Thermal imaging diagnostics of heat engineering equipment. Heat engineering equipment - commissioning and testing

3.2. The organization, no later than three days after the end of the investigation, sends the materials of the investigation of accidents to the Federal Supervision Authority and its territorial body that conducted the investigation, the relevant bodies (organizations), whose representatives took part in the investigation of the causes of the accident, the territorial association of trade unions, the prosecutor's office at the location of the organization.

3.3. Based on the results of the investigation of the accident, the head of the organization issues an order providing for the implementation of appropriate measures to eliminate the causes and consequences of the accident and ensure accident-free and stable operation of production, as well as to bring to justice those who violated safety rules.

3.4. The head of the organization submits written information on the implementation of the measures proposed by the accident investigation commission to the organizations whose representatives participated in the investigation. The information shall be submitted within ten days after the completion of the deadlines for the implementation of measures proposed by the accident investigation commission.

3. Characteristics of the organization (object, site) and the place of the accident.

In this section, along with data on the time of commissioning of a hazardous production facility, its location, it is necessary to provide design data and the actual implementation of the project; give an opinion on the state of the hazardous production facility before the accident; mode of operation of the object (equipment) before the accident (approved, actual, design); indicate whether there have been similar accidents at this site (object) before; reflect how the license requirements and conditions, the provisions of the safety declaration were observed.

4. Qualification of service personnel of specialists, responsible persons involved in the accident (where and when he was trained and instructed in safety, knowledge testing in the qualification commission).

5. Circumstances of the accident.

Give a description of the circumstances of the accident and the scenario of its development, information about the victims, indicate what factors led to emergency and its consequences, how the technological process and the labor process proceeded, describe the actions of the attendants and officials, and outline the sequence of events.

6. Technical and organizational causes of the accident.

Based on the study of technical documentation, inspection of the accident site, interviewing eyewitnesses and officials, and expert opinion, the commission draws conclusions about the causes of the accident.

7. Measures to eliminate the causes of the accident.

Outline measures to eliminate the consequences of the accident and prevent such accidents, the deadlines for the implementation of measures to eliminate the causes of accidents.

8. Conclusion on the persons responsible for the accident.

This section identifies the persons responsible for their actions or omissions that led to the accident. Specify what requirements normative documents not performed or violated by this person, the performer of the work.

9. Economic damage from the accident.

The investigation was carried out and the act was drawn up:

_____________________________

(day month Year)

Appendix: investigation material on _______ sheets.

Chairman________________

Commission members.

List of accepted abbreviations

VL- overhead power lines

GOST- state standard

ESKD– Unified system of design documentation

K, KR– overhaul

I&C– instrumentation and automation

CL– cable lines

MTS– logistics

NTD– regulatory and technical documentation

OGM- department of the chief mechanic

OGE- department of chief power engineer

UGP- department of the chief instrumentalist

OKOF- all-Russian classifier of fixed assets

PBU- accounting position

MPC- maximum permissible concentration

PPB– rules of industrial (production) safety

PPR– scheduled preventive maintenance

PTE– rules of technical operation

PUE- rules for the installation of electrical installations

R- repair

RZA– relay protection and automation

SNiP– building codes and rules System

PPR EO– system of preventive maintenance of power equipment

T, TR- Maintenance

TD– technical diagnostics

THEN- Maintenance

THAT– technical conditions

CHP– combined heat and power plant

1.2.

ORGANIZATION OF REPAIRS OF HEAT ENGINEERING EQUIPMENT

Currently, there are three forms of organization of repair heating equipment: economic, centralized and mixed.

In the economic form of organizing the repair of equipment, all work is carried out by the personnel of the enterprise. At the same time, repairs can be carried out by the personnel of the corresponding workshop (shop method) or by the personnel of the enterprise (economic-centralized method). With the workshop method, repairs are organized and carried out by a workshop in which heating equipment is installed. This method is currently rarely used, as it does not allow to fulfill the required volumes in a short time. repair work. With the economic-centralized method of repairing equipment, a special repair shop is created at the enterprise, the personnel of which performs repair work on all equipment of the enterprise. However, this method requires the creation of specialized teams and can only be used at large enterprises that have heating equipment in many workshops.

The most progressive form of repair at the present time is centralized, which allows complex repair work to be carried out according to uniform norms of technological processes using modern equipment and mechanization. With this form, all repair work is carried out by a specialized organization under a contract. The performance of repair work by specialized organizations reduces equipment downtime and ensures high quality repair.

A mixed form of organization of repair is a combination of economic and centralized forms of repair.

The most complex and time-consuming is the overhaul of equipment, especially modern boiler units. To carry out the overhaul of boiler units in a short time, a repair organization project (ROP) is drawn up. The project for the organization of work on the overhaul of equipment usually contains the following documents: statement of the scope of work , schedule of preparatory work, schemes of cargo flows, technological repair schedule, flow charts, specifications for replacement parts and assemblies, a list of tools and materials, repair forms, instructions for organizing a workplace.

The bill of quantities is one of the most important documents. It provides a description technical condition equipment according to entries in the watch and repair logs, equipment inspection certificates, emergency reports, results of operational observations and tests. The statement also indicates the work on the reconstruction of equipment, if any, is planned. The scope of work depends on the condition of the equipment.

The bill of quantities should be prepared in advance in order to prepare spare parts, materials, drawings, etc. After stopping the unit and inspecting it, adjustments should be made to the bill of quantities.

A schedule is drawn up in accordance with the statement of scope of work preparatory work. The schedule indicates the work on the supply of welding gas to the workplaces, compressed air, water, installation of rigging mechanisms and other devices necessary for repair work.

The scheme of cargo flows is developed for the rational movement of goods and materials, as well as for the removal of waste and worn-out equipment and parts. The diagram should indicate the placement of mechanisms and devices that facilitate the movement of cargo flows.

For execution major works for the reconstruction or replacement of worn-out equipment (for example, replacement of air heater cubes), a scheme should be developed for the removal and removal of this equipment from the workshop. When developing schemes, special conditions for the safety of work performed near existing equipment should be taken into account.

Technological repair schedules, compiled on the basis of a statement of volume, should determine the sequence, duration and mode of operation, as well as the number of workers employed.

AT technological maps, drawn up only for the most important repairs, indicate the following necessary information: all operations and their scope, specifications, standards, tools and materials, as well as the devices used.

The specification for replacement parts and assemblies allows them to be prepared in advance before the equipment is taken out for repair, and during repair work, they can be installed instead of worn ones. This allows you to significantly reduce the amount and duration of work performed during the idle period of the unit.

Repair forms allow you to gain experience in clarifying standards and tolerances, determine the repair technology, the service life of individual parts and the quality of the repair.

The instructions for organizing the repairman's workplace should contain a list of fixtures, tools and materials that are necessary for repair work. Maintenance personnel themselves must take care of the organization of their workplace. Therefore, before starting the repair, it is necessary to familiarize the personnel with the scope of work and the timing of their implementation.

REPAIR OF THERMAL POINTS

The current repair of heating points is the main type of preventive maintenance engineering systems and equipment for heating points. It is produced monthly according to the schedule for current repairs. Holding current repair and adjustment of systems and equipment should prevent premature failure of equipment, assemblies and parts due to violation of various adjustments, wear of individual parts, seal failure, loosening of fasteners, and also facilitate the economic and safe operation of the entire complex of equipment included in the heating point until the next overhaul.

The current repair of a heating point provides for troubleshooting by replacing or repairing individual quickly wearing and faulty parts, assemblies, mechanisms, instruments and assemblies, as well as carrying out the necessary inspection, adjustment, fixing, adjustment, electrical measuring, emergency repair and other work. The current repair of heat points is planned in accordance with the structure and duration of overhaul periods. The duration of the current repair of the heating point is determined depending on the total labor intensity, cost and design features work performed. The scope of work depends on the purpose of the equipment, its mode of operation, the magnitude of the load and the power of the heating point.

The current repair of heat points is financed from the funds allocated for this type of repair, and is usually carried out without shutting down local heating systems, hot and cold water supply. During current repairs, visual inspection of all equipment, determine the operability and serviceability of its individual elements, perform repair and adjustment work. Information about the current repair of the heating point is recorded in the operational log. Upon completion of the current repair, all changes in the main equipment (replacement of defective parts with new ones or repaired ones) should be recorded in the passport of the heating point.

The current repair of the heating point consists of the following types repair work:

Repair of heating equipment and heat pipelines;

Repair of thermal insulation;

Repair of electrical equipment;

Repair of automation and instrumentation;

Adjustment work.

Repair of heating equipment and heat pipelines. When repairing heat engineering equipment and heat pipelines of a heating point, an external inspection is first carried out to detect water leaks through flange connections of pipelines, valves, valves, water heaters, elevators, etc. If necessary, flange connections are tightened or gaskets are replaced. The absence of fistulas and cracks on pipelines and fittings is also checked, if necessary, fistulas and cracks are welded in compliance with all requirements for welding. Then, the glands of the shut-off and control valves are checked for tightness, which, if necessary, tighten or replace the gland packing. Control the reliability of the closure stop valves and smooth running of valve spindles. Valve spindles are cleaned of dirt and lubricated thin layer lubricants. Syringe valves (if there are oilers on them). They clean the equipment from rust, dust and oil smudges. Check the condition of the stuffing box seals of the pumps, if necessary, tighten the stuffing boxes or replace the stuffing box packing. Control the presence of lubrication in oil baths (casings, bearings) of pumps, fill with lubrication to the specified level.

During the repair process, the operation of the pumps is checked for heating, vibration, extraneous noise, and, if necessary, measures are taken to identify the causes of malfunctions or eliminate them. Determine the alignment of the shafts of pumps and electric motors and the condition of the elastic couplings. In case of wear of the rubber fingers of the couplings, the fingers are replaced. Establish the reliability of fastening of pumping units to the frames, tighten the bolted connections. The operation of all standby and additional pumps is checked by briefly turning them on in manual control mode. Clean the discharge and suction valves hand pumps. Check and lubricate cuffs. Worn cuffs are replaced. If necessary, during the current repair, it is possible to partially disassemble the equipment with the repair of individual components or their replacement.

Details and assemblies before their installation must be subjected to an external inspection to identify defects that could appear during their storage or transportation to the installation site at the heating point. For the lubrication of various units and assemblies, lubricants are used that are provided for by the requirements of the operating instructions and passports for each specific unit, unit.

Thermal insulation repair. During the current repair of the heating point, the damaged heat-insulating structure is restored. Insulation repair is carried out after hydraulic tests. Before execution partial renovation thermal insulation, metal surfaces to be thermally insulated are thoroughly cleaned of dust, dirt, rust, scale, dried and coated with anti-corrosion materials.

Repair of electrical equipment. During the current repair of the electrical equipment of the heating point, an external inspection of all elements of equipment and wiring is carried out. Check the serviceability of the consoles (shields) and, if necessary, replace burned-out signal lamps and room lighting lamps. The presence and serviceability of protective dielectric means are checked, while protective means with an expired shelf life are replaced. Control the reliability of grounding of all electrical equipment. They check the operability of the emergency lighting of the heating point, as well as overheating of the contact joints of the tires and other contact parts (if there are any burns, discoloration of the tires or contact parts, ozone smell). The integrity of the fuses is checked, for this the contact surfaces are cleaned of oxides and the correspondence of the rated current of the fuses to the load current is monitored. Check the fastening of electrical appliances (if necessary, tighten the nuts and screws), as well as the tightening of all terminal connections. Establish the serviceability of the covers on the machines and the tightness of their closure. Determine the nature of the buzz of working contactors and magnetic starters. With a strong buzz, check the tightening of the screws securing the core, the integrity of the short-circuited coil (by external inspection) and the tightness of the armature to the core. The fastening strength of the magnetic contact system and magnetic starters, the fastening strength of the coils and the state of their insulating cover are determined. Inspect the contacts of magnetic starters and contactors, in case of slight burning of the contacts, clean them to a metallic sheen without changing the contact profile. Check and, if necessary, adjust the contact system of the magnetic starter.

They inspect thermal relays, control buttons for contactors and magnetic starters. Friction surfaces are lubricated with instrument oil. They check the functioning of installation machines, contactors and magnetic starters, as well as the clarity of fixation of batch switches in all positions. External inspection determines the integrity of the insulation of all openly laid cables. Checking the closing of the doors electrical cabinets, assemblies, consoles and the reliability of their constipation. Replenish the lubricant in the bearings of the electric motors. Determine the heating of the housings of electric motors during their operation. If the temperature is above 60 – 70 °C, identify the causes that contribute to overheating, and eliminate them. Check the reliability of the fastening of the electric motors to the frames and, if necessary, tighten the bolted connections. Check that the impeller of the electric motor fan does not touch the casing (according to extraneous noise during the operation of the electric motor), if necessary, eliminate the touching.

During the current repair of electrical equipment, if necessary, it is partially disassembled with repairs individual elements or their replacement.

Repair of automation and instrumentation (KIP). During the current repair of automation and instrumentation of a thermal station, an external inspection of all elements of hydro- and electric automation, as well as instrumentation, is first carried out. They check the absence of water leaks through the connections of the automation elements, if necessary, measures are taken to eliminate them (tighten seals, replace gaskets, etc.). Determine the presence of lubrication in gearboxes executive bodies, if necessary, replenish the lubricant to the specified level. They check the operation of the three-way valves, purge the pressure gauges by briefly opening the valves, clean the filter and impulse lines hydraulic regulators by removing throttle washers and water supply with a pressure of 0.3 – 0.5 MPa into the upper fitting of the filter, while there must be a free drain of water from the side fitting of the filter.

Check the serviceability of thermometers, replace defective (broken) thermometers. They determine the operability of the switches on the automation unit, the integrity and serviceability of the signal lamps, and replace the burned-out signal lamps. Check the completeness of the heating point with thermometers and pressure gauges. The serviceability of the instrumentation and the correctness of their installation are monitored, faulty devices are removed, replacing them with checked and serviceable ones.

In the course of commissioning and verification work, the serviceability and performance of hydroelectric automation elements are monitored. In case of malfunctions, the cause of the malfunction is identified and eliminated by carrying out adjustment work, partial disassembly of the elements and replacement of individual failed parts.

Repair of hydroelectric automation and instrumentation during current repairs provides for following works: dismantling of automation elements in the volume necessary for the production of repairs; replacement of individual failed parts and assemblies of automation elements; cleaning and washing of individual parts; checking their condition; tightening and repair of fasteners of terminal connections; replacement of gaskets and seals.

Adjustment work. Compound adjustment works during the current repair of the engineering equipment of the heating point, it includes: a) checking and setting up pumping equipment, spare fittings, pressure regulators, check valves for design modes of the heat and water supply system, taking into account pressure and temperature fluctuations in main heat networks and city water supply; b) checking, adjustment and adjustment of equipment and circuits of individual control circuits (circuit breakers, relays, magnetic starters, push-button posts, contactors, etc.) of electric motors; c) checking the reliability of contact connections; testing the control circuit under voltage; checking the operation of contactors and automatic machines at reduced and rated voltage of the operating current, checking the operation of electric motors at idle without load and under load; d) check and adjustment of temperature controllers, flow and sensors for design modes; e) checking the quality and stability of the systems automatic regulation, temperature and flow.

The acceptance of the heat point after the current repair is carried out by a commission with the participation of representatives of the operating and heat supply organizations. After the current repair, the engineering equipment of the heating point must meet the following requirements: be in good working condition; thermal and hydraulic modes the operation of the equipment must be debugged (corrected); all automatic systems available at the substation must be used. The heating point must be fully equipped with serviceable and tested instrumentation, serviceable and tested protective and fire fighting equipment, and also equipped with the necessary technical documentation. The electrical equipment of the heating point must be reliably grounded. The doors of the electrical cabinets must be locked and there must be no foreign objects inside the electrical cabinets. Electrical equipment must have proper fuses. All equipment must be appropriately labeled and inscribed. Technological pipelines, water heaters should not have sections with broken thermal insulation, restored sections should be painted in the established colors. Entrance doors heating point must have reliable constipation. Acceptance after the current repair must be documented.

Production and industrial technologies

Types of repair of heating equipment. Their planning and organization. The main malfunctions arising during the operation of boilers and heat engineering equipment are capital repairs. Current repairs are carried out at the expense of working capital and capital due

Types of repair of heating equipment. Their planning and organization. The main malfunctions that occur during the operation of boilers and heating equipment

overhauls. Maintenance carried out at the expense of working capital, and capital - due to depreciation deductions.Refurbishmentcarried out at the expense of insurance

enterprise fund.

The main goal of the current repair is to provide reliable operation equipment with design capacity during the overhaul period. During the current repair of equipment, it is cleaned and inspected, partial disassembly of units with wear parts, the resource of which does not ensure reliability in the subsequent period of operation, if necessary, replace individual parts, eliminate defects identified during operation, make sketches or check drawings for spare parts , draw up preliminary lists of defects.

Maintenance of boiler units should be carried out once every 3-4 months, and heating networks - at least once a year.

Minor defects in heating equipment (steaming, dusting, air suction, etc.) are eliminated without stopping it, if this is permitted by safety regulations. The duration of current repairs for boilers with a pressure of up to 4 MPa is on average 8 - 10 days.

The main purpose of equipment overhaul is to ensure the reliability and efficiency of its operation during the autumn-winter maximum. During a major overhaul, an external and internal inspection of the equipment is carried out, its heating surfaces are cleaned and the degree of their wear is determined, worn components and parts are replaced or restored. Simultaneously with major repairs, work is usually carried out to improve equipment, modernize and normalize parts and assemblies. Overhaul of boiler units is carried out once every 1-2 years.

Simultaneously with the boiler unit, it is being repaired auxiliary equipment, measuring instruments and automatic control system.

In thermal networks that operate without interruption, major repairs are carried out once every 2-3 years.

Unscheduled (restorative) repairs are carried out during the elimination of accidents, in which individual components and parts are damaged. An analysis of equipment damage that necessitates unscheduled repairs shows that they are usually caused by equipment overload, improper operation, as well as low quality scheduled repairs.

Planning repairs of heating equipment industrial enterprise is to develop long-term, annual and monthly plans. Annual and monthly plans for current and overhauls made up of employees of the department of the chief power engineer (chief mechanic) and approves Chief Engineer enterprises.

When planning a PPR, one should provide for the duration of the repair, the rational distribution of work, the determination of the number of personnel in general and according to the specialties of the workers. Planning for the repair of heating equipment should be linked to the repair plan technological equipment and its mode of operation.

Currently, three forms of organizing the repair of heat engineering equipment are used: economic, centralized and mixed.

With economic form of organization of equipment repair, all work is carried out by the personnel of the enterprise. In this case, the repair can be performed by the personnel of the corresponding workshop (shop

method) or by the personnel of the enterprise (economic-centralized method).

At the workshop In this way, the repair is organized and carried out by the workers of the workshop in which the heat engineering equipment is installed. Currently, this method is rarely used, since it does not allow the necessary amount of repair work to be completed in a short time.

At economic-centralizedway of repairing equipment at the enterprise, a special repair shop is created, the personnel of which performs repair work on all equipment

enterprises. However, this method requires the creation of specialized teams and can only be used at large enterprises that have heating equipment in many workshops.

Currently, the most progressive form of repair iscentralized, which allows complex repair work to be carried out according to uniform standards and technological processes using modern equipment and mechanization. With this form, all repairs are performed by a specialized organization under a contract, which reduces equipment downtime and ensures high quality repairs.

mixed the form of organization of repair of heat engineering equipment is various combinations of economic and centralized forms of repair.

ORGANIZATION AND PLANNING OF REPAIRS OF THE HEAT ENGINEERING EQUIPMENT

1.1. TYPES OF REPAIRS AND THEIR PLANNING

The reliability and efficiency of the operation of heat engineering equipment largely depends on the timely withdrawal for repair and the quality of the repair work carried out. System of planned decommissioning of equipment from technological process is called preventive maintenance (PPR). In each workshop, a system of scheduled preventive repairs should be developed, which are carried out in accordance with a specific schedule approved by the chief engineer of the enterprise. In addition to scheduled repairs to eliminate accidents during the operation of heat engineering equipment, restoration repairs are carried out.

The system of preventive maintenance of heat engineering equipment includes current and major repairs. Current repairs are carried out at the expense of working capital, and capital repairs are carried out at the expense of depreciation. Restorative repairs are carried out at the expense of the company's insurance fund.

The main goal of the current repair is to ensure the reliable operation of equipment with design capacity during the overhaul period. During the current repair of equipment, it is cleaned and inspected, partial disassembly assemblies with rapidly wearing parts, the resource of which does not ensure reliability in the subsequent period of operation, repair or replacement of individual parts, elimination of defects identified during operation, making sketches or checking drawings for spare parts, drawing up a preliminary list of defects.

The current repair of boiler units should be carried out once every 3-4 months. The current repair of heating networks is carried out at least once a year.

Minor defects in heat engineering equipment (vapor, dusting, air suction, etc.) are eliminated without stopping it, if this is permitted by safety regulations.

The duration of the current repair for boilers with a pressure of up to 4 MPa is on average 8–10 days.

The main purpose of equipment overhaul is to ensure the reliability and efficiency of its operation during the autumn-winter maximum. During a major overhaul, external and internal inspection of the equipment, cleaning of its heating surfaces and determining the degree of their wear, replacement and restoration of worn components and parts are carried out. Simultaneously with major repairs, work is usually carried out to improve equipment, modernize and normalize parts and assemblies. Overhaul of boiler units is carried out once every 1-2 years. Simultaneously with the boiler unit, its auxiliary equipment, measuring instruments and automatic control system are being repaired.

In thermal networks operating without interruption, major repairs are carried out once every 2-3 years.

Unscheduled (restorative) repairs are carried out to eliminate accidents in which individual components and parts are damaged. An analysis of equipment damage that necessitates unscheduled repairs shows that their cause, as a rule, is equipment overload, improper operation, and poor quality of scheduled repairs.

During a typical overhaul of boiler units, the following work is performed:

Complete external inspection of the boiler and its pipelines at operating pressure;

Complete internal inspection of the boiler after its shutdown and de-cooling;

Checking the outer diameters of pipes of all heating surfaces with the replacement of defective ones;

Flushing superheater pipes, superheat regulators, samplers, coolers, etc.;

Checking the condition and repair of the boiler fittings and the main steam pipeline;

Checking and repairing the mechanisms of layered furnaces (fuel feeder, pneumo-mechanical thrower, chain grate);

Inspection and repair of mechanisms of chamber furnaces (fuel feeder, mills, burners);

Checking and repairing the boiler lining, fittings and devices designed to clean the external heating surfaces;

Pressure testing of the air path and air heater, repair of the air heater without replacing cubes;

Pressure testing of the gas path of the boiler and its sealing;

Checking the condition and repair of draft devices and their axial guide vanes;

Inspection and repair of ash collectors and devices designed to remove ash;

External and internal cleaning of heating surfaces of drums and collectors;

Inspection and repair of the ash-ash removal system within the boiler;

Checking the condition and repairing the thermal insulation of hot boiler surfaces.

Planning repairs of heat engineering equipment of an industrial enterprise consists in the development of long-term, annual and monthly plans. Annual and monthly plans for current and major repairs are drawn up by the department of the chief power engineer (chief mechanic) and approved by the chief engineer of the enterprise.