GB/T 16507.8-2022 PDF in English
GB/T 16507.8-2022 (GB/T16507.8-2022, GBT 16507.8-2022, GBT16507.8-2022)
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Water-tube boilers - Part 8: Installation and operation
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GB/T 16507.8-2022: PDF in English (GBT 16507.8-2022) GB/T 16507.8-2022
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 27.060.30
CCS J 98
Replacing GB/T 16507.8-2013
Water-tube boilers - Part 8: Installation and operation
ISSUED ON: MARCH 09, 2022
IMPLEMENTED ON: OCTOBER 01, 2022
Issued by: State Administration for Market Regulation;
Standardization Administration of the People's Republic of China.
Table of Contents
Foreword ... 3
Introduction ... 8
1 Scope ... 10
2 Normative references ... 10
3 Terms and definitions ... 11
4 Basic requirements ... 11
5 Foundation, support (structure) frame and steel structure ... 15
6 Drum, start-up (steam water) separator, water storage tank and header, desuperheater
... 21
7 Heating surface ... 25
8 Air preheater ... 32
9 Boiler proper piping and piping within boiler range ... 37
10 Safety accessories and instruments ... 39
11 Combustion device ... 44
12 Auxiliary devices ... 48
13 Platforms, escalators, railings ... 49
14 Hydrostatic test ... 49
15 Furnace wall masonry, pouring and insulation ... 51
16 Chemical cleaning, flushing and purging ... 52
17 Conditioning ... 55
18 Quality acceptance ... 56
19 Operation ... 57
Annex A (informative) Allowable deviation of fire grate installation for layer-fired
boilers ... 61
Bibliography ... 63
Water-tube boilers - Part 8: Installation and operation
1 Scope
This document specifies the requirements for the installation, commissioning, quality
inspection and operation of the water-tube boiler proper and the piping within the scope
of the boiler.
This document applies to water-tube boilers defined in GB/T 16507.1. The
transformation and repair of water-tube boilers can use this document as reference.
2 Normative references
The following referenced documents are indispensable for the application of this
document. For dated references, only the edition cited applies. For undated references,
the latest edition of the referenced document (including any amendments) applies.
GB/T 1576, Water quality for industrial boilers
GB/T 2900.48, Electrotechnical terminology of boilers
GB/T 12145, Quality criterion of water and steam for power plant and steam-
generating equipment
GB/T 16507.1, Water-tube boilers - Part 1: General requirements
GB/T 16507.4, Water-tube boilers - Part 4: Strength calculation of pressure parts
GB/T 16507.6, Water-tube boilers - Part 6: Inspection, testing and acceptance
GB/T 16507.7, Water-tube boilers - Part 7: Safety appurtenances and instruments
GB 50016, Code for Fire Protection Design of Buildings
GB 50041, Standard for design of boiler plant
GB 50204, Code for quality acceptance of concrete structure construction
GB 50205, Standard for acceptance of construction quality of steel structures
GB 50273, Standard for construction and acceptance of boiler installation
engineering
GB 50275, Code for construction and acceptance of fan, compressor and pump
installation
DL/T 777, Boiler refractory material for thermal power plant
DL/T 852, Guide of boiler start-up commissioning
DL/T 902, Abrasion resistant refractory material
NB/T 47013 (all parts), Non-destructive testing of pressure equipment
3 Terms and definitions
The terms and definitions defined in GB/T 2900.48 and GB/T 16507.1 as well as the
followings apply to this document.
3.1 commissioning
A general term for that boilers and related equipment and systems are adjusted,
calibrated and tested in accordance with the design and equipment technical documents
after installation.
NOTE: Commissioning is short for adjustment and test.
3.2 commissioning of individual equipment and system
Dynamic inspection and test for a single piece of equipment or system.
3.3 start up and commissioning
On the basis of completing the commissioning of individual equipment and system, the
start-up commissioning that is jointly participated by commissioner, producer and
constructer to carry out the joint electrical and thermal automation of the complete set
of steam turbine and boiler equipment.
4 Basic requirements
4.1 The location and building where the boiler is installed shall meet the relevant
regulations of GB 50016 and GB 50041 and meet the requirements of the design
drawings. The installation position of the piping within the boiler range shall keep a
sufficient safe distance from crowded places (such as control room, duty room). When
the safety distance requirements cannot be met, the building shall take necessary
explosion-proof and isolation measures.
4.2 Boiler installation shall be carried out after the basic civil work is completed and
accepted.
4.3 Before installing all parts of the boiler, relevant technical documents and quality
4.13 During the installation and construction process, it is not allowed to smash holes
on building components, damage load-bearing components, or perform welding
construction on component reinforcements without structural checks.
4.14 During the installation and construction process, measures shall be taken to prevent
noise, dust, arc light and radiation pollution. Reduce construction waste discharge.
4.15 During the boiler installation process, the constructer shall implement the
requirements of the quality assurance system. Accept the supervision and inspection of
the establishment and operation of the quality assurance system by the inspection
agency as well as the supervision-inspection of items related to safety performance.
4.16 During the boiler installation process, the constructer shall conduct non-
destructive testing on the welded joints of boiler pressure elements and components in
accordance with NB/T 47013 and meet the following requirements.
a) The testing method shall be selected according to the design, process and technical
conditions. Develop a corresponding testing process. If multiple non-destructive
testing methods are used for testing, they shall be evaluated according to their
respective acceptance standards. The non-destructive testing can be considered as
accepted only after all the tests are accepted. When the time-of-flight diffraction
method (TOFD) is selected, it shall be combined with the pulse-echo method (PE)
for testing. The testing conclusion is judged comprehensively based on the results
of TOFD and PE methods.
b) The non-destructive testing of welded joints shall be carried out after the shape,
size and appearance quality inspection is accepted. Materials with a tendency to
delayed cracking shall be subjected to non-destructive testing 24h after welding.
Welded joints prone to reheat cracking shall be retested by surface non-
destructive testing after final heat treatment.
c) The technical level of non-destructive testing and the quality level of welded joints
meet the following requirements:
1) During magnetic particle testing, the quality level shall not be lower than level
I.
2) During penetrant testing, the quality level shall not be lower than level I.
3) Radiographic testing technology level shall not be lower than level AB. The
quality level of welded joints shall not be lower than level II.
4) The technical level of pulse echo ultrasonic testing and phased array ultrasonic
testing shall not be lower than level B. The quality level of welded joints shall
not be lower than level I.
5) The ultrasonic testing technology level of diffraction time-of-flight method
shall not be lower than level B. The quality level of welded joints shall not be
lower than level II.
4.17 During boiler installation, the requirements for rework and post-repair inspection
of welded joints of pressure elements and components are as follows:
a) When the welded joints of the pressure elements are found to have excessive
defects after inspection, the constructer shall find out the reasons. Make a feasible
rework plan before rework can be carried out.
b) Defects shall be completely removed before rework welding.
c) Rework welding at the same position shall not exceed 2 times. If it is more than 2
times, it shall be approved by the technical director of the constructer.
d) After repair welding, the repair welding area shall be subjected to visual
inspection and non-destructive testing of the same non-destructive testing process.
For welded joints requiring post-weld heat treatment, final non-destructive testing
shall be carried out after heat treatment is completed.
4.18 Boilers shall be equipped with necessary pressure, temperature, water level
measuring devices and alarm devices, boiler overpressure interlock protection devices,
water level overrun interlock protection devices, furnace pressure monitoring and
protection devices, and ignition program control and flameout protection devices.
4.19 The installation and construction of auxiliary equipment such as boiler blower,
induced draft fan, feed water pump and circulating water pump shall meet the
requirements of GB 50275.
4.20 Boilers shall be equipped with water treatment equipment that meets boiler feed
water requirements as well as necessary water vapor sampling and quality monitoring
devices and systems. For boilers with rated working pressure not less than 9.8MPa,
continuous monitoring of water vapor quality shall also be realized.
4.21 After the installation of the boiler is completed, the pressure elements, components
and main connecting tubes of the boiler proper and the tubes within the boiler range
shall be cleaned and flushed. Power plant boilers generally need to be purged.
4.22 After the boiler installation is completed, the overall tightness test (or air leakage
test) shall be carried out. Check the tightness of the furnace and flue gas duct.
4.23 Operations during boiler commissioning shall be carried out by operators who
have been trained and have obtained corresponding special equipment operator
certificates under the supervision and guidance of commissioning personnel.
a) The slope is not less than 0.2%.
b) The expansion is free and does not hinder the thermal expansion of the drum,
header and piping.
c) The exhaust air duct leads to a special emptying place.
d) Sewage and drainage pipes with different pressures are not connected to the same
pressure-bearing piping.
e) For drainage pipes that may form a closed-circuit during operation, the selection
of the pressure level is the same as that of the connecting pipes.
f) When the upstream design pressure of the piping is greater than 3.8MPa, at least
two valves connected in series shall be installed in the piping. At least one of the
valves is close to the outlet of the piping.
9.1.9 The piping support and hanger shall be arranged reasonably. The structure shall
be firm. It can not only meet the support and expansion requirements of the piping load,
but also avoid deformation and vibration of the piping due to insufficient restraint.
9.2 Piping elements
9.2.1 A check valve and a cut-off valve shall be installed at the outlet of the feed water
pump. A feed water check valve shall be installed between the feed water pump and the
feed water cut-off valve. It is also closely connected with the water supply cut-off valve.
The inlet of the economizer of the unit may not be equipped with a cut-off valve, a
check valve and a main pipe water supply system. Each boiler economizer inlet shall
be equipped with cut-off valve and check valve. The outlet of the cast iron economizer
shall also be equipped with a shut-off valve and a check valve.
9.2.2 For the piping within the scope of the boilers operated by the main pipe, no less
than two isolation valves with cut-off function shall be installed between every two
boilers on the main pipe.
9.2.3 The installation position of the valve and its transmission device shall be
convenient for operation and maintenance. Pay attention to the flow direction of the
medium when installing the valve. It is not advisable to install the valve backwards.
9.2.4 The installation of the valve actuator shall meet the following requirements:
a) Correctly adjust the limit switch position according to the characteristics of the
actuator. Ensure that the valve can open and close in full stroke.
b) The torque protection test has been done according to the equipment technical
documents. When the specified torque is exceeded, the protection can operate
reliably.
9.2.5 The setting and installation of sewage discharge and water discharge devices shall
meet the following requirements:
a) Drainage valves are required to be installed at the bottom of steam boiler drum,
vertical boiler bottom ring and water circulation system. Use quick-open
blowdown valves for boilers with rated working pressure less than 3.8MPa. The
nominal diameter of the blowdown valve is 20mm~65mm.
b) For steam boilers with rated evaporation greater than 1t/h and hot water boilers
with rated working pressure less than 3.8MPa and outlet water temperature
greater than 120°C, install two valves in series on the sewage pipe. At least one
of them is a blowdown valve, and it is installed on the side close to the outlet of
the blowdown pipeline.
c) Install a drain valve at the lowest header (or pipeline) of the superheater system,
reheater system, and economizer system.
d) The steam boiler drum with superheater needs to be equipped with continuous
sewage discharge device.
e) Each boiler is equipped with an independent sewage pipe. Reduce the number of
elbows when arranging the sewage pipes, so as to ensure smooth sewage
discharge and connect to a safe place or to the sewage expansion tank (expansion
vessel).
f) When multiple boilers share one discharge main pipe, technical measures shall be
adopted to prevent more than two boilers from discharging sewage at the same
time.
g) Boiler blowdown valves and blowdown pipes shall not be threaded.
10 Safety accessories and instruments
10.1 Safety valve
10.1.1 The safety valve shall be installed vertically at the highest position of the drum
and header. Exhaust pipes with sufficient cross section shall be installed. Between the
safety valve and the drum or between the safety valve and the header, there shall be no
pipelines and valves for taking steam or hot water.
10.1.2 When installing a spring safety valve with threaded connection, it shall be
connected with a short pipe with thread. The connection between the short pipe and the
drum or header shell shall be welded.
10.1.3 When multiple safety valves need to be installed on the same piping connected
to the drum or header, the flow area of the piping shall not be less than the sum of the
moving parts that may change its set pressure.
10.1.11 Control-type safety valves (including forced exhaust valves) shall be subjected
to control circuit reliability test and opening performance test respectively.
10.2 Water level measurement and display control device
10.2.1 The water level gauge (direct-reading type) shall be installed in a place that is
convenient for observation and operation. When the vertical distance between it and the
operating plane of the boiler is higher than 6m, a remote water level measuring device
and a water level TV monitoring system shall be installed.
10.2.2 The drum of each pressure level of waste heat boiler with multiple pressure levels
shall be equipped with two independent water level gauges (direct-reading type).
10.2.3 There shall be at least two reliable remote water level measuring devices in the
boiler control room. The signals shall be able to be taken out independently. The water
storage tank and the start-up (steam-water) separator in the start-up system of the DC
steam boiler shall be equipped with a remote water level measurement device.
10.2.4 The water level gauge (direct-reading type) and the steam side connecting pipe
of the drum shall be inclined to the direction of the water level gauge. The water side
connecting pipe shall be inclined to the direction of the drum. When the steam-water
connecting pipe needs to be provided with a bracket, it shall be installed independently
of the drum. It shall not hinder the thermal expansion of the connecting pipe.
10.2.5 Water level gauge (direct-reading) steam-water connecting pipe shall be
insulated according to the requirements of the drawing. The balance container shall be
insulated strictly according to the heat insulation method of the design drawing to
ensure that the condensation section can be fully cooled.
10.2.6 The water level gauge (direct-reading type) shall be based on the center line of
the drum after installation. At least mark the normal, high and low water level lines on
the water level gauge. The deviation shall not be greater than 1mm. When installing a
boiler water level gauge with a rated working pressure greater than 9.8MPa, the
measurement error caused by the difference in density between the water level gauge
and the liquid in the drum shall be corrected.
10.2.7 The steam and water connecting pipes of the water level gauge (direct-reading
type) shall be equipped with quick shut-off valves. When electric valves are used as
quick shut-off valves, explosion-proof electric actuators shall be selected. For boilers
with rated evaporation less than 0.5t/h, valves may not be installed on the steam-water
connecting pipe between the water level gauge and the drum.
10.2.8 Water level gauge (direct-reading) glass pressure plate and mica sheet cover joint
surface shall be sealed with copper gasket. The sealing surface shall be flat and tight. If
necessary, it shall be installed after grinding. The direct-reading water level gauge only
conducts the working pressure hydrostatic test. It does not participate in the boiler
proper hydrostatic test.
10.2.9 The mica sheet, glass plate and quartz glass tube used in the water level meter
(direct reading type) shall meet the following requirements:
a) The mica sheet is transparent, straight and uniform, without spots, wrinkles, cracks,
bends and other defects.
b) The thickness of the mica sheet is selected according to the steam pressure at the
working position of the water level gauge. When the working pressure is less than
9.8 MPa, the total thickness is 0.8mm~1.0mm. When the working pressure is not
less than 9.8MPa, the total thickness is generally 1.2mm~1.5mm.
c) The compressive strength and thermal stability of the glass plate and quartz glass
tube meet the requirements of the steam pressure at the working position. The
sealing surface is good.
10.3 Pressure measuring device
10.3.1 Pressure gauges shall be installed at the following parts of the boiler:
a) the steam space of the steam boiler drum;
b) in front of the water supply regulating valve;
c) economizer outlet;
d) between superheater outlet and main steam valve;
e) reheater outlet and inlet;
f) on the start-up (steam-water) separator of the DC steam boiler or its outlet pipe;
g) DC steam boiler economizer inlet, water storage tank and circulation pump outlet;
h) in front of the shut-off valve at the outlet of the evaporating heating surface of the
DC steam boiler (if a shut-off valve is installed);
i) on the drum of the hot water boiler;
j) the outlet of the water inlet valve and the inlet of the water outlet valve of the hot
water boiler;
k) the outlet and inlet of the circulating water pump of the hot water boiler;
l) the oil pump inlet (oil return) and outlet of the ignition oil system of oil-fired
boilers and coal-fired boilers;
combustion devices shall also meet the following requirements:
a) An appropriate expansion gap is reserved between the secondary air baffle door
and the air shell.
b) The allowable deviation of the concentricity of the primary and secondary air
ducts is not greater than 5mm without an adjustment mechanism. It is not more
than 3mm when there is an adjustment mechanism.
c) The connection between the primary and secondary air ducts is tight.
d) The swirl direction is correct.
11.3 DC combustion device
The installation of the DC combustion device shall also meet the following
requirements:
a) The allowable deviation of the tangent of the imaginary combustion tangent circle
is not more than 0.5°.
b) The gap between the nozzle and the primary air duct is not greater than
5mm~8mm.
c) The gap between the nozzle and the rib of the secondary air duct is not greater
than 10mm~15mm.
d) The allowable deviation of the horizontality of the second and third air outlets is
not more than 2mm.
e) The nozzle swing angle meets the requirements of the design drawing. The scale
indication of driving angle is correct.
11.4 W-type flame combustion device
The installation of W-type flame combustion device shall also meet the following
requirements.
a) The arrangement position of each burner and the swirl direction of the air flow are
correct and meet the requirements of the design drawings.
b) Check the movement of the internal and external secondary air blades before
hoisting and after installation. Ensure that the blades, adjustment rods, and
handles are all flexible and adjustable. Observe whether the position of each blade
is correct, otherwise, it shall be adjusted in time. After the burner is installed in
place, pay full attention to the position of the secondary air adjustment sleeve of
the burner and keep it in place according to the design drawings. There mustn’t
be offset. Ensure that the rollers on the secondary air adjustment sleeve are in
the swirl diffuser and the direction of the swirl flow comply with the requirements
of the design drawing.
d) The joints in the oil gun (especially the joint surface with the oil return device)
are well sealed and have no leakage.
e) The oil gun propulsion mechanism is flexible in operation without jamming.
f) The installation position of the high-energy ignition device shall be constructed
strictly according to the design drawings.
11.7 Large bellows combustion device
The installation of the large bellows combustion device shall also meet the following
requirements:
a) The thermal expansion gap is reserved for the sliding dampers of the primary and
secondary air to ensure flexible operation during operation.
b) The electrode operating device for electrical ignition is not jammed.
c) The combustible gas system used for ignition is subjected to an airtightness test
to ensure that the system is tight and leak-free.
11.8 Grate devices
The quality requirements for grate installation of floor-fired boilers can refer to Annex
A.
12 Auxiliary devices
12.1 Installation of steam soot blower and its piping system
12.1.1 The allowable deviation between the installation position of the steam soot
blower and the design position is ±5mm.
12.1.2 The levelness of the entire length of the soot blowing pipe of the steam soot
blower shall meet the requirements for drainage of the system during operation.
12.1.3 The soot blowing tube of the steam soot blower shall be in the center of the soot
blowing hole.
12.1.4 The steam soot blower piping shall have a drainage slope of not less than 2%.
The system has no position for deposit condensed water. The condensed water is
discharged in time through the steam trap.
12.1.5 The piping of the steam soot blower shall meet the thermal expansion
......
Source: Above contents are excerpted from the PDF -- translated/reviewed by: www.chinesestandard.net / Wayne Zheng et al.
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