锅炉补给水系统调试措施概要

BALCO EXPANSION PROJECT -1200 MW THERMAL POWER PLANT

Commissioning procedure

Procedure of chemical water treatment system 锅炉补给水系统调试方案

Complied by:

编写：史勉 shimian

Revised by:

审核：冯荣彬 fengrongbin

Approved by:

批准：于心水 yuxinshui

目录

CONTENTS

1.概述summarize

2.调试范围The scope of commissioning

3.调试应具备的条件Precondition before commissioning

4.调试步骤commissioning step

5.安全事项Safety precautions

1 概述

本工程锅炉补给水系统设计有双介质过滤器，活性炭过滤器，阳床、阴床、混床等过滤除盐设备。Double medium filter, active carbon filter, cation bed, anion bed and mixed bed, etc filtering and DM equipment are designed for chemical water treatment system of this project.

2调试范围The scope of commissioning

包括双介质过滤器、活性炭过滤器、阳床、阴床、混床单元和其附属系统设备（酸碱贮存槽、酸碱计量箱、再生系统、除盐水泵、除盐水箱、压缩空气系统等）。double medium filter, activated carbon filter, strong acid cation exchanger, strong caustic cation exchanger, mix bed exchanger and pertain to system and device(acid and caustic storage tank 、acid and caustic daily/meter tank、regeneration system、DM water pump 、DM water storage tank and so on) are included.

3调试应具备的条件Precondition before commissioning

3.1对土建施工的要求Requirements to civil engineering

3.1.1水处理设备运行间、再生设备间、水泵、酸碱计量间、控制室的地坪、上下水、阀窗、通风照明、内部粉刷、油漆等项工作按设计要求施工完毕，验收合格。

The construction of ground, water supply and discharge, doors and windows, vent and lighting, internal whitewash and painting of operating room for water treating plant equipment, regenerating equipment room, water pump, acid and alkali metering room, control room and laboratory test room have been completed according to the requirement of design.

3.1.2所有需要防腐的混凝土构筑物，地面、沟道、墙壁等按设计要求施工完毕，沟道清扫干净并盖好沟盖板。

The construction of concrete structures, ground, ditches and walls requiring anti-corrosion have been completed as per the requirement of design. The ditches should be cleaned-up with slab/fine cover in place.

3.1.3防腐完毕的中和池其质量应符合相关标准要求，灌水试验要求24小时不泄漏。

The quality of the neutralization system, which has been finished with corrosion-resistance, should be conformed to the relative regulations. There should be no leakage in filling water test for 24 hours.

3.1.4控制室和空调设施施工完毕，控制室具备防尘、防盗和恒温条件。Construction of control room and air conditioning facilities should be completed. The control room should be in conditions of dustproof, guard against theft and constant temperature.

3.1.5化验间的地坪、平台、水源、排水和电源插座按设计施工完毕并完好，化

验间整体具备使用条件。

In the laboratory test room, ground and construction of platform have been completed; water supply and discharge facilities as well as the power sockets have been completed and perfected. The laboratory test room is ready for using.

3.1.6所有转动设备基础二次灌浆工作结束，因安装工作需要而无法避免的建筑物局部破损修补完毕。

Base secondary grouting for all the rotating equipment has been finished. All of local disrepair of construction should be complete repaired.

3.2对安装施工的要求

Requirements to erection

3.2.1水处理车间的主设备、附属设备及其管道的安装工作全部完成。Installation of the main equipment, attached equipment and their piping of the water treatment plant have been finished.

3.2.2在通水前对主设备、附属设备进行检查，确认设备内部无异常，重点检查法兰是否上紧，过滤嘴是否损坏，并按质量标准完成设备与系统的水冲洗。The main equipment and attached equipment should be checked and then confirm there is no foreign matter inside the equipment prior to supplying water .Focus the check on whether the flange is fastened, whether the filter tip is damaged. The foreign matters inside the pipe must be cleaned away. If all is finished and complete the flush of the equipment and system.

3.2.3本系统所有转动机械经分步试运合格，转机的空转和实转试验

All the rotating machinery in this system should be qualified subject to pre-commissioning operation.

Dry and wet test

3.2.3.1电机试验electrical device test

a.合闸merger test

b.连续空转continuity test

c.参数试验function test

d.控制试验control test

e.转机实转试验mechanical test and rotating equipment

f.仪表校准试验test and ensure that all instrument have been calibration。

g.控制系统试验test and ensure control system can work as control philosophy。

3.2.4所有罐体和衬胶管道的电火花试验合格。

Spark test should be conduct to all the rubber lined pipe prior to installation and to all the rubber lined equipment after installation.

3.2.5系统的水压试验，即按厂家设计要求完成工作水压试验，试验合格方可使用。

Conduct hydraulic test to main system and attached system according to “Instruction for design and installation”.

3.2.6不承压容器（酸、碱计量箱）进行灌水试验（同时检测液面计灵敏度），试验合格方可使用。

Conduct water filling test to non-pressure-withstanding vessel (test the sensitivity of level indicator)

3.2.7按设计规定完成所有设备保温和油漆工作。

Heat insulation and paint of all equipment have been completed according the regulations of the design.

3.2.8水处理系统的电气、热工（包括程控）所有安装工作结束，并进入调试阶段，本系统内所有电气、热工、化学在线仪表、就地仪表校验合格安装完毕，并具备投运条件。

All the electrical and thermodynamic (including program control) installation in water treatment system have been completed and proceed to commission stage. All the electrical, thermodynamic and chemical on line instruments and local instruments should be completed for installation and qualified subject to calibration as well satisfies the conditions of putting into operation.

3.2.9完成空气系统的检查和试验，完成所有气动阀的就地及远方操作试验（软手操）和手动阀的操作试验。

Local and remote operation test (soft manual operation) of all pneumatic valves and operation test of manual valves have been completed.

所有气动阀门充压后要求通气管道、电磁阀和气动阀门本体没有漏气现象。Pipe, electromagnetic valves and pneumatic valve proper filling with gas of all the pneumatic valves are required without leakage after filling pressure.

●气动阀的静态操作试验（包括就地和远方操作试验），确认模拟操作盘上阀门按钮的命名与开关位置和系统上阀门的实际状况一一对应。

●Static operation test (including local and remote operation test) of pneumatic valves should be conducted, and confirm the name of valve button and switch position on the panel is correspondent with the practical condition on valves.

●启动水泵进行系统气动阀的动态试验和手动阀的操作试验，要求工作压力下阀门开关自如、无泄漏。

Start the water pump to conduct dynamic test to pneumatic valves and to switch test to manual valves in pressure system. Valves are required to open and close freely without leakage under the working pressure.

3.2.10通讯设施按设计要求安装完毕，并能满足试运工作的需要。The communicate on facilities have been installed according to the requirement of design and can meet the requirements of trail operation

3.2.11在启动试运工作中热工（包括程控）机务等专业应有试运值班员，设备出现故障后应能及时消除。

There should be trial operators of thermodynamic (including program control) and steam turbine specialties on duty, who can eliminate the faults of equipment in time when it emerged.

3.2.12酸碱储存间和计量间的安全水源可投入使用。

The safe water supply of acid and alkali storage room and metering room should be in available.

3.2.13检查和确认所有系统和设备被正确的安装和冲洗

Check and ensure all the system and facilities have been cleaned and flushed.

3.2.14再生药品及离子交换树脂的质量需符合设计要求及有关规程的规定。The quality of regeneration chemical and ion-exchange resin should conform to the regulations of contract and the relative codes. It can be prepared according to the following quantity.

3.2.15石英砂的装填load quartz

根据厂家说明书来装填石英砂。

Refer to manufacture procedure for resin loading.

3.2.16树脂装填load resin

3.2.16.1根据厂家说明书来装填树脂。

Refer to manufacture procedure for resin loading.

3.2.16.2根据厂家说明书计算混床树脂的体积和装填高度。

Refer to manufacture procedure to know volume and height of mix bed.

3.2.16.3根据厂家说明书来确定化学药品的数量。

Refer to manufacture procedure for chemical loading.

3.3对电厂生产准备的要求

Requirements to preparation of plant production

3.3.1参加试运工作的值班员应经培训考试合格,明了水处理设备的特性,并能胜任本职工作。

The personnel taking part in the trial operation should know clearly the performance

of the water treatment equipment and is competent for his work.

3.3.2试运操作人员应具备熟练操作技能，试运操作记录要及时准确无漏项。The Trial operator should be skillful in operation. The record of trial operation should be correct and in time without omission.

3.3.3化验分析仪器、仪表、药品、运行规程及记录报表准备齐全，化验间、操作间的桌椅备齐。

Instruments and chemicals for analysis should be prepared. Lab test room and operation room are equipped with complete and enough desks and chairs and satisfy the conditions for chemical analysis

3.3.4按有关规定完成对设备、阀门上的命名编号，管道上的走向标记也应同时完成，并备好各种运行状况的标志牌。

All equipments, valves, local indicators (including level, flow, pressure and temperature indicators) and on-line chemical instruments have been installed and provided with correct KKS NO. Tags. The orientation remark of pipeline should be done.The marking signs for various operational conditions at the same time.

4调试步骤commissioning step

4.1 设备的水冲洗及水压试验equipment water flushing and hydro test

需要冲洗的设备有过滤器、阳床，阴床、中间水箱、混床、再生系统，除盐水箱等及其相关管路，冲洗至出水澄清。设备冲洗完毕后，对所有设备应进行水压试验，确保系统无泄漏。

The equipments required to be flushed until outlet water clarified include filter, cation bed, anion bed, intermediate water tank, mixed bed, regeneration system, DM water tank, etc and related piping. All equipments shall be conducted hydro test to ensure the system leak free after equipment flushing.

4.2压缩空气系统吹扫compressed air system purging

将压缩空气储存罐压力充到0.6Mpa以上，然后逐步对整个压缩空气系统进行吹扫。吹扫的原则是先主管路后支管，吹扫方法是将相应的法兰或接头解开，吹扫至出口无水滴或杂物为止，吹扫过程中如果压缩空气储存罐压力降到0.4Mpa，应暂停吹扫，待压力上升到0.6Mpa以上再开始吹扫，吹扫完毕后及时将解开的接口恢复，然后接着吹扫下一部分。压缩空气罐使用前要打开人孔进行清理检查，安全门试验调整后投入使用。

吹扫必须进行到每个气动设备的进气管。

Compressed air storage tank pressure shall be above 0.6Mpa, and then purging to the whole compressed air system shall be carried out step by step. Purging principle is

first main piping and then branch piping. Purging method is to unfasten relevant flange or connection and purge until no water drop or inclusion in the outlet. In the course of purging, in case that compressed air storage tank pressure falls to 0.4Mpa, purging shall suspend. Purging can be resumed only if pressure rises above 0.6Mpa. The unfastened connection shall recover after completion of purging and then the next part shall be purged subsequently. Access hole shall be opened for cleaning and inspection prior to usage of compressed air tank. The same can be put into use after adjusting of emergency exit test.

Purging shall be conducted up to each inlet pipe of pneumatic equipment.

4.3设备或阀门就地操作equipment or valve local operation

4.3.1控制柜、电磁阀箱送电送气，气压在0.4MPa以上，将控制柜上、电磁阀上的方式选择切换开关打在手动位或就地关位；

Control cabinet and solenoid valve supply power and air. Air pressure is above 0.4Mpa. The way on the control cabinet and solenoid valve chooses switch to hit the manual position or local off position.

4.3.2就地逐一试验设备的启停或阀门的开关操作并检查阀门是否能严密关闭。Start-up and shutdown of equipment shall be tested or valve switch shall be operated locally and in sequence. Valve shall be inspected whether it is shut closely or not.

4.4过滤器的调试filter commissioning

4.4.1过滤器填料的装填filter material filling

用人工将滤料倒入罐内，装填过程中，要防止杂物进入罐体。干装载过程要注意水位的情况，保持罐内净水位不低于1米。装填过程中不允许从下部排水。装够后封闭人孔。浸泡至少8小时。

Filter material shall be dumped into tank manually. Inclusion shall be prevented into tank in the course of filling. Water level condition shall be noticed during dry filling. Purified water level in the tank shall maintain no less than 1m. Drainage in the bottom is not allowed during filling. Access hole shall be closed after filling adequately. Soaking shall be at least 8 hours.

4.4.2 滤料的反洗filter material backwashing

反洗步骤：满水后，启动反洗系统，用约1/4正常反洗流量进行反洗，直至废水清澈。增加反洗流量到约1/2正常反洗流量进行反洗，直至废水清澈。增加反洗流量到约3/4正常反洗流量进行反洗，直至废水清澈。增加反洗流量到正常反洗流量进行反洗，直至废水清澈。

Backwashing steps: backwashing system shall start up after full water. Around 1/4

normal backwashing flow shall be used for backwashing until effluent is clear. Flow shall be increased to around 1/2 normal backwashing flow for backwashing until effluent is clear. Flow shall be increased to around 3/4 normal backwashing flow for backwashing until effluent is clear. Flow shall be increased to normal backwashing flow for backwashing until effluent is clear.

通常洗出大多数的粉末和细粉，用瓶子取废水样品进行观察，为了良好的过滤器操作，细粉必须除去，但是如果整颗粒介质开始反洗出过滤器的话，反洗流速应暂时地降低，然后再开始缓慢提高到需要的反洗流速。

Generally most powder and fine powder can be washed out. Effluent sample shall be taken out by bottle for inspection. For the sound operation of filter, fine powder shall be removed. On account that the whole particle medium is started to be washed out from filter, backwashing flow rate shall bring down tentatively and then slowly rise up to required backwashing flow rate.

4.5除碳器的填料装填carbon remover material filling

检查除碳风机，确认转动方向是否正确。检查除碳器的承载格栅，确认无裂纹、无缺损。多面球搬运和储存过程中应小心避免损坏袋子，使其泄露和受污染量降至最低。

Decarbonization fan shall be checked to confirm whether running direction is correct or not. Bearing grating of carbon remover shall be checked to confirm the same has no crack and no defect. Care shall be taken to avoid damaging bag in the course of polyhedral ball transport and storage so that leakage and contaminated amount can

fall to the least.

多面球的装载，先确定装载高度，再人工装填。装载过程应小心、缓慢、少量倾倒。该过程要注意不要将任何包装物（塑料袋、包装纸、线头、合格证等）倒入罐内。

Regarding loading of polyhedral ball, loading height shall be confirmed and then filling manually shall be conducted. Loading course shall be careful, slow and dump in small quantity. Notice shall be taken to avoid dumping any packing (plastic bag, packing paper, thread end, certificate, etc) into the tank.

封闭人孔后，启动除碳风机，用活性炭出水冲洗除碳器，并从除碳器水箱底排和溢流排出水，直至水清澈。

Decarbonization fan shall be start up after closing of access hole. Carbon remover shall be flushed with active carbon outlet water. Discharge is from carbon remover water tank bottom drain and overflow drain until water is clear.

4.6阳离子交换器的调试cation exchanger commissioning

4.6.1阳树脂的装填cation resin filling

根据现场具体情况决定水力装填或人工装填，最好使用水力装填。人工装填时要注意：千万不可使树脂整袋掉落以防碰坏罐内设备，阳树脂装填完毕后封闭人孔。Hydraulic filling or manual filling shall be decided based on site actual condition. Hydraulic filling is preferred. Notice shall be taken for manual filling: the whole bag resin shall never fall to prevent from damaging equipment in the tank. Access hole shall be closed after completion of cation resin filling.

4.6.2阳树脂的反洗cation resin backwashing

手动操作进行大反洗，洗出细小的树脂颗粒和密度小的颗粒。

Manual operation shall be done for complete backwashing to wash out fine resin particle and small density particle.

4.6.3制备软化水。Preparation soft water

冲洗阳离子交换器，硬度小于50umol/L时可以回收于除盐水箱。此软化水用于树脂的预处理和首次再生。

To flush cation exchanger, the same can be recovered to DM water tank as its hardness is less than 50umol/L. this soft water is used for resin pretreatment and initial regeneration.

4.7阴离子交换器的调试anion exchanger commissioning

阴离子交换的调试参见阳离子交换器的调试

For anion exchanger commissioning, please refer to cation exchanger commissioning.

4.8混床的调试mixed bed commissioning

4.8.1混床在装填树脂前，应做喷水试验。按最大额定流量反复大反洗三次，以检验水帽布水均匀性和紧固程度。

Water spraying test shall be carried out prior to mixed bed resin filling. complete

backwashing shall be repeated three times as per maximum rated flow to inspect the uniformity and fastening degree of cap water distribution.

4.8.2混床加树脂及树脂预处理mixed bed resin filling and resin pretreatment

混床先加阳树脂。反洗后人进入混床内部，将高于中排中部的树脂用小铲子盛到袋子中拿出，然后再装阴树脂。树脂装完后，混床大反洗，将细小的阴脂用水力作用洗出。

Cation resin shall be filled into mixed bed. Man shall go inside mixed bed after backwashing and use trowel to catch the resin above central drain middle into the bag and take out. Then anion resin shall be filled. After completion of resin filling, mixed bed complete backwashing shall be conducted to wash out fine anion resin by hydraulic action.

4.9 阴、阳床的再生cation and anion bed regeneration

阴、阳床的首次再生采用双倍剂量再生，再生液浓度，酸2-5%，碱2-4%。阴、阳床再生完毕后，制备一级除盐水，供再生混床用。

Initial regeneration of anion and cation bed shall apply double dose regeneration. Regenerant concentration is that acid is 2-5% and alkali is 2-4%. After completion of anion and cation bed regeneration, first class DM water shall be prepared for regenerating mixed bed.

4.10混床的再生mixed bed regeneration

4.10.1混床的首次再生采用双倍剂量再生，再生液浓度，酸2-5%，碱2-4%。Initial regeneration of mixed bed shall apply double dose regeneration. Regenerant concentration is that acid is 2-5% and alkali is 2-4%.

4.10.2再生后，阴树脂正洗，从中间排水出口取样，碱度≤0.5mmol/L时，可串联正洗，串联正洗出口导电度≤10μs/cm时可进行混合。

The SBA has been washeda after regeneration, taking water sampling from middle water space and analyse it,when its alkalinity≤0.5mmol/L and it should been washed in series until conductivity of outlet ≤10μs/cm , SBA and SAC should been mixed.

4.10.3混合前，应将混床内水垫层放至树脂层面上150-200mm，混合时混床的压缩空气门应慢慢开启，母管压力小于0.4MPa，混合时间2-3分钟。

Before mixed resin,drain untill water subfill of mixed-bed only higher 150-200mm than bedding

plane of resin,when mix resin of mixed-bed open slowly the fan valve,and about 2-3 minute.

4.10.4混合后进行正洗，出口导电度≤0.2μs/cm；硅酸根≤20μg/L时，可投入运行。

Washing it after mixed resin，when conductivity of outlet≤0.2μs/cm and silicon dioxide≤20μg/L，running the mixed－bed

注：除盐水控制指标note：index of DM water

硬度 / hardness 0

≤20μg/L

SiO

2

导电度/conductivity≤0.2μs/cm

5安全事项Safety cautions

5.1参加调试的所有工作人员应严格执行《安规》及现场有关安全规定，确保调试工作安全可靠地进行。

All the personnel that take part in commissioning process must strict perform《safety regulation》and about safety provision and ensure commissioning perform safety and reliability.

5.2如在调试过程中可能或已经发生设备损坏、人身伤亡等情况，应立即停止调试工作，并分析原因，提出解决措施；

If equipment been damage or will been damage and personnel casualty and so on ,commissioning must be stop immediately ,analyse the cause and resolve it.

5.3现场发现异常情况，应及时处理，并立即汇报指挥人员。Any abnormal situation on the site shall be immediately handled and the commissioning principal should be informed right now.

5.4调试全过程均应有各相关专业人员在岗，以确保设备运行的安全。

All personnel should work in water treatment plant in the all process ensure equipment running safety。

5.5盐酸、烧碱都是腐蚀性化学药品、新设备再生时应注意防止酸、碱喷溅伤人。Hydrochloric and caustic soda are corrosive chemicals. Avoid the acid or alkali spray to injure person during the regeneration of new equipment. Guard matters should be prepared.

5.6现场应做好隔离工作并悬挂相应的警示牌，对于不能操作的电气开关和操作按钮等应悬挂“禁止操作”的警示牌。The site shall be isolated with relevant warning plate . Electrical switches and push buttons that cannot be operated shall be hung warning plate such as “no operation”.

5.7系统中的手动阀门由于不参加程控，所以所有的手动阀门的开启和开度有调试人员现场调试整定。无关人员不应轻易地改变相应的阀门状态，以免影响系统的正常运行和造成设备损坏。Due to manual valves shall not be involved in process control, the opening and opening degree of all manual valves on this system shall be set by commissioning people. The other people shall not change their opening and opening degree freely after they have been put into formal operation, otherwise the normal running of the system shall be impacted and even damages may be caused.注：本措施部分条款可根据实际情况，加以修改。

Note：Some items of this procedure can be revised as per special situation.