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GB/T 16508.7-2022Shell boilers - Part 7: Installation (English PDF)

锅壳锅炉第7部分：安装

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Issued by

State Administration for Market Regulation; Standardization Administration of China

Level / Type

National · Recommended

Issue date

March 9, 2022

Implementation date

October 1, 2022

Scope

GB/T 16508.7-2022 is the English-translated version of 锅壳锅炉第7部分：安装.

GB/T 16508.7-2022 is the Chinese national standard on shell boilers - part 7: installation, in the field of energy and heat transfer engineering. The /T suffix marks it as a recommended standard: it is not compulsory by itself, but it becomes binding as soon as a contract, a tender or a customer specification calls it up - which in practice is how most foreign buyers meet it. It was issued on 9 March 2022 by the State Administration for Market Regulation; Standardization Administration of China, and has been in force since 1 October 2022. Classification: ICS 27.060.30, CCS J98. This page is published from the official record of the standard held by the Chinese standards administration: the identification, the dates, the classification and the issuing body are taken from there. The clause text, the tables and the numeric limits are in the document itself, which is delivered complete in English translation.

Document preview — GB/T 16508.7-2022

National Standard of the People's Republic of China

ICS: 27.060.30
Classification: J98

Issued by: State Administration for Market Regulation; Standardization Administration of China

1 Scope
2 Normative references
3 Introduction...
4 Basic requirements...
5 Installation base...
6 Steel structure installation...
7 Boiler shell, header and heating surface installation...
7.2 Installation of boiler shell, header and rear heating surface
7.4.8 Expand the pipe according to the requirements of
7.5 Hydrostatic test
8 Instrument and valve installation...
9 Combustion equipment installation...
9.2 Burner installation
10 Furnace wall masonry and insulation layer construction
11 Packaged boiler and assembled boiler installation
12 Auxiliary equipment installation...
12.3 Installation acceptance
13 Boiler baking, boiler boiling, tightness test and commissioning
13.1 Boiler baking
13.3 Tightness test and commissioning
14 Acceptance

1 Scope

This document specifies the requirements for installation, commissioning and acceptance of shell boilers. This document applies to shell boilers defined in GB/T 16508.1.

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 16508.1, Shell boilers - Part 1: General requirements

GB/T 16508.4, Shell boilers - Part 4: Fabrication, inspection and acceptance

GB/T 16508.6, Shell boilers - Part 6: Combustion systems

GB 50126, Code for construction of industrial equipment and pipeline insulation engineering

GB 50211, Code for construction and acceptance of industrial furnaces building

GB 50231, General code for construction and acceptance of mechanical equipment installation engineering

GB 50264, Code for design of industrial equipment and pipeline insulation engineering

GB 50273, Standard for construction and acceptance of boiler installation engineering

GB 50275, Code for construction and acceptance of fan, compressor and pump

a) There shall be no mechanical damage to the boiler shell, header surface and welded short pipe. Welds shall have no obvious defects such as cracks.

7 Boiler shell, header and heating surface installation...

7.2 Installation of boiler shell, header and rear heating surface

7.2.1 The boiler shell shall be installed and fixed in the steel structure before it can be hoisted into place. For boiler shells directly supported by non-steel beams, firm temporary supports shall be installed. Temporary supports shall be removed before water is fed for the boiler hydrostatic test.

7.2.2 When the boiler shell and header are in place, the expansion gap of the support shall be reserved according to the expansion direction. It shall be temporarily fixed.

7.2.3 Carry out the following inspections when installing the internal devices of the boiler shell:

a) The number of parts shall not be missing.

b) The connection of steam and water supply connection partitions shall meet the requirements of technical documents.

c) The flange joint surface shall be tight.

d) The connection of the connectors shall be firm. There shall be an anti-loosening device.

7.2.4 After the boiler shell and header are installed, the center line of the boiler shell

7.4.1 Before expansion joint installation, the heating surface pipe meets the following requirements:

a) There shall be no defects such as heavy skin, cracks, flattening and severe corrosion on the surface of the pipe.

b) Alloy steel pipes shall be inspected one by one.

c) Heating surface pipes shall be inspected and corrected for shape.

d) The heating surface pipes shall be arranged neatly. The deviation between the local pipe section and the designed installation position shall meet the requirements of the drawing.

e) The inclination of the end face of the expansion joint shall comply with the design drawings and technical documents.

7.4.8 Expand the pipe according to the requirements of

GB/T 16508.4, and meet the following requirements:

a) After the pipe end is installed in the pipe hole, it shall be expanded immediately.

b) After the reference pipe is fixed, it shall be expanded from the middle to both sides.

c) Calculate the pipe expansion rate according to the inner diameter control method or the outer diameter control method. When using the inner diameter control method, the pipe expansion rate shall not exceed the range of 1.0%~2.1%. When using the outer diameter control method, the pipe expansion rate shall not exceed the range of 1.0%~1.8%.

7.5 Hydrostatic test

7.5.1 During boiler installation, the pressure elements shall undergo hydrostatic test after non-destructive testing and heat treatment.

7.5.2 After the installation of the pressurized steam and water system of the boiler and its accessories is completed, a hydraulic test shall be carried out. Before installation of cast iron economizers, it is advisable to carry out hydrostatic test one by one (or group).

7.5.3 The main steam valve, water outlet valve, blowdown valve and feed water shut- off valve shall be subjected to hydrostatic test together with the boiler. The safety valve shall be subjected to pressure test independently.

7.5.4 Carry out the following checks before the hydrostatic test.

a) Internal cleaning and surface inspection shall be carried out for pressure components (elements) such as boiler shells and headers.

b) Water cooling walls, convection pipe bundles and other pipes shall be kept unblocked.

c) There shall be no less than 2 pressure gauges installed. For boilers with rated working pressure less than

2.5 MPa, the accuracy level of the pressure gauge shall not be lower than 2.5. For boilers with a rated working pressure of not less than

2.5 MPa, the accuracy level of the pressure gauge shall not be lower than 1.6. The pressure gauge shall be calibrated as qualified. The range of the dial shall be

1.5 to 3 times the test pressure, preferably 2 times.

d) Install drainage pipes at the lowest point of the system. Install a vent valve at the highest point of the system.

7.5.5 During the installation process of the boiler, the hydraulic pressure test of the requirements:

a) The materials, elements and manufacture of pressure piping shall meet the requirements of relevant manufacturing supervision and inspection of boiler components.

b) The opening of pressure piping and equipment shall meet the requirements of design drawings and process documents.

9 Combustion equipment installation...

9.2 Burner installation

9.2.1 Matching burners shall meet the requirements of technical documents. Product technology, quality, and environmental certification materials shall be complete.

9.2.2 The reserved burner installation position shall be correct. Prevent the flame from directly scouring the surrounding heating surface.

9.2.3 Before the burner is installed, the overall dimensions of the burner shall be checked. The installation of the burner shall meet the requirements of technical documents, product instructions and GB/T 16508.6.

10 Furnace wall masonry and insulation layer construction

10.1 Furnace wall masonry shall pass the boiler water pressure test. The installation quality of all the parts built into the wall, the water pipes and the supporting and hanging devices of the furnace top meet the design requirements.

10.2 The construction of furnace wall masonry and insulation layer shall comply with the relevant regulations of GB 50211, GB 50126 and GB 50264.

10.3 The type of insulation layer, the location of expansion joints, and the strength, bulk density, thermal conductivity, and specification of insulation materials shall meet the requirements of the technical documents.

10.4 Before the construction of the heat insulation layer, the oil stains and rust on the surface of the heat insulation parts such as the boiler shell, header, metal flue, air duct, and pipe shall be removed. Apply corrosion-resistant paint according to the requirements of technical documents.

10.5 The construction of the heat insulation layer shall be carried out after the strength test or tightness test of the metal flue, air duct, pipe and other insulated parts have been passed. When the thermal insulation material is made of molded products, the seams shall be staggered, and the inner and outer layers shall be seamed. The allowable deviation of the heat insulation layer shall meet the requirements of the technical documents.

11 Packaged boiler and assembled boiler installation

11.1 Before installation, the boiler or parts shall be counted according to the boiler exit- factory data. Review the integrity of boiler equipment. Check whether there is any damage or deformation during transportation.

11.2 Before the boiler or components and parts are put in place, the foundation size and position shall be checked. The allowable deviation shall comply with the technical documents or the requirements of Chapter 5.

11.3 Before the boiler or components and parts are in place, the components and parts shall be placed in the designated place according to the requirements of the boiler installation technical data. Carry out boiler or components and parts in place according to the requirements of technical documents. In-place movement can be done in the following ways:

a) When pulling to move, place multiple steel pipes under the moving support of the boiler part. Pull with a wire rope. Pay attention to the position where the wire rope is placed. Do not damage the boiler or its components or parts. requirements of technical documents and product instructions.

12.2.2 Before the pump is installed, unpacking and acceptance shall be carried out according to the following requirements:

a) The pump and supporting parts shall be free from missing parts, damage and corrosion, etc. Inlet and outlet protection shall be intact.

b) The main installation dimensions of the pump shall comply with the requirements of technical documents and product instructions.

12.2.3 The installation of the pump shall comply with the requirements of technical documents and product instructions. When the requirements are not clear, it shall comply with the requirements of GB 50275.

12.2.4 In addition to complying with the provisions of GB 50231, the installation of piping shall also meet the following requirements:

a) The inside of the pipe and the end of the pipe shall be cleaned and cleared of debris. The sealing surface and thread shall not be damaged.

b) Suction piping and output piping shall have separate brackets. The pump shall not bear the weight of the piping directly.

12.2.5 The test run of the pump shall be carried out after the separate test run of its subsidiary systems is normal. The test run shall be carried out in the presence of medium. The medium or substitute medium for trial operation shall meet the requirements of technical documents and product instructions.

12 Auxiliary equipment installation...

12.3 Installation acceptance

12.3.1 Fans and pumps shall pass the test run before going through the project acceptance procedures.

12.3.2 The following information shall be available for project acceptance:

a) Exit-factory technical documents of the equipment;

b) Unpacking inspection records;

c) Basic review records;

d) Relevant information on design changes;

e) Various actual measurement records and concealed process records during the installation process;

f) Completion data such as test run records.

13.1 Boiler baking

13.1.1 Before baking the boiler, a boiler baking plan shall be formulated and the following requirements shall be met:

a) The boiler and its water treatment, steam water, sewage discharge, material conveying, slag removal, air supply, dust removal, lighting, circulating cooling water and other systems have been installed and passed the test run.

b) After the furnace body masonry and insulation layer construction is completed, the furnace body air leakage test is qualified.

c) The thermal and electrical instruments (such as water level gauges, pressure gauges, temperature measuring instruments, etc.) required for boiler baking shall be installed and debugged.

d) Boiler feed water shall meet the requirements of GB/T 1576 or GB/T 12145.

e) After the expansion indicators on the boiler shell and header are installed, they shall be adjusted according to the requirements of the technical documents in the cold state.

f) Temperature measurement points or mortar sampling points on the furnace wall shall be set.

g) There shall be an oven temperature rise curve.

h) Piping, air ducts, flue ducts, gray ducts, valves and baffles shall be marked with medium flow direction, opening direction and opening degree indication.

i) The inside and outside of the boiler and all passages shall be cleaned.

13.1.2 According to the site conditions, flame, steam and other methods can be used for boiler baking. Shell boilers with water cooling walls shall use steam to bake.

13.1.3 Boiler baking with flame shall meet the following requirements:

a) The flame shall be concentrated in the center of the hearth. It is suitable to bake with slow fire at the beginning. The fire shall be uniform and increase slowly.

b) The mechanical grate shall be rotated regularly during the baking process to prevent the grate from burning.

13.3 Tightness test and commissioning

13.3.1 After the boiler is baked and boiled, the tightness pressure test shall be carried out according to the requirements of the technical documents. Follow the requirements below:

a) After the pressure is increased to

0.3 MPa ~

0.4 MPa, the bolts of flanges, manholes, handholes and other connecting parts within the boiler pressure test range shall be fastened once in a hot state.

b) After continuing to increase the pressure to the rated working pressure, check the tightness of manholes, hand holes, valves, flanges and cushions within the pressure test range. At the same time, observe the thermal expansion of the boiler shell, header, pipeline and support.

13.3.2 After the tightness pressure test is qualified, the safety valve shall be finally adjusted. The adjusted safety valve shall be locked or sealed immediately.

13.3.3 After the safety valve is adjusted, the boiler shall be commissioned in the cold state of the system and the hot state of the overall startup.

13.3.4 During the startup process of the boiler, the pressure shall be increased slowly according to the requirements of the pressure increase curve provided by the boiler manufacturer.

13.3.5 After commissioning, the assembled boiler shall be continuously tested for 48 h under a certain load. It is advisable to conduct a continuous test run of 4 h ~ 24 h for the packaged boiler.

14 Acceptance

14.1 After the boiler has passed continuous test runs, the project acceptance can be carried out. Unaccepted boilers shall not be put into use.

14.2 The acceptance of the installation project of the assembled boiler shall at least have the following information:

a) Commencement report;

b) Inventory records of boiler technical documents (including related documents of design modification);

c) Equipment defect list and repair records;

d) Installation foundation inspection records;

e) Steel structure installation records;

f) Quality inspection records of pad iron and grouting layer under the bottom plate of steel structure column;

g) Passing ball test records of heating surface pipes of boiler proper;

h) Valve hydraulic test records;

i) Installation records of boiler shell, header, economizer, superheater and air preheater;

j) Pipe end annealing records;

k) Actual measurement records of expansion pipe holes and pipe ends;

l) Boiler expansion records;

......
This preview omits tables, figures, formulas and parts of the technical clauses. The complete document — 32 pages — is available in the English PDF.

Referenced standards

Normative references

GB 50126 · GB 50211 · GB 50231 · GB 50264 · GB 50273 · GB 50275

Similar standards

GB/T 10180-2017|GB/T 10868-2018|GB/T 12145-2016|GB/T 16507.3-2022|GB/T 16507.7-2022

Editions of GB/T 16508.7

Edition	Title	Revision	Status
GB/T 16508.7-2022	Shell boilers - Part 7: Installation	current edition	Current
GB/T 16508.7-2013	Shell Boilers - Part 7: Installation	previous edition	Superseded

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