Boiler Operator Safety Technology

Author: Zhou Guoqing Sun Tao
Publisher:
Publishing Date: 2005-05-01
Features: This book is one of the series "Worker Safety Technology Training Readers." It systematically introduces the basic knowledge of boilers and professional technologies related to safety and economic operation, including boiler structure, combustion equipment, boiler safety accessories and instruments, boiler auxiliary equipment, boiler water treatment and descaling, boiler automatic control, boiler operation, boiler inspection and repair, common boiler faults and troubleshooting, and boiler accidents and handling. It incorporates the latest technological advancements from recent years, offering advanced and practical content. This book is suitable for boiler operators, boiler management personnel, and boiler safety inspectors.
Table of Contents
Table of Contents
Chapter 1 Basic Knowledge of Industrial Boilers
Section 1 Classification of Boilers
Section 2 Boiler Models
1. Coal, Oil, and Gas Boilers
2. Organic Heat Carrier Boilers
3. Electric Heating Boilers
Section 3 Boiler Parameters
1. Evaporation Capacity
2. Pressure
3. Temperature
Section 4 Common Professional Names for Boilers
1. Boiler
2. Boiler Body
3. Boiler Auxiliary Heat Absorbing Surfaces
4. Steel Consumption
5. Circulation Circuit
6. Circulation Multiplicity
7. Steam Carryover
8. Combustion Heat Load
9. Highest Fire Boundary
10. Lowest Safe Water Level, Highest Allowable Water Level, Normal Operating Water Level
11. Positive Pressure Combustion
12. Negative Pressure Combustion
13. Layer Combustion
14.
15.
16. Air Volume, Excess Air Factor
17. Combustion Temperature
18. Flue Gas Volume
19. Primary Air
20. Secondary Air
Section 5 Boiler Working Process
1. Fuel Combustion Process
2. Heat Transfer from Flame and Flue Gas to Boiler Water and Steam
3. Water Heating and Vaporization Process
Section 6 Heat Transfer and Thermal Expansion and Contraction
1. Specific Heat Capacity
2. Heat Transfer Methods
3. Thermal Expansion and Contraction
Section 7 Water, Steam, and Water Circulation
1. Properties of Water
2. Properties of Saturated Water and Steam
3. Water Circulation
Section 8 Fuels and Combustion
1. Solid Fuels
2. Liquid Fuels
3. Gas Fuels
4. Combustion
Section 9 Organic Heat Carriers
1. Properties of Organic Heat Carriers
2. Quality and Performance Indicators of Organic Heat Carriers
Section 10 Boiler Thermal Efficiency and Heat Loss
1. Boiler Thermal Efficiency
2. Boiler Heat Loss
Section 11 Common Materials for Boilers
1. Classification of Common Boiler Materials
2. Mechanical Properties of Metal Materials for Boilers
3. Common Metal Materials for Boilers
4. Common Non-metallic Materials for Boilers
Chapter 2 Boiler Structure
Section 1 General Requirements for Boiler Structure
1. Safety Requirements for Boiler Structure
2. Economic Requirements for Boiler Structure
Section 2 Main Pressure Parts of Boilers
1. Boiler Drum (Steam Drum)
2. Steam-Water Separation Device
3. Water-Cooled Walls
4. Evaporator Tube Bundle
5. Head (Manway Plate)
6. Header (Manway)
7. Support Members
8. Smoke and Flue Tubes
9. Furnace
10. Manholes, Manhole Covers, Handholes, and Handhole Covers
Section 3 Vertical Boilers
1. Vertical Horizontal Tube Boilers
2. Vertical Horizontal Fire Tube Boilers
3. Vertical Vertical Tube Boilers
4. Vertical Curved Tube Boilers
5. Vertical Tubeless Boilers
Section 4 Horizontal Water-Fire Tube Boilers
1. Horizontal Internal Fire Tube Boilers
2. Horizontal External Fire Tube Boilers
Section 5 Water Tube Boilers
1. Single Drum Vertical Water Tube Boilers
2. Single Drum Horizontal Water Tube Boilers
3. Double Drum Vertical Water Tube Boilers
4. Double Drum Horizontal Water Tube Boilers
Section 6 Atmospheric Hot Water Boilers
Section 7 Fuel-Oil and Gas Boilers
1. Structural Features and Types
2. Small-Scale Vertical Fuel-Oil and Gas Boilers
3. Horizontal Internal Fuel-Oil and Gas Boilers
4. Water Tube Fuel-Oil and Gas Boilers
Section 8 Organic Heat Carrier Boilers
1. Structural Features
2. Types
Section 9 Electric Heating Boilers
1. Structural Features
2. Types
Section 10 Fluidized Bed Boilers
1. Structural Features
2. Types
Chapter 3 Combustion Equipment
Section 1 Combustion Methods
Section 2 Hand-Fired Boilers
1. Structure of Hand-Fired Boilers
2. Combustion Characteristics of Hand-Fired Boilers
3. Advantages and Disadvantages of Hand-Fired Boilers
Section 3 Double-Fired Grates and Reverse-Fired Boilers
1. Structure
2. Combustion Characteristics
3. Advantages and Disadvantages
Section 4 Chain Grate Boilers
1. Structure of Chain Grates
2. Combustion Characteristics of Chain Grates
3. Requirements for Coal Types in Chain Grate Boilers
Section 5 Reciprocating Grate Boilers
1. Structure of Reciprocating Grates
2. Combustion Characteristics of Reciprocating Grates
3. Advantages and Disadvantages of Reciprocating Grates
Section 6 Coal Pulverizer Boilers
1. Features of Coal Pulverizer Boilers
2. Pulverizing Equipment
3. Burners and Arrangement Types
Section 7 Fuel-Oil and Gas Boilers
1. Burners
2. Oil Nozzles
3. Air-Ratio Adjustment Devices
4. Types of Burners
Section 8 Fluidized Bed (Boiling) Combustion Boilers
1. Combustion Principle
2. Structural Features
Section 9 Furnace Walls and Furnace Arches
1. Structure of Furnace Walls
2. Materials for Furnace Walls
3. Furnace Arches
Chapter 4 Boiler Safety Accessories and Instruments
Section 1 Function, Types, and Installation Requirements of Safety Valves
1. Function of Safety Valves
2. Types of Safety Valves
3. Installation and Usage Requirements for Safety Valves
Section 2 Function, Structure, Principle, and Installation Requirements of Pressure Gauges
1. Function of Pressure Gauges
2. Structure and Principle of Pressure Gauges
3. Installation and Usage Requirements for Pressure Gauges
Section 3 Function, Types, Principle, and Installation Requirements of Water Level Gauges
1. Function of Water Level Gauges
2. Types and Principle of Water Level Gauges
3. Installation and Usage Requirements for Water Level Gauges
Section 4 Function and Types of High and Low Water Level Alarms
1. Function of Water Level Alarms
2. Types of Water Level Alarms
3. Usage Requirements for High and Low Water Level Alarms
Section 5 Function, Types, and Usage Requirements of Blowdown Valves
1. Function of Blowdown Valves
2. Types of Blowdown Valves
3. Usage Requirements for Blowdown Valves
4. Operation Method of Regular Blowdown
5. Requirements and Precautions for Boiler Blowdown
Section 6 Structure and Purpose of Other Common Valves
1. Cut-off Valves
2. Control Valves
3. Gate Valves
4. Check Valves
5. Plug Valves
6. Pressure-Reducing Valves
7. Drain Valves
8. Requirements for Valves
Chapter 5 Boiler Auxiliary Equipment
Section 1 Fuel Handling Equipment
1. Coal Transport System
2. Coal Preparation Equipment
3. Coal Lifting and Horizontal Transport Equipment
4. Coal Yard Transport Machinery
5. Supply System for Fuel-Oil and Gas Boilers
6. Gas Supply System
Section 2 Ventilation Equipment
1. Ventilation Methods
2. Fans and Air Ducts
3. Chimneys and Flue Ducts
Section 3 Ash Removal Equipment
1. Mechanical Ash Removal Equipment
2. Hydraulic Ash Removal Equipment
Section 4 Dust Removal Equipment
1. Boiler Flue Gas and Emission Standards
2. Classification of Dust Removal Equipment
Section 5 Structure, Principle, Installation, and Usage Precautions of Water Supply Equipment
1. Steam Reciprocating Pumps
2. Centrifugal Pumps
3. Water Injectors
4. Deaerators
5. Heat Exchangers
6. Selection and Calculation of Water Supply Equipment
Section 6 Other Auxiliary Equipment
1. Water Tanks
2. Sampling Condensers
3. Steam Distribution Tanks
4. Blowdown Expansion Tanks
5. Steam Collection Tanks
6. Blowdown Devices
7. Layered Coal Feeders
8. Sediment Traps
Chapter 6 Boiler Water Treatment and Descaling
Section 1 Importance of Boiler Water Treatment
1. Boiler Scale Formation
2. Boiler Metal Corrosion
3. Steam Quality Pollution
Section 2 Boiler Water Quality Standards
1. Steam Boiler Water Quality Standards
2. Hot Water Boiler Water Quality Standards
Section 3 External Water Treatment
1. Purpose and Technical Requirements of Boiler Water Treatment
2. Softening of Boiler Feed Water
3. Sodium Ion Exchange Softening System
4. Fixed Bed Ion Exchange System
Section 4 Internal Water Treatment
1. Common Chemicals
2. Chemical Addition Devices
3. Chemical Addition Requirements
Section 5 Removal of Internal Boiler Scale
1. Mechanical Descaling
2. Chemical Descaling
Chapter 7 Boiler Automatic Control
Section 1 Automatic Control
1. Basic Types of Automatic Control
2. Automatic Adjustment Systems
Section 2 Application of Microcomputers in Industrial Boiler Control
1. Industrial Boiler Microcomputer Control
2. Functions of Microcomputers in Industrial Boiler Production Control
3. Boiler Startup and Shutdown
4. Boiler Accident Analysis and Handling
5. Control Methods of Microcomputers in Boiler Operation
Section 3 Automatic Control of Electric Heating Boilers
1. Overview
2. Automatic Control of Electric Heating Boilers
Section 4 Operation and Commissioning of Boiler Automatic Control
Chapter 8 Boiler Operation
Section 1 Basic Requirements
1. Necessary Conditions for Boiler Operation
2. Operation Precautions for Boiler Operation
Section 2 Drying and Cleaning of Boilers
1. Drying of Steam Boilers
2. Cleaning of Steam Boilers
3. Drying and Cleaning of Hot Water Boilers
4. Dual-Use Steam and Hot Water Boilers
Section 3 Pre-Startup Inspection and Preparation
1. Pre-Startup Preparation for Steam Boilers
2. Pre-Startup Preparation for Hot Water Boilers
Section 4 Ignition, Pressure Raising, and Combining Boilers
1. Ignition Precautions
2. Ignition
3. Pressure Raising Operation
4. Combining Boilers
5. Heating and Combining of Hot Water Boilers
Section 5 Normal Boiler Operation
1. Water Level Regulation
2. Pressure Regulation
3. Steam Temperature Regulation
4. Combustion Regulation
5. Furnace Negative Pressure Regulation
6. Blowdown
7. Ash Removal
8. Fire Stoking
9. Cleaning the Furnace
Section 6 Operation of Combustion Equipment
1. Operation of Hand-Fired Boilers
2. Operation of Chain Grate Boilers
3. Operation of Reciprocating Grate Boilers
4. Operation of Coal Pulverizer Boilers
5. Operation of Fluidized Bed Boilers
6. Operation of Fuel-Oil and Gas Boilers
7. Operation of Electric Heating Boilers
8. Operation of Hot Water Boilers
Section 7 Boiler Shutdown and Maintenance
1. Fire Shutdown
2. Normal Shutdown
3. Emergency Shutdown
4. Daily Maintenance
5. Regular Maintenance
6. Pressure Maintenance
7. Wet Maintenance
8. Dry Maintenance
9. Gas Maintenance
Chapter 9 Boiler Inspection and Repair
Section 1 Boiler Inspection
1. External Inspection
2. Internal and External Inspection
3. Hydrostatic Test
Section 2 General Methods of Boiler Inspection
1. Visual Inspection Method
2. Hammer Test Method
3. Drilling Inspection Method
4. Non-Destructive Testing
5. Hydrostatic Test
Section 3 Boiler Repair
1. Patch Repair
2. Welding Repair
3. Crack Repair
4. Repair of Defects in Welds
5. Tube Repair
6. Economizer Repair
Chapter 10 Common Boiler Faults and Troubleshooting
Section 1 Common Faults and Troubleshooting of Combustion Equipment
1. Down-Fed Grates
2. Double-Fired Grates
3. Inclined Reciprocating Grates
4. Horizontal Reciprocating Grates
5. Chain Grate Boilers
6. Coal Pulverizer Boilers
7. Fluidized Bed Boilers
Section 2 Common Faults and Troubleshooting of Fuel-Oil and Gas Boiler Burners
Section 3 Common Faults and Troubleshooting of Electric Heating Boilers
Section 4 Common Faults and Troubleshooting of Safety Accessories and Valves
1. Pressure Gauges
2. Water Level Gauges
3. Safety Valves
4. High and Low Water Level Alarms
5. Blowdown Devices
6. Valves
Section 5 Common Faults and Troubleshooting of Water Pumps and Fans
1. Reciprocating Pumps
2. Electric Centrifugal Pumps
3. Water Injectors
4. Fans
Section 6 Common Faults and Troubleshooting of Water Supply Treatment Equipment
Section 7 Common Faults and Repairs of Control Panels
1. Precautions
2. Common Faults and Maintenance
Section 8 Steam-Water Boiling
Section 9 Boiling of Hot Water Boiler Water
Section 10 Boiler and Pipe Water Hammer
1. Water Hammer in Boiler Drum
2. Water Hammer in Feed Water Pipes
3. Water Hammer in Steam Pipes
4. Water Hammer in Economizers
Section 11 Damage to Furnace Walls
Section 12 Safety Requirements for Boiler Rooms
Chapter 11 Boiler Accidents and Handling
Section 1 Classification of Boiler Accidents
1. Definition of Boiler Accidents
2. Categories of Boiler Accidents
Section 2 Boiler Water Shortage
Section 3 Boiler Water Overflow
Section 4 Boiler Overpressure
Section 5 Boiler Tube Rupture Accidents
1. Rupture of Water-Cooled Wall Tubes or Evaporator Tubes
2. Rupture of Superheater Tubes
Section 6 Boiler Heat Transfer Surface Deformation Accidents
Section 7 Explosion of Furnace and Flue
Section 8 Secondary Combustion in Rear Flue
Section 9 Boiler Accident Reporting and Handling Procedures
1. Accident Reporting
2. Protection of the Accident Site
3. Formation of the Accident Investigation Team
4. General Procedures for Accident Investigation
5. Content and Requirements of Accident Investigation
6. Technical Inspection, Testing, and Appraisal
7. Analysis of Accident Causes and Consequences
8. Determination of Accident Nature and Responsibility Analysis
9. Recommendations for Accident Handling
10. Accident Investigation Report
11. Holding an Accident Investigation Briefing Meeting
Appendix: Safety Assessment Regulations for Boiler Operators
References