越南余热锅炉使用说明书

CDQ Waste Heat Boiler

Operating Instruction

产品型号：QC190/930-73-10.3/540

Product Model: QC190/930-73-10.3/540

编 号：50HL1146-0-0SM3

Number: 50HL1146-0-0SM3

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 第壱章 总则 Chapter 1 general rules

1.1 一般要求 general rules

1.1.1 锅炉是否能准确操作将直接影响锅炉的使用寿命，因此必须根据
系统的特点，结合有关规定以及设计院所制定的说明书及本说明
书，制定出操作规程和相关规章制度。才能有效地实施运行管理，
维护保养，定期检修。 Whether the boiler can operate correctly will
directly influence boiler service life. For this reason, only when the
operation manual and related rules and regulations is established
according to system characteristics, related regulations and instruction
made by design institute and this instruction, then operational
management and maintenance can be performed effectively and repair
can be done periodically.
1.1.2 锅炉管理人员必须严格执行相关规程和规章制度，了解锅炉各部

件的结构、性能和特点。 Boiler management personnel must strictly

execute related regulation and rules and learn structure, performance
and characteristic of each boiler component.
1.1.3 严格水质管理工作，定期进行水质分析。Be strict with water quality
management work, perform water quality analysis periodically.
1.1.4 在锅炉运行中经常检查锅炉受压部件有无泄漏现象。 Frequently
check during boiler operation if there is leakage in boiler pressure
parts.
1.1.5 锅炉运行中不准带压对承压部件进行焊接、维修。 Welding and
repair of pressure part under pressure during boiler operation is not
allowed.
1.1.6 检修期间进入锅筒内部时，首先要做好清理工作，以防杂物落入
接管中。进入烟道工作，炉外应有明显标识，并应有人监护 。
Cleaning work must be done firstly when entering drum inside during
examine and repair period to prevent foreign matter from falling into
nozzles. When working inside gas flue, there shall be evident
designation sign outside of furnace and also guard man watching.
1.1.7 启动和验收运行按 DL5190.2-2012《电力建设施工技术规范 第

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 2 部分：锅炉机组》以及《火力发电厂基本建设工程启动及竣工验

收 规 程 》 有 关 章 节 执 行 。 Start-up and check and acceptance and

operation shall be according to related DL5190.2-2012 《 Technical

specification for thermal power erection and construction Part 2:boiler
unit 》 and <fire power construction project start-up and completion
check and acceptance specification> related chapters.

第弐章 启动 chapter 2 start-up

2.1 准备 preparation
2.1.1 启动前全面检查炉内各部件包括锅炉附件，确认受压部件内无杂

物 。 Before start-up entirely check each component inside furnace

including boiler attachment to make sure there is no foreign object
inside pressure parts.
2.1.2 工作人员各就各位，岗位责任明确。 All work staff shall be ready at
their positions and responsibility shall be clearly defined.
2.1.3 各门孔都已关闭、密封，给水泵、循环风机等设备无异常情况 。
Each door and hole shall have already been closed and sealed and feed
water pump and circulation fan etc equipment shall be free from
abnormal conditions.
2.1.4 控制装置的气源、电源处于待用状态。Gas and electricity source for
controlling equipments shall be at ready for use status.
2.1.5 确认阀门的开启状态。Confirm the open or close status of valves.

关闭 close：给水控制阀及其前后截止阀； Feed water control valve

and its front and rear shutoff valve.
锅筒排污阀、放水阀； Boiler drum blow down valve, water
discharge valve
主蒸汽阀及其疏水、旁路阀。Main steam valve and its steam trap
and bypass valve.
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 开 启 open ： 锅 筒 及 蒸 汽 连 通 管 的 空 气 阀 ； air valve
between boiler drum and steam connecting pipe
水位表的汽水连通阀； steam-water connecting valve of water
level gauge
过热器的排水阀及排空阀； super heater water discharge valve
and air discharge valve
与锅炉设备连接的所有仪表及控制装置阀门及减温器减温水
前后控制阀。 All instruments and control equipment valve and front
and rear control valve of de-super heater water, which are connected to
boiler equipment.
启动 start-up
2.1.6 开启给水阀缓慢上升至锅炉最低水位处停止供水，停止供水后，

锅筒水位应维持水位不变，进水时间约 1 ～ 1.5 小时。 Open feed

water valve to let the water slowly reach boiler minimum water level
and stop feeding water then, after stopping feeding water, the boiler
water level shall keep no change, feed water time is about 1 ～ 1.5

hours.

2.1.7 导入循环烟气缓慢升温，至升压供汽的时间不少于 12 小时，炉水

升温速度不超过每小时 30℃。Lead in circulation gas to slowly rise

the temperature. The time from leading in circulation gas until raising
the pressure and feeding of steam shall be minimum 12 hours, boiler
water temperature increase speed shall not exceed 30℃per hour.
2.1.8 启动后水位将逐渐升高，应随时注意，利用放水来维持正常水位 。
After start-up the water level will gradually rise, so attention shall be
paid at any moment so as to maintain the water level at normal
condition by discharging of water.
2.1.9 当锅筒内汽压升到 0.05～0.1Mpa 时，应冲洗锅炉压力表及水位

计，以保持其工作正常。 When boiler inside steam pressure rises to

0.5～1.0Mpa, boiler pressure gauge and level indicator shall be flushed

to ensure normal functioning.
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2.1.10 当汽压升到 0.15～0.2Mpa 时，关闭空气阀并检查安全阀是否泄

漏，如有泄漏应立即采取措施，予以排除。 When steam pressure

rises to
0.15 ～ 0.2Mpa, close air valve and check if safety valve has leakage, if it
has leakage, measures shall be taken immediately to eliminate it.
2.1.11 当锅炉汽压升到 0.2～0.25MPa 时，要对汽包及集箱进行一次排
污（排污时锅炉水位应在最高水位线处），排污后要检查各排污
阀是否关严、有无泄漏现象，并用手摸触感觉汽包和集箱各部位温
度是否均匀。When boiler steam pressure rises to 0.2～0.25MPa, blow
down steam drum and header for once(boiler water level shall be at
highest level line during blowing down), after blowing down, each
blow down valve shall be checked if it has been closed tightly and has
leakage or not and with finger to feel if steam drum and header
temperature is even at all places.
2.1.12 当锅炉汽压升到 0.3～0.4Mpa 时，要全面检查锅炉受压元件的
紧固件。如人孔及各个法兰螺栓是否松动，并进行一次热拧紧（不
准强力拧紧、扳手柄上严禁加长套筒）。同时对锅炉各膨胀指示器
作一次检查，并开始作情况记录。 When boiler steam pressure rises

to 0.3 ～ 0.4Mpa, fasteners for boiler pressure parts shall be overall

checked, for example, if manhole and each flange bolt is loose and
carry out one-time hot tightening if it is loose (high strength tightening
is not allowed, long sleeve shall not be added on spanner handle as
prohibited). Meanwhile, one time check shall be done to each
expansion indicator of the boiler, and start to record the situation.
2.1.13 在升压过程中，锅炉在正常水位时便可连续排污（此时水位由现

场监视）当水位下降时，汽包应及时补水。 During pressure rising

period, under normal water level the boiler can blow down
continuously (this time the water level shall be watched by site), when
water level drops, steam drum shall be fed with water in time.
2.1.14 利用过热器的排水阀和放空排汽阀调整好过热器出口蒸汽温度，

通常比额定负荷低 50～100℃。Use super heater water drain valve

and air vent and steam exhaust valve to adjust super heater outlet steam

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 temperature, normally it is 50~100℃ lower than rated load.

2.1.15 当锅炉汽压升到工作压力时关闭过热器上的疏水阀，调整安全阀 。
When boiler steam pressure rises to working pressure, close the water
distribution valve on the super heater and adjust safety valve.
2.1.16 汽包和过热器的安全阀整定压力应按中国标准执行。
Pressure of safety valve for steam drum and super heater shall be
according to requirement of Chinese Industrial Standards.
2.1.17 安全阀调整后，要进行一次动作试验。检查安全阀开启压力是否正
确、排汽能力是否够。安全阀校验后应加铅封或加锁，严禁用重物
压或用物卡死。安全阀校验后，应及时办理签证。After safety valve
has been adjusted, one time action test shall be carried out. Check if
safety valve start-up pressure is correct and steam exhaust capacity is
enough. After calibration, safety valve shall be lead sealing or added
with lock, pressing with heavy object or stuck with object is prohibited.
After calibration, safety valve shall be added visa in time.
2.1.18 启动升压曲线：start-up pressure rising curve

10
MPa

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0 1 2 3 4 5 6 7 8 9 10
T (h)

注： 1. 锅炉温度上升常以 30℃/h ，但开始至 1.0Mpa 时间需约

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 1.5 小时。

2．本曲线系从冷态到该炉工作压力下饱和蒸汽温度所需时间。

Note: 1. boiler temperature rising rate is usually 30℃/h ， however, from

start to 1.0Mpa the required time is about one hour and 30 minutes.
2. This curve is the required time from cold status to this boiler saturated
steam temperature under operational pressure.

第参章 运行 chapter 3 operation

3.1 安全阀调整 adjust of safety valve

3.1.1 安全阀整定压力为：汽包两个整定为 11.0,11.33Mpa；过热器安

全 阀 整 定 为 11.03Mpa 。 Safety valve adjusted pressure is: steam

drum is 11.0,11.33Mpa；super heater safety valve is 11.03Mpa.

3.2 过热器吹洗及试运行 super heater blow wash and trial operation

3.2.1 过热器吹洗时锅炉应维持工作压力的 75% 左右，吹管系数大于

1。
At the time of super heater blow wash, boiler shall be maintained about
75% of working pressure; pipe blowing factor shall be greater than 1.
3.2.2 吹洗过程中应有一次停炉冷却（12h 以上）提高吹洗效果。
During blow wash, there shall be one time stop boiler for cooling (over
12 hours) to improve blow wash effect.
3.2.3 吹洗完后，应整理记录，办理签证。After blow wash, records shall
be collected and visa shall be added.
3.2.4 锅炉在完成上述工作及部分试运行合格后，必须按 GB50273-

2009《锅炉安装工程施工及验收规范》和 DL5190.2-2012《电力

建设施工技术规范第 2 部分：锅炉机组》，全负荷下连续运行 72
小时，运行过程中应注意检查，以各部件和各附件均运行正常为
合格。 After boiler has been finished with above-mentioned work and
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 qualified part of trial assembly, must continuously operate the boiler for
72 hours at full load according to GB50273-2009 <code for
construction and acceptance of boiler installation engineering> and
DL5190.2-2012 《 Technical specification for thermal power erection

and construction Part 2:boiler unit 》。 During operation, shall check if

all components and attachments operate normally, if they operate
normally, then it is qualified.
3.2.5 试运行结束后，应根据工程验收规定办理整套试运行签证和设备

验收移交工作。 After trial operation finished, shall be added whole

set trial assembly visa and equipment inspection for acceptance

and hand over work according to project inspection for acceptance

specification.

3.3 正常运行 normal operation

3.3.1 主蒸汽管道暖管 main steam piping heating pipe

3.3.1.1 在打开主蒸汽阀前，先进行主汽管道排污、清理工作。Before open

main steam valve, first blow down and clean main steam piping.
3.3.1.2 当锅炉压力升压 9.81MPa 时开始暖管，暖管中利用过热器排水阀
和放空排汽阀调节过热器的蒸汽流量，防止过热器出口蒸汽超温。
Start to heat the pipe when boiler pressure rises to 9.81MPa, during
heating of pipe, use super heater water drain valve and air vent steam
exhausting valve to adjust super heater steam flow to prevent super
heater outlet steam from over temperature.
3.3.1.3 暖管要领 key points for heating pipe

1. 全开主蒸汽阀前的排水阀和放空排汽阀，打开主蒸汽阀的旁路

阀。 Fully open water drain valve and air vent and steam exhaust
valve in front of main steam valve, and open by-pass valve of main
steam valve.
2. 缓慢打开主蒸汽阀，全开时，关闭旁路阀、排水阀、放空阀。
Slowly open main steam valve, close by-pass valve, water drain valve
and air vent valve when main steam valve is fully open.
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3.3.2 保持送汽稳定，并且蒸汽温度稳定，达到汽机要求后向汽机送汽，
在开始向汽机送汽的同时，开大汽水调节阀保持汽包水位，此时
给 水 从 手 动 切 换 为 自 动 。 Maintain steam feed stable and steam
temperature stable, when steam turbine requirement is met, feed steam
to steam turbine. At the same time of beginning to feed steam to steam
engine, open steam water adjusting valve wider to maintain steam drum
water level, at this time feed water shall be switched from manual
mode to automatic mode..
3.3.3 主蒸汽温度由减温器调节，使用时应严格按说明书操作。 Main
steam temperature shall be adjusted by de-super heater, when applying
main steam temperature, shall operate strictly according to instruction
book.
3.3.4 炉水处理 boiler water treatment
3.3.4.1 给水、炉水要求：feed water, boiler water requirement:

给水水质：除盐水 feed water quality: de-mineralized water

PH： 8.8～9.3 硬度：rigidity/hardness ≤0μmol/l

联氨 hydrazine：≤30μg/L 溶氧：dissolved oxygen ≤7μg/L

全铁：all iron ≤30μg/L 全铜：all copper ≤3μg/kg

硅：Si 应保证蒸汽符合标准
Shall guarantee that steam conforms to stardard
电导率：conductivity ≤0.3μs/cm

3.3.4.2 炉水控制主要由加药与排污来调节。 Boiler water control is mainly

controlled by adding chemical and blowing down
3.3.4.2.1 排污目的是使炉水含盐量、可溶残渣、磷酸根量不变。
The purpose of blow down is to keep boiler water mineral content,
dissolvable residue and phosphate acid radical no change.
3.3.4.2.2 加 药 的 目 的 是 调 整 PH 值 ， 除 去 硬 度 。 The purpose of adding
chemical is to adjust PH value and remove hardness/rigidity.
3.3.4.2.3 排污量应根据水化学分析的结果而定，一般为 blow down quantity
shall be according to the result of water chemical analysis, normally is
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 排污量=α/βX100%×汽水量
Blow down quantity-α/βX100%×steam and water quantity
式中 α：给水水质成分日标

β：炉水水质成分控制值

要求总排污≤2%

In the formula, α：feed water quality composition daily target

β：boiler water quality composition control value

The required total blow down≤2%

3.3.4.2.4 排污应在锅炉低负荷下进行，时间应尽可能短。 Blow down shall

be carried out under low work load; the time shall be as short as
possible.
3.3.4.2.5 排污时进水到汽包最高水位，并密切注意水位变化，每次排污以

降低汽包内水位 25 ～ 50mm 为准。 When blowing down, water

shall be fed to steam drum highest water level, and water change shall
be watched closely. Each time blow down shall be according to
lowering the steam drum inner water level 25～50mm.

3.3.4.2.6 排污时先开第二个阀门，再微开第一个阀门暖管后接着再开大，
控制排污量。关闭时先关第一个阀门，后关第二次阀门。
When blowing down, first open the second valve, then slowly open the
first valve, after heating of the pipe, open it more widely to control
blow down quantity. First close the first valve, and then close the
second valve.
3.3.4.2.7 严 禁 用 加 长 手 柄 开 启 排 污 阀 。 Open blow down valve with long
handle is prohibited.
3.4 正常停炉 normal stop of boiler

一般一年一次大修，维修时间 20 天。维修时人员由人孔装置进入
锅炉，特别是汽包，应轻装，严防携带随身物品（钥匙等）落入
下降管或划伤受热面管子。 Normally, there is one main repair each
year; the period duration is 20 days. During maintaining, people shall
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 enter boiler through manhole, especially, when entering steam drum,
people shall take as less articles as possible, for example, keys etc.
shall not be taken for the reason that it may drop into down comer or
scratch heating pipes.
3.4.1 停炉前对锅炉系统做好全面检查工作，了解设备损伤情况，拟订

检 修 项 目 . Before stop of boiler, overall inspection of boiler system

shall be done to find out equipment damage situation in order to make
repair plan.
3.4.2 降低负荷，逐步减少进炉烟气量，按规定的要求降低炉温，直至

蒸汽汽量指示近于 0 ，将主蒸汽阀缓缓关闭。 Decrease the load,

gradually decrease the gas quantity coming into boiler, as per regulated
requirements, and reduce boiler temperature until steam quantity
indicates approximate to zero. Slowly close main steam valve.
3.4.3 炉气温度从 850℃降到 600℃时间不少于 3.5 小时，降气速度不

超过 70℃/时，从 600℃降到 300℃不少于 3 小时，降气速度不

超过 100℃/ 时，从 300℃ 降到室温不少于 5 小时。 The time for

decreasing boiler temperature from 850℃ to 600℃ shall not be less
than 3.5 hours, temperature decrease rate shall not exceed 70℃/hr, the
time for decreasing temperature from 600℃ to 300℃ shall not be less
than 3 hours, temperature decrease rate shall not exceed 100℃/hr, the
time for decreasing temperature from 300℃ to room temperature shall
not be less than 5 hours.
3.4.4 汽包由额定压力降到 0.98Mpa ，时间不少于 10 小时。再降到

0.69Mpa，不得少于 1 小时。再降到 0.29Mpa，不少于 1.5 小时。

压力再降到 0 ，应在 1 小时以上。 The time for decreasing steam

drum from nominal pressure to 0.98Mpa shall not be less than 10
hours.
3.4.5 锅炉降压期间应关闭所有取样器阀门和连续排污阀，停止加药和

定期排污，自动上水切换为手动控制。停炉后 6 小时以内，不允

许打开炉门和人孔门。 During boiler pressure reducing period, all

sampling device valve and continuous blow down valve shall be
closed, stop chemical adding and periodical blow down, shift
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 automatic water feeding to manual control. Within 6 hours after boiler
shutdown, it is not permitted to open furnace door and manhole.
3.4.6 为避开锅炉急剧冷却，应使之处于密闭状态，不允许进入冷风，

不允许上水，放水。一般 12 小时后可以打开烟道门，放灰门进行

自然通风冷却，并上水放水一次。 14 小时后再上水放水一次，以

后每 2 小时上水放水一次，以便锅炉各部分均匀冷却。26 小时左

右汽包温度降到 70～80℃时，就可以将锅水全部放出。 To avoid

boiler sudden/rapid cooling, make it be sealed and closed, forbidden
cold air to enter, forbidden water to be fed and water to be drained.
Normally open flue door after 12 hours, naturally vent and cool ash
release hole, and feed and drain water once. After 14 hours feed and
drain water once again; and later feed and drain water every 2 hours to
facilitate uniform/even cooling of each boiler parts. After about 26
hours when steam drum temperature can be lowered to 70 ～ 80℃, all
of boiler water can be drained.
3.5 紧急停炉 urgent shutdown of boiler

3.5.1 锅炉运行时，遇有下列情况之一时，应立即停炉。 During boiler

operation, if one of following cases happens, boiler shall be shut down
immediately.
3.5.1.1 锅炉水位低于水位表最低可见边缘。Boiler water level is lower

than lowest visible line of water level gauge.

3.5.1.2 不断加大锅炉给水及采取其它措施，但水位仍继续下降。 Keep

feeding water to boiler and adopt other measures, however water level
still drops.
3.5.1.3 锅炉水位超过最高可见水位（满水），经放水仍不能见到水位 。
Boiler water level exceeds highest visible water level (full), through
water discharge, water level stays invisible.
3.5.1.4 给水泵全部失效或给水系统故障，不能向锅炉进水。 All water
feeding pumps fail or water feeding system malfunction, thereby water
feeding to boiler cannot be achieved.
3.5.1.5 水位计或安全阀全部失效。 Water level gauge and safety valve all
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 fail.
3.5.1.6 设置在汽空间的压力表全部失效。 All pressure gauges at steam area
fail.
3.5.1.7 锅炉元件损坏且危及运行人员安全 boiler elements are damaged and
operators life and safety are being threatened.
3.5.1.8 系统故障进入锅炉的烟温变化较快，必须采取一定的技术措施，

以免出现新的事故。System failure that the gas temperature entering

boiler changes quickly. Certain technical measures shall be taken to
prevent new accidents from happening.
3.5.1.9 快速断绝进入锅炉的烟气时，要很快地降低负荷，除发生满水事

故外，要注意调整给水以维持正常水位。 When rapidly cutting

down gas entering boiler, boiler load shall be lowered rapidly. Except
for the accident of overflow of water, feed water adjustment shall be
noticed to maintain normal water level.
3.5.1.10 紧急停炉冷却过程和正常停炉相同，但时间可减少一半。 Urgent
boiler shutdown cooling process is the same with that of normal boiler
shutdown; however, time can be reduced by a half.

第四章 停炉后的保养
Chapter 4: maintenance after shut-down of the
boiler

4.1 湿法保养法——碱液保养法 wet method of maintenance-alkali

liquor maintenance
4.1.1 碱 液 保 养 法 一 般 为 短 时 间 保 养 （ 5 天 内 ） 。 Alkali liquor
maintenance generally is short time maintenance (within 5 days).
4.1.2 将锅炉内外污垢全部清除后，进行严密隔离，即将所有阀门紧闭 。
After removal of all fouling inside and outside of boiler, perform strict
isolation, that is, close all valves.
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4.1.3 加保护溶液至低水位，保护液主要成份为 Add protection solution
up to low water level, the composition of protection liquor are:
NaOH ： 100mg/ 升 P2O5 ： 100 mg/ 升 Na2SO4 ：

250 mg/升

NaOH：100mg/liter P2O5：100 mg/ liter Na2SO4：250 mg/ liter

4.1.4 加入保护溶液后，使锅炉产生 0.2 ～ 0.3Mpa 的压力，保持 2 ～

3h，压力降低后，保护液灌满整个锅炉，用加入溶液产生 0.15～

0.4Mpa 压力，并使此压力在整个保养期保持。 After adding of

protection solution, which permits the boiler produce a pressure of 0.2
～ 0.3Mpa, keep the pressure for 2 ～ 3h, after pressure having been
reduced, protection liquor will fill up the whole boiler. Generate a
pressure of 0.15 ～ 0.4Mpa with the added solution and maintain this
pressure during all maintenance period.
4.1.5 必须同期检查保护液的浓度，当磷酸钠的浓度降低时就应加以补

充 。 Must simultaneously check the density of protection liquor, add

sodium phosphate if its density lowered.
4.1.6 同时必须保证锅炉的外部和外衬等没有潮湿现象，因此要周期地
进行干燥工作，所有风门、人孔等在保养期内尽可能关闭
Meanwhile must ensure that there is no wetting phenomenon at the
outside of boiler and in outer line, so periodical drying is desired, try to
close all air door and manhole etc. during maintenance period.
4.2 干 法 保 养 — — 长 时 间 停 炉 的 保 养 方 法 dry method of
maintenance-maintenance method for long time boiler shutdown.
4.2.1 主 要 采 用 充 氮 保 护 法 。 Mainly apply nitrogen filling protection
method.
4.2.1.1 锅炉炉水全部排放干净，清除内部污垢。 After draining up of all
boiler water, clean inside fouling and dirt.
4.2.1.2 将 N2 压入锅炉内，保持压力 0.02 ～ 0.049Mpa ，防止空气进入，
13
 氮气纯度一般>99%。Press N2 into boiler and keep the pressure 0.02

～ 0.049Mpa to prevent air from entering, nitrogen purity is usually

>99%.
4.2.1.3 充氮后，气体检查含 O2 量以 0.2%左右合格。After nitrogen filling,
O2 content about 0.2% shall qualify gas content inspection.
4.2.1.4 在烟道内放置干燥剂， 0 防止烟道及受热面腐蚀。 Put desiccant
inside of gas flue to prevent gas flue and heating surface corrosion.
4.2.1.5 在保养期间应经常监视压力的变化，定期取样分析，及时补充 。
Regularly watch the change of pressure during maintenance period and
periodically take sample and analyze it and supply with new in time.
4.3 余热干燥法——主要用于检修 waste heat drying-mainly used
for examine and repair
4.3.1 锅炉正常停运后，待汽包压力降至 0.8～0.5Mpa，开启放水阀进

行 全 面 快 速 放 水 。 After normal shutdown of boiler, open water

draining valve to allow whole rapid water draining till steam drum
pressure drops to 0.8～0.5Mpa.

4.3.2 压力降至 0.2～0.15Mpa 时，全开放空阀，向空排气，疏水阀强

制 疏 水 ， 对 锅 炉 进 行 余 热 烘 干 。 When pressure drops to 0.2 ～

0.15Mpa, fully open atmospheric valve to allow the venting; Besides
bleeder valve forcefully operate and dry boiler with waste heat.

第伍章 事故与处理
Chapter 5: accident and treatment

5.1 水位计爆裂 level gauge blow out

在锅炉开车过程及正常运行中，特别是在冲洗水位计时，水位计的
玻璃板（管）突然爆裂，炉水及蒸汽喷出。有时也会发现水位计玻
璃板（管）有细小裂纹，但未破裂，都称为水位计破裂。 During
boiler startup and proper operation, especially when flushing level
gauge, that glass plate (duct) of level gauge suddenly blows out and thus
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 boiler water and steam bursts. Sometimes is will be found that there is
minor crack in level gauge glass plate (duct), however not to the extent
of break, all are called level gauge blow out.
5.1.1 发生水位计爆裂的原因 cause of level gauge blow out

1. 水位计玻璃板（管）质量不符合规定，制造质量差，有缺陷 。
The quality of level gauge glass plate (duct) doesn’t meet regulated
requirements; Fabrication quality is bad with defects.
2. 安装不正确，受热膨胀后引起压力不均造成破裂。Installation is
incorrect, which results in uneven pressure due to heat expansion and
causes crack.
3. 冲洗操作不当，没有对水位计充分预热就猛开猛关水位计阀门 。
Flushing operation is not proper, suddenly open and close level gauge
valve without adequately preheat water gauge.
5.1.2 水位计爆裂处理方法 disposal method of level gauge blow out

1．二只水位计当其中一只爆裂时，应监视另一只水位计。立即关闭
爆裂水位计的汽、水阀门，迅速更换爆裂的玻璃板（管）。安装好后
先开少许（半扣）汽空间阀门，使用微量蒸汽吹热玻璃板（管），
再开炉水端阀门，打开放水阀，直至放水阀有汽水混合物放出，然
后将放水阀关严，再将汽、水二端阀门开至正常操作位置。If one of
the two level gauges blows out, the other level gauge shall be watched.
Immediately close steam water valve of the cracked level gauge, rapidly
replace glass plate(pipe) with new one. After replacement, first half open
steam valve to heat glass plate (pipe) by blowing steam, and then open
boiler water side valve, open water draining valve until there is steam
water mixture coming out, and then tightly close water draining valve,
then open valves of steam side and water side to normal operational
position.
2．当汽包上所有水位计都同时爆裂时，应立即按紧急停炉事故处
理，然后迅速更换玻璃板（管），待水位计全部修复后再使锅炉按
开车程序投入运行。 If all level gauges of steam drum blow out at the
same time, this shall be treated as an urgent boiler shutdown accident,
then rapidly replace glass plate (pipe), after all level gauges have been
repaired, make boiler operate as per boiler startup procedure.
5.2 省煤器管损坏 damage of economizer pipe

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5.2.1 省煤器管损坏现象：economizer pipe damage phenomenon:
进入锅炉的给水明显减少，水位连续下降。锅炉下部烟气出口有潮
湿或有水滴出，泄漏严重时排烟温度较正常工况有所下降。The
feeding water entering boiler obviously reduces, water level
continuously drops. Boiler lower part gas outlet has dampness or water
leakage. When leakage is serious, discharged gas temperature is some
lower that under normal operation condition.
省煤器管损坏的原因 cause of economizer pipe damage

1．制造时对接接头（指弯头处）检验不严。焊接缺陷没有暴露，热

态工况后，出现漏水现象（一般在开车 48 小时内会暴露）。 Abut

joint (at elbow area) inspection during fabrication is not strict. Welding
defect is not detected, at hot operation condition, water leakage occurs
(normally within 48 hours after boiler startup it will occur).
2．由于给水品质未达到锅炉给水要求，含氧量过高对省煤器管内

壁造成严重腐蚀。 Because feed water quality doesn’t meet boiler feed

water requirements as it contains too much oxygen, which results in
serious corrosion of economizer pipe inside wall.
3．给水温度偏低，造成管外壁腐蚀严重。 Feed water temperature is
too low, which results in serious corrosion of tube outside wall.
4．给水压力周期变化，造成省煤器管内水冲击，也会对省煤器使

用 寿 命 造 成 影 响 。 Periodical change of feed water pressure causing

water impact inside economizer tube will also influence economizer
service life.
5.2.2 省煤器损坏处理方法：disposal method of economizer damage

1．首先必须紧急停炉。Fist must urgently shut down boiler.

2．人员进入炉内，此时采取紧急放水措施并开启给水泵。迅速查出

管子的损坏部位。每次检查时间不得超过 5 分钟，严格控制汽包水

位 在 正 常 工 况 。 When personnel enter furnace, adopt urgent water

draining measures and open feed water pump. Rapidly find out the
damage area of tube. Each time inspection shall not exceed 5 minutes.
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 Strictly control steam drum water level under normal working condition.
3．若单根管泄漏，可以在进口集箱及出口集箱接管处切断，并堵

死上下集箱连接管，放尽该根受热面管内部结水，与大气连通。 If
single tube leaks, may cut off at the area of inlet header and outlet header
and tightly block the connection pipe between upper and lower headers,
drain up inside water of the single heating tube and make it be connected
to atmosphere.
4．管子泄漏根数超过 20%时，采用堵管损失受热面的办法，将影
响排烟温度及给水温度，使锅炉正常操作参数偏移。建议停炉整体
更换。If the number of leaked tubes exceeds 20%, then adopt the method
of blocking damaged heating surface. However, it will influence outlet
gas temperature and feed water temperature so as to change boiler
normal operation parameter. It is suggested boiler be shut down for entire
change of damaged pipes.
5.3 蒸发区管损坏 damage of evaporative bundle pipe
5.3.1 蒸发区管损坏现象 evaporative bundle pipe damage phenomenon
蒸发区管件发生爆管时，有沉闷振动声，进入炉内的饱和水迅速气
化上升，从而使炉内烟气阻力降立即直线上升。烟气含水量也成倍
上升，随后阻力降又回落，直至正常工况左右，严重时伴随水位升
降，若不迅速停车处理，操作工况将恶化。If evaporative bundle pipe
blows out, there will be a vibration clunk and the saturated water
entering boiler will be rapidly evaporated and rise, consequently the gas
resistance drop will increase sharply. Gas moisture will also fold
increase; afterwards resistance drop will decrease again to about normal
working condition. Under the serious condition, water level will go up
and down, in the case, rapidly shut down the boiler, otherwise,
operational condition will worsen.
5.3.2 蒸发区损坏的原因 cause of evaporative bundle pipe damage

1. 原材质及焊接质量原因。Raw material and welding quality cause

2. 给水水质未达要求，内壁腐蚀严重。 Feed water quality doesn’t

meet requirements, inside wall corrosion is severe.
5.3.3 蒸 发 区 管 损 坏 的 处 理 disposal method of evaporative bundle pipe
damage

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 1 ．停炉，冷炉，人员进入炉膛。 Boiler shut down, boiler cooling,
personnel enter furnace.
2 ．检查泄漏及爆破处，爆破管子四周光滑无集灰并呈灰白色 。
Check leakage or damaged area, the damaged pipe is smooth and has no
ash collection around and appears white grey.
3．处理：Disposal

a ．对翅片蒸发区而言，若破损仅有一根（一排）管或二根（二
排）管，可采用省煤器堵管办法应急处理。不同的是出口集箱在炉
内作业不太方便，要注意事项是堵出事故这一排的管子，炉内炉外
千万不要弄错。For fin evaporative bundle area, if only one pipe or one
row of pipes, or if only two pipes or two rows of pipes are damaged, then
we can use economizer blocking pipe method as a emergency disposal
method. The difference is that it is not very convenient to work on outlet
header inside of boiler. One thing that you shall pay attention to is that it
can not be wrong for inside or outside of furnace of the blocked accident
pipe or row of pipes.
若受热面破损三排以上，建议大修，全部或局部更换受热面。 If
three or over three rows of heating pipes are damaged, it is suggested
that it be heavily repaired, i.e. entirely or partly change heating surface.
b ．对光管受热面而言，破损三排以下，采用进出口堵管处理，三

排以上必须停炉全部更换为妥。 For bare tube heating surface, if less

than three rows of pipes are damaged, then adopt inlet and outlet pipe
blocking disposal method, if over three rows of pipes are damaged, then
must shut down boiler and change all damaged pipes.
c．受热面泄漏与爆管事故通常在锅炉已通过 72 小时考核期后，排
除水质问题，一般在正常操作二年后才会发生。若水质有保证，一
般经验可维持 5 年以上，无须维修。Heating surface leakage and pipe
blow down accidents normally happen after two years of normal
operation provided the boiler has qualified 72 hours of trial operation
except there is water quality problem. If water quality is guaranteed,
generally there is no such accident within 5 years and need not to be
repaired.
5.4 过热器的爆管 super heater blow out

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5.4.1 过热器爆管的现象 super heater blow out phenomenon

炉膛内发出清脆的尖哨声伴随着蒸汽的喷射声。 A brilliant whistle

sound will come from furnace inside together with steam injection
sound.
5.4.2 过热器爆管的原因 the cause of super heater blow out

1．事故主要发生在过热器前三排管子上，因气流中颗粒冲刷磨损
加上高温材质强度下降，管道内蒸汽高速流动产生的推力，综合导
致受热管某薄弱点无法承受高压蒸汽的冲击而爆管。事故一般发生
在第一 次开 车阶段及三年以后 某一操作不当之时。 The accident
mainly happens to super heater first three rows of pipes because of gas
contained particle washing abrasion plus high temperature material
strength drop and also the pushing force of high speed piping steam flow,
these factors all together result in some heating pipe weak point can not
stand high pressure steam impact, therefore the pipe blows out. The
accident generally happens at first time boiler startup or a time of
improper operation after three years of boiler operation.
2．低负荷运行是导致过热器爆管的罪魁祸首。Low load operation is
the key factor that causes super heater pipe blows out.
锅炉开停车及正常运行时负荷忽然的变化（指高温烟气量及烟
气中焓值的下降），蒸发量（的降低）偏离设计值过多，人为造成
“届时工况”过热器面积过大，过热蒸汽温度超出既定设计值，管
材壁温使强度值接近或超过材质屈服限，导致爆管。这种事故在开
停车时占有突出的比例，而且锅炉过热器爆管中， 80%以上事故是

锅炉低负荷运行带来的恶果。 Boiler startup and shutdown and also

sudden load change during boiler normal operation (referring to high
temperature gas and gas enthalpy decrease, therefore evaporation
capacity (decrease) is far from the designed, which makes that super
heater area is too large at that specific working condition and super
heater temperature exceeds designed, consequently pipe wall
temperature makes pressure exceeds or approaches material yield
strength and thus pipes blow out. This accident covers certain percentage
during boiler startup and shutdown, and in all boiler super heater
blowing out cases, over 80% accidents are the results of boiler low load
operation.
3．蒸汽品质不好或减温水不符合要求，管壁结垢严重或管端堵塞，

19
 也 是 导 致 过 热 器 烧 坏 爆 管 的 主 要 因 素 。 Low steam quality or
disqualification of cooling water, severe pipe wall corrosion or pipe end
blocking are all main factors that cause super heater burns out or blows
out.
5.4.3 过热器爆管的处理 disposal method of super heater pipe blowing out

1．判断出过热器事故后，紧急停炉。Urgently shut down boiler upon

judgment of super heater accident.
2．人员进入查找漏点，事故管的周围管段面光洁无尘。爆口一般沿

管长方向呈微 V 开口。外观上爆破点比正常管段略粗。用电筒照明查

找 比 蒸 发 区 查 找 要 快 捷 得 多 。 Personnel enters furnace to look for

leakage point, the pipe around accident pipe is glabrous and dustless. The
damaged pipe appears V hatch. In appearance, the damaged point is
slightly wider pipe good area. It is much quicker to use torch light
instead of evaporation zone to look for the leakage point.
3．在过热器下留有一定的维修空间。因此，对过热器而言，首先考

虑更换一段爆破处的管段（管段长度＞600 mm 为宜），此时的对

接 焊 采 用 氩 弧 焊 。 Leave certain repair space under super heater.

Therefore, for super heater, prior consideration is to change a pipe
section of broken area(pipe section length ＞ 600 mm is appropriate), in
this case, abut joint welding adopts GTAW.
4．若爆破处不宜采用更换管段法处理，可采用与蒸发区一样的堵
管法处理。注意的是被堵管排应与大气相通。但在过热器采用堵管法
时，只允许一排管束。若有二排管束连续爆管，建议大修处理。If it
is not appropriate to apply the disposal method of changing pipe section,
then blocking pipe method may be used as that used in evaporative
bundles. One thing that shall be noticed is to make the blocked pipe row
to be connected to atmosphere. However, if blocking pipe method is
applied to super heater, it is only allowed for one row of tube bundle. If
two or over tube bundles are damaged, it is suggested heavy repair be
adopted.
5.5 水冷壁管的事故 membrane wall pipe accident

20
5.5.1 事故现象 accident phenomenon

1．外护板处有大量或间断热气流涌出。At outside guard plate, there is

large quantity of discontinuous hot gas flow coming out.
2 ．烟侧系统阻力降直线上升，汽包水位迅速下降，且无法维持 。
Gas side system resistance drop increases rapidly, steam drum level
rapidly decreases and can not be managed.
5.5.2 事故原因 cause of the accident

1．水冷壁翅片与管焊接有缺陷，或制造及安装时严密性实验不认

真，导致热态工况或一定时效后泄漏。 Defect of welding between

membrane wall fin and tube or gas tight test during fabrication and
erection is not careful and strict may results in leakage under hot
condition or some time of aging.
2 ．水冷壁管受含尘高温热烟气冲刷减薄而爆管。 Membrane wall
pipe wall thickness thins and blows out bearing high temperature gas
flush.
5.5.3 事故处理 disposal method of the accident

1．首先打开泄漏烟尘处的外护板，沿烟气直线方向向下用手触感
高温点，打开此处保温，进行水冷壁翅片补焊（此时，无须人员入
炉），这种情况通常并非一个点泄漏，因此，要注意周边焊缝的查
核和补焊。其中注意事项是补焊焊高一般不得大于 4 mm，防止损

伤水冷壁管。 First open outside guard plate of gas leakage area, touch
and feel high temperature point with hand along gas linear direction
downwards, open insulation at this area to perform membrane wall fin
repair weld (at this time, no personnel is needed to enter furnace). In this
case, generally there is not only one leakage point, so it shall be noticed
of the around weld seam checking and repairing. One thing shall be
noticed that repair weld throat thickness shall not be higher than 4mm to
prevent the damage to membrane wall tubes.
2．若发现是水冷壁墙与墙之间的密封扁钢焊缝泄露，其补焊长度

（对称泄露点）不得小于 150mm，焊缝高度 6mm.If it is detected

that weld seam of membrane wall sealing flat steel between walls has
leakages, then repair weld length (symmetrical leakage points) shall not
21
 be shouter than 150mm, weld throat thickness is 6mm.
3．余热锅炉水冷壁爆管通常发生在后墙上部高温烟气对冲处。由于
处于受热面上部空间，结构布置上留有很大的维修作业面，因此事
故处理可采用炉内外措施共同进行排除。Waste heat boiler membrane
wall pipe blowing out normally happens at rear wall upper area of high
temperature gas impacting. As damaged pipes locate at upper area of
heating surface, in layout large area of repair and operation place is left
there, therefore, accident repair disposal shall be carried out both from
inside and outside of furnace.
4．对锅炉门洞处的水冷壁管弯头上下对接焊缝，由于经常受到外
部及人员进出的接触，多年后也会发生泄露，一般不采用换管方法，
而是补焊修复方可。 For boiler door membrane wall elbow upper and
lower abut joint weld seam, as it often contact personnel coming in and
going out, after many years, leakage of door will also happen, normally
we don’t apply pipe replacement method, but repair weld.
5．紧急停炉后，进行更换爆破管的作业，更换的管子长度视能回

避高温气流直接冲击为准。一般不短于 1500mm。After urgent boiler

shutdown, the changed pipe length depends upon that can avoid high
temperature direct impacting, generally not shorter than 1500mm.

第六章 其他事故处理
Chapter 6: the treatment of other accidents

6.1 锅炉在工况下的运行，管件及配件、阀门等时有损坏及泄露，应在锅

炉操作守则规定的程序下，给予更换。 Piping, fitting and valve etc.

sometimes have damage and leakage during boiler operation, thus they
shall be replaced according to boiler operation rules.
6.2 其他具体事宜请详见设计院设计说明书。 For other details, please see
design instruction book by design institute.

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