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Installation Instruction for Electric Steam Boilers

Catalogue

1, boiler body installation

2, pipelines, valves, instrument installation
3, installation of control circuit
4, auxiliary equipment installation
5, installation notification
6, hydrostatic test

horizontal-electric-boiler

1. Boiler Proper Installation


1)  When boiler is carried to using site, we must make the following preparations before installation:

①    Boiler Installation Company
Installation Company must have boiler installation license (In China).  Before installation, you should deal with bureau of quality and technical supervision “special equipment installation modification maintenance notice”, and then you can start the installation construction; and send for the local qualified inspection organizations to supervise and inspect the process of installation.

②    Train Relevant Person
Train Relevant Person to be familiar with “steam boiler safety technology supervision regulation” 1996 edition (hereinafter referred to as the “evaporate rules”), GB50273-2009 boiler installation engineering construction and acceptance standard, boiler room design pattern (users entrust professional design institute of design), boiler drawings, installation instructions and other documents, in order to understand and get the characteristics of the equipment and installation, lifting operation, determine the installing sequence, make installation plan.

2)  Installation Location

①    Installation location should be close to the steam location. The purpose is to shorten the steam outlet pipe line, reduce capital expenditure, and reduce pipeline heat loss.
②    Water supply and drainage is convenient.
③    Unobstructed transport is needed when installation.
④    Boiler room decoration should comply with the “steam boiler safety technology supervision regulation (1996), chapter 8 of the regulation of” boiler rooms “.Boiler room layout should be enough light, well ventilated, the ground should not have water. In order to ensure the operation and maintenance convenience, 3 meters before furnace, furnace back spare no less than 1 meter, height not less than 6 meters.

3)  Foundation Building Preparation

Foundation drawing is made by the civil engineering department according to the boiler, auxiliary engine load. Before doing foundation construction, first of all, we should check whether main installation size of boiler is accord with the boiler room design. if there is no mistake, we can carry on the basic construction. Pre dig anchor bolt location of pumps.

Foundation surface should be smooth level; the surface roughness is not more than 3 mm. When the foundation is qualified, figure out boiler installation datum line according to the boiler foundation.

Boiler datum line should have clear mark; the displacement deviation is not more than 5 mm.

4)  Equipment Check, Accept and Installation

① after the boiler is transported to your place, count the accessories according to the shipping list sent by manufacturers, according to the boiler factory data, check the integrity of the equipment, check if the boiler’s big deformation is damaged in transit, etc., if there is any missing parts or damage you should timely contact with my factory.
② When lifting the boiler furnace body, you can use the specified lifting lug. Do not lift in any other position.
③ Boiler before installation and during the installation process, if the pressed part is found quality problems which can affect the safe using, you must stop the installation and report to local safety supervision institutions.
④ after the boiler is placed ,reference GB50273-2009 boiler installation engineering construction and acceptance standard, according to the installation of piping system such as system diagram.
⑤ after the check and accept of boiler installation, the company who use the boilers should go through registration formalities according to the regulation one by one, and  the boiler which is not deal with the formalities that register, shall not be put into use.
⑥ After the boiler is put into use, any company or individual shall not change the structure of the boiler and system piping installation, the valve without permission.

2. Installation of pipelines, valves, instrument


1)    Before installation you should check the  safety valve, pressure gauge function in relating authorities.
2)    When installing piping, valves and meters, according to the drawings for installation, the pump should be poured foundation, after turning on the power, supply test run (see the general layout and system installation drawing of piping, meter).
3)    Install the filter process before connect pump imported after the softening of water, install pressure gauge between pump and check valve.
4)    Water check valve should be installed according to the structure form: lift should be installed vertically, swing should be horizontally installed, and the clamp type wafer check valve should be installed vertically.
5)    Relief valve shall be installed after water pressure test. Safety valve should connect with drain pipes and drain pipes should connect with safety place, which have enough sectional area and anti-freezing measures. Prohibit reducing the diameter of the leakage pipes, to ensure smooth discharge.
6)    Drainage pipe should connect to expansion tank or other safe place, the pipe should be fixed, to prevent pollution accidents such as shift or burns. Drainage pipe should reduce as far as possible elbow, to ensure drainage unblocked. Using pressure of expansion tank, sewage tank shall be installed on the relief valve, drain valve and drain pipe should not adopt thread connection.
7)    Main steam piping installation, on the main steam pipe at least one elbow, otherwise should be equipped with telescopic pipe, pipe outer wall should be heat preservation.
8)    When install pressure gauge, dial face should be vertical, pressure gauge dial should draw the red line to show the boiler ‘s highest working pressure, gauge pressure rotating flexible, shall not be leakage, hydrophobic should be unblocked, pressure gauge tube is prohibited heat preservation.
9)    If you have platform ladder, platform escalators and rail should be connected according to the drawing requirements in installation field.
10)    Being water table elevation deviation should be no more than plus or minus 2 mm, on table should be correctly mark “the highest water level of security”, “minimum security level” and “normal level” tag, should draw the red line mark at the “normal level”. Water gauge lower drain pipe must be connected to the safe place, water table joins rotating flexible, shall not be leakage, water gauge must be installed lighting equipment, convenient for observation.
11)    Water level alarm installation to ensure smooth road of steam and water, prevent false water level, regular cleaning the dirt on the probe.

3. Installation of Control Circuit


1)    Boiler entering line should have enough cross section, and should have leakage protection device of electricity (see the electrical schematic diagram).
2)    Boiler and boiler electric cabinet must be reliable grounding. Ground terminal and the grounding connecting resistance should not be greater than 0.1 Ω; Grounding resistance should be less than 4 Ω.
3)    Water alarm and water level controller should assemble according to drawing. After boiling furnace, should remove conductive sundry adhere to the electrode. Insulation resistance value measured between the electrode and the flange shall not be less than 0.5 M Ω.

4)    installation according to the discretion of the boiler pressure, pressure controller in the bent pipe pressure gauge on the right, in order to install pressure controller 1, pressure controller 2 (protect), pressure controller 3 (second stage fire).

4. Auxiliary Equipment Installation


Special remind

When installing auxiliary,
you should read various installation instructions with auxiliaries, and regard
them as installation guide.

    After the installation, data of
auxiliary and the boiler factory should be properly archive and custody!!

5. Installation Notification:


1)    boiler feed water softening treatment must be conducted, and in line with the GB/T1576-2008 industrial boiler water quality requirements and tests for boiler water on a regular basis. Schedule of water quality standard.

Item

Feeding
water

Presser
of rated hot water/MPa

≤1.0

1.0P≤1.6

1.6P≤2.5

Kinds of supplemental water

Softened
water

Treated
water

Softened
water

Treated
water

Softened
water

Treated
water

Turbidity /FTU

≤5.0

≤2.0

≤5.0

≤2.0

≤5.0

≤2.0

hardnessmmol/L

≤0.030

≤0.030

≤0.030

≤0.030

≤0.030

≤0.030

PH value25

7.09.0

8.09.5

7.09.0

8.09.5

7.09.0

8.09.5

dissolved oxygen

 amg/L

≤0.10

≤0.10

≤0.10

≤0.050

≤0.050

≤0.050

oil/mg/L

≤2.0

≤2.0

≤2.0

≤2.0

≤2.0

≤2.0

Total
iron/
mg/L

≤0.30

≤0.30

≤0.30

≤0.30

≤0.30

≤0.10

conductivity25)(Ms/cm

≤5.5×102

≤1.1×102

≤5.0×102

≤1.0×102

Item

Boiler
water

Presser
of rated hot water/MPa

≤1.0

1.0P≤1.6

1.6P≤2.5

Kinds
of supplemental water

Softened
water

Treated
water

Softened
water

Treated
water

Softened
water

Treated
water

PH
value
25

10.012.0

10.012.0

10.012.0

10.012.0

10.012.0

10.012.0

Alkalinity

 b/ mmol/L

No
super heater

6.026.0

≤10.0

6.024.0

≤10.0

6.016.0

≤8.0

Have
a super heater

≤10.0

≤12.0

≤8.0

phenolphthalein
alkalinity

/mmol/L

No
super heater

4.018.0

≤6.0

4.012.0

≤6.0

4.012.0

≤5.0

Have
a superheated

≤6.0

≤8.0

≤5.0

dissolved
solid matter

mg/L

No
super heater

≤4.0*103

≤4.0*103

≤3.5*103

≤3.5*103

≤3.5*103

≤3.5*103

Have
a super heater

≤3.0*103

≤3.0*103

≤2.5*103

≤2.5*103

phosphate
radical

c/mg/L

10.030.0

10.030.0

10.030.0

10.030.0

Sulfurous
acid root

d/mg/L

10.030.0

10.030.0

10.030.0

10.030.0

Relative
alkalinity e

0.20

0.20

0.20

0.20

0.20

0.20

2)    Power 220 v, 380 v / 50 hz.
3)    Sewage sewer should leave enough space to operate and maintain.
4)    Location should be ventilated, dry, conform to the requirements of the fire protection; near storing, the inflammable, explosive, easy to corrosion items is prohibited.
5)    Places around should not have interference of high voltage, heavy current.
6)    Piping installation shall comply with GB50236 field equipment construction and acceptance of industrial pipe welding engineering, electrical installation shall comply with GB7251 low-voltage complete switch equipment and control equipment.
7)    Once based should comply with the bearing condition of boiler installation; vertical boiler furnace base with light foot screws, you must obtain the permission from building department , if installation on the roof.
8)    Water pressure test: after installing, boiler overall instrument should be hydrostatic test according to the following table, pressure maintaining 20 min, test procedure shall be carried out in strict accordance with the JB/T1612 the condition of boiler water pressure test technology.

6. Hydrostatic Test


1)    Boiler in the water pressure test, water pressure should be slowly rise and fall, step up to 0.1 ~ 0.2 MPa, dealing with the boiler within the scope of the flange, manhole, hand holes and other connection bolt fastening under thermal state at a time.
2)    When water pressure rises to the pressure of work, should suspend boost, check whether leakage or abnormal phenomenon, and then step up to the hydrostatic test pressure, pressure not less than 20 minutes, and then to check under work pressure. Pressure should be kept constant during inspection; Check the leak proofness of manhole, hand hole, valves, flange and the place such as bedding, at the same time observe the thermal expansion of boiler barrel, pipeline and the support conditions.
3)    Hydraulic test should be performed when the environment temperature is higher than 5℃, otherwise must be anti-freezing measures. Water used for hydrostatic test should be kept above the dew point temperature, in order to prevent boiler surface condensation, but also should not be too hot to prevent evaporation and big temperature difference stress, usually for 20 ~ 70℃.
4)    There is no drop of water and water mist on pressure components wall and weld metal; No visible residual deformation; Hydrostatic test for qualified.

Name

Boiler
barrel
shellwork presser

Test
pressure

Boiler
body

0.8MPa

1.5Pno
less than 0.2 MPa

Boiler
body

0.8-1.6MPa

P+0.4MPa

Boiler
body

1.6MPa

1.25P

Super
heater

Any
pressure

The
same pressure as boiler body

Separated
economizer

Any
pressure

1.25P+0.5MPa

This boiler hydrostatic test pressure value can be found in the instrument layout of safety accessories.
9)    check and accept after installation:
①check whether the bearing base is strong;
②the ground fault protection line is reliable and efficient.
③piping system installation meet safety requirements and heat preservation requirements;

Read More:  Electric Steam BoilerElectric Hot Water Boilers

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