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Pre-installation preparation work

The installation unit of the organic heat transfer heater must have a thermal oil furnace installation qualification certificate issued by the competent authority that covers the installation scope, contact the local boiler supervision agency, fill in the installation notification, and accept the installation supervision and inspection of the local boiler inspection and testing unit.

After the installation is completed, promptly handle the registration and entry procedures for the organic heat transfer heater according to relevant regulations.

The boiler user unit should assign a dedicated person to be responsible for the installation of the organic heat transfer heater. During the installation of the organic heat transfer heater, a boiler operator should participate, and there should be pipe fitters, fitters, riggers, cold workers, welders, and auxiliary workers.

Study relevant materials

Relevant personnel should carefully study the "Organic Heat Transfer Heater Safety Technical Supervision Regulations" (93), the organic heat transfer heater drawings, installation and operation manuals, and other technical documents to understand and master installation, lifting, operation, and other matters.

Determine the installation location

(1) The installation location should preferably be close to the heat-using location to shorten the pipeline.

Reduce infrastructure costs and minimize heat loss.

(2) Ensure smooth transportation during boiler installation.

Installation of major components

(1) Equipment acceptance

After the gas-fired thermal oil boiler arrives, check the parts and components against the manufacturer's delivery list.

Verify the completeness of the equipment according to the boiler drawings, and check whether the major components have been damaged or deformed during transportation.

(2) Main unit positioning

When positioning the main unit, it must be in an upright state. Use lifting equipment to lift the base lifting lugs; do not tie any other parts.

Pipeline installation

Pipeline installation should comply with the "Organic Heat Transfer Heater Safety Technical Supervision Regulations" and refer to this manual and the process flow diagram. The main material of the gas boiler used for pressure pipelines should have a corresponding quality certificate. Pipeline connections, except for flanges, should be welded as much as possible.

Pipeline welding must be performed by qualified welders. The pipeline layout should have a slope of 2-3%. Set an exhaust port at the highest point of the pipeline and a drain port at the lowest point. For straight pipe sections over 20 meters, thermal expansion joints should be installed. The oil-gas separator should be installed with the upper part connected via an expansion pipe.

For fuel-fired thermal oil boilers, the expansion pipe should be arranged with an upward slope to ensure smooth exhaust, and have a certain length for heat dissipation. This pipe should not be insulated, and no valves should be installed. Pipe flanges should be PN1.6MPa (pg) or higher.

Valves should be flanged with a rating of at least PN1.6MPa (pg) and temperature resistance above 400°C. Flange gaskets should be metal-wound graphite gaskets. The weight of the thermal oil pipeline must not be supported by the furnace body or the thermal oil circulation pump, and thermal expansion should be fully considered. The flow direction of the thermal oil in the heat-using equipment should be low in and high out to facilitate exhaust.

After pipeline installation is complete, except for the expansion tank and oil storage tank which do not participate in the pressure test, the rest should undergo a hydraulic test at 1.5 times the rated working pressure. After the hydraulic test, drain all liquid from the system and flush the pipeline with compressed air to remove residual debris and liquid. The main pipeline material should be 20# low and medium pressure boiler seamless steel pipe. During the system pipeline hydraulic test, the installation supervision and inspection personnel of the local boiler inspection unit must be present. After pipeline installation is complete, except for flange connections which should be insulated after temperature rise commissioning, the rest can be insulated, and color marking should be carried out according to relevant regulations.

Installation of accessories

Pressure gauge, liquid level gauge, thermometer:

After the pressure gauge is installed, a red line should be drawn on the dial to indicate the maximum allowable working pressure. The pressure gauge cock should work flexibly without leakage, and the pressure gauge siphon pipe should be unobstructed and not insulated.

The pressure gauge is strictly prohibited from use under any of the following conditions:

(1) For pressure gauges with a stop pin, if the pointer cannot return to the stop pin after rotation when there is no pressure; for pressure gauges without a stop pin, if the pointer deviates from zero by more than the allowable error specified for the pressure gauge when there is no pressure.

(2) The glass is broken or the dial scale is unclear.

(3) The seal is damaged or the inspection period has expired.

Liquid level gauge: The upper and lower cocks of the liquid level gauge should be tightened to ensure no leakage, and the glass should be free of dirt and damage.

Thermometer: The thermometer indication should be clear and accurate.