EPCB 1Ton/h Coal Fired Steam Boiler Installation & Operation Instruction

East power Boiler your reliable choice
QINGDAO EAST POWER INDUSTRY EQUIPMENT CO,LTD
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DZL1-1.25-AII
Horizontal Coal Fired Steam Boiler
Installation and Operation Manual
Qingdao East Power Industry Equipment Co., Ltd.

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Catalogue
I. Product introduction
i. Structure introduction
ii. Performance characteristics
iii. Introduction of out of factory
II. Installation
i. Preparations before installation
ii. Installation of boiler
iii. Installation of I.D. Fan
iv. Installation of chimney
v. Installation of F.D. Fan
vi. Installation of pipes, valves, instruments
vii. Installation of electric control panel
viii. Hydraulic testing
ix. Inspection before furnace drying and boiler boiling
x. Furnace drying and boiler boiling
xi. Adjusting safety valve
xii. Trial operation with a load
xiii. Segmented acceptance and overall acceptance
III. Operating introduction
i. Normal economic operation
ii. Blowdown
iii. Shutdown boiler
IV. Maintenance
V. Inspection and hydrostatic test of pressure devices

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I. Product introduction
i. Structure introduction
The boiler is horizontal water fire tube, shell assembled boiler. The left and right
sides of the furnace fitted water wall tubes, eight-shaped flue is arranged at both sides
of drum, threaded smoke pipes inside of the drum. With arched tube plate, and
hand-fired single grate as combustion equipment.
Fuel put into the grate from hopper to burn in the furnace, flame and high
temperature flue gas flow into lower through the upper of baffle wall, then transferred
to the smoke chamber, entering eight-shaped flue of both sides after flow into the top,
after flowing through the front of threaded pipe, the flue by a I.D. fan then discharged
through the chimney.
ii. Performance characteristics
DZL series steam boiler assembled before delivery, the specific characteristics as
follows:
⑴ Using threaded smoke pipes, arch tube sheet, etc. mature technology of
company, so that the boiler is safe and reliable, energy-saving effect is remarkable,
high thermal efficiency.
⑵ Flexibly adjusting air for combustion and convenient operation.
⑶ Using chain-grate, convenient adjustment.
⑷ Evenly inlet air on both sides, good combustion.
⑸ Automatically control feed water, convenient operation and reduce the labor
intensity of boiler worker.
⑹ Assemble before delivery, easy and stable installation, low infrastructure
investment.
iii. Introduction of out of factory
When DZL assembled steam boiler delivery, sub-parts package as follows:
⑴ Assembled boiler includes boiler proper and grate and insulation layer of
furnace wall, smoke box of furnace door, etc.
⑵ F.D. Fan and I.D. Fan and their motors include air volume control devices.
⑶ Electric control panel and electrical components.
⑷ Water pumps & instruments & valves
⑸ Platform ladder
⑹ Boiler worker working tools
⑺ Technical documents:
a. Boiler general drawing for installation, foundation drawing, pipes &
instruments & valves drawing.
b. Installation and operation manual

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II. Installation
i. Preparations before installation
After boiler transported to the running site, in order to quickly operate, you must do
the following preparations before installation :
⑴ Organize the necessary personnel:
Boiler installation company must be approved by the quality and technical
supervision departments for examination and approval, boiler installation must have a
specialized responsible person. Boiler workers and plumbers, fitters, riggers, cold
laborers, welders and auxiliary workers participate.
⑵ Organize relevant personnel to learn
Learning the relevant provisions of "Steam Boiler Safety Technology Supervision"
and GB50273-2009 “Boiler Installation Construction and Acceptance Norms";
Familiar with the boiler relevant information and installation & operation manual and
other technical documents, in order to understand and master the installation of lifting
operation, maintenance and other operating matters.
⑶ Determine the installation place
a. Installation site preferably close to the heating location to shorten the delivery
pipeline, reducing based construction costs, reducing piping heat loss.
b. Convenience blowdown and feed water
c. Convenience store and fuel and ash transport
d. Smooth foundation when boiler installation
e. Boiler room layout should be consistent with the relevant provisions of "Steam
Boiler Safety Technology Supervision" in Chapter ten. Light adequate and well
ventilated, the ground should not be water, in order to ensure easy run operation and
maintenance, vacant three meters before furnace, vacant one meter after furnace, left
and right side margins of not less than 1 meter.
⑷ Foundation preparation
Construction according to the foundation drawing. By the civil engineering
department determines the pouring thickness of foundation based on boiler load and
local soil. Foundation surface should be smooth, the roughness is not more than 3 mm;
After the foundation acceptance, drawing boiler installation baseline according to
foundation drawing; Longitudinal centerline of the drum as a reference line, outside
of front panel as the lateral reference line, boiler reference line must have clearly
marks, the displacement deviation is less than 5 mm.
⑸ Acceptance of equipment
a. After arrival of boiler, check all parts and components based on the
manufacturer’s list, according to installation drawings of boiler, review the integrity
of device, checking whether large part of boiler is damaged or deformed during the
transportation.
b. When unloading large part of boiler, 8-10 tubes can be placed under iron sheet of
both sides of base, pulling with wire rope, making large part of boiler move slowly on
rolling tubes; stringing up of wire rope shall be under two drag boards with holes

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below former arch panel and shall not damage any large part.
C. For lifting large part, heavy equipment strength shall be taken into consideration,
lift or jack slowly at four lugs at top of boiler, lifting and jacking at other locations are
not allowed. For large boilers lifting, you should consider the ability of lifting
equipment. The boiler lifting position is the four rings on the top of boiler.
ii. Installation of boiler
After large parts of boiler in place on the foundation, the left and the right sides to
maintain level, and allowed inclination is not more than 5 mm.
iii. Installation of I.D. Fan
After installation of large parts, assemble induced draft fan, motor, flue dust
collector and economizer at the rear of boiler body based on drawing. Asbestos rope
shall be embedded at flange connections to ensure there is no stuck, air leakage and
other defects. Then put through power supply for commissioning, checking rotating
state of the motor and test run, running time shall not be greater than five minutes
when conducting test run and starting cold furnace; turn down control valve of flue
gas, because load of motor will be increased by several times during cold operation,
which may burn out the motor.
iv. Installation of chimney
Boiler chimney generally owned by the user. If users want to purchase from us, it
should separately make order. We can supply the suitable steel chimney.
Embedding asbestos rope between flanges when chimney installation. And using
the method of hanging perpendicular to check the verticality of the chimney, if there
is deviation that can be corrected at the place of flange connections. Iron chimney
pulls solid with thin steel wire rope, wire rope turnbuckle bolt tensioning, note the
extent taut of the three ropes should be equal.
v. Installation of F.D. Fan
First install the blower on pre-poured foundation, and then install suction pipe of
the blower; prior to start, check whether connection part of the blower is solid and
tight, whether opening and closing of adjusting damper is flexible, and whether
positioning is correct, then put through the power for commissioning.
Check whether rotation of the motor is correct, whether there is abrasion or
vibration, and vibration shall not be greater than 0.1 mm. Whether the motor and
bearing temperature is normal, the temperature rise generally not higher than 40 ℃.
vi. Installation of pipes, valves, instruments
⑴ Installation according to pipes, valves and instruments drawing, fixing electric
pumps in proper place and well pouring foundation, then put through power for
commissioning.
⑵ The safety valve should be installed after hydrostatic test, the safety valve should
be connected to the exhaust pipe, and guide exhaust steam to safe place outside the
boiler room.
⑶ Sewage pipes are connected to the sewage box or other safe place. Pipes should
be fixed to prevent displacement or occurred back scalding accident when sewage.
⑷ Steam pipe in addition to main steam valve shall be installed by the user, and

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main steam valve pipe shall be equipped with at least one elbow, otherwise extension
pipes shall be added and their exterior wall shall be kept insulation.
⑸ Elevation deviation for water gauge of both sides shall not exceed ± 5 mm, mark
properly “highest water level”, “lowest water level” and “normal water level” on the
surface, leaky pipe at the bottom of water gauge must be connected to safe places,
water level cock rotation is flexible, free of leakage, water level gauge must be
equipped with lighting device for easy observation.
⑹ When installing pressure gauge, keep dial disc vertical and mark red line on the
disc to display maximum permissible working pressure of boiler, pressure gauge
corker rotating flexible, free of leakage, water delivery shall be smooth and insulation
for pressure gauge is forbidden.
vii. Installation of electric control panel
Electric control panel brings together all of the switch button of motors (F.D. fan,
I.D. fan, pumps, etc.) in boiler system. Users can firstly connect wires to each motor,
then turn on the main power, enclosure should protective ground, electric control
panel can play to ensure the safe operation. Commissioning and operation of the
electrical control panel refer "Electrical control panel manual." Electric control panel
should be installed in the front of boiler, close to the wall, easy to operate by boiler
worker, conducive to monitor the normal operation of each instrument of boiler.
viii. Hydraulic testing
After installing boiler piping, valves and instruments, inspect and clean interior of
the boiler, turn off the manhole and handhole, and then conduct hydraulic test
according to the relevant provisions of Chapter 10 "Steam Boiler Safety Technology
Supervision" and the relevant provisions of Chapter 6 "Installation and Operation
Manual".
ix. Inspection before furnace drying and boiler boiling
⑴ The grate shall be subject to cold state test for more than four hours, and grate
bar shall be free of friction and getting stuck.
⑵ Do not allow extraneous parts (bolts, nuts and nails, etc.) to be stuck at anywhere
in grate.
⑶ Distance between the left and right sides of damper and the grate surface are
equal.
⑷ Various adjusting dampers of grate and smoke damper in flue shall open and
close flexibly.
⑸ Trial operation of F.D. fan, I.D. fan, water pump and slag remover shall be
normal.
⑹ Whether manhole, handhole and head hole are tight and whether associated
spare parts are complete.
⑺ Whether furnace wall is normal and whether smoke box is tight.
⑻ Whether steam pipe, water supply pipe and blow-out pipe line are tight.
⑼ Whether flue gas channel is smooth.
⑽ All bearings and oil cups should be filled with lubricating oil.
⑾ Sealing device (cam box) in front of grate should be added to lubricating oil,

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full-scale of oil level shall be within visible range of the oil cup.
x. Furnace drying and boiler boiling
After inspection and test run upon completion of various parts of boiler, all parts are
confirmed to be ready for safe start, furnace drying and boiling out can be started, and
furnace drying shall not be less than four days, two days of which, furnace drying and
boiling out are conducted together.
⑴ The purpose of furnace drying is to dry up brick wall of boiler slowly to prevent
cracking during usage; The main purpose of boiler boiling is to remove impurities and
grease inside the boiler, thus appropriate drugs shall be added in the drum during
boiling so that boiler water can be changed into alkaline to remove grease and other
objects.
⑵ Close all manhole, han dhole, main steam valve and inject softened water to
boiler. The inlet water temperature is no more than 40℃, close water supply valve and
observe whether the water level drops after water level in the boiler is stable, and
check whether water leakage exists in han dhole cover, flange joints and blowdown
valves of boiler, in case of leakage, tighten the bolts and close the valve.
⑶ Open ignition door, lay cinder of 20～30 mm within 1～1.5 m in front of grate,
use wood (strictly prohibited to use wooden boards with nails) and diesel and waste
cotton or other fire accelerant to ignite, open adjusting damper of F.D. fan and I.D. fan
for natural ventilation.
Firewood shall be strengthened gradually to avoid sudden heating, first furnace
drying with wood shall be conducted for 48 hours, in the two days the boiler shall
always be maintained at normal pressure, if the pressure rises to more than 0.1MPa,
open the safety valve immediately to drain steam, when the water level drops, input
water immediately.
⑷ Furnace drying and boiler boiling in last two days
Boiler boiling can adopt 5 kg of soda ash (Na2CO3), or 3 kg of trisodium phosphate
(Na3PO4 • 2H2O) and other drugs per cubic meter drum volume.
Above drugs shall be uniform solution with concentration of 20% for boiler boiling,
do not directly inject them to the drum.
Pause burning, open the upper manhole, inject the prepared drug solution to drum,
close manhole and safety valves, and continue to put in fuel for combustion.
When pressure of boiler is gradually increased to 0.4MPa, maintain for 24 hours,
then stop the combustion to reduce the pressure gradually to below 0.1MPa, and open
the drain valve after the water temperature is below 70℃ to drain boiler water.
⑸ After cooling of the boiler, open the manhole and hand hole to rinse drum and
interior of header with water, and inspect, in case of any grease stain, repeat the above
approach until there is no grease stain inside the drum.
xi. Adjusting safety valve
⑴ Safety valve on the drum should be adjusted and checked according to the
specified pressure in the following table.

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P ≤ 0.8
Working pressure+0.03MPa
Working pressure+0.05MPa
0.8 < P ≤ 5.9
1.04 times of working pressure
P > 5.9
Note: ①There must be a safety valve by adjusted according to the lower pressure of
table.
②The working pressure in the table is the working pressure of safety valve
installation place.
⑵ Safety valve should be no leakage and shock phenomenon.
⑶ Safety valves should be immediately locked or seals after adjustment.
xii. Trial operation with a load
The boiler can run only after passing the above work, and continuous trial operation
at full load for 48 hours. Boiler operation under full load to inspect the installation
quality. By testing under high temperature conditions, to identify intensity and rigor of
boiler pressure parts, check whether auxiliary equipment, ancillary equipment,
thermal instruments, etc. compliance with requirements. If not found unusual
phenomenon, also it can be ensured that the boiler works under normal parameters,
that is considered the installation quality can be accepted.
xiii. Segmented acceptance and overall acceptance
Acceptance of boiler installation is according to different stages, conducted by
boiler installation company and user. Boiler is completed acceptance after installation.

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III. Operating introduction
i. Normal economic operation
The users should ensure normal operate of boiler load 70%~100%, normal
combustion in furnace, stable steam pressure, normal steam temperature in outlet, low
air leakage, heating surface of flue gas should be regularly cleaning, kept clean and
improve thermal efficiency. Uniform air distribution of boiler, normal combustion in
furnace, small water resistance in boiler, low power consumption to run the pump,
stable water pressure, normal water temperature, instruments and valves work
properly. Boiler worker should note saving fuel, keep clean of boiler and boiler room,
strengthen the monitoring of various machinery and equipment and instrumentation to
ensure safe and reliable operation of the boiler, to prevent accidents. And regularly
summarize experience, and continuously improve the operational level, to ensure
economic operation of the boiler.
⑴ Water pump
a. Check whether the pump is normal when worker shift, if failure to exclude
immediately.
b. If the steam temperature of boiler outlet can’t up to design requirement, worker
can suitably adjust the opening degree of outlet valve of water pump to control the
outlet steam temperature.
⑵ Pressure gauge
Pressure gauge elbow should be washed once per shift. Check whether the pressure
gauge is normal, if found pressure gauge damaged should immediately shutdown and
repair or replace. In order to maintain the accuracy of pressure gauge, should check
once every six months for emission testing to verify the safety valve is normal.
⑶ Thermometer
Periodic inspection whether thermometer is normal, if found damaged should
immediately shutdown and repair or replace. In order to ensure the accuracy of the
thermometer, checking at least once every six months, if found thermometer damaged
should be repaired or replaced.
⑷ Safety valve
Note whether the safety valve is normal. In order to prevent sticking of valve disc
and seat valve, regularly pull the lift handle of safety valve for trial. Elevated
pressures once every 2-4 weeks for emissions testing to verify the safety valve is
normal.
⑸ Blowdown valve
Note whether blowdown valve is tight to prevent leaking.
⑹ Normal operation
a. The normal combustion of furnace shows: flat fire bed, dense and uniform flame,
not wearing cold air crater. The negative-pressure of furnace keep 20-30Pa, and avoid
lager negative-pressure.
b. According to the situation of steam consumption to uninterrupted adjust boiler
load and the operation of the combustion chamber, ensuring steam pressure and outlet

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steam temperature is stability. When the boiler load is reduced, firstly reduce the air
volume of F.D. fan, then reduce the amount of the flue gas of I.D. fan. When the
boiler load increases, firstly increase the amount of the flue gas of I.D. fan, then
increase the wind of F.D. fan, increase thickness of fuel if necessary.
By adjusting door of fans to increase or reduce the air volume, and keep
negative-pressure at 20-30Pa after adjustment.
c. When the fuel normal combustion on grate, negative-pressure of furnace is 1 mm
to 3 mm of water column, fire bed is flat, no fire-breathing holes.
Completely open air door of I.D. fan when ignition; opening the furnace door
which is located in the front and lower of the boiler; Putting into firewood from the
upper furnace door. When all covered fire bed, firewood gradually burn on the grate.
And put fuel into grate, also gradually open F.D. fan and I.D. fan according to fire of
grate.
In normal operation, turn off the upper and the lower furnace doors, open the F.D.
fan, I.D. fan. The large pieces of slag can be scraped out from the upper furnace door
after combustion, Debris automatically fall into the water seal ash pit, was withdrawn
by mud pump when flow to the front. When smoulderings, boiler worker should stop
the operation of F.D. fan and I.D. fan, open damper of I.D. fan, hold down the fire of
grate using coal, shut off the lower furnace door.
⑺ The cleaning of boiler room
a. Boiler room should be kept clean and tidy, the boiler room should not be stacked
with other debris.
b. Boiler room should have bright lights, the surface of pressure gauges, water level
meters, etc. various instruments should be clean and have good lighting to make
boiler worker a glance, to keep abreast of running condition of the boiler and ancillary
parts.
⑻ Shift change
In order to ensure safe and reliable economy operation, boiler worker should do the
following work when shift change:
a. The take over boiler worker should arrive boiler room before the stipulated time,
prepare to take over.
b. The work of take over boiler worker
① Boiler pressure is normal;
② Stable combustion in furnace;
③ Normal operation of each equipment;
④ Safe, sensitive and reliable of each boiler accessories (including pipes, valves &
instruments);
⑤ Boiler room clean and tidy, brightly lit.
c. Both sides of shift change should record the situation and the issue during shift
change to running log book.
ii. Blowdown
Despite feed water is softened before into boiler, but it still contains more or less
minerals. The minerals will remain in the boiler and precipitate on the surface of

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boiler inner Wall after concentration. The longer operating time, the more precipitate.
In order to prevent scale and water slag to cause damage of boiler must be sewage.
Sewage water frequency according to the specific situation of local water quality, can
be once a day or once per shift.
Boiler water quality should be consistent with the relevant provisions of
GB1576-2008 "Industrial boiler water quality". Sewage water should note the
following:
⑴ If there is two or more than two boilers using the same sewage pipe, also no
check valve on it, please note when sewage water.
a. Prohibiting sewage water at same time of two boilers.
b. If another boiler is maintenance, must be off the overhauled boiler and sewage
pipe before sewage water.
⑵ Sewage water should be carried out at low load, pay close attention to water of
boiler and added water, do not allow the boiler to cool too quickly.
⑶ If the sewage pipe hisn’t connected with sewage tank or sewage well, also no
safe equipment. Boiler worker must confirm there is nobody near the end of sewage
pipes before blowdown, avoid mishaps.
⑷ The specific operation when sewage water as follows:
Drum and right left headers of each boiler are equipped with two pieces of
blowdown valve. When sewage water, firstly fully open the secondary blowdown
valve (far away from the boiler), then slightly open the first blowdown valve (nearest
with drum and headers) to pre-heat the sewage pipes. Slowly turn up the first
blowdown valve after pre-heated. Boiler worker must slowly turn down the first
blowdown valve after finish blow downing, then turn off secondary valve after the
first one is turned off. The purpose is to control sewage water of first blowdown valve
to maintain rigor of secondary blowdown valve. When the first blowdown valve is
leakage, the secondary blowdown valve still can be used to control sewage water. If
there is impact sound in the sewage pipes when blowdown, the boiler worker should
turn down the first blowdown valve until the impact sound disappear, then slightly
open larger. Sewage water should not be continuous for a long time, so as to affect the
output capacity of steam.
⑸ After sewage water, shut down blowdown valve and check whether the valves
are tight. The checking method is that after some time of shut down blowdown valves
to touch the pipe behind the secondary valve. If it’s not cool, blowdown valve with
leakage should be treated in time.
iii. Shutdown boiler
⑴ There are four cases for Downingtown boiler.
a. If encountering grate rupture, in order to quickly troubleshoot should temporary
failure shutdown (also known as short-term asmoulder).
b. Temporarily shutdown boiler with long time no operation.
c. In order to clean, inspect or repair should emptying boiler water and shutdown.
d. When encounter special circumstances, for safety reasons must emergency
shutdown boiler.

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Upper shutdown boiler with four different circumstances, also with different
specific requirements as follows:
⑵ Temporary failure shutdown boiler, firstly turn off F.D. Fan, slightly open I.D.
Fan, quickly deal with the failure, if it can't be removed in 1 to 2 hours, should
continue to solve according to the case of temporarily shutdown boiler.
⑶ Temporarily shutdown boiler:
Temporarily shutdown boiler should be planned, and pay attention to safety and
proper maintenance equipment, also need to save coal and water. The specific steps as
follows:
Before shutdown boiler, the boiler worker according to the heat consumption
condition 20~30 minutes in advance to stop to supply coal, and proper turn down F.D.
Fan to burn out fuel, at last to stop F.D. Fan and I.D. Fan.
⑷ Safety shutdown boiler
Safety shutdown boiler should be planned (generally operate 1~3 months), pay
attention to safe and maintenance equipment when shutdown boiler. After shutdown
boiler according to the steps of temporarily shutdown, emptying boiler water after
water temperature < 50℃. At this time safety valve should be lifted up so that the
drum inner can communicate with atmosphere to shorten the cooling time. Also can
inject cool water through water inlet pipe, and drain hot water through sewage pipe.
After emptying boiler water, open manhole & han dhole to clean scale.
⑸ Emergency shutdown boiler
During the operation of the boiler, it is necessary to emergently shutdown boiler
and inform the related department if one of the following circumstances occurs:
a. Boiler water temperature is sharply rising and out of control.
b. All water pump failure.
c. All failure of pressure gauges and safety valves.
d. Boiler component is damaged and endanger the safety of operating personnel.
e. Water pump continuously feed water, but boiler pressure still continuously full
down.
f. Combustion equipment damaged, furnace wall collapsed or boiler structure was
red-hot, etc. phenomenon serious threat to the safe operation of the boiler.
g. Other abnormal operating conditions, and exceeds the allowable range of safe
operation.
Emergently shutdown boiler should focus on the prevention of accidents expansion,
specific steps as follows:
① Firstly stop F.D. Fan, then stop I.D. Fan;
② Removing all fuel of grate, open upper furnace door and let the furnace
temperature down.

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IV. Maintenance
⑴ Please pay attention to the following during boiler operation:
a. Do not allow the furnace spitfire and positive combustion, positive combustion
easy to burn out furnace door, etc.
b. If I.D. fan occurs severely vibrate, boiler worker should stop and check, that
generally caused by internal impeller wear and should be swapped.
c. Water is not available on the ground of boiler bottom, to prevent moisture
corrosion of the base.
⑵ Boiler operates 2~3 weeks should do once inspection.
a. Checking whether former arch, furnace wall is broken or fall off.
b. Opening front smoke box to check whether it to fouling. If there is fouling boiler
worker should be removed; If there is no fouling, boiler worker can extend the
opening time; Open once a month, if there is still no fouling, the time can be extended
to 2~3 months, at the same time to check whether the smoke box is closed tight.
c. Appropriate tension triangular belt of I.D. fan to prevent skidding when operation,
eliminating reduction of the amount of wind and pressure and belt wear.
d. Valves, pipes, flanges, etc., if any leaks should be repaired.
⑶ Shutdown boiler and conduct a comprehensive inspection and maintenance after
boiler operates 3~6 months. In addition to doing the above work, also need to perform
the tasks as follows:
a. Check the smoke tube and remove the soot fouling (if dust accumulates).
b. Remove scale and sludge of the inside of drum & Waterville tubes & headers,
and rinsing with water.
c. Checking the inside and outside of boiler, such as welds of pressure parts,
whether have the corrosion of inside and outside of boiler, if found serious defects
should be repaired immediately, if it’s not serious can be repaired when shutdown
boiler next time. If there are suspicious circumstances, but does not affect the safe
production, should make a record for future reference.
d. After checking, it is timely coated paint to prevent corrosion.

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e. Check whether rolling bearing of F.D. fan is normal, the wear degree of the
impeller and the casing, if it's severely worn should be replaced.
f. If necessary, casing to furnace wall and outside, remove the insulation layer for a
thorough examination. If found seriously damaged parts must be repaired before
continuously using. At the same time, boiler worker should fill in inspection results
and repair situations to the registration book of boiler safety technology.
⑷ Boiler insulation layer and boiler base (including grate and duct elbow) are
painted at least once a year.
⑸ Maintenance methods of boiler long-term no operation: Dry preservation method
& Wet preservation method; Dry preservation method should be adopted for
shutdown boiler more than 1 month; Wet preservation method for less than 1 month.
a. Dry preservation method:
Emptying boiler water after shutdown boiler, completely remove inside dirt, rinsing
clear, drying furnace with micro flame (don’t use strong fire), then dispensing massive
quicklime (10~30mm) to opening containers and placing in the boiler.
Note: Don’t let the quicklime touch with the metal of boiler.
The amount of quicklime is 8kg per cubic meter of inner volume of drum. The total
consumption is 30kg, then shut off all manhole & han dhole & pipes & valves, check
once per 3 months. If quicklime crumbled into powder need to be replaced
immediately, remove quicklime and containers when boiler re-running.
b. Wet preservation method:
Emptying boiler water after shutdown boiler, completely remove inside dirt, rinsing
clear, re-injecting treated water to full, then heat water to 100℃, exhausting gas in
water out of drum, shut off all valves.

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V. Inspection and hydrostatic test of pressure devices
⑴ According to "Steam Boiler Safety Technology Supervision", if boiler has one of
the following conditions, should conduct inspection and hydrostatic test for each
pressure part.
a. After new installation, modified installation and removal installation.
b. Stop running more than one year need to resume operation.
c. After pressure components through major repairs.
d. According to the boiler operation, when there is doubt for equipment must be
tested.
⑵ Boiler inspection and hydrostatic test should be conducted accordance with the
relevant provisions of "Steam Boiler Safety Technology Supervision" and JB/T1612
current standards.
⑶ Cutdown boiler and completely remove the internal scale and external ash and
soot before inspection. Inspection points are as follows:
a. Whether docking welds of drum and fillet welds of pipe hole, etc. are normal or
leakage.
b. Whether there is corrosion or drum kits or deformation, etc. inside and outside of
boiler plate.
c. Whether the smoke tubes are bending or there are cracks between the pipe end
and tube sheet.
d. Whether there are bending, deformation, corrosion, swelling, etc. Situations for
Waterville tubes.
e. Whether there are defects in the connections of water supply pipes and sewage
water pipes and drum.
⑷ If severe corrosion, before doing hydrostatic testing should do strength checking.
⑸ Hydrostatic testing steps:
a. Hydrostatic testing, water inlet temperature should be maintained at around
20~30 ℃ . Too low temperature is easy to condense dew around boiler wall and
confusion with water seepage, etc. not serious situations to increase the difficult of

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inspection. The surrounding atmosphere temperature is higher than 5 ℃ , or should
take freezing measures. Surface temperature is too high to make the water droplets
evaporate, leaks difficult to find.
b. After the water is full, gradually increase the pressure to 0.4MPa to conduct a
rigorous examination. If necessary, tighten the flange and compression nut of manhole
cover and han dhole cover.
c. When hydrostatic testing, water pressure should slowly rising and falling. When
pressure rises to the working pressure should be paused and check whether water
leakage or abnormalities, then boosted to testing pressure for 20 minutes, if the
pressure does’t drop that down to the working pressure for checking.
d. If found any leaks should make records to reduce the pressure to atmospheric
pressure for repair.
⑹ Hydrostatic testing meets the following conditions, namely qualified.
a. Without water drops and mist on welds and metal walls of pressure components.
b. After the hydrostatic testing no residual deformation.
⑺ Safety measures and precautions:
a. When the pressure is more than four atmospheres, strictly prohibit to tight the
flanges and screws.
b. It should have special marks when hydrostatic testing to avoid danger under
condition of many people.
c. Shall not directly stand in front of the weld flanges and valves when there is
pressure.
⑻ Boiler inspection results shall be recorded in boiler technology files and signed
by the inspectors.

EPCB 1Ton/h Coal Fired Steam Boiler Installation & Operation Instruction

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EPCB 1Ton/h Coal Fired Steam Boiler Installation & Operation Instruction