670MW火电机组锅炉水压试验方案

1、1.编制依据1. Basis of compilation 1.1电力建设施工质量验收及评定规程第2部分：锅炉机组DL/T5210.2-20091.1 “Quality acceptance and evaluation regulations for Electric power construction(the second part:Boiler unit) ”DL/T5210.2-20091.2电力建设施工技术规范第2部分：锅炉机组DL/T5190.2-20121.2 “Electrical power construction technical manual, the second

2、 part:boiler Unit” DL 5190.2-20121.3火力发电厂汽水管道设计技术规定DL/T5054-19961.3“Technical regulation of the Thermal power plant steaming-water piping design” DL/T5054-19961.4电力建设施工质量验收及评定规程第5部分：管道及系统DL/T 5190.5-20121.4“Quality acceptance and evaluation regulations for electric power construction engineer (the f

3、ifth part: pipeline and system) ” DL/T 5190.5-20121.5电力基本建设热力设备化学监督导则DL/T 889-20041.5“Guide of chemistry supervision of thermalequipmentsfor power station capital construction” DL/T 889-20041.6火力发电厂焊接技术规程DL/T869-2012；1.6The thermal power plant welding technical regulation DL/T869-2012；1.7ASME动力管道B31

4、.1-20101.7“ASME CODE FOR POWER PIPING”B31.1-20101.8电力建设安全工作规程第1部分：火力发电厂DL5009.1-2002；1.8“Power plant construction security standard” DL5009.1-2002；1.9工程建设强制性条文(电力工程部分)2011版；1.9“Engineering construction compulsory provisions ”（electricity part）2011；2.0锅炉说明书·锅炉安装（哈尔滨锅炉厂有限责任公司编制）2.0“Boiler specifi

5、cation ·boiler installation”(Harbin boiler plant Co., Ltd, preparation)2.1锅炉本体说明书（哈尔滨锅炉厂有限责任公司编制）2.1“Boiler proper specification”(Harbin boiler plant Co., Ltd, preparation)2.作业范围及工程量2 Construction scope and engineering quantity 2.1工程概况2.1 Project profile电厂1×670MW机组锅炉是哈尔滨锅炉厂有限公司，根据哈锅自主研发技术设

6、计、制造的超临界锅炉。该锅炉为变压运行、一次中间再热、单炉膛、平衡通风、固态排渣、全钢架悬吊结构、露天布置的“”型超临界直流锅炉。带有内置式再循环泵的启动系统，采用低NOX燃烧技术，24只燃烧器分6层布置，采用切圆燃烧方式，配北京电力设备总厂6台ZGM133G-中速磨煤机直吹式制粉系统，锅炉在BMCR工况下，5运1备。1 × 670MW unit boiler belongs to Harbin boiler plant co., Ltd., and it is supercritical boiler designed and manufactured according to t

7、echnology independent researched by the Harbin boiler plant co., Ltd.This boiler is type supercritical once-through boiler of variable pressure operation, once reheating, single furnace, balanced ventilation, dry slagging, full steel suspension structure, and open layout. With start-up system of bui

8、lt-in recirculation pump, using low NOx combustion technology, 24 sets burns are arranged in 6 layers, using tangential firing method, with 6 sets ZGM133G-medium-speed coal mill direct blowing type coal pulverizing system from Beijing power equipment group, in the BMCR work condition the 5 sets boil

9、er operation and one for preparation. 锅炉采用全钢结构构架，高强螺栓连接。受热面呈“”型布置，炉膛上部有屏式过热器；水平烟道中布置有末级过热器、末级再热器；后烟道有中间隔墙，竖井前部布置水平低温再热器、立式低温再热器，竖井后部布置水平低温过热器、立式低温过热器和省煤器。Boiler adopts the full steel structure framework, connection with high strength bolts. Heating surface arrangement by type, there is platen superh

10、eater in the furnace upper part; arrange the final-stage superheater and final-stage reheater in the horizontal flue; rear pass has midfeather, in the front of vertical shaft arrangement horizontal low-temperature reheater and vertical low-temperature reheater, in the back of vertical shaft layout h

11、orizontail low-temperature superheater, vertical low-temperature superheater and economizer.锅炉型号boiler model：HG2076/25.4HM16主要参数 main parameter过热蒸汽superheated steam：BMCR流量flow 2076.41t/hBMCR出口压力outlet pressure 25.4MPaBMCR出口蒸汽温度steam temperature of outlet571°C再热蒸汽reheated steam: BMCR蒸汽流量steam fl

12、ow 1728.61t/h进/出口蒸汽压力steam pressure of inlet&outlet4.464/4.274MPa 进口/出口蒸汽温度steam temperature of inlet & outlet318.8/569给水温度feed-water temperature：291.42.2作业范围及主要工程量2.2 construction scope and main engineering quantity锅炉水压试验范围:Boiler hydraulic test scope:本次水压包括一次汽系统及连接管道、二次汽系统及连接管道、锅炉本体范围内一次门以

13、内的承压管道。具体如下：This hydraulic test includes superheater steam system with connection pipeline, reheater steam system with connection pipeline, pressure-bearing pipeline within first valve within the boiler proper scope. Specific as following: 2.2.1一次汽系统包括：主给水及给水旁路电动闸阀（10LAB70AA003、10LAB70AA002）、过热器减温水总

14、管3#闸阀后至省煤器入口集箱间管道、省煤器、省煤器连接导管（溢流管路暖管至10HAC13AA005电动截止阀）、循环泵暖管、四侧水冷壁、汽水分离器、贮水箱、启动循环泵壳（含临时堵板）、顶棚过热器、包墙过热器、中间隔墙、低温过热器、一级减温器（至过热器一级喷水减温10LAE11AA002、10LAE11AA004电动截止阀）、分隔屏过热器、二级减温器（至过热器二级喷水减温10LAE12AA002、10LAE12AA004电动截止阀）、末级过热器、主汽管道（J列柱中心向炉前2190mm处）水压堵板前部分。锅炉本体过热器系统：末级过热器出口至安全阀水压试验堵头。2.2.1Superheater st

15、eam system includes: main feed-water and electric gate valve of feed-water bypass （10LAB70AA003、10LAB70AA002）, from the back of 3# gate valve of superheater desuperheating water main to the header pipeline of economizer inlet, economizer, economizer connection tube (from the warming pipe of overflow

16、 pipeline to 10HAC13AA005electric stop valve), circulating pump warming pipe, four sides water-cooled wall, steam-water separator, water storage tank, start-up circulating pump casing （including engineered temporary blocking plate）, roof superheater, enclosure wall superheater, midfeather, low-tempe

17、rture superheater, first level desuperheater (to 10LAE11AA002、10LAE11AA004 electric stop valve of superheater first level spray desuperheating), separate platen superheater, second level desuperheater (to 10LAE12AA002、10LAE12AA004 electric stop valve of superheater second level spray desuperheating)

18、, final-stage superheater, front part of the hydraulic test blocking plate of the main steam pipeline (at the 2190 mm from J column center to the boiler front).Superheater system of the boiler proper: hydraulic test plug, from the final-stage superheater outlet to safety valve hydraulic test cap.2.2

19、.2二次汽系统包括：冷段管道水压试验堵阀后至低温再热器入口集箱间管道、低温再热器、减温器喷嘴暖管、再热器减温器（至再热器喷水减温器管路10LAF70AA011、10LAF70AA013电动截止阀）末级再热器、末级再热器出口管道水压堵阀前部分。2.2.2Reheater steam system includes: from the back of the hydraulic test blocking valve of cold section to the header house of the low temperature reheater inlet, low temperature

20、reheater, warming pipeline of desuperheator nozzle, reheater desuperheator (to 10LAF70AA011、10LAF70AA013 electric stop valve of the reheater spray desuperheator pipeline) final-stage reheater, the front part of the hydraulic test blocking valve of the final-stage reheater outlet pipeline.2.2.3锅炉本体范围

21、内一次门以内承压管道2.2.3Pressure-bearing pipeline within the first valve in the boiler proper scope.2.2.3.1疏放水管道：2.2.3.1Drain& blow-down pipeline:包墙及低过疏水wrapped wall and low drainage給水疏水 feed-water drainage折焰角入口汇集集箱疏水drainage of the furnace arch inlet collection header水冷壁中间集箱疏水drainage of the header at t

22、he water-cooled wall middle低温再热器疏水 drainage of the low temperature reheater减温水疏水 drainage of the desuperheating water循环泵再循环管疏水 drainage of the circulating pump recirculating pipe水冷壁疏水 drainage of the water-cooled wall2.2.3.2放气管道2.2.3.2Blow-off pipeline顶棚入口管道放气air vent of the ceiling inlet pipeline顶棚

23、旁路管道放气air vent of the ceiling bypass pipeline分离器入口连接管道放气air vent of the separator inlet connection pipeline下降管放气air vent of the downcomer水冷壁中间集箱平衡管放气air vent of the balance pipe of the water-cooled wall middle header 包墙连接管放气air vent of the wrapped wall connection pipe分隔屏入口集箱连接管放气air vent of the conn

24、ection pipe of the separated platen inlet header省煤器出口放气air vent of the economizer outlet充氮管道放气air vent of the nitrogen filling pipeline2.2.3.3蒸汽及炉水取样管道：2.2.3.3sampling pipeline of the steam and boiler water顶棚入口管道取样 sampling of the ceiling inlet pipeline溢流管取样 sampling of the overflow pipe省煤器入口取样 samp

25、ling of the economizer inlet过热器减温器取样 sampling of the superheater desuperheator循环泵再循环管取样 sampling of the circulating pump recirculating pipe过热器出口取样 sampling of the superheater outlet再热器出口管道取样 sampling of the reheater outlet pipeline2.2.3.4本体及预热器吹灰器汽源引出管及一次门2.2.3.4Steam source educing pipe and the fir

26、st valve of boiler body and preheater soot blower2.2.3.5锅炉本体水压试验临时系统。2.2.3.5Engineered temporary system of the boiler proper hydraulic test2.3锅炉本体水压时各系统水容积2.3Each system water capacity when making boiler proper hydraulic test名称 name省煤器economizer启动系统Start-up system水冷壁Water-cooled wall过热器superheater再热

27、器reheater临时系统Temporary system合计total容积（M3）capacity602582166382507652.4水压试验用药量2.4Dosage of the hydraulic test锅炉水压上水加药量按照联氨含量为250300mg/L、PH值为1010.5。The additional dosage for the boiler hydraulic test water filling following the hydrazine content 250300mg/L, and PH value is 1010.5.加药量计算：水压用水容积为2000 m&#

28、179;（包括附属管道和临时管道及冲洗用水，按照2.6倍水容积准备除盐水）The additional dosage calculation: Hydrostatic test water use volume is 2000 m³（including auxiliary pipeline, temporary pipeline, and flushing water, and prepare desalted water following 2.6 times of water capacity）故50%浓度联氨（N2H4）用量为：2000×1000×300&#

29、215;10-6 ÷50%=1200kgHence, The hydrazine (N2H4) with 50% concentration content: 2000×1000×300×10-6 ÷50%=1200kg考虑裕量：50%浓度联氨用量按1400kg备药Consideration allowance: ammonium hydrazine(N2H4) with 50% concentration content according to the 1400kg medicine preparation.25%浓度的氨水（NH3

30、3;H2O）含量按500 mg/L计算The ammonium hydroxide(NH3 ·H2O) with 25% concentration content calculation according to 500mg/L.25%浓度的氨水用量为：2000×1000×500×10-6÷25%=4000kgThe ammonium hydroxide(NH3 ·H2O) with 25% concentration content is: 2000×1000×500×10-6÷25%=40

31、00kg考虑裕量：25%浓度的氨水用量按4200kg备药。Consideration allowance: ammonium hydroxide(NH3 ·H2O) with 25% concentration content according to the 4200kg medicine preparation.2.5锅炉整体水压试验压力2.5Pressure of the hydraulic test for the whole boiler直流炉水压试验按ASME规范分两部分进行，锅炉的汽水系统、过热器和省煤器作为一次汽系统，以1.5倍锅炉末级过热器出口设计压力（最高允许工作

32、压力）进行水压试验；再热器系统以1.5倍一级再热器入口集箱设计压力（最高允许工作压力）进行水压试验。即：一次汽水压试验压力为27.5×1.5=41.25MPa二次汽水压试验压力为5.2×1.5=7.8MPaAccording to the ASME specification dividing the Once-through boiler hydraulic test into two parts for operation, steam-water system, super-heater and economizer of the boiler as the supe

33、rheater steam system, making the hydraulic test with the pressure that is 1.5 times of design pressure of the final-stage superheater outlet (the maximum allowable working pressure); the reheater system makes hydraulic test with the pressure that is 1.5 times of design pressure of the first level re

34、heater inlet header (the maximum allowable working pressure). That is: the superheater steam hydraulic test pressure is 27.5×1.5=41.25MPaThe reheater steam hydraulic test pressure is 5.2×1.5=7.8MPa2.6水压试验的目的：2.6 The objective of the hydraulic test2.6.1检验锅炉受压部件的强度。2.6.1Inspecting the streng

35、th of the boiler pressure parts.2.6.2检验锅炉受压部件的严密性。2.6.2Inspecting the rigor of the boiler pressure parts.3.施工前具备的条件3. Conditions prepared before the construction 3.1水压试验方案编制完成，经审批合格。3.1 The hydraulic testconstruction scheme shall be completed and approved.3.2水压范围内的所有受压件焊接工作全部结束，并已无损检测和热处理完毕，返修口已全部处理

36、完并检验合格。所有合金元件的材质均经过核对，并确认无错用现象。3.2 Welding work for all pressure parts all over in the hydraulic test scope, and the non-destructive testing and heat treatment have been completed, rework mouth has been completely processed and inspection qualified. Material of all alloy elements has through checked

37、 and confirms there is no misuse phenomenon.3.3锅炉密封装置一次密封件安装、焊接完毕（主要包括顶棚及分隔屏内护板、后烟道顶棚管内护板、后烟道烟气分配折流板、水平烟道后部内护板、后烟道膨胀节、尾部烟道膨胀密封装置等）。3.3installation and welding for primary sealing workpiece of boiler sealing device are finished. (mainly includes ceiling, division screen inner protect plate, rear air

38、duct ceiling pipe interior protect plate, rear air duct distribute baffle plate, horizontal air duct rear interior protect plate，rear air duct expansion joint, tail air duct expansion sealing device, etc.)3.4锅炉附件安装完毕（主要包括吹灰孔、看火孔、检修孔、热工测点密封盒、火焰电视监视孔、绳孔装置等）。3.4 Boiler accessories installation complete

39、 (main includes soot blowing hole, observation hole, manhole, thermal measure point seal box, monitoring hole of fire eye, rope-hole device, and so on.).3.5所有吊杆受力均匀，临时加固支撑件全部拆除，悬吊部件全部处于自由状态。3.5 All suspenderforce evenly, remove all temporary strengthening strutting pieces, suspension parts all in a

40、state of freedom.3.6临时上水管施工结束，排水通畅，楼梯通道畅通安全，炉膛内外照明良好。3.6 Temporary water supply pipeline construction finished, drainage unobstructed, stair channel is unimpeded and safe, lighting good on the interior and exterior of the furnace.3.7水压试验临时管路冲洗完成，目测水质澄清，上水泵、启动升压泵经试转合格。3.7 Flushing complete for the te

41、mporary pipeline in the hydraulic test, visual inspection the water clean without sundry and quality well, through test run the feed-water pump and start-up booster pump qualified.3.8所有膨胀指示器安装完毕并调整到零位。3.8 All the expansion indicator installation finished and adjusted to zero.3.9 3000m³除盐水箱除盐水满足

42、水压用水量和水质要求。锅炉整体水压试验要求环境温度不得低于5；3.9 Demineralized water of 3000m³demineralized water tank meet the requirements of the hydraulic test water consumption and the water quality. The required environmental temperature cannot less than 5 in the whole boiler hydraulic test.3.10水压试验用压力表、温度表等仪表经校验合格，安装位

43、置合理，并配备有备用表，防止升压过程中因为管道震动而造成压力表损坏。3.10 The pressure gauge, thermometer and other instruments that is used in the hydraulic test through the calibration qualified, the installation position is reasonable, and are equipped with a spare table, to prevent pressure gauge damage because of the pipeline vi

44、bration during raising pressure.3.11水压试验用的临时堵板必须经过强度校核，水压试验期间非工作人员不得进入现场，停止锅炉范围内的一切施工。3.11 The temporary blocking plate must pass intensity checking that used for the hydraulic test, during the hydraulic test the non-working personnel shall not enter the site, stop all construction within the scope

45、of boiler.3.12在水压试验前对受压部件进行风压试验，风压试验压力为0.3MPa，试验介质为压缩空气。3.12 Making the air pressure testfor the pressure parts before the hydraulic test, the pressure of the air pressure test is 0.3 MPa, the test medium is compressed air.3.13水压试验安全、技术、质量措施已交底并办理相关手续，水压试验组织机构和人员分工已落实。参与水压试验的系统、阀门、水泵及电气操作设备均应标识清楚，并挂

46、临时标识牌。操作卡已编制好，操作人员已掌握。3.13 The security, technology, and quality measures of the hydraulic test have disclosure and deal with relevant formalities, hydraulic test organization structure and personnel division of labor have been implemented. The system, valve, water pump and electrical operation equi

47、pment that are involved and related to the hydraulic test shall be clearly marked, and hang a temporary identity card. Operation card have been prepared completely, the operator has been mastered.3.14水压试验系统图、升降压曲线图、组织机构图已张挂于现场。3.14 The hydraulic test system diagram, the lifting pressure curve, and o

48、rganization chart have been hanged in the site.3.15锅炉注水前与业主一同对锅炉钢结构的沉降观测点进行检查。3.15Inspect the settlement observation point of boiler steel structure with the owner before boiler pressure pipeing filling water 4.工期要求及劳动力配备4. Construction Duration and Labor Allocation4.1工期要求4.1 Construction duration计划

49、开工日期2015年11月20日，计划完成日期2015年11月30日。 Plan to start installation on November -20-2015, and complete on November -30-2015.4.2劳动力配置计划4.2 labor force allocation plan序号No.作业人员/工种Types of worker数量quantity职责duty1总指挥General director1负责锅炉水压的整体控制工作。In charge of boiler hydraulic pressure. 2副总指挥Vice director-gene

50、ral2协调、组织水压试验的实施工作。Coordinate and organize implementation works of hydraulic test.3操作组负责人Operation group director2负责锅炉上水、停泵检查、升压、泄压等所有操作的指挥、控制工作。In charge of all the operation commands and control works related to water filling, pumping cease inspection, boost, pressure relief and so on. 4阀门操作负责人Val

51、ve operation director2负责水压过程中阀门操作的安排及检查工作。Responsible for arranging and inspection work pressure during the valve operation. 5水泵操作负责人The pump operation director2负责上水泵、升压泵的启动及停止操作工作，负责上水泵、升压泵的检查及维护工作。In charge of charging pump, booster pump launch and halt operations, and inspection and maintenance o

52、perations about charging pump and booster pump. 6水箱加药负责人Water tank dosing director1负责上水前除盐水箱加药工作，负责加药数量的记录工作。In charge of demineralized water tank dosing operation, and the dose quantity record before water charging. 7升压力记录人Pressure recorder1负责水压期间一、二次系统升压及泄压记录工作。In charge of records about primary,

53、secondary system boost and pressure relief during water charging. 8供电负责人Power supply director2负责水压期间锅炉照明、上水泵、升压泵的电力保障工作。In charge of power supply for boiler illumination, charging pump and booster bump during water charging. 9检查组负责人Inspection group director2负责各检查阶段的设备检查、人员组织及清点工作，对检查情况进行记录并报告操作组负责人。

54、In charge of equipment inspection, personnel organization and checking operation in every stage and record all the inspection result, report to operation director. 10膨胀检查记录人Expansion inspection  recorder1负责水压期间膨胀检查、膨胀指示记录工作。In charge of recording about expansion inspection, indication during hy

55、draulic test. 11物资供应负责人Material support director3负责整体水压设备、材料、表计、药品采购及供应工作；负责水压药品合格证提供工作。In charge of procurement and supplying for whole hydraulic equipment, material, meter and chemicals, ensure hydraulic chemicals certification presentation. 12后勤保障负责人Logistical support director3负责水压期间各项后勤保障工作，负责应急

56、救护工作。In charge of various logistical service during water charging and emergency rescue. 13安全组负责人Safety group inspection director4负责整体水压前及过程中的安全检查及验收工作。In charge of safety inspection and acceptance before and during whole water charging. 14取样检验负责人Sampling director 1负责水压用水的水质取样及送检工作。In charge of hydr

57、aulic test water sampling and inspection. 15检查验收组Quality supervision group 41.负责水压前压力表计校验送检及取证工作；2.负责水压药品合格证保存及报验工作3.负责水压用水的取样送检及取证工作；4.负责整体水压试验前及过程中的质量检查、验收取证及签证办理工作。1. in charge of pressure meter calibration inspection and certification acquirement; 2. in charge of hydraulic chemicals certification preservation and declaration; 3.in charge of hydraulic test water sampling and certification acquirement; 4, in charge of quality test, acceptance inspection and certificates applying before and durin