Detailed Introduction to the Debugging Steps of Thermal Oil Furnace
Thermal Oil Furnace Debugging Instructions:
Debugging is an important task to further verify the installation quality, system performance, and familiarity with operation procedures, ensuring normal operation. It should be participated by management personnel, technical personnel, and operators. After the initial startup of the equipment, the equipment working conditions should be measured and recorded to ensure the normal operation of the system in the future.
1. Debugging Purpose:
Check whether each unit equipment operates normally.
Check whether the system operates normally under cold conditions.
Enable operators to become familiar with and master operation essentials.
2. Debugging Requirements:
All motor rotations are correct, equipment loads are normal, and actions are correct, running continuously for more than 2 hours.
The circulating oil pump should undergo cold debugging before the water pressure test.
Keep debugging operation records, promptly eliminate possible faults, and make all preparations before debugging.
Debugging work is divided into two steps: cold state and hot state.
I. Cold State Debugging:
After the boiler installation inspection is completed, cold state debugging of each part is required. Cold state debugging must be operated by boiler operators.
1. Air Leakage Test:
(1). Air Side Test: During the test, close the last damper, start the forced draft fan, open the inlet regulating door to maximize system air pressure, check flanges, welds, and other leak-prone areas, mark them, and handle after shutdown.
(2). Flue Gas Side Test: During the test, first close all dampers, doors, and holes in the furnace flue. For positive pressure test, start the forced draft fan to pressurize the flue gas side, adjust the damper to maintain a positive pressure of 200-400MPa in the furnace, fully open the grate air doors, close the ash discharge doors, fully open all dampers along the flue gas flow, close all ash discharge doors, slag discharge doors, furnace doors, observation holes, and seal the dust collector with water. Check leak locations, mark them, and handle after shutdown.
Leak-prone areas are often at furnace wall expansion joints, pipe penetration points, flue connection flanges, and welds.
Test method: Add white powder or ignite a combustible that produces smoke at the forced draft inlet, so that white powder traces or smoke escape at leak points.
Leak elimination methods: For furnace wall expansion joints, fill with asbestos rope; for door and hole leaks, scrape the contact surfaces flat; for flue connection flanges, add asbestos rope and tighten bolts; for welds, repair welding.
3. Cold State Debugging of Piping and Circulation System
Debugging Steps:
Check whether all equipment and piping installation conforms to drawing requirements.
Check whether system pressure test and flushing meet requirements.
Check whether electrical system and control instruments are properly installed.
Inject lubricating oil or grease into the hot oil pump bearing housing and other transmission mechanisms as required.
Run each moving mechanism individually to check whether the rotation direction is correct and the sound is normal.
Adjust each valve of the system to prepare for oil filling and test run.
Use the oil filling pump to inject oil into the high-level expansion tank.
Start the hot oil circulation pump.
Observe whether the display of instruments such as hot oil circulation pump inlet and outlet pressure, furnace pressure drop, inlet and outlet oil temperature, and exhaust gas temperature is normal.
Run continuously for more than four hours in cold state. If no abnormal phenomena occur, hot state debugging can be performed.
II. Organic Heat Carrier Furnace Installation Inspection and Acceptance:
After the organic heat carrier furnace is fully installed, the main unit and auxiliary equipment should be carefully inspected and accepted item by item to meet the requirements for ignition operation. A comprehensive inspection should at least include the following items:
1. External Inspection of the Furnace Body: Mainly check whether there are deposits or blockages inside the furnace and flue, whether the furnace inner wall is intact, with no cracks, protruding bricks, or falling off. Whether the insulation layer is intact, all flue doors, inspection doors, etc. are intact, operate flexibly, and seal tightly.
2. Grate Inspection: Mainly check the necessary clearance between the moving and fixed parts of the grate, check whether the handle of the moving grate can be pushed and pulled freely and reach the specified position.
3. Fan Inspection:
For fan inspection, first manually rotate the coupling or transmission V-belt to check for any abnormal conditions such as friction, collision, or jamming between moving and stationary parts. The fan inlet regulating plate should switch flexibly and seal tightly. Check the fan rotation direction, the impeller rotates smoothly without friction or collision.
4. Other Inspections:
Check all pipes and valves of the organic heat carrier circulation system (including oil filling pump and hot oil circulation pump).
Check all pipes and valves of the blowdown system.
Check all pipes, valves, and insulation of the steam supply system.
Check the dust collector outlet
