated steam into the main pipe, the steam boiler water level should be
the lowest security level, in order to avoid the steam with water.
③Analysis steam before merge the generated steam into the main pipe, the steam quality
should be qualified.
④Merge the generated steam into the main pipe, bypass valve should be open firstly, then
open combine steam valve. Slowly open valve, shut down bypass valve, drain valve before
combine steam valve and drain valve of super heater after open combine steam valve..
⑤Merge the generated steam into the main pipe process should close attention to pressure,
temperature and water level changes.
20
⑥Open economizer’s flue damper after the steam goes into the main pipe. If there is no bypass
flue, close the recirculation pipe’s valve on the economizer, so that the economizer will operate
normally.
⑦Open continuous blow down valve. When the boiler reach 70% rated load, and the water
level is normal, water supply and combustion automatic adjustment device start operation.
7、Normal economic operation instructions
Install a qualifying boiler must refer TSG G0002-2010 "supervision and management
regulations for boiler’s energy saving technologies".
（1）The boiler during normal economic operation, safety accessories should be sensitive
and reliable quality, stable combustion will ensure steam quality and boiler’s safe operation.
Keep the furnace normal water level, steam pressure stability and maintaining the cleanliness
of the boiler room, they are required, in addition, to do well shifting of duty.
Should ensure steam quality.
1）Water quality requirements CAUTION: Water quality does not meet the
requirements, the sediment will deposit in drum and collecting box bottom, they will
form incrustation and lead to destruction of the water circulation, so that the tube
overheating, deformation, burst pipes, and even lead boiler crack or explosion due to
boiler shell over-burning.
Boiler feed water need to be softened, water treatment method can be add drugs in boiler or
chemical treatment outside of the boiler, the softened water quality should comply with
GB/T1576-2008 "industrial boiler water quality," following table provides:
21
Mpa
P≤1.0 1.0＜P≤1.6 1.6＜P≤2.5

nominal steam
Item pressure
water type
softened desalted softened desalted softened desalted
water water water water water water
FTU turbidity ≤5.0 ≤2.0 ≤5.0 ≤2.0 ≤5.0 ≤2.0
(mmmol/L)
≤0.030 ≤0.030 ≤0.030 ≤0.030 ≤0.030 ≤0.030
Hardness
（25℃）
7.0～9.0 8.0～9.5 7.0～9.0 8.0～9.5 7.0～9.0 8.0～9.5
pH value
water (mg/L)
≤0.10 ≤0.10 ≤0.10 ≤0.050 ≤0.050 ≤0.050

supply
(Dissolved Oxygen)
（mg/L）oil ≤2.0 ≤2.0 ≤2.0 ≤2.0 ≤2.0 ≤2.0
（mg/L）
≤0.30 ≤0.30 ≤0.30 ≤0.30 ≤0.30 ≤0.10
total iron
（25℃）/（µS/cm）
2 2 2 2
- - ≤5.5×10 ≤1.1×10 ≤5.0×10 ≤1.0×10
conductivity
No
superhe- 6.0～26.0 ≤10.0 6.0～24.0 ≤10.0 6.0～16.0 ≤8.0
(mmol/L) ater
With
Total
superhe- - - ≤14.0 ≤10.0 ≤12.0 ≤8.0
boiler alkalinity
ater
water
(mmol/L) No
superhe- 4.0～18.0 ≤6.0 4.0～16.0 ≤6.0 4.0～12.0 ≤5.0

Phenolpht
ater
-halein
With
- - ≤10.0 ≤6.0 ≤8.0 ≤5.0
alkalinity superhe-
22
ater
10.0～ 10.0～
（25℃）pH value 10.0～12.0 10.0～12.0 10.0～12.0 10.0～12.0
12.0 12.0
No
3 3 3 3 3 3
superhe ≤4.0×10 ≤4.0×10 ≤3.5×10 ≤3.5×10 ≤3.0×10 ≤3.0×10
（mg/L）
ater
Dissolved
With
solids 3 3 3 3
superhe - - ≤3.0×10 ≤3.0×10 ≤2.5×10 ≤2.5×10
ater
10.0～
- - 10.0～30.0 10.0～30.0 10.0～30.0
Phosphate radical
30.0
（mg/L）
d
10.0～
- - 10.0～30.0 10.0～30.0 10.0～30.0
30.0
Sulfite radical（mg/L）
Relative alkalinity ＜0.20 ＜0.20 ＜0.20 ＜0.20 ＜0.20 ＜0.20
Note 1: Unit of measurement of hardness and alkalinity is the concentration of the amount
of a basic unit of material.
2: when the stop using (backup) boiler starts, the water quality should meet the
standard requirements after boiler water concentration ratio reach normal standard.
A, The controlling value of dissolved oxygen is suitable for the water which passed
deoxidize equipment treatment. When the rated evaporation output more than or equal to
10t / h, the water should be deoxidized. If rated evaporation output is less than 10t / h, if
you find localized corrosion on the boiler, should adopt deoxidize treatment.
B, If there is no high requirement about the steam quality and without superheater
about the boiler, boiler water’s total alkalinity upper limit value may be relaxed, but
relaxed boiler water’s PH value (25 ℃) should not exceed the limit.
C, Phosphate scale inhibitors which applicable to the boiler. When use other scale
inhibitors, scale inhibitors’ residual volume should be consistent with the specification of
23
the manufacturer.
D, Sulfite deoxidant which applicable to the boiler supply water. When use other
deoxidant, deoxidize’ residual volume should be consistent with the specification of the
manufacturer.
E, All welded construction boiler, relax the relative alkalinity.
2）Boiler water level
The water level should within the scope according to drawing and document requirements,
can’t higher than the highest water level or below the lowest water level, it’s normal that
there is a slight shaking up and down phenomenon about water level inside of the water gauge.
If the water level gauge is stationary, indicating that may be clogging, water level should be
immediately washed.
（2）water level gauge
Clean the water level gauge at least once per shift, kept the glass of the gauge is clean, so that
ensure accurate and reliable water level data. Tighten the padding if find leaking water or steam
on glass pipe washer, replace the water level gauge if glass is blurred or water line looks not
obvious and they are still bad after wash, each boiler is equipped with two independent water
level gauge, if one is damage should be repaired immediately, if both of them damage at the
same time should be immediately shut down the boiler, operate the boiler until one water level
gauge is normal.
（3）Water supply equipment:
1）Start every water supply equipment at least once per shift, check it whether the device is
operating normally if failure should be repaired.
2）Boiler feed water as much as possible to take continuous water supply, keep the water
supply steady by control the water pump outlet valve, economizer outlet water temperature
should be lower 40 ℃ than the maximum working pressure saturation temperature, if more than
the specified temperature, then need adjust the water temperature by connect it to water tank
for recycle. Stand by pump should be set near the feed water pump, when anyone feed
24
water pump stops working, the rest pump’s total flow should be able to meet all running boilers
110% requirement for water at the rated evaporation output, economizer should be intact, use
asbestos to seal if the economizer air leakage.
（4）Vapor pressure:
As far as possible to maintain a stable working pressure, avoid vapor pressure more than the
maximum permitted working pressure.
（5）Pressure gauge:
Pressure gauge bent pipe need to be washed once per shift, check the pressure gauge
whether normal, if found pressure gauge damaged, shutdown the boiler and replace it
immediately, pressure gauge need to examine at least once every six months.
（6）Safety valve:
Note the safety valve whether normal, proceed exhaust test by pulling the lift handle on safety
valve periodically to prevent the valve disc and seat stick, rise the vapor pressure once per 2~4
weeks, verify the function of steam safety valve by exhaust test.
（7）Drain valve:
Periodic blow down (see item 8, "pollution discharge")
（8）Add fuel to the boiler operating instructions
When firing, add the ignition material such as wood in furnace door, after wood ignited, open
induced draft fan (turn down the flue gas damper) before ignition. Open the blower feeding
device blow rice husk fuel into the furnace after the ignition material combustion exuberant,
then open the blower and adjust the wind to ensure normal combustion. Fuel feed quantity and
the blast volume depend on the user self-regulation in the use of the process according to the
actual situation, a air butterfly valve mounted on the air inlet pipe of the blower feeding device, it
will control fuel quantity which will blow to furnace by change the blast capacity, When large
combustion fuel required, through the door into the furnace.
（9）Normal operation of the economy general requirements:
25
Steam pressure need to be stable when the boiler operate, but the stable pressure is connect
with boiler load, feed water quantity and consumption of fuel (wave and stable combustion), in
order to achieve stable combustion each stoker member must constantly summary and learn
the regulation in actual operation. In general, observe fire and water frequently, adjust it
frequently, keeping uniformity of the feeding fuel. In general condition, then the furnace
temperature is high, the combustion will be stable. In order to achieve a high furnace
temperature must supply appropriate amount of wind, note adjust the induced wind capacity
and blast volume, should keep furnace negative pressure in 1.3 × 10-4 ~ 2.7 × 10-4 Mpa
and do not let the flame and smoke emitted from the door. Therefore, adding coal and
water before increase load, when the load is reduced, if the furnace negative pressure is too
high, it will indraft air from the furnace door, lower furnace temperature, lead to combustion
instability and the boiler efficiency will decline, in order to keep stable vapor pressure when load
changes, we must learn the load change rule of whole 24 hours in everyday, so that make
advance preparation. For example: when the load increases, the steam pressure will be
reduced, while the water level will be reduced, thus blowing the fuel (rice husk) and feed water
before the load increased, when the load is reduced, the vapor pressure increases, thus should
decrease ventilate, reducing the amount of feeding fuel, lowering the water level before the
load reducing, so that feed water when the load is reduced and the pressure increased. It had
better to shorten the feeding fuel apart time when the load increased, don’t increase the feeding
fuel quantity in every time, extended the feeding fuel apart time when the load decreased,
under above situation, we should appropriate adjustments induced wind and the blast volume,
first adjust induced wind then increase the blast volume when the load increased, first turn
down blast volume then adjust the induced wind when the load decreased.
（10）Clean furnace:
When the boiler running, ash will increase gradually on the grate, affecting ventilation, then you
need to clean the furnace. Clean furnace work had best to do when the load is low, boiler
water level should high than the normal water level before clean furnace, in case that
steam behind the requirement and water level drop when the combustion un-normal after clean
furnace, don’t feed water to avoid drop pressure when clean furnace, clean furnace action
should be fast to avoid plenty of cold air into the furnace.
（11）Burn-out room clean:
The two sides’ passageway after flexed smoke wall and deposition of burn-out room should be
26
cleaned frequently, at least once per week.
（12）Boiler Room Clean:
1）Boiler room should be kept clean, boiler room should not be stacked with other
sundries.
2）Note indoor lighting, water level gauge, pressure gage must be watched clearly by
stoker under the well light, stoker should usually make an inspection tour about the boiler
around, inspect if the boiler and accessories are normal. Attention safety, fire protection,
anti-skidding.
（13）shifting of duty
1）In order to ensure boiler running economic and safe, when shifting of duty, the jobs as
follows must be done. The successive stoker must arrive at boiler room on time and complete
prepared for succession.
2）Shift stoker must to do:
①Steam pressure and water level are normal.
②Boiler safety accessory is sensitive and reliable.
③There is no special phenomenon of boiler proper.
④Finish clean and combustion is normal.
⑤Boiler room is tidy, clean and bright.
3）When workers shift of duty, they must do it serious and thoroughly, at the same time,
write the situation and problem in succession in boiler running record.
8、Pollution discharge
Caution: discharge don’t follow the rule will lead to drum swell, header
and water wall tube jam, it will caused booster and the result is boiler
will over-burning, flaw, explode!!!
In general, supply water have more or less mineral substance, after the water changed into
steam, mineral substance still stay in boiler, after concentrating to a certain degree then deposit
in boiler bottom. The more sediment following large evaporation output and long boiler operate.
We must control the water quality on boiler in order to prevent incrustation and other sediment
damage the boiler.
Pollution discharge at least one or twice per shift. Blow-down rate ≤5%
Each boiler should have independent drain pipes, and drain pipes need to reduce
27
elbow possible, making sure discharging unblocked and connect to safety place outside.
Notice following items before discharging:
（1）If two or more boilers use one head discharge pipe, Notice as follows:
1）Forbid two boilers discharge at same time.
2）If one boiler is maintaining, it necessary separated it from discharging pipes
before discharging.
（2）Proceed discharge at condition of low load, high water level.
While discharging, concrete operation as follows:
Every boiler have two discharge valves, while discharging, the second valve (far from the boiler)
should be opened fully, then first valve （near the boiler）began to open slowly, open fully after
pipes preheat. While close the valves, first close first one valve slowly, after closed fully then
close the second one. Operating like this the purpose is use first one valve control discharging,
ensured the second one is rigorous, when first one leak, the second one is still can control the
leaking valve, repair or change the leaking valve until shutdown the boiler in the future. While
discharging, the pipes have impact noise, immediately turn down the blow-down valves,
opening slowly until the noise vanish, In order to keep water circulation, discharged can’t
continuous running too long.
9、Shut down furnace
General three situations need to shut down boiler:
（1）Vacation or others, steam isn’t required for a short time.
（2）For cleaning, inspection, or repairing, boiler water must discharge from boiler and shut
down boiler.
（3）Urgency shut down boiler if there is special circumstances for security.
Different shut down processes because of above different situations, respectively explain as
following:
①shut down boiler temporarily：
It’s planned to shut down boiler, so pay attention to safety and proper maintenance equipments
while shut down boiler, in addition, need to do coal saving and water saving.
②shut down boiler completely：
Should be planned, general boiler stop running per 1 ~ 3 months, pay attention to safety
and maintenance equipments when shut down boiler. Discharge the boiler water from the boiler
when the water temperature lower than 70℃ after shut-down. At this moment, lift the
28
safety valve let the inside of drum connect with atmosphere air, feeding cold water by feeding
water pipe if you need shorten the time for boiler water cooling, at the same time, discharge hot
water through discharge pipe, but note that the water level can’t low than normal water level.
Open manhole and handhole, then swash dirt water after discharge the boiler water.
③Emergency shut down boiler：
Warning: once the boiler happen water shortage accident, it is strictly prohibited feed
water to the boiler, otherwise, will lead to the boiler exploded!
In the operation of the boiler, in case of one of the following circumstances, should
immediately shut down boiler emergency, and inform the relevant departments.
（1）Boiler water level is below the visible edge of water level gauge bottom;
（2）Water level continue to decline though increase feed water quantity and take
other measures;
（3）The boiler water level more than the highest visible water level (full water) on
the water gauge, still can’t see the water level after discharge;
（4）Feed water pumps are failure or feed water system failure, can’t feed water to
the boiler;
（5）All water gauge and safety valve failure;
（6）Pressure gauge which set in the vapor space failure.
（7）Boiler components damage, endanger the operating personnel security;
（8）Combustion equipment damage, the furnace wall collapsed or boiler frame
burned red, a serious threat to the safe operation of the boiler;
（9）Other unusual situations endanger the safe operation of the boiler.
Emergency shut down boiler should focus on accident prevention, specific steps are as
follows:
①shut induced draft fan after shut blower.
②clean the fuel which on the fire grate.
10、Maintenance
When the boiler during operation, should pay attention to the following:
① Prohibit furnace sting-out and combustion under positive pressure, or it will burn
furnace door and other components.
② If former arch hanging piece falls off, should shut down furnace for replacement
in time.
29
③ If the induced draft fan vibration strongly, should stop it for checking, in general,
the reason is the inside impeller abrasion, if right, should change it.
（1）Check the boiler per 2 ~ 4 weeks.
① Clean the deposition in furnace and burn-out chamber, check that if the fire grate,
furnace wall, ash discharge device and fan are normal.
② Flush the smoke pipe and clean the deposition in smoke boxes, check that whether
smoke boxes are tight, pipe end is no leakage, if leakage, should repair welding.
③ Check whether there is leakage in valve and pipeline.
（2）Shut down the boiler and check complete per 3 ~ 6 months, besides, carry on the
following work:
①Sweep away the boiler incrustation and washed with water.
②Sweep dust and ash in water wall tubes and drum heating surface.
③Inspection the boilers both inside and outside, such as if the boiler weld line, steel plate
inside and outside have corrosion phenomena, if found serious defects should be repaired as
soon as possible, if the defect is not serious, also can repair it in next time when the boiler shut
down, if found suspicious part but does not affect the safety operation, should make a record for
future reference.
④ Painting boiler paint to prevent corrosion after inspection.
⑤ Inspect boiler auxiliary equipments, such as, check the induced draft fan impeller and
cover wear pattern, if rolling bearing is normal, user should often maintain spare parts of the
impeller.
⑥Clean the chimney dust if necessary.
⑦Demount the boiler wall and insulating cover if necessary for exhaustive test, use it
unless repair it if found serious defects part, at the moment, write the check result and the
damage situation in the boiler safety technology register.
（3）boiler maintenance methods if don’t use the boiler in long time:
There are dry and wet process two kinds for boiler maintenance, use dry maintenance
method if shut down boiler more than one month, use wet maintenance method if shut down
boiler in one month.
Dry maintenance method:
Discharge boiler water after shut down boiler, clean the inside dirt thoroughly, drying
furnace by slight fire (no use big fire) after wash the furnace, and then take 10 ~ 30 mm
30
calcined lime in block on the plate, put it inside of the drum, should not let the lime contact the
metal surface, the weight of lime is calculated by boiler volume 8 kg/m3.
Then close all manholes, hand holes, pipes, valves, check it per three months, replace
the lime timely if the lime smash into powder, take away the lime and plate before the boiler
operation again.
Wet maintenance method:
Discharge boiler water after shut down boiler, clean the inside dirt thoroughly, feed softened
water to the boiler until full after wash the furnace, heat the water reach 100℃, close all valves
after discharge gas from the water, don’t use wet maintenance method if the weather is
cold to avoid freeze damage the boiler.
11、Inspection of pressure parts and hydrostatic test

（1）Inspection work include external inspection, both inside and outside inspection when
shut down boiler regular and hydrostatic test, the plan of shut down boiler inspection regular
and hydrostatic test should report to competent department and local quality & technology
supervision.
（2）Running boiler should proceed external inspection each year, proceed inside
inspection each two years, proceed hydrostatic test each 6 years.
（3）Besides, external inspection must be taken if any condition as follows:
①Before new install、refit、move boilers put into operation;
②Shut down the boiler more than one year, but now need use the boiler;
③Pressure parts was repaired thoroughly and running one year after repairing.
④Doubt the safe reliability depend on boiler actual operation situation;
（4）The key points of shut down boiler for inside inspection regular as follows:
①The problem parts of in last inspection;
②Both inside and outside surface of pressure parts, especially in open pore、welding line
and so on, check it if have flaw、gap and corrosion.
③Whether abrading or corroding on tubes wall, especially the position of high velocity of
flue gas;
④Whether the juncture of tension parts and tension brace of boiler have flaw、breakage
and corrosion.
⑤Whether pressure parts have sunken、curve、swell、over heating;
31
⑥Whether the contact location between drum and bricking have corrosion.
⑦Whether pressure parts or boiler frame happen overheating caused by brick wall or fire
wall damage.
⑧Whether water side of the pressure parts have incrustation、grain slag;
⑨Whether connectors which connect drum, water inlet pipe and drain outlet pipe have
corrosion、flaw, whether pontes of blow-down valves and drain pipes are firmed.
⑩Whether safety accessories are sensitive and reliable, whether tubes which connect
boiler body and safety valve、pressure gage are jammed.
（5）Inside and outside inspection must be done before hydrostatic test, and calculate
strength if necessary, water pressure can’t decide the boiler working pressure.
（6）Hydrostatic test must accord with NO.207《Steam boiler safety technique supervise
rules》
（7）During hydrostatic test, pressure must go up or down slowly, pause rise pressure when
water pressure reach to working pressure, to inspect if there is water leakage or any others
unusual phenomenon. Then going up to test pressure, boiler should keep 20 minutes under
test pressure conditions, at last, down to working pressure to inspection again, and keep the
same pressure among inspection.
（8）Hydrostatic test need accord with conditions as follows:
① No droplet and spray on metal wall and welding line of pressure parts.
② No residual deformation observed by eyes after hydrostatic test.
③ No water leakage on economizer connector.
12、safety precautions and matters need attention
（1）Prohibit tightening flange nut when the pressure over 0.4Mpa;
（2）While hydrostatic test, distinctive mark should be showed, avoid danger happen
in crowd people.
（3）Prohibit standing in the front of welding junction flange and valve under
pressure.
13、Others
（1）Inquire problem
①Contract No. and general drawing should be declared when user inquire technical
data from manufacturer.
32
②When inquiry the quality of quality, serial number should be showed (on boiler
proper nameplate).
（2）Boiler transfer
If transfer boiler, relevant technique files must be enclosed.
Henan Province Sitong Boiler Co., Ltd

ADD: Sitong Boiler Industrial Park
Zhoukou . Henan . China
33

DZH Installation and Operation Manual

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Installation & Operation Manual Henan Province Sitong Boiler Co,.

DZH series horizontal fired biomass boiler

Installation & Operation Manual

Henan Province Sitong Boiler Co.,Ltd.

Chapter One Brief introduction of boiler structure

2、System design overview

safe、stable、efficient. Reasonable heating surface arrange. Select rational economic velocity of

consumption of water、electric、heat and others consume under the premise of safety, to

temperature discrepancy too large.

blowdown extender according to gross of continuous blowdown. Escaping、emiting、dropping、

recoverable condensate water.

Boiler system as follows:

(4)、Blast blower system

into furnace passed by handle fire grate coal seam.

(5)、Blast feeding system

through air blower.

Chapter 2 Installation introduction

1、Prepare for Installing

2、 Boiler & Auxiliary equipments lifting

4、Auxiliary equipments installation

5、 Boiler pipeline & Instrument Installation

6、The Instructions of Control system

⑵. Water level control:

The test pressure shall conform to Table 2

Table 2. Test pressure of the steam boiler

1.5P, not less than 0.2

The boiler proper 0.8～1.6 Mpa P+0.4 Mpa

（2）Preparation work before Hydrostatic test：

The Third Chapter Operation Instruction

(Light Brick furnace wall drying chart）

NaOH 2~3 3~4

Na3Po4 2~3 2~3

3、Verify the safety valve and the pressure gage.

Rated steam pressure(Mpa) Set-pressure of the safety valve

≤0.8 Working pressure +0.03Mpa

Working pressure +0.05Mpa

0.8<P≤5.9 1.04 times of the working pressure

7、Normal economic operation instructions

Should ensure steam quality.

P≤1.0 1.0＜P≤1.6 1.6＜P≤2.5

water water water water water water

FTU turbidity ≤5.0 ≤2.0 ≤5.0 ≤2.0 ≤5.0 ≤2.0

≤0.030 ≤0.030 ≤0.030 ≤0.030 ≤0.030 ≤0.030

7.0～9.0 8.0～9.5 7.0～9.0 8.0～9.5 7.0～9.0 8.0～9.5

≤0.10 ≤0.10 ≤0.10 ≤0.050 ≤0.050 ≤0.050

（mg/L）oil ≤2.0 ≤2.0 ≤2.0 ≤2.0 ≤2.0 ≤2.0

≤0.30 ≤0.30 ≤0.30 ≤0.30 ≤0.30 ≤0.10

superhe- 6.0～26.0 ≤10.0 6.0～24.0 ≤10.0 6.0～16.0 ≤8.0

superhe- 4.0～18.0 ≤6.0 4.0～16.0 ≤6.0 4.0～12.0 ≤5.0

Relative alkalinity ＜0.20 ＜0.20 ＜0.20 ＜0.20 ＜0.20 ＜0.20

E, All welded construction boiler, relax the relative alkalinity.

2）Boiler water level

（2）water level gauge

（3）Water supply equipment:

Periodic blow down (see item 8, "pollution discharge")

（8）Add fuel to the boiler operating instructions

11、Inspection of pressure parts and hydrostatic test

Henan Province Sitong Boiler Co., Ltd

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