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

1、印度古德洛尔印度古德洛尔 2X600MW 燃煤电站项目燃煤电站项目INDIA CUDDALORE 2600MW POWER PROJECTBLD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 BYNortheast China Institute of Electric Power Engineering Kaiyuan Sci&Tech

2、Co.Ltd东北电院开元科技有限公司印度古德洛尔印度古德洛尔 2 600MW燃煤电站项目专用燃煤电站项目专用1目录目录Contents2600MW.1系统安装系统安装 SYSTEM INSTALLATION.11.1安装结构 INSTALLATION STRUCTURE.11.2测点安装 INSTALLATION OF OBSERVATION POINTS.2声导管结构Structure of Sound Meatus.3测点安装位置Installed Location of observation points.4测点开孔方法The Method of Boring Hole.6声导管安装方

3、法The Method of Installing Sound Meatus .9声导管的维护Maintenance of Sound Meatus.10传感器的安装 Installation of the transducer.111.3电缆安装 INSTALLATION OF CABLE.12接线盒的安装Installation of Junction box.12电缆及接线Cable and Connection.131.4系统安装接线 SYSTEM CONNECTION.14系统接线System Connection .14辅助信号Auxiliary Signals.151.5防腐清灰

4、装置 CLEANING DEVICE.16安装方案Installation Scheme.16技术要求Technical Request .17技术规范(仅供参考) Technical Specification (For Reference).181.6软件安装 INSTALLATION OF SOFTWARE.18系统调试系统调试 SYSTEM DEBUGGING.11.7调试准备：PREPARE FOR DEBUGGING: .1调试条件Condition of Debugging.1开启系统Turn on the System.1防腐清灰系统风量调整Adjustment of Clea

5、ning System.11.8初步调试 PRIMARY DEBUGGING.2关闭报警Close Alarm.2调整总因子Adjust Total Factor .3调整流量因子Adjust Flow Factor.4设定采样间隔Set Sampling Interval.51.9参数调试 PARAMETERS DEBUGGING.5自动生成警界线Auto-generation for Alarm Line.5手动调整警界上线Manual Adjustment of Upper Limit of Alarm Line .6手动调整警界下线Manual Adjustment of Lower

6、Limit of Alarm Line .8手动调整基础噪音Manual Adjustment of Basic Noise .9通道参数统调Channel Parameters Centralized Adjustment.91.10调试中的几个问题 SEVERAL PROBLEMS IN DEBUGGING.10维维护护检检修修参参考考 MAINTENANCE AND REPAIR REFERENCE.121.11监测主机维护 MONITORING HOST MAINTENANCE.1前、后面板说明Explanation of Front Panel and Back Panel .1监测

7、主机内部结构Internal structure of monitoring host.3传感器及引线Transducer and Down-lead.41.12常见故障的处理 DEAL WITH COMMON FAILURES.61.13器件型号说明 THE EXPLAIN OF THE TYPE OF DEVICE.10附图附图 APPENDIX DRAWING.11、监测机柜结构图 THE STRUCTURE OF MONITORING CABINET.12、盘内电气接线图 THE ELECTRIC CONNECTION IN PLATE.33、监测主机箱插件表 MONITORING H

8、OST PLUG-IN TABLE.44、单台炉测点布置图 LAY WATCHPOINTS DIAGRAM.65、系统单元接线图 UNIT CONNECTION DIAGRAM.7-6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 Structure1系统安装系统安装 System Installation锅炉承

9、压管泄漏在线监测系统，是一套专门为及时发现锅炉“四管”泄漏（内漏）事故而设计的“计算机在线监测系统” ，该系统主要分为就地检测部分和操作监测部分。BLD Type On-line Leakage Monitoring System for Pressurized Tubes in Boiler, is a “on-line monitoring computer” which is designed specifically for detecting leakage (leakage inside) of “4 Tubes” of boiler in time. The system inc

10、ludes: grounded monitoring part and operation monitoring part.系统的就地检测部分安装在锅炉现场，操作监测部分则集成在监测机柜中，安装在单元控制室或电子设备间内。Grounded monitoring part is installed at boiler onsite; operation monitoring part is integrated in monitoring cabinet, installed in unit control room or electronic-equipment room.1.11.1 安装结

11、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. Operat

12、ion 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

13、 Boiler（Installation and Maintenance Manual） Chapter 1 System Structure2图 1.1锅炉泄漏监测系统安装结构框图Figure 1.1Monitoring 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 instal

14、lation，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 mon

15、itoring 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

16、HostBLD-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

17、 Monitoring System for Pressurized Tubes in Boiler（Installation and Maintenance Manual） Chapter 1 System Structure3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 603.5mm 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. Usual

18、ly it is made of steel tube which is 603.5mm. 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 meatusJ 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

19、 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

20、 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 pressure makes flue gas enter sound meatus; the flue gas becomes sulfuric acid at low temperature, 870可移动白钢套Steel tube-6型锅

21、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 Structure4and 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

22、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, i

23、s 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 612m。布置传感器的数量应保证对全炉承压受热面泄漏

24、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 612m. The number of transducer should ensure that all heating surfaces leakage can be detected, and ensure that theres 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

25、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 sourceA603.57001029-4 HoleADirection 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 Structure5Because of differen

26、t 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 l

27、ocation 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 612m，避免监测出现盲区。（1）In order to avoid blind space, the effective radius of transducer is 612m.（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

28、30O。测点上部要留有足够空间。（2）Installed angle of J-sound meatus is an elevation of 45except 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 fo

29、r 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-roofTop-roof炉墙Furnace wall清灰孔Cleaning hole100045O-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 Structure6（4） Observation point

30、 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

31、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 abo

32、ve 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.应该注意应该注意：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. 看火孔、

33、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 Structure7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

34、method of boring hole which makes use of fire hole on water-cooled wall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。Theres 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

35、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 meth

36、od 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。AAA-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 Pressuri

37、zed Tubes in Boiler（Installation and Maintenance Manual） Chapter 1 System Structure8If theres no fire hole on water-cooled wall can be used as observation point, usually the space between water-cooled wall tubes is narrow; in view of safe factor, finned narrow hole on water-cooled wall can be bored.

38、 Two rectangular holes are bored on contiguous fins of vertical water-cooled wall, and width is the same with fins 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 wh

39、ich 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。Theres broad space between enclosure-wall super-heaters, usually sip

40、hon is not needed to install sound meatus, and finned hole is already enough. While the safety of super-heater is guaranteed, the 鳍片开孔Finned hole水冷壁管Water-cooled wall tube2mm方箱370装传感器Install transducer球阀Ball valve可移动套筒 Sleeve tube300-6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 Mo

41、nitoring System for Pressurized Tubes in Boiler（Installation and Maintenance Manual） Chapter 1 System Structure9caliber of finned hole should be the same as sound meatuss caliber; when the spaces between fins is less than the sound meatuss internal diameter, finned hole is bored elliptical, at the s

42、ame 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 si

43、de-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 ma

44、intaining 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 isnt allowed that sound meatus is insert

45、ed 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 Structure10侧

46、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

47、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 fig

48、ure 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 meatu

49、s 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 shouldnt 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

50、，保证声导管的畅通，当计算机显示声导-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 Structure11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。Cleaning should be taken periodically during operation in order to ensure

51、 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 tran

52、sducer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 M830 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 ovenproo

53、f rubber mat in the middle, then fixed by M830 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 -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 -6

54、Type On-line Leakage Monitoring System for Pressurized Tubes in Boiler（Installation and Maintenance Manual） Chapter 1 System Structure12spring mat. Make sure the bolt isnt screwed too tight to avoid flange being distorted.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, de

55、mount 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。Install

56、ation 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

57、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 observa

58、tion 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，-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 Structure13

59、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 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 ZRKVVP41.0 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

60、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