BLD型锅炉承压管泄漏在线监测系统运行维护安装维护中英文

印度古德洛印度古德洛尔尔 2X600MW 燃煤燃煤电电站站项项目目 INDIA CUDDALORE 2 600MW POWER PROJECT BLD型锅炉承压管泄漏在线监测系统 BLD On line Leakage Monitoring System for Pressurized Tubes in Boiler 安装维护说明书 安装维护说明书 Installation and Maintenance Manual SUBMITTED BY Northeast China Institute of Electric Power Engineering Kaiyuan Sci operation monitoring part is integrated in monitoring cabinet installed in unit control room or electronic equipment room 1 11 1 安装结构 Installation Structure 整个系统的就地检测部分包括测点声导管 一体化传感器 就地接线盒 就 地信号电缆以及防腐清灰装置等 操作监测部分则包括工控计算机 彩色监视器 监测系统主机 彩色打印机以及系统监测机柜等 Grounded monitoring part includes sound meatus of observation points integrated transducer grounded junction box grounded signal cable and anticorrosive cleaning device etc Operation monitoring part includes industrial control computer color monitor monitoring system host color printer and monitoring cabinet etc 系统安装结构如图 1 1 所示 Installation structure see figure 1 1 6型锅炉承压管泄漏在线监测系统用户手册 安装维护说明书 第1章 系统结构 BLD 6Type On line Leakage Monitoring System for Pressurized Tubes in Boiler Installation and Maintenance Manual Chapter 1 System Structure 2 图 1 1 锅炉泄漏监测系统安装结构框图 Figure 1 1 Monitoring system installation structure 锅炉承压管泄漏在线监测系统的全套设备为贵重仪器 在安装搬运过程中 应尽量注意避免冲击和振动 以免系统设备产生损坏 造成不应有的损失 The whole equipments of the monitoring system are very expensive During transport and installation concussion and shake should be avoided so as not to damaged and avoid unnecessary losses 整套设备应使用一组单独额定热工供电电源 电压 240V1A 50HZ 该电源应引 入监测机柜中的端子排上 The whole equipment uses a single rated thermal power supply the specification is 240V and 1A 50HZ The power should be placed on terminal strip in monitoring cabinet 1 21 2 测点安装 Installation of Observation points 锅炉承压管泄漏在线监测系统的测点安装 可分为声导管和传感器两部分 其中关键在于声导管的安装 Installation of observation points of the monitoring system includes sound meatus and transducer part The key point rests with installation of sound meatus part 显示器 Display 打 印 机 Printer 计 算 机 主 机 Host BLD 6 型泄漏监测 主机 BLD 6 Monitoring Host 就 地 接 线 盒 Grounded junction box 就 地 传 感 器 Grounded transducer 声 导 管 Sound catheter 键盘 鼠标 Keyboard Mouse 辅助信号 Auxiliary Signal 锅炉 本体 Boiler 锅炉 本体 Boiler 操作监测部分 Operation Monitoring Part 就地监测部分 Grounded Monitoring Part 6型锅炉承压管泄漏在线监测系统用户手册 安装维护说明书 第1章 系统结构 BLD 6Type On line Leakage Monitoring System for Pressurized Tubes in Boiler Installation and Maintenance Manual Chapter 1 System Structure 3 声导管结构Structure of Sound Meatus 声导管用于从炉内传递噪声信号至传感器 通常由 60 3 5mm 钢管制成 分为 J 型声导管和 Y 型声导管 其结构见图 1 2 和图 1 3 Sound Meatus is used for transmitting noise signal from furnace to transducer Usually it is made of steel tube which is 60 3 5mm It includes J Sound meatus and Y Sound meatus see figure 1 2 and figure 1 3 1 J 型声导管结构 Structure of J Sound meatus J 型声导管主要用于非水平烟道的测点 其结构见图 1 2 图中白钢套 的作用是向上移动露出开孔 通过此孔清理声导管内前端的积灰或结焦 还可以适当作看火孔用 此孔平常处于关闭状态 J sound meatus is used for observation points of non level flues its structure is shown in figure 1 2 Steel tube is the role of exposing hole while moving up The sound meatus can be cleaned through this hole It also could be seen as fire hole when necessary it is usually closed 图 1 2 J 型声导管结构 Figure 1 2 J Sound meatus 2 Y 型声导管结构 Structure of Y Sound meatus 锅炉为平衡通风系统 水平烟道区域易发生正压 正压使烟气进入声 导管后在低温结露化合成硫酸 使传感器很快腐蚀 同时声导管前端易积 灰 Boiler is a balanced ventilation system Level flue is easy to produce plus pressure and the plus 870 可移动白钢套 Steel tube 6型锅炉承压管泄漏在线监测系统用户手册 安装维护说明书 第1章 系统结构 BLD 6Type On line Leakage Monitoring System for Pressurized Tubes in Boiler Installation and Maintenance Manual Chapter 1 System Structure 4 pressure makes flue gas enter sound meatus the flue gas becomes sulfuric acid at low temperature and makes tranducer etched quickly at the same time it is easy to pile up ash in the front of sound meatus 为避免腐蚀和积灰 在水平烟道区域采用图 1 3 Y 型结构声导管 这种 结构声导管有一个气源入口 通过它不断的送入来自锅炉送风机出口的风 用来抵消来自炉膛内部的正压 从而起到防止传感器结露造成的腐蚀 以 及防止声导管前端堵灰的作用 In order to avoid being eroded or piling up ash Y Sound meatus is used at the level flue part see figure 1 3 Y sound meatus has an entrance for air source air from the outlet of forced draught fan is sent though constantly which is used to counteract plus pressure from furnace In this way the transducer can be prevented from being corroded and piling up ash 图 1 3 Y 型声导管结构 Figure 1 3 Y Sound meatus 测点安装位置Installed Location of observation points 声导管安装位置由传感器有效监测半径确定 原则为 6 12m 布置传感器 的数量应保证对全炉承压受热面泄漏进行有效的监测 且监测应做到无盲区 The location of sound meatus is decided by the effective radius of transducer monitoring usually it is 6 12m The number of transducer should ensure that all heating surfaces leakage can be detected and ensure that there s no blind space 由于锅炉型号的不同 结构的不同 安装工艺的不同以及锅炉安装地域的不 同 因此 测点位置和数量也不同 具体位置应根据锅炉的具体情况而设计 参 见测点位置图 附图 气源入口 Entrance of air source A 60 3 5 700 102 9 4 Hole A Direction A 法兰 Flange 6型锅炉承压管泄漏在线监测系统用户手册 安装维护说明书 第1章 系统结构 BLD 6Type On line Leakage Monitoring System for Pressurized Tubes in Boiler Installation and Maintenance Manual Chapter 1 System Structure 5 Because of different boiler types structures installation techniques and locations of the boilers the number and location of observation points should also be different Specific location should be designed according to details of boiler see attached figure Steel girder 图 1 4 侧墙与顶棚声导管安装示意图 Figure 1 4 The installed location of sound meatus on sidewalls and top roof 测点布置应遵循以下原则 Principles of installing location of observation points should observe these principles 1 传感器有效监测半径为 6 12m 避免监测出现盲区 1 In order to avoid blind space the effective radius of transducer is 6 12m 2 安装角度除了顶棚外其它 J 型声导管为仰角 45O 见图 1 4 Y 型声导管 为仰角 30O 测点上部要留有足够空间 2 Installed angle of J sound meatus is an elevation of 45 except top room see figure 1 4 Installed angle of Y sound meatus is an elevation of 30 Enough space should be kept at upside of observation point 3 测点位置要有走台 以便于维护 3 Platform should be located near the observation point for maintenance 4 测点确定应避开吹灰器和有压缩风吹扫的其它测点 钢梁 300 顶棚 Top roof Top roof 炉墙 Furnace wall 清灰孔 Cleaning hole 1000 45O 6型锅炉承压管泄漏在线监测系统用户手册 安装维护说明书 第1章 系统结构 BLD 6Type On line Leakage Monitoring System for Pressurized Tubes in Boiler Installation and Maintenance Manual Chapter 1 System Structure 6 4 Observation point should be kept away from soot blower and other observation points which are blown by compression air 5 水冷壁区域的测点应尽量利用看火孔 人孔门或闲置不用的其它测点 5 The observation points near the water cooled wall should make use of fire holes man holes or other unused observation points 测点开孔方法The Method of Boring Hole 1 水冷壁利用看火孔上方三角区开孔方法 1 Boring hole on water cooled wall making use of triangle area above the fire hole 大容量锅炉通常为膜式水冷壁 水冷壁间距较小 应尽量利用原有备用吹灰 孔 看火孔 人孔门等上方的三角区 减少工作量 避免弯管开孔而破坏水冷壁 的原结构 The large capacity boiler usually is membrane tube wall space between water cooled walls is too small so the triangle are above the soot blowing hole fire hole and man hole should be used as much as possible in order to reduce the workload boring hole on syphon should be avoid in order to protect the structure of water cooled wall 应该应该注意注意 正在应用的吹灰器孔不能利用 Note The soot blower hole which is in use cannot be utilized 图 1 5 水冷壁利用看火孔上方三角区开孔示意图 Figure 1 5 The method of boring hole which makes use of fire hole on water cooled wall 看火孔 备用吹灰器孔或人孔门 或人孔门 Fire hole soot blower hole or man hole 炉墙 Furnace wall 声导管 Sound meatus 6型锅炉承压管泄漏在线监测系统用户手册 安装维护说明书 第1章 系统结构 BLD 6Type On line Leakage Monitoring System for Pressurized Tubes in Boiler Installation and Maintenance Manual Chapter 1 System Structure 7 水冷壁上的原有开孔均有较大的裕度 完全可以利用原开孔上方的空闲三 角区安装声导管 见图 1 5 There s usually enough surplus on original holes on water cooled wall so the triangle area above the original holes can be used for installing sound meatus see figure 1 5 2 水冷壁弯管开孔方法 2 The method of boring hole on the syphon of water cooled wall 当水冷壁必须弯管开孔时 其具体开孔方法可参见图 1 6 图 When boring hole on water cooled wall is necessary on syphon the method see figure 1 6 图 1 6 水冷壁弯管开孔示意图 Figure 1 6 The method of boring hole making use of syphon on water cooled wall 3 水冷壁鳍片开孔方法 3 The method of boring hole making use of finned hole of water cooled wall 如果水冷壁测点没有相应的看火孔等可利用 通常锅炉水冷壁管间距较小 考虑到安全因素 则采用在水冷壁鳍片上开窄孔的方式 竖向结构水冷壁在相邻 的鳍片上开两条长的矩形孔 宽度按鳍片实际尺寸 利用方箱过渡进行满焊 再 将声导管安装到方箱上 见图 1 7 If there s no fire hole on water cooled wall can be used as observation point usually the space AA A A 鳍片开孔 Finned hole 6型锅炉承压管泄漏在线监测系统用户手册 安装维护说明书 第1章 系统结构 BLD 6Type On line Leakage Monitoring System for Pressurized Tubes in Boiler Installation and Maintenance Manual Chapter 1 System Structure 8 between water cooled wall tubes is narrow in view of safe factor finned narrow hole on water cooled wall can be bored Two rectangular holes are bored on contiguous fins of vertical water cooled wall and width is the same with fin s width Making use of box as transition for full jointing then sound meatus will be installed on the box See figure 1 7 Box 图 1 7 利用水冷壁鳍片开孔安装声导管 Figure 1 7 The method of boring hole which makes use of finned hole on water cooled wall 4 包墙过热器开孔方法 4 Boring hole making use of enclosure wall super heater 锅炉包墙过热器节距较大 安装声导管时一般不需弯管 只需将鳍片开孔即 可 鳍片开孔时在保证过热器安全的前提下 尽可能使其与声导管口径相同 当 鳍片间距小于声导管内径时 鳍片开孔为一椭圆孔 同时将声导管前端适当压扁 开孔方法见图 1 8 There s broad space between enclosure wall super heaters usually siphon is not needed to install sound meatus and finned hole is already enough While the safety of super heater is guaranteed the caliber of finned hole should be the same as sound meatus s caliber when the spaces between fins 鳍片开孔 Finned hole 水冷壁管 Water cooled wall tube 2mm 方箱 370 装传感器 Install transducer 球阀Ball valve 可移动套筒 Sleeve tube 300 6型锅炉承压管泄漏在线监测系统用户手册 安装维护说明书 第1章 系统结构 BLD 6Type On line Leakage Monitoring System for Pressurized Tubes in Boiler Installation and Maintenance Manual Chapter 1 System Structure 9 is less than the sound meatus s internal diameter finned hole is bored elliptical at the same time the front of sound meatus should be made flat to fit the hole see figure 1 8 图 1 8 利用包墙壁鳍片开孔安装声导管 Figure 1 8 The method of boring hole which is making use of super heater of enclosure wall 声导管安装方法The Method of Installing Sound Meatus 1 侧墙声导管安装方法 1 The method of installing sound meatus on side wall 侧墙声导管斜段长度大于 700mm 现场安装确定实际应留长度 The length of bevel edge of sound meatus on side wall should be bigger than 700mm actual length is decided during installation 声导管的安装原则应保证其上部法兰盘便于安装及检修传感器 法兰盘上 部传感器安装高度为大于 300mm 见图 1 4 Installing sound meatus should ensure the convenience of installing and maintaining the transducer The installing height above the flange should be more than 300mm see figure 1 4 安装声导管时应保证声导管根部与水冷壁平齐 不允许声导管伸入水冷壁 内侧 When installing sound meatus the hemline of sound meatus and water cooled wall should be kept at the same level It isn t allowed that sound meatus is inserted into water cooled wall 声导管与包墙护板满焊 固定可靠 所有侧墙声导管安装时 型声导管与侧 墙呈 45 角 仰角 45 Y 型声导管则仰角为 30 角 以避免运行时积灰堵塞声导 声导管 Sound meatus 鳍片开孔 Finned hole 包墙管 Enclosure wall tube 焊接Jointing 6型锅炉承压管泄漏在线监测系统用户手册 安装维护说明书 第1章 系统结构 BLD 6Type On line Leakage Monitoring System for Pressurized Tubes in Boiler Installation and Maintenance Manual Chapter 1 System Structure 10 管通道 影响准确报警 声导管与侧墙相对位置见图 1 4 左图 Sound meatus and enclosure wall are full weld fixed and credible All angels between J sound meatus and sidewall are 45o elevations are 45o elevation angle between Y sound meatus and sidewall are 30o in order to avoid ash blocking sound meatus and affecting accurate alarm see figure 1 4 on the left 2 侧包墙声导管安装方法 2 The method of installing sound meatus on side enclosure wall 侧包墙过热器声导管安装方法基本与图 1 4 相同 鳍片开孔为一椭圆孔 与 护板满焊 The method of installing sound meatus on side enclosure wall super heater is basically the same as figure 1 4 finned hole is elliptical sound meatus and protecting board are full jointing 详见安装施工方案 Details see installation scheme 3 顶棚声导管的安装方法 3 The method of installing sound meatus on top roof 顶棚声导管的前端直段应根据保温层厚度确定 见图 1 4 右图 保温层外声 导管直段长度不小于 1000mm 可以用同类型的钢管延长连接 The front straight part of sound meatus on top roof should be decided according to thickness of thermal insulating layer see right figure 1 4 The length of sound meatus outside of thermal insulating layer shouldn t be less than 1000mm steel tube of the same type can be used for extention 声导管的维护Maintenance of Sound Meatus 运行期间应定期清理积灰及结焦 保证声导管的畅通 当计算机显示声导管 堵灰信息时 应及时打开清灰孔检查堵灰情况并进行清灰处理 6型锅炉承压管泄漏在线监测系统用户手册 安装维护说明书 第1章 系统结构 BLD 6Type On line Leakage Monitoring System for Pressurized Tubes in Boiler Installation and Maintenance Manual Chapter 1 System Structure 11 Cleaning should be taken periodically during operation in order to ensure that sound meatuss are expedited When computer displays the information of ash blockage should open hole check ash blocking and cleaning should be taken as soon as possible 锅炉大小修期间应检查声导管焊接部分是否脱落或产生裂纹 During check up period cracks on the meatus should be checked 传感器的安装 Installation of the transducer 传感器的外型如图 1 9 所示 是一个带有法兰盘的柱体 安装时 将传感器 的法兰盘与声导管的法兰盘对准 中间再加上 3mm 厚的石棉垫或 3mm 厚的耐 热橡胶垫 然后用 M8 30 的螺栓固定好即可 The exterior of transducer see figure 1 9 it is a column with flange During installation make the flange of transducer aim at the flange of sound meatus adding 3mm asbestos pad or 3mm ovenproof rubber mat in the middle then fixed by M8 30 bolt 图 1 9 传感器外型图 Figure 1 9 The exterior of transducer 因为传感器的法兰盘是采用绝缘材料制成的 因此 螺栓要加平垫和弹垫 注意螺栓不要拧的过紧 以防止电木法兰变形 Because flange of transducer is made of insulated material bolt should be underlaid by flat mat and spring mat Make sure the bolt isn t screwed too tight to avoid flange being distorted 6型锅炉承压管泄漏在线监测系统用户手册 安装维护说明书 第1章 系统结构 BLD 6Type On line Leakage Monitoring System for Pressurized Tubes in Boiler Installation and Maintenance Manual Chapter 1 System Structure 12 更换传感器时 先拧下航空插头 再卸掉四个螺栓 换上新的传感器再将航 空插头接上即可 When transducer is being replaced demount the avigation plug and other four bolts first then exchange new transducer and connect the aviation plug 传感器为贵重元件 应严格避免振动 更不能用任何物品敲打 以避免造成 不应有的损失 Transducer is expensive shaking or beating should be avoided to prevent loss 1 3 电缆安装 Installation of cable 就地部分的安装除声导管和传感器以外 还包括电缆敷设 接线盒的安装 Installation of grounded part includes laying cables and installing junction box in addition to installing sound meatus and transducer 接线盒的安装Installation of Junction box 接线盒的安装数量为 4 个 选用 20 线左右的热工信号端子箱 The number of junction boxes usually is 4 using thermal signal junction box with about 20 threads 端子箱的位置一般应靠近所要接入的所有测点 并且尽量靠近热工电缆走 线槽或电缆桥架 锅炉的甲 乙两侧适当位置各放一个 在尾部烟道测点附近放 置一个 在水平烟道处放置一个 The location of junction box should be close to all of observation point which will be joined and placed as close to thermal cable slot or cable bridge as possible Put one box on both sides of the boiler one near observation points of tail flue and one on the level flue 如果用户的锅炉为 670 吨或更小的锅炉 也可以省掉水平烟道的接线盒 将 水平烟道的测点就近分别引入甲 乙两侧的接线盒和尾部烟道处的接线盒 甲 乙两测的接线盒位置应相对提高 If the boiler is 670t or smaller junction box of level flue can be spared but the junction boxes at 6型锅炉承压管泄漏在线监测系统用户手册 安装维护说明书 第1章 系统结构 BLD 6Type On line Leakage Monitoring System for Pressurized Tubes in Boiler Installation and Maintenance Manual Chapter 1 System Structure 13 first and second sides of the boiler should be heightened 电缆及接线Cable and Connection 本系统现场由接线盒到传感器的电缆采用 ZRKVVP4 1 0 的电缆 实际使 用中 只取用其中的 3 芯 另一芯备用 由接线盒到控制柜的电缆采用 ZRKVVP6 14 22 1 0 的两种电缆 The system on site by the junction box to the sensor cable adopts ZRKVVP4 x 1 0 cable in actual use only use one of the three core another core Set aside From connector to the control cabinet of cable using ZRKVVP6 14 22 x 1 0 two kinds of cable 接线盒至控制盘内端子排的电缆 采用多芯 其芯数的多少 视接入该接线 盒传感器的数量而定 基本原则为 传感器个数 2 1 芯公共线 1 芯备用 其接 线方法可参考图 1 10 注意注意 为为了了检检修方便公共修方便公共线线以不超以不超过过 个 个测测点引出一根点引出一根 From junction box to terminals in control panel multi core cable should be used The number of cores is decided according to the number of transducers being connected The principle is that the number of transducers 2 1 common thread 1 spare thread The method of connecting is shown in figure 1 10 Note in order to make overhaul convenient there should be one common thread for at most 6 observation points Goto terminals in control panel ZRKVVP 1 0 n 2 2 图 1 10 接线盒接线示意图 Figure 1 10 Connection 接 1 号传感器 Connect No 1 transducer 去盘内端子排 ZRKVVP 1 0 n 2 2 1 234 5 67 8 9 接线盒 Junction box 接 2 号传感器 Connect No 2transducer 接 3 号传感器 Connect No 3 transducer 接 N 号传感器 Connect No N transducer 6型锅炉承压管泄漏在线监测系统用户手册 安装维护说明书 第1章 系统结构 BLD 6Type On line Leakage Monitoring System for Pressurized Tubes in Boiler Installation and Maintenance Manual Chapter 1 System Structure 14 1 4 系统安装接线 System Connection 系统接线System Connection 如果用户选择带机柜的监测系统 设备安装结构见附录机柜结构图 如不采 用本系统专用机柜则计算机主机与彩色监视器 计算机键盘间应就近放置 主机 将有 2 4 条电缆接入泄漏监测端子排上 一般情况下计算机主机在泄漏监测主 机上方 这样便于电缆的连接 以上电缆均由厂家向用户提供 If user chooses the monitoring system with cabinet the structure of installation is shown in appendix with cabinet structure If user doesn t choose cabinet the host computer color monitor and keyboard should be put together There are 2 4 cables connecting host with monitoring cabinet Usually put the host on the monitor host for convenient connection Cables bare provided by manufacturer 系统整体安装接线如图 1 11 所示 The whole connection see figure 1 11 图 1 11 系统整体接线框图 注 接线盒至系统监测机 柜内端子排的就地电缆采 用多芯的热工屏蔽电缆 传感器 1 24 路 可向上 移动白钢套 套 4 接线盒 XA 就地电缆 炉 墙 监 测 主 机 系 统 监 测 机 柜 内 端 子 排 计 算 机 打 印 机 接线盒 XC 接线盒 XB 接线盒 XD 6型锅炉承压管泄漏在线监测系统用户手册 安装维护说明书 第1章 系统结构 BLD 6Type On line Leakage Monitoring System for Pressurized Tubes in Boiler Installation and Maintenance Manual Chapter 1 System Structure 15 Note grounded cables which connect terminals to junction box adopt multi core cables Figure 1 11 The whole connection 辅助信号Auxiliary Signals 辅助信号和就地的监测信号均应接入相应表盘的盘内端子排上 然后 用截 面为 0 5mm 左右的软导线接入泄漏监测主机的插件上 泄漏监测系统对辅助信 号的要求如下表所示 Auxiliary signals and grounded monitoring signals should connect with appropriate terminals of dial plate then connected to plug in of monitor by flexible circuit conductor whose section is 0 5mm The request for the auxiliary signals are as follows 序号 number 名称 Name 数量 Amount 规 格 Spec 连接设备 Connect equipment 用途或来源 Use or origin 开关量输出 Switch output 对 1 pair 常开 240V5A Normally opened contact 240V5A 光字排或报警器 Light words or annunciator