哥伦比亚锅炉清洗方案中-英对照版

1、哥伦比亚GECELCA 3号燃煤发电站1608T/h循环流化床锅炉化学清洗方案/Chemical Cleaning Plan for 1608t/h CFB of GECELCA 3 Coal-fired Power Station in Colombia编制/Producer：刘祥富/Liu Fuxiang 审核/Examiner：孙宏斌/Sun Hongbin 审定/Approver：李峥嵘/Li Zhengrong 天华化工机械及自动化研究设计院有限公司/Tianhua Chemical Machinery and Automation Institute Co., Ltd.二一三年八月

2、四日/Aug.4,2013 *：甘肃省兰州市西固合水北路三号 E-mail：thlean2008 (FaxP.C：730060目 录/Contents1.编制依据/Basis for Chemical cleaning plan22.化学清洗的目的/Purpose of chemical cleaning23.化学清洗的范围/ Scope of chemical cleaning34.化学清洗系统流速计算及回路划分/ Cleaning system flow rate calculation and cleaning loops divi

3、ded45.化学清洗的准备工作/Preparations before cleaning operation96.清洗剂的选择、清洗泵站的建立和配管/ Selecting cleaning solutions, establishing pump station and tubing147.化学清洗工艺程序、条件及措施/Cleaning process, conditions and measures158.清洗施工中几个问题的处理办法/Solutions to matters bothering cleaning operation249.化学清洗质量要求及检验/Quality requir

4、ements and inspection2610.化学清洗废液处理及排放/Wasteliquid treatment and disposal2611.化学清洗工程安全措施及施工管理/Safety measures and construction management29附件1 化学清洗流程及接管示意图/Appendix 1. Cleaning process and tubing sketch31附件2 化验分析方法/Appendix 2.Lab Analysis methods33附件3 清洗记录表格/Appendix 3. Record sheets for cleaning36附件

5、4.施工材料清单/Appendix 4 Bill of construction materials 42附件5.化工原材料清单/Appendix 5.Bill of Chemical materials441.编制依据/ Basis for chemical cleaning plan本方案是根据608T/h循环流化床锅炉的有关技术资料而编制的，同时还参考了如下标准规范：a. DL/T 794-2012火力发电厂锅炉化学清洗导则；b. TSG G5003-2008 锅炉化学清洗规则；/ c. HG/T2387-2007工业设备化学清洗质量标准；d. GB 8978-1996污水综合排放标准；

6、1.Basis for chemical cleaning planBased on relevant technical data for the 608t/h CFB(circulating fluidized bed boiler) and with reference to the following standards, this plan is prepared：a.DL/T 794-2012 Chemical Cleaning Guidelines for Thermal Power Plant Boilers;b.TSG G5003-2008 Rules for Chemica

7、l Cleaning of Boilers;c.HG/T2387-2007 Quality Standards for Chemical Cleaning of Industrial Equipment;d.GB 8978-1996 Comprehensive Discharge Standard for Wastewater or Sewage;2.化学清洗的目的参照水电部DL/T 794-2012火力发电厂锅炉化学清洗导则的技术规定，新建锅炉开工前必须进行化学清洗，以除去油污、锈垢、金属碎屑、焊渣、灰尘、砂土等杂物，使该系统在开车时，尽快获得优质纯净的高压蒸汽，以推动蒸汽透平机组。否则，因

8、上述杂物的存在而造成蒸汽品质一时难以调整达标，大大延长装置的联动试车时间，造成浪费和损失，严重时将直接导致蒸汽透平叶轮污染或损伤，并且还影响其它需用蒸汽工序的产品质量。2. Purpose of Chemical cleaningAs the DL/T 794-2012 Chemical Cleaning Guidelines for Thermal Power Plant Boilers stipulated that before to be put into operation, the new boiler must be cleaned chemically to remove an

9、y grease, rust, metal chip, welding slag, dust, sand and other debris so that the boiler system in operation can obtain quality and pure high-pressure steam as soon as possible to drive a steam turbine units, otherwise, the presence of the above-said debris can result in poor steam quality and great

10、ly-prolonged linked trial-run time and waste or losses, seriously, it will contaminate and damage the steam turbines impellers and influence the quality of other products which asking for high-quality steam.3.化学清洗的范围为达到上述清洗目的，根据委托要求及DL/T 794-2012的技术规定，将该锅炉开工前化学清洗的范围确定为：表1.化学清洗范围序号部件名称 序号 部件名称1锅炉给水管线

11、2一、 二级省煤器及其进出口集箱3高压汽包及汽包集中下降管4水冷壁及其进出口集箱5水冷分离器及其进出口集箱6水冷屏及其进出口集箱7高压汽包内件（旋分分离器、百叶窗分离器）3.Scope of chemical cleaning In view of the employs requirements and DL/T794-2012 technical provisions, the scope of boilers chemical cleaning in advance can be determined as follows : Table 1.Scope of chemical clea

12、ningSerial No.Name of partsSerial No.Name of parts1Boiler feedwater pipeline2Master and secondary coal economizer and exit header thereof 3High-pressure steam drum and its bottom downcomer4Water wall and its inlet/outlet header5Water-cooling separator and its inlet/outlet header6Water screen and its

13、 inlet/outlet header7High-pressure steam drum internals(cyclone separator, corrugated scrubber)4.化学清洗系统流速计算及回路划分锅炉的汽水循环系统包括锅筒、大直径下降管、水冷屏下降管、水冷分离器下降管、水冷壁、水冷屏、水冷分离器、水冷分离器进口烟道和引出管，共分三个独立的并联回路。第一个回路是从锅筒水空间引出4 根356 的大直径下降管，然后每根大直径下降管分成4 根219 的小直径管分别与炉膛后、左、右侧墙水冷壁下集箱连接，四周水冷壁下集箱采用三通连接成环形，其中的介质互相连通。水冷壁管子加扁钢拼

14、接成膜式管屏，锅水流经炉膛水冷壁吸热后形成的汽水混合物自上部出口集箱，通过32 根168 的汽水引出管进入锅筒；第二个回路是从锅筒水空间引出2 根273 的水冷屏下降管，然后两根水冷屏下降管通过汇合集箱一分为三（219），共同向炉膛上部的3 片水冷屏供水，流经水冷屏吸热后形成的汽水混合物自上部出口集箱由6 根168 的汽水引出管进入锅筒；第三个回路是从锅筒水空间引出2 根324 的水冷分离器及进口烟道下降管，然后通过10 根168 的分散下降管分别向水冷分离器及进口烟道供水，流经水冷分离器及进口烟道吸热后形成的汽水混合物自上部出口集箱由16 根168 的汽水引出管进入锅筒。为了保证清洗质量，必

15、须对化学清洗时的流速进行计算，以便合理划分清洗回路。4.Cleaning system flow rate calculation and cleaning loops dividedThe boilers steam-water circulating system consists of boiler drum, large-diameter downcomer, water screens downcomer, water-cooled separators downcomer, water wall, water screen, water-cooled separator, wate

16、r separators inlet and outlet flues, and three independent loops in parallel jointly constitute this circulating system. The first loop consists of 4 large-diameter downcomers (356) which leading to boiler drums water space; and each large-diameter downcomer connects with 4 small-diameter tubes( 219

17、) which respectively leading to the header under the left and right water walls of the boiler furnace; the header under the water wall around employs a T-connection and ring form where the medium can interconnect. The water wall employs a structure of tube plus fin, and the steam-water mixture from

18、boiler water which flowing through water walls can be transmitted into the boiler drum from the upper header via 32 steam-water outlet ducts (168). The second loop consist of water-cooled screens 2 downcomers(273) leading to the drum water space and then they are divided into three tubes(219)via the

19、 collecting header to feed water to 3 water-cooled screens above boiler furnace, and the steam-water mixture from water which flowing through the upper header will be led to boiler drum via 6 steam-water outlet ducts (168). The third loop consists of 2 downcomers(324) which leading to the boiler dru

20、m for water-cooled separator and inlet flue respectively, and then they feed water to both water-cooled separator and inlet flue via 10 dispersed tubes(168), and the steam-water mixture from the water which flowing through the flue will be transmitted to the boiler drum from the upper outlet header

21、via 16 outlet ducts(168) . To ensure the quality of chemical cleaning, the flow rate must be calculated for a reasonable division of cleaning loops.4.1 流速计算及回路划分 表2. 流速计算及回路划分序号分类传热管规格mm管数根流通面积m2流通面积m2清洗泵流量m3/h流速m/s回路划分1水冷壁前墙水冷壁F6062050.3711.0783900.100第一独立并联回路2后墙水冷壁F6062050.3713左墙水冷壁F606930.1684右墙水

22、冷壁F606930.1685水冷分离器及水冷屏水冷分离器F4864800.4880.8533900.127第二独立并联回路6进口烟道/Inlet flue ductF606760.1377水冷屏/Water screenF63.56.51140.2288省煤器一级省煤器F514.53000.4150.4153900.261总进路 4.1 Flow rate calculation and cleaning loops division Table 2Flow rate calculation and cleaning loops divisionSerial No.DivisionHeat t

23、ransfer tube specificationsmmTube numberFlow aream2Flow aream2Pumping capacitym3/hFlow ratem/sLoops division1Water wallFront water wallF6062050.3711.0783900.1001st independent loop in parallel2Back water wallF6062050.3713Left water wallF606930.1684Right water wallF606930.1685Water-cooled separator a

24、nd water screenWater-cooled separatorF4864800.4880.8533900.1272nd independent loop in parallel6Inlet flue ductF606760.1377Water screenF63.56.51140.2288EconomizerMaster economizerF514.53000.4150.4153900.261General inlet 4.2化学清洗流程及接管示意图详见附件1和附件2。根据回路划分要求，构成清洗回路时需做以下割管处理（暂定，具体部位现场确定），具体部位如下： 表3.分配管割管处理

25、序号处理部位割管数量及要求处理意见1水冷壁左侧墙下集箱手孔 1处 断口安装阀门和临时清洗管相接 2水冷壁右侧墙下集箱手孔1处断口安装阀门和临时清洗管相接3水冷壁后墙下集箱手孔2处 断口安装阀门和临时清洗管相接4分离器集中下降管至进口烟道左下集箱分配管 1处, 现场焊接口断开，具体部位现场确定两侧断口均安装阀门和临时清洗管相接5分离器集中下降管至进口烟道右下集箱分配管 1处, 现场焊接口断开，具体部位现场确定两侧断口均安装阀门和临时清洗管相接6水冷屏集中下降管至水冷屏进口分配集箱 分配管 1处, 现场焊接口断开，具体部位现场确定两侧断口均安装阀门和临时清洗管相接4.2 Cleaning proc

26、ess and tubing sketch See Appendix 1 and 2 for details.As the loop division required, cutting tubes becomes necessary while constituting the cleaning loop, the specific parts to be cut depend on the site conditions.Table 3 Tubing and Cutting tubesSerial No.Location needs treatmentNumbers of tube cut

27、Treatment suggestions1Hand hole of the header under the left side of the water wall One Install the valve at the cut section and connect it with temporary cleaning tube. 2Hand hole of the header under the right side of the water wall OneInstall the valve at the cut section and connect it with cleani

28、ng tube.3Hand hole of the header under the back side of the water wallTwo Install the valve at the cut section and connect it with temporary cleaning tube.4Separators common downcomer to header distribution pipe lower left of inlet flueOne, Disconnect weld spot, the exact location depends on the sce

29、ne conditions.Install the valve at the cut section at two sides and connect to temporary cleaning tube.5Separators common downcomer to header distribution pipe lower right of inlet flue One, Disconnect weld spot, the exact location depends on the scene conditions.Install the valve the cut section at

30、 two sides and connect to temporary cleaning tube.6Water screens common downcomer to header distribution pipe One , Disconnect weld spot, the exact location depends on the scene conditions.Install the valve the cut section at two sides and connect to temporary cleaning tube.4.3流程说明a.第一回路正循环清洗 清洗站(自备

31、)给水泵出口临时管线一级省煤器二级省煤器高压汽包前后墙水冷壁、左右墙水冷壁及其下降管清洗临时管线清洗站(自备) a.第一回路反循环清洗 清洗站（自备）清洗临时管线前后墙水冷壁、左右墙水冷壁及其下降管高压汽包二级省煤器一级省煤器给水泵出口临时管线清洗站(自备)b.第二回路正循环清洗 清洗站(自备)给水泵出口临时管线一级省煤器二级省煤器高压汽包水冷屏、水冷分离器、进口烟道及其下降管清洗临时管线清洗站(自备)b.第二回路反循环清洗 清洗站（自备）清洗临时管线水冷屏、水冷分离器、进口烟道及其下降管高压汽包二级省煤器一级省煤器给水泵出口临时管线清洗站(自备)在化学清洗的各工序过程（如水冲洗、酸洗、钝化）

32、中，依次采用第一回路、第二回路的顺序进行，各回路循环清洗时间约1h，具体时间根据各工序的分析数据进行调整。正循环完成后，切换为反向循环，反向循环时，依次采用第一回路、第二回路的顺序进行，各回路循环清洗时间约1h，具体时间根据各工序的分析数据进行调整。4.3 Description of cleaning processa. Normal circulation cleaning of the 1st loop Cleaning station ( self-prepared ) temporary pipeline at feed pump outlet master economizerse

33、condary economizerhigh-pressure steam drum water walls around and their downcomerstemporary cleaning pipelinecleaning station ( self-prepared )a. Reverse circulation cleaning of the 1st loop Cleaning station ( self-prepared )temporary cleaning pipeline water walls around and their downcomers high-pr

34、essure steam drum secondary economizer master economizertemporary pipeline at feed pump outlet cleaning Station ( self-prepared )b. Normal circulation cleaning of the 2nd loop Cleaning station ( self-prepared ) temporary pipeline at feed pump outlet master economizersecondary economizer high-pressur

35、e steam drum water screen, water-cooled separator, inlet flue and its downcomertemporary cleaning pipelinecleaning station ( self-prepared )b. Reverse circulation cleaning of the 2nd loop Cleaning station ( self-prepared )temporary cleaning pipelinewater screen, water-cooled separator, inlet flue an

36、d its downcomerhigh-pressure steam drumsecondary economizermaster economizertemporary pipeline at feed pump outlet cleaning Station ( self-prepared )In chemical cleaning, each stage like water flush, pickling and passivation will be carried out from the 1st loop to the 2nd loop in turn. The time for

37、 each stage will last for one hour about, and the specific time for them only depends on the data analysis of each stage finished. The normal circulation cleaning will be switched to the reverse one as soon as the former is completed; in reverse circulation, the 1st loop will operate first, them com

38、es the 2nd loop, and the circulation cleaning time of each loop will last for one hour about, and the specific time for them only depends on the data analysis of each stage finished.4.4化学清洗回路处理部位表4.化学清洗回路处置部位序号处理部位处理部件处理意见1汽包内悬挂标准腐蚀试片2汽包内集中下降管设置f50mm限流孔板，并点焊在下降管入口处/3汽包内件旋风分离器、百叶窗分离器拆除，单独在清洗槽内处理4汽包连排

39、管10HAD40/AA401 10HAD40/AA403 10HAD40/AA405常关5汽包加药管 10HAD20/AA601 10HAD20/AA602常关6汽包紧急放水管 10HAD10/AA401 10HAD10/AA402常关7汽包顶部10HAD20/AA191 10HAD20/AA192 10HAD20/AA19310HAD20/AA301 10HAD20/AA302 10HAD20/AA30310HAD20/AA304 10HAD20/AA305 10HAD20/AA30610HAD20/AA307 10HAD20/AA308 10HAD20/AA30910HAD20/AA310

40、 常开常关常关常关常关常关8汽包两侧10HAD20/AA311 10HAD20/AA312 10HAD20/AA31310HAD20/AA314 10HAD20/AA315 10HAD20/AA31610HAD20/AA317 10HAD20/AA318 10HAD20/AA31910HAD20/AA320 10HAD20/AA327 10HAD20/AA32810HAD20/AA331 10HAD20/AA332 10HAD20/AA33310HAD20/AA334 10HAD20/AA335 10HAD20/AA33610HAD20/AA337 10HAD20/AA338 10HAD20/

41、AA33910HAD20/AA340 10HAD20/AA347 10HAD20/AA348常关常关常关常关常关常关常关常关9水冷壁集中下降管的疏水 10HAD21/AA401 10HAD21/AA40210HAD22/AA401 10HAD22/AA40210HAD23/AA401 10HAD23/AA40210HAD24/AA401 10HAD24/AA402各工序中定时开关10水冷壁左墙下集箱、右墙下集箱及后墙下集箱的疏水 10HAD22/AA411 10HAD22/AA41210HAD22/AA421 10HAD22/AA42210HAD24/AA411 10HAD24/AA41210

42、HAD24/AA421 10HAD24/AA42210HAD21/AA411 10HAD21/AA412各工序中定时开关11高压给水管线10LAB40/AA00110LAB40/AA002 10LAB40/AA00310LAB40/AA00410HAD10/AA001 10HAD10/AA002 10LAB40/AA401 10LAB40/AA402 10LAB40/AA40310LAB40/AA301 10LAB40/AA302 10LAB40/AA303 10LAB40/AA30410LAB40/AA305 10LAB40/AA30610LAB40/AA601 10LAB40/AA6021

43、0HAD12/AA301 10HAD12/AA302 10HAD11/AA301 10HAD11/AA302 拆除常关拆除或抽芯各工序中定时开关常关常关常关常关常关常关常关12临时管路系统选取有代表性的水冷壁管做监视管，两端焊接法兰，加装阀门安装在清洗泵出口4.4Parts treated in the cleaning loopTable 4Parts treated in the cleaning loopSerial No.Parts treatedElements treatedTreatment suggestions1Steam drumHanging standard corro

44、sion specimen2Common downcomer Set an orifice plate (f50mm) and having it welded at the entrance of the downcomer3Steam drum internalsRemove both cyclone separator and corrugated scrubber, and having them treated in the rinse tank respectively.4Steam drum tube bank10HAD40/AA401 10HAD40/AA403 10HAD40

45、/AA405NC5Steam drums dosing tube 10HAD20/AA601 10HAD20/AA602NC6Steam drums emergency drain tube 10HAD10/AA401 10HAD10/AA402NC7Steam drum top10HAD20/AA191 10HAD20/AA192 10HAD20/AA19310HAD20/AA301 10HAD20/AA302 10HAD20/AA30310HAD20/AA304 10HAD20/AA305 10HAD20/AA30610HAD20/AA307 10HAD20/AA308 10HAD20/A

46、A30910HAD20/AA310 NONCNCNCNCNC8Two sides of steam drum10HAD20/AA311 10HAD20/AA312 10HAD20/AA31310HAD20/AA314 10HAD20/AA315 10HAD20/AA31610HAD20/AA317 10HAD20/AA318 10HAD20/AA31910HAD20/AA320 10HAD20/AA327 10HAD20/AA32810HAD20/AA331 10HAD20/AA332 10HAD20/AA33310HAD20/AA334 10HAD20/AA335 10HAD20/AA336

47、10HAD20/AA337 10HAD20/AA338 10HAD20/AA33910HAD20/AA340 10HAD20/AA347 10HAD20/AA348NCNCNCNCNCNCNCNC9Drainage at water walls common downcomer 10HAD21/AA401 10HAD21/AA40210HAD22/AA401 10HAD22/AA40210HAD23/AA401 10HAD23/AA40210HAD24/AA401 10HAD24/AA402Open or closed at fix time in each stage10Drainage a

48、t the header of left and right and back water walls10HAD22/AA411 10HAD22/AA41210HAD22/AA421 10HAD22/AA42210HAD24/AA411 10HAD24/AA41210HAD24/AA421 10HAD24/AA42210HAD21/AA411 10HAD21/AA412Open or closed at fix time in each stage11High-pressure water pipelines10LAB40/AA00110LAB40/AA002 10LAB40/AA00310L

49、AB40/AA00410HAD10/AA001 10HAD10/AA002 10LAB40/AA401 10LAB40/AA402 10LAB40/AA40310LAB40/AA301 10LAB40/AA302 10LAB40/AA303 10LAB40/AA30410LAB40/AA305 10LAB40/AA30610LAB40/AA601 10LAB40/AA60210HAD12/AA301 10HAD12/AA302 10HAD11/AA301 10HAD11/AA302 RemoveNCRemove or loose coreOpen or closed at fix time i

50、n each stageNCNCNCNCNCNCNC12Temporary piping systemTake representative waterwall tube for the monitoring , and have the flange welded at its two sides, including the valve installation at the cleaning pumps outlet.5.化学清洗的准备工作5.1建设安装方5.1.1应完成对锅炉系统的水压试验、气密试验、低温烘炉、保温工作。5.1.2负责清洗临时管路的焊接和拆除复位工作，在清洗泵出口安装水

51、冷壁监测管。注：化学清洗经质量验收合格后必须用氮气封存，以备试车，氮封后的设备严禁进行水压试验。否则，产生二次浮锈施工方不承担责任。化学清洗施工前应完成锅炉本体的保温工作，否则，化学清洗施工中需要的工艺温度将难以保证，从而影响清洗质量。 5.1.3为施工方提供临时工作室，用以存放原料、分析化验等。5.1.4指定施工负责人及相应的配合人员与施工方协作。5.1.5参与施工方系统升温过程，共同控制温升速度。5.1.6化学清洗工程公用条件，应按要求接至泵站。表5.化学清洗工程公用条件名称规格名称规格水除盐水(200m3h 蒸汽中压过热蒸汽（T260,10T/h）)电220V、380V(1110KW)氮

52、气或压缩空气干燥无油5.2化学清洗施工方5.2.1准备化学清洗的化学药剂及原材料、分析监测仪器及试剂、标准腐蚀试片等，并应在开工前准备就绪。5.2.2保质保量按时完成化学清洗各工艺过程及其化学分析及监督。5.2.3为了监测系统的清洗效果及设备的腐蚀程度，在化学清洗施工之前，应将相当于设备材质的标准腐蚀试片分别悬挂于汽包内和循环槽中，汽包内和循环槽内各悬挂3片，共计6片。5.2.4临时系统上设立压力测试点和分析取样点。5.2.5注意定期高点放空及低点导淋。5.Preparations before cleaning operation5.1Boiler installer 5.1.1 Compl

53、ete the boiler systems hydrostatic test and leak test, and then dry the boiler off at low temperature and do insulation.5.1.2 Answer for both welding and removal of temporary cleaning pipelines and their reset; install water walls monitoring tube at the outlet of the cleaning pump.Notes: After the c

54、hemical cleaning, the boiler met the acceptance checks must be sealed with nitrogen for later trial run, and any hydraulic test on it is prohibited, otherwise, the construction party undertakes no responsibility for any rust reoccurred there. Before the chemical cleaning, the boiler body insulation has to be completed to ensure a process temperature required so that the quality of cleaning can be guaranteed 5.1.3 Provide the construction party with temporary place for the storage of materials, and that for lab analysis and test.5.1.4 Assign a p