Detailed Introduction to Thermal Oil Heater Commissioning Steps
Thermal Oil Heater Commissioning Instructions:
Commissioning is an important task to further verify installation quality, system performance, and familiarize operators with procedures, ensuring normal operation. It should be participated by management, technical personnel, and operators. During the initial operation after startup, equipment conditions should be measured and recorded to ensure normal system operation in the future.
1. Commissioning 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 operating procedures.
2. Commissioning Requirements:
All motors should have correct rotation direction, equipment load should be normal, and actions should be correct with continuous operation for more than 2 hours.
The circulating oil pump should undergo cold commissioning before the water pressure test.
Keep commissioning operation records and promptly eliminate possible faults. Prepare all preparations before commissioning.
Commissioning work is divided into two steps: cold state and hot state.
I. Cold State Commissioning:
After the boiler installation inspection is completed, cold commissioning of each part is required. Cold commissioning 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 and 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, open all grate dampers, close the ash discharge door, 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 air 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, perform repair welding.
3. Cold Commissioning of Piping and Circulation System
Commissioning Steps:
Check whether all equipment and piping installation meets 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 if the rotation direction is correct and the sound is normal.
Adjust each valve in the system to prepare for oil filling and test run.
Use the oil filling pump to fill oil into the high-level expansion tank.
Start the hot oil circulation pump.
Observe whether the inlet and outlet pressure of the hot oil circulation pump, pressure drop across the boiler body, inlet and outlet oil temperature, exhaust gas temperature, and other instrument readings are normal.
After continuous cold operation for more than four hours, if no abnormalities occur, hot commissioning can proceed.
II. Organic Heat Transfer Heater Installation Inspection and Acceptance:
After the organic heat transfer heater is fully installed, the main unit and auxiliary equipment should be carefully inspected and accepted item by item to meet the requirements for ignition and operation. A comprehensive inspection should at least include the following items:
1. External Boiler Body Inspection: 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. Check whether the insulation layer is intact, all flue doors, inspection doors, etc. are in good condition, operate flexibly, and seal tightly.
2. Grate Inspection: Mainly check the necessary clearance between moving and fixed parts of the grate, and check whether the handle for moving the grate can be pushed and pulled freely and reach the specified position.
3. Fan Inspection:
For fan inspection, first manually rotate the coupling or drive belt to check for any friction, collision, jamming, or other abnormalities between moving and stationary parts. The fan inlet regulating plate should open and close flexibly and tightly. Check the fan rotation direction, and ensure the impeller rotates smoothly without friction or collision.
4. Other Inspections:
Check all pipes and valves of the organic heat transfer 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
