DIVISION C BOILER MOUNTINGS VOLUME C1 SOOT BLOWERS LIST OF CONTENTS Location TAB-1 (1-4)
Description
Ref. No. / Drg. No
SOOT BLOWERS LRD IIE Views
1-00-076-60601
Furnace Temp. Probe Views ( FTP IE- AC)
1-00-076-60602
Wall Deslagger Views ( WB IE )
2-00-076-60990
Soot Blower Arrangement
3-00-076-60354
TAB-2 (5-18)
Soot Blower Operations - Emergency Check List
Pub. No. 7515
TAB-3 (19-36)
AC Induction Motor(For Soot Blowers)
Pub. No. 7506
TAB-4 (37-63)
Soot Blower - General Instructions
Pub. No. 7501
TAB-5 (64-91)
Wall Deslagger -Model WB IE
Pub. No. 7503
TAB-6 (92-131)
Furnace Temperature Probe Model FTP IE & IIE
Pub. No. 7505
TAB-7 (132-193)
LRD IIE Long Retractable Soot Blower
Pub. No. 7514
TAB-8 (194-268)
Methods And Procedures For Installation Soot Blowers
Pub. No. 7508
TAB-9 (269)
Soot Blower Arrangement
4-00-076-60871
1610 – 1611 JINDAL ANGUL
VOLUME-C1
PAGE 1 Of 1
TAB - 1
P 10
04
05 06 07 08
01 02
03
09
DURING BOILER HOT CONDITION
1610 - 1611 VOL - C1 TAB - 1 - 1
C
B
A B 01 VIEW-A
F
F SECTION-GG
SECTION-FF
SECTION-EE
E 04 G
G
03
D 02
E DETAIL-C
VIEW-D
VIEW-BB
WALL & SLEEVE SECTION
1610 - 1611 VOL - C1 TAB - 1 - 2
1610 - 1611 VOL - C1 TAB - 1 - 3
1610 - 1611 VOL - C1 TAB - 1 - 4
TAB - 2
INSTRUCTION MANUAL SOOT BLOWER OPERATIONS EMERGENCY CHECK LIST
Bharat Heavy Electricals Limited Tiruchirapalli
PUB. NO. 7515 1 1610 - 1611 VOL - C1 TAB - 2 - 5
CONTENTS INTRODUCTION SOOT BLOWER OPERATION -EMERGENCY CHECK LIST SOOT BLOWER JAMMING BLOWER MOTOR OVERLOAD SOOTBLOWER OVERRUN STEAM PRESSURE LOW STEAM TEMPERATURE LOW STEAM NO FLOW A. C. CONTROL SUPPLY/ POWER SUPPLY FAILURE SOOT BLOWER SEQUENCE INTERRUPTION VALVE MOTOR OVERLOAD PHILOSOPHY OF JAMMING RELAY PROTECTION AND OVERLOAD RELAY PROTECTION IN SOOTBLOWER MCC.
2 1610 - 1611 VOL - C1 TAB - 2 - 6
INTRODUCTION This manual deals with the emergency actions that are to be carried out when an annunciation occurs during Sootblower operation. Even though many protections are available in the sootblower control panel, sometimes it is likely mal-operation can happen. At that time the operating and maintenance engineers may be in search of correct course of action. We hope this manual will help the operating and maintenance engineers to know what safe action they can take to protect the sootblowers as well as the boiler tubes. The contents of the manual has been carefully prepared. However, it must be understood that no amount of written instructions will replace intelligent thinking and alertness on the part of the operator during an emergency to reason the causes of mal-f unctions and to take ‘immediate remedial actions demanded by the situation. Suggestions for the improvement of the manual would be welcome.
3 1610 - 1611 VOL - C1 TAB - 2 - 7
SOOT BLOWER OPERATION -EMERGENCY CHECK LIST The control panel is normally supplied with the following audible and visual annunciations.
S 1. N o. 1.
S ootblow er jam m ing
Type of annunciation audible/visual
2.
S ootblow er m otor overload
audible/visual
3.
S ootblow er overrun
audible/visual
4.
S team pressure low
audible/visual
5.
S team tem perature low
audible/visual
6.
S team no flow
audible/visual
7.
A .C . control supply failure
audible/visual
8.
S ootblow er sequence com pletion.
audible/visual
9.
V alve M otor overload
audible/visual
10.
S equence interruption
audible/visual
D escription of annunciation
The above alarms can be actuated during the operation of (a) long retractable soot blower (b) wall deslagger (c) rotary blower (d), half retractable soot blower and (e) airheater cleaner (retractable). The possible causes and solutions for each of annunciations for long retractable Soot blowers & wall deslaggers are described in this manual. For other blowers, the causes and solutions may be more or less similar to long retractable soot blowers.
4 1610 - 1611 VOL - C1 TAB - 2 - 8
1.
SOOT BLOWER JAMMING This alarm will be actuated when soot blower gets jammed mechanically in the forward direction. The alarm is given through an instantaneous overload relay which is actuated instantaneously and will reverse the blower to bring to the home position. The instantaneous overload relay will actuate the timer which will be set at 2 secs., normally current will be 105 percent of the rated current.
1.1 Sl. No. (i)
(ii)
Long retractable soot blower Probable causes and solutions for jamming Probable Causes
Solution
Lance tube fouling with the boiler tubes or wall sleeve
During shut down the boiler tubes should be rectified so that a gap of 100-150 mm is kept in between the lance tube OD and the boiler tube OD. Realign any tube obstructing the lance movement. Physical obstruction for the travelling Check the blower for proper clearance for the carriage in the housing travelling carriage. This can be checked only by local operation
(iii)
If direction of rotation for traverse motor is incorrect
Change the power cable loads with power off and run blower again.
(iv) (v) (vi)
Failure of reverse limit switch Valve stem jammed/pitted Overtightened gland packing in travelling carriage
Replace the defective switch Remove the stem and replace or rectify Loosen the gland
1.2 (i)
Wall Deslagger : Probable Causes and Solutions for Jamming: Swivel tube fouling with shroud Position the blower in such a way that the tube swivel tube does not foul with the shroud tube and the perpendicularityto the water wall is to be maintained. (ii) Dust accumulation on the guide Clean the guide rods and the swivel tube rods and the swivel tube once in a week. If the accumulation of dust is severe, and morefrequent provide additional covers. (iii) Direction of traverse motor is inChange the direction of motor by correct changing powerleads. (iv) Wrong setting of limit switches Reset the Cam. LSTS and LSTE (v) Too much of Gland tightness Loosen the gland nuts to have enough on wall blower body. freeness. (vi) Valve stem/pitted jammed Remove the item and replace or rectify. 'Reset'push button on the panel should be pressed to continue the sequentialoperation after bypassing the faulty blower.
5 1610 - 1611 VOL - C1 TAB - 2 - 9
2.
SOOT BLOWER MOTOR OVERLOAD
This annunciation will come on as soon as the motor gets overloaded the traverse motor will get stopped. The thermal overload relay is set to act normally when the current exceeds 105 percent of the rated current. The probable causes and solutions for his are given below : 2.1
Long retractable soot blower - Motor overload- Probable Causes and Solutions :
Sl. No. (i) (ii) (iii) (iv) (v) (vi)
Causes
Solutions
Lance tube fouling with boiler tubes Overtightened gland packing
Same solution as indicated under sootblower jamming. Do not overtighten the glands. A slight leakage of steam is allowed. Wrong overload relay setting Check the overload relay setting and set the relay at the correct value. Dust accumulation over the rails Clear the dust and debris. Wrong motor installation in Check the overload relay setting and powerpacks. set the relay at the correct value. Damaged power/control cables (Short circuit in any two phases in M.C.C. or Terminal box)
Check the power cables. It is likely that cables damage will result in short-circuiting. (a) Check the power cable from MCC. to blower terminal box. (b) Check the power cable from the motor to terminal box. (c) Check the terminal box of motor. Refer the motor instructions manual.
(vii) Motor winding fault 2.2 (i)
Wall deslagger: Swivel tube fouling with the boiler tubes (ii) Wrong overload relay setting (iii) Short circuit in the powerloads in M.C.C. or in terminal box (iv) Motor winding fault (v) The rack comes out of pinion
Same solution as indicated under ‘Sootblower jamming’. Do as suggested in 2. 1. (iii) Do as suggested in 2.1 (vi)
Do as suggested in 2.1 (vii) Sometimes because of loose screws of cams the rotary gear box is likely to come out of pinion. For this (a) an easy solution would be to put two rubber washers on guide rods. (b) Periodically tighten the cam screws. (vi) Improper meshing of gears Dismantle the gear box and check the meshing of gears. Overload relay should be reset in M.C.C. before operating the same blower. After ensuring the lance of the particular blower is withdrawn to the home position only, the sequential operation should be continued. Physical checking is a must.
6 1610 - 1611 VOL - C1 TAB - 2 - 10
3.
SOOTBLOWER OVERRUN The total time for forward and reverse operation of sootblowers is supervised by elapsed timers. When the blower stays for a longer time than its normal working time the blower overrun annunciation will come and will stop automatic sequence operation and at the same time retract the blowers to its initial position. Normally the timer is set in excess by 1 or 2 minutes of blower operating time. The probable causes and suggested solutions are given below 3.1 Long Retractable Soot blower-Soot blower overrun-Probable causes and solutions
Sl. No.
Causes
Solutions
(i)
Faulty reverse limit switch
If the blower is not withdrawn auto-matically Immediate action Allow the steam flow if the blower is located in hot zone. Send one man for closing the regulating valve manually. Switch off the power, Then withdraw the lance manually. Caution Do not allow the lance inside the boiler for a longer time with blowing medium. Later Check the limit switch contacts, spring, etc. If it is in serviceable condition service and put back the switch. If it is not possible then replace the switch with a new one.
(ii)
Wrong timer setting
Normally the timer is set more than 1 minute than the operating time. Check the timer setting and set correctly. Check the forward and reverse contactor, clean the terminals and' contacts and put back in M.C.C. Immediate action : (a) Allow the steam flow not more than 5 minutes. (b) Wrap a chain or rope around the travelling carriage through a winch. If this takes too much of time, stop the steam flow. By doing so it is likely that the lance may get bent. In case of blowers located in low temperature zones, the steam flow can be cut off just after the jamming has occurred (c) And now stop the steam flow. (d) Pull out the lance tube. Later : Replace the damaged chain link, using connector link. Immediate Action : (a) Cut off power supply. (b) Allow the steam flow for not more than 5 minutes. (c) Retract the lance, using the hand crank. Later Assemble a new motor and check the direction of rotation before the blower is put into operation again.
(iii) Failure of contactor and contactor reverse (CR) coils (iv) Traverse chain failure due to the weak link
(v) Traverse Motor shaft breakage
7 1610 - 1611 VOL - C1 TAB - 2 - 11
Sl. No.
Causes
(vi)
Burnt out or damaged traverse Motors.
(vii)
Thermal overload Relay for traverse motor blows as a result of which the traverse motor stops.
3.2
Wall Deslagger:
(i) ‘ LSTR ' limit switch fails to operate or damaged, missing switch arm.
(ii)
Wrong timer setting
(iii)
Faulty rotary contactor (CRO)
(iv)
Failure of Traverse motor -shaft or rotary motor shaft
(v)
Burnt Out or damaged motors
Solutions Immediate Action : (a) Cut off the power supply. (b) Allow the steam flow for not more than 5 minutes. (c) Retract the lance tube using the hand crank, after cutting off steam supply. Later Assemble a new motor or repaired one and check the direction of rotations before the blower is put into operation again. Immediate Action (a) Cut oft the power supply. (b) Allow the steam flow for not more than 5 minutes. (c) Retract the lance tube using the hand crank as suggested in 3.1.(i) Later Check why the motor has stalled. Find out the cause
Immediate Action: (a) Switch off the power supply. (b) Using the hand crank, withdraw the swivel tube. (Hand cranking is possible with steam on).
Normally the time is set for 120 secs. Check thetimer setting and set correctly. Check the rotary contactor, clean the terminals and contacts and put back in M.C.C. Immediate Action (a) Switch off the power supply. (b) Using the hand crank withdraw the swivel tube. (Withdrawl of swivel tube by hand cranking is possible with steam on) Later : Assemble a new motor and check the direction of rotation before ,he blower is put into operation again
Immediate Action : (a) Cut off the power supply. (b) Retract the swivel tube using the hand crank. Later : Assemble new motors and 'check the direction of rotation before the blower is put into operation again. Reset push button on the panel should be pressed to continue the sequential operation after ensuring the particular blower is in home position. Physical checking is a must.
8 1610 - 1611 VOL - C1 TAB - 2 - 12
4.
STEAM PRESSURE LOW This annunciation will come to the operator as soon as the system pressure is lower than the set value. As soon as the annunciation is received, retract the blower immediately and stop the sootblowing operation. The probable causes and suggested solutions are as follows:
S1. No. (i)
Probable Causes
Suggested Solutions
Multiple leaks in the system (a) sootblower valve passing. (b) Sootblower flange leakage. (c) Drain valve heavy leakage. Mal-functioning of pressure reducing valve
(ii)
(iii)
Hand stop valve partially closed
(c) Then proceed with SB operation. (iv) Erratic action of pressure switch or damaged pressure switch.
(v)
Broken supply line
Stop the sootblower operation. Later Identify the leakage in the system and attend the leaks. Immediate Action: Stop the sootblower operation. Later : Attend to this problem. Ref.detailed instructions for trouble shooting of pressure reducing valve. Immediate : (a) Stop the sootblower operation (b) Open the valve fully.
Immediate Action: Sootblowing can be continued by watching the pressure indicator available on the panel. Later : Attend to pressure switch or replace with a new one. CAUTION : Close the steam supply before attending the work. Immediate : Stop the sootblower operation. Later : Close the steam supply. Repair the failed steam piping. Then proceed with Sootblower operation.
‘Reset’ push button on the panel should be pressed to continue the sequential operation. Physical checking is a must wherever necessary.
9 1610 - 1611 VOL - C1 TAB - 2 - 13
5.
STEAM TEMPERATURE LOW This annunciation is provided so that the operator will be cautioned when the medium temperature is low. It is likely that low steam temperature will cause condensation which will lead to boiler tube wastage. This may be due to inadequate ‘warm up’ and poor insulation. The solutions will be sufficiently warm up the line and ensure sound insulation. Another cause may be choking in the drain line. The solution would be to remove the condensate properly. ‘Reset’ push button should be pressed after rectifying the fault to continue the sequential operation further.
10 1610 - 1611 VOL - C1 TAB - 2 - 14
6.
STEAM NO FLOW During the operation of the blower, if steam supply is interrupted for a longer time than the set time in the timer, then the annunciation will come, stop the sequence and retract the lance to the home position. ‘Steam no flow’ interlock was caused by failure to turn on the blowing medium approximately 45 secs after a signal was sent to sootblowers. The probable causes and solutions are as follows :
Sl. No. Probable causes 6.1 (i)
Solutions
Long retractable sootblower. Missing blowing adjustment bar or broken adjustment bar.
As soon as the alarm is initiated check whether the blower lance is retracted back to the home position bypass the blower and proceed with sequential operation. Later : Assemble the blowing adjustment bar. (ii) Mal-adjusted or damaged flow switch If adjustment is to be corrected, correct the switch. If (common for wall deslagger) you have found that the switch is damaged then attend to the damage. If it requires longer time proceed with the sootblower operation bypassing the inter-lock. But this can be done only if one or two men are kept near the blower. (iii) An improper setting in the timer Adjust the timer to initiate annunciation after 45 sees. (common for wall deslagger) (iv) Valve not opening due to Immediate If the blower is retracted back then bypass the blower (applicable for wall deslagger) and proceed with, sequential operation.. (a) missing and damaged pins of valve opening mechanism Later Check the pins. If any pins have damaged replace them. Check the lever engagement pull tod cam etc. (b) Mal-operation of valve If it is not OK make it sleight. operating mechanism (c)
Overtightened gland packing
d) Stem pitting
(e) Missing of valve opening screw on lever
6.2 (i)
Wall deslagger Missing ramp cam on the rack
Check the valve opening and closing. Make the glands loose. Slight leakage is permissible. Before removing the valve close the steam supply. If the stem pitting is severe replace with a new stem. Check the presence of screw. If the screw is not in position, new screw is to be assembled. Immediate Make sure the unit is retracted back immediately. Bypass the blower and proceed with sequential operation. Later :
Check physically the blower and replace new cam. If the blower has been retracted to the original position, bypass the blower and press the reset button for proceeding with sootblower sequential operation.
11 1610 - 1611 VOL - C1 TAB - 2 - 15
7.
A. C. CONTROL SUPPLY/ POWER SUPPLY FAILURE When the A.C. supply fails during the operation of blowers, an alarm is annunciated. If the sootblowing operation is proceeding at that time, send a gang for withdrawing the blower back out of the boiler. Proceed as follows : 7.1
Long Retractable Soot blower
(1)
Send one man for closing the manual operated valve.
(2)
Send another man with hand crank. After declutching withdraw immediately.
7.2 Wall deslagger Send a man with a hand crank to withdraw the lance tube. “Reset” button must be pressed in the control panel before proceeding with the operation after the power is restored.
8.
SOOT BLOWER SEQUENCE INTERRUPTION This annunciation will come to the operator when the blower does not start even after the sequencing signal is given to the other blower to start. If the blower does not start after 10 secs. even after the completion of operation of the previous blower then this annunciation will come. The probable causes and solutions are as follows :
Sl. No. (i)
(ii)
(iii)
Probable causes
Solutions
Motor burnt out or damaged traversing motor
Immediate: Bypass the blower from sequence operation Press ' reset ' button and proceed with other blower operation. Later : Check the motor. If possible repair the same or replace with a new motor. Immediate: Bypass the blower from sequence operation and proceed with other blower operation. Later : Identify the problem and rectify the system.
Failure of motor starter, broken wires, motor overload.
Defective cabling.
Immediate: Bypass the blower from sequence operation. Press "reset" button and proceed with other blowers operation. Later : Identify the problem and rectify the system. Press "reset" button in the panel before operation is continued.
12 1610 - 1611 VOL - C1 TAB - 2 - 16
9.
VALVE MOTOR OVERLOAD This annunciation will come if the main supply valve actuator is overloaded. The probable causes and solutions are as follows :
Sl. No. (i)
Probable causes
Solutions
Too much gland overtightening
Ensure correct gland packing and tightness. (ii) Score marks on stem Check Recondition/ Replace stem if necessary. (iii) Non-release of motor brake Remove the brake mechanism and service. (iv) Wrong setting of limit switch on the Set the limit switches correction as actuator. instructed in 0 & M manual. (v) Wrong overload relay setting. Check and set overload relay at the recommended value. (vi) Excessive torque setting of torque Set the torque switches at the switches. recommended value as per 0 & M manual No. 7001. (vii) Jamming of moving components in Bypass the whole steam line and the guide ways. then do servicing, For detailed repairing procedure refer the relevant 0 & M manuals. After attending to the fault, press 'reset' button in the panel before the operation is continued.
13 1610 - 1611 VOL - C1 TAB - 2 - 17
10. PHILOSOPHY OF JAMMING RELAY PROTECTION AND OVERLOAD RELAY PROTECTION IN SOOTBLOWER MCC. 1.
Overload protection is for all motors and for all blowers.
2.
The setting of overload relay shall be 105% for all the motors for all types of blowers. All motors in all types of blowers have 110% capacity for 30 mts.
3.
The normal loading of motors in all the blowers when the blower is working with steam is likely to be around 50%.
4.
The overloading of motor in LR blowers is expected due to hitting of tubes etc.
5.
The overload relay which is set at 105% when about 300% current (starting current) is flowing will act in about 25/30 secs. (When the relay is hot/ cold).
6.
Jamming relay protection is only for long retractable type blowers. The jamming relay shall be connected in Traverse Motor power line. Jamming relay will act instantaneously.
7.
The current setting of the jamming relay shall be 105% of traverse motor rated current.
8.
A time delay relay (0-10 secs.) is provided in Jamming relay protection circuit and is set at 2 secs. This is to avoid the nuisance which may arise due to action of Jamming relay 7during the starting of traverse motor. The starting time of traverse motor is 0.3 sec. The starting current of traverse motor is 3.0 Amps.
9.
Jamming relay with its circuitry will act when overloaded to 105% due to overload/ jamming while on forward operation and reverse the blower. Overload relay will act when overloaded to 105% while on traverse operation. The blower stops operating. However the motor is protected.
10.
Locked rotor withstand time for traverse motor is 40 secs. in hot and 75 secs. in cold conditions.
11.
Selection of jamming relay and C.T. CAG 19 English Electric Relay with 5 Amps. operating coil and 20-80%setting range. 5/5A ratio C.T. 5P20, 15VA
14 1610 - 1611 VOL - C1 TAB - 2 - 18
TAB - 3
INSTRUCTION MANUAL AC INDUCTION MOTOR (FOR SOOT BLOWERS)
Bharat Heavy Electricals Limited Tiruchirapalli PUB. NO. 7506
1610 - 1611 VOL - C1 TAB - 3 - 19
CONTENTS GENERAL INFORMATION GENERAL STORAGE LOCATION OF MOTORS AND CONTROL APPARATUS GEAR DRIVES DRYING OUT REVERSAL OF ROTATION INSPECTION AND TESTING5 GENERAL MECHANICAL ELECTRICAL MAINTENANCE PROTECTION OF EXPOSED SURFACE6 GENERAL INSULATION RESISTANCE REMOVAL AND REPLACEMENT OF BEARINGS BALL AND ROLLER BEARINGS LUBRICATION CONTROLLERS, STARTERS AND RHEOSTATS SAFETY DEVICES CHECK CHART AC MOTOR CHECK CHART MAINTENANCE SCHEDULE1 LIMITS OF TEMPERATURE RISE DATA SHEET FOR SOOT BLOWER MOTORS
2 1610 - 1611 VOL - C1 TAB - 3 - 20
GENERAL INFORMATION 1.1
GENERAL
Where the magnitude of the installation justifies the cost, a set of record plans should be provided by the installation engineer or contractor, clearly indicating the complete layout of the installation. There is always the possibility that hair, hands or clothing may be caught in moving parts of electrical machines, which should thus be so located or guarded as to minimize the risk of such injuries to those who may come in contact. In the case of equipment subject to the provisions of the Factories Act such mechanical protection is a statutory requirement. 1.2
STORAGE
If the machine has got to be stored for some time before installation, the same has to be done in a clean, dry place. If the location is susceptible for vibrations transmitted due to working of heavy machinery, proximity to rail track, etc. it is desirable to have a resilient pad between the floor and the machine. Also keep the shaft of the motor locked so that, bearings are not damaged during storage. However, periodically rotate the shaft free and relock it. 1.3
LOCATION OF MOTORS AND CONTROL APPARATUS
Apparatus shall be so located that all current-carrying parts are adequately ventilated in relation to the losses to be dissipated in the form of heat. Note:
In no circumstances should the motor be enclosed in a box or other covering hat restricts or excludes the ventilating air to a significant extent. Such restriction may result in the burning out of the motor when a sustained load approaching the full value is reached.
The motor and control apparatus shall not be located where it is liable to exposure to water, corrosive liquid, oil, steam, carbon, copper dust, dirt or other adverse condition or to risk of mechanical damage, unless it is suitably enclosed to withstand such conditions. Adequate access shall be provided to all working parts. The possible need for facilities for removing the equipment at a later date for repairs or maintenance should be considered in relation to the accessibility of the equipment. Note:
For handling heavy equipment it is often advisable to arrange for the incorporation of a lifting beam in the structure of the building, the beam being located immediately over such parts of the equipment as may require attention and being capable of supporting the maximum weight involved.
The placing of apparatus in situations where inflammable material may be present should be decided in relation to the fire risk involved, and where it is impracticable to segregate the apparatus from such material, the use of totally enclosed or pipe ventilated apparatus should be considered. Where resistors are used which are liable to operate at high temperatures, they should be adequately spaced away from combustible materials such as wood-work, in order to combat the risk of fire. Whenever the temperature of the casing of the apparatus is liable to exceed 194 Deg. F (or 90 Deg.C) the casing should be so located or guarded as to prevent accidental contact by persons or with combustible materials. 1.4
GEAR DRIVES
With gear drives, alignment is equally important. The centre of the pinion shall be in line with the centre of the spur wheel and the two wheels perfectly parallel, the latter being checked by means of feeler gauges between the teeth of the respective wheels. The gear wheels shall be fully meshed both in depth and along their width of face and the check for meshing shall be made all the way round the driven wheel in case it is out of truth. Should the driven wheel be out of truth and the meshing adjusted correctly at the lowest point of the driven wheel, the gears would jam when the high parts engage and probably bend the motor shaft. 3 1610 - 1611 VOL - C1 TAB - 3 - 21
Bevel or single helical gears will impose an end thrust on the motor shaft, and are not therefore recommended unless provision is made to take the thrust. Double helical gears may also transmit an end thrust if the end-play in the bearings of the driven gear is greater than the end-play in the motor bearings. Where mechanical conditions are severe it is sometimes necessary, particularly in the case of large motors, to employ an outboard bearing for the motor shaft and in some cases to mount the driving pinion in two separate bearings and couple it to the motor through a suitable flexible coupling. A flexible coupling is invariably necessary when a motor is coupled to a selfcontained gear box. It is advisable, when any drives of the above mentioned or similar types are considered, that this be specified so that provision can be made to suit the conditions. Where motors are fitted with ball and roller bearings, care shall be taken to ensure that no axial strain is imposed on the bearings when the half-couplings are bolted together. 1.5
DRYING OUT
All motors shall be dried out before the full voltage is applied to the terminals, if the insulation resistance is below one megaohm when the machine is cold. A convenient method of doing this is to block the motor so that it can not rotate and apply a very low voltage of about 10 percent of the normal to the stator terminals. In the case of slip-ring motors, the rotor windings should be short-circuited. Close supervison is necessary during the process of drying out with this method. The heat generated in the windings is not easily dissipated and one part of the winding may be exceeedingly hot before another part has had time to expel the moisture. This may be obviated to some extent by taking every precaution to exclude draughts from the exposed parts of the windings. The motor can be placed in oven, if available, but the temperature shall not be allowed to exceed 180 Deg. F (or 82.2 Deg.C). Alternatively, hot air may be blown into the motor but the air should be clean and dry and at a temperature of not more than 180 Deg.F. If no other means are available, coke braziers or electric radiators may be placed round the machine. Carbon filament lamps placed inside the machine can be employed quite satisfactorily, but care shall be taken that the hot bulb is not in contact with any windings. If it is not possible to reach a sufficiently high temperature the ventilation may be reduced by covering the stator with a tarpaulin. Whichever of the above methods of drying out is adopted, the heating shall be continuous and shall be carefully watched to ensure that it does not attain a temperature sufficiently high to damage the insulation. The maximum safe temperature of the windings measured by thermometer is 180 Deg. F (or 82.2 Deg.C). At the same time the temperature should not be allowed to fall too low as otherwise re-absorption of moisture would take place. The insulation resistance will be found to drop considerably as the motor warms up, will reach the minimum and then remain constant for sometime depending upon the dampness of the machine and as the drying proceeds the insulation resistance will gradually rise. The drying out shall be continued as long as the insulation resistance rises, or until a sufficiently high value has been reached, i.e. not less than 1 megaohm per 1000 volts at 75 Deg.C. During the drying out period, readings of temperature and insulation resistance shall be taken atleast once an hour in order to see how the drying out is progressing. The temperature of the motor shall be kept as constant as possible, otherwise the insulation resistance readings may be misleading. NOTE: 1.6
The motor should be watched constantly whilst drying out. REVERSAL OF ROTATION
Reversal of rotation, if required shall be effected by interchanging two of the three supply leads connected to the stator switch, breaker or starter. 4 1610 - 1611 VOL - C1 TAB - 3 - 22
2.
INSPECTION AND TESTING 2.1
GENERAL
All electrical equipment shall be inspected and tested by competent persons at regular intervals, the frequency of such inspection depending on the type of equipment and on the operating conditions. A record of each inspection and of the result of tests should be kept. 2.2
MECHANICAL
Machines shall be checked for alignment to ensure that undue stresses are not imposed on their bearings. Where oil-lubricated bearings are employed care should be taken to see that oil does not penetrate on to windings or other insulation. In addition clearances shall be kept to reasonably close limits as too large a clearance may affect correct alingment and may cause fouling of the stator by the rotor, whilst too small a clearance may disturb running mechanical balance. Oil should be checked to see that it is clean and up to the right level. The air gaps in sleeve bearing machines shll be checked before commissioning. This check should be repeated at periodic intervals. Mechanical operation of motors control gear and protective devices shall be checked for freedom from external material, care being taken when commissioning to see that all packing materials are removed. In the case of motors and control gear, attention should be paid to all contacts, the contact pressure and contact area being checked and verified as being proper to the operating conditions involved. If ball roller bearing motors have been kept idle for periods longer than six months whether new, spare or stand-by plant, the bearing covers should be removed for inspection of grease. If it is found that the grease has a skin over the surface, the bearings should be washed out thoroughly in kerosene, and three drops of fine oil added to the race. The bearing housings should be repacked with new grease recommended by the makers, care being taken to ensure that the balls or rollers will not churn in the grease. One of the chief functions of grease is to prevent the entry of dust to the races, very little being required for lubrication. 2.3
ELECTRICAL
All fixed connections shall be checked for tightness and where heavy currents are involved a check shall be made to see that contact adequate in area and pressure to prevent undue heating is effected between all contact surfaces. Before the equipment is put into service, it shall be tested for insulation resistance and other tests as may be necessary should be made. Continuity tests shall be carried out, particular attention being given to the secondary connections of current transformers. Before switching in for the first time, protective devices shall be set at their minimum current values and at the minimum time setting in order to minimise the consequence of any fault condition which may arise. The rating of fuses shall be checked by inspecting the marking on the cartridge-type fuses or inspecting the gauge and type of wire in the case of semi-enclosed type-fuses. Where practicable, the operation of overload, no volt and other types of protective device shall also be checked. The results of such checking should be related to the ascertained resistance of the earth-fault current path so as to determine the prospect of the protective device operating in the event of a fault to earth. Earth leakage protection should be adopted in the following cases: a.
If the ascertained resistance is such as to restrict the fault current to a value below the operating value of the overload releases.
b.
If the margin is too small to ensure reliability in all seasons. 5 1610 - 1611 VOL - C1 TAB - 3 - 23
c.
If, where fuses are used, the resistance is such that sufficiently rapid operation cannot be ensured, and the earthing conditions cannot be improved.
Protective fuses shall be examined regularly, and, as far as possible tested. Where relays are used in conjunction with current transformers, the test should preferably stimulate working conditions by utilizing the injection method whereby current is passed through the relays by the application of a variable injection voltage from a transformer designed for the purpose.
3.
MAINTENANCE PROTECTION OF EXPOSED SURFACE 3.1
GENERAL
Protective paint and varnish shall be maintained in good condition by repainting or revarnishing when necessary, it being noted that in many instances, such as that of machine windings, spraying is the only effective means of application of such protection. MOTOR Cleaning of Machines Motor shall be blown out at regular intervals to keep their ventilating passage clear, it being emphasised that many types of totally enclosed motors required such attention, particularly when operating in dusty atmosphere. Moisture, oil, dirt, grease and carbon or metallic dust are the principal causes of breakdown. The motor should therefore be kept clean and dry; water dropped on the machine will soon cause trouble, unless the motor has been designed to withstand such conditions. The stator and rotor windings must be kept free from oil and grease, damp and dirt. Periodic cleaning with dry compressed air, bellows or a brush, is very necessary. All motors require to be examined and dismantled from time to time and the frequency of successive cleanings will depend upon the conditions under which the machine operates. During periodic cleanings care shall be taken to clear air passages in the stator and rotor of any accumulated dirt. Terminals and screw connections shall be kept clean and tight. If they become dirty or corroded, they shall be disconnected and all contact surfaces made clean and smooth. Bad contact leads to sparking and ultimate breakdown. After reassembly, the gaps shall be tested as a precautionary measure by means of a feeler gauge. If it is found that the air gap measurements of two diametrically opposite points differ by as much as 25% the machine shall be examined, because the brackets or bearing housings will not be correctly aligned. Gap measurements shall always follow reassembly, since rubbing between stator and rotor will cause extensive damage. 3.2
INSULATION RESISTANCE
The insulation resistance of the windings shall be tested periodically during service and where this is found to drop below 1 megaohm/KV with a minimum of 1 Megohm the motor shall be dried out and put in service. If weak insulation, resistance becomes a regular feature the windings shall be given a coat of good insulating varnish after the machine has been dried out. Where the motor is installed in locations, subject to dampness, chemical fumes, etc., the installation indicator such as a neon lamp to show the condition of the insulation of the motors is recommended. 3.3
REMOVAL AND REPLACEMENT OF BEARINGS
In small frame motors, the bearings can be removed with a bearing puller. The cartridge type bearing housing is employed in large frame motors. After cleaning, the housing should be greased with the specified grade grease and the bearing replaced by applying even pressure to the outer race. Having ensured that the bearing is square with the housing, it may be necessary to tap lightly into position. 6 1610 - 1611 VOL - C1 TAB - 3 - 24
Having ascertained that the outer race beds firmly against the housing shoulder, the whole may be slipped over the shaft which should be cleaned and oiled. The bearing may now be forced on to the seating by means of a tube placed over the shaft and applied to its inner race; this method ensures even pressure and the bearing may be driven home against its locating shoulder. On no account must the inner race mounted by hitting the outer race and pressure should not be applied to the outer race during the process. The blows should be equally distributed all round the inner race and care should be taken to avoid hitting or applying pressure to the lip of the inner race, in the case of a roller bearing. Otherwise the bearing along with the bearing housing can be heated in medium oil Shell Tellus – 33 Deg. at a temperature not exceeding 100 Deg. C for about one hour to enable easy mounting by push fit. 3.4
BALL AND ROLLER BEARINGS
Climatic conditions affect the lubrication and it is necessary to ensure that the bearings do not run hot. This shall be tested from time to time by placing the hand on the bearing cap. A moderate warmth to the hand is a ready indication that the bearing is running at its best. Higher or lower temperatures are not dangerous in themselves but increasing temperature or noise are sure signs that the bearing needs immediate attention. It may be that the addition of a small amount of grease will arrest and cure the trouble. When opening up bearings for inspection and cleaning, all dirt and foreign matter shall be removed from the neighbourhood of the bearing caps. The caps shall then be removed and the bearings, caps and housings washed with kerosene, all old grease also being removed in the process and the parts thoroughly cleaned. If the bearing is in good condition, fresh grease shall be pressed well between the cage, races, balls and rollers. We recommend Shell Alvania No.3 grease or it’s equivalent. After packing the bearing, any superfluous grease shall be wiped off. If the bearing appears dirty or if the grease has become hard and disintegrated the bearing shall be removed from the shaft, withdrawn from the housings and closely inspected for signs of wear. 3.5
LUBRICATION
It is often assumed that with the substitution of rolling motion for sliding motion in antifriction bearings, the sources of friction are eliminated and lubrication is of secondary importance. But this is not correct since sliding friction still occurs at the cage which separates the rolling elements or between the element themselves if they are not separated. The smooth and silent running of antifriction bearings depends to a large extent on the high degree of finish imparted to the tracks and rolling elements, and quite apart from its function of minimising wear on rubbing surfaces, the lubricant is required to protect these highly finished working parts. The rolling element bearings require a small amount of lubricant depending upon the size and type of bearing and generally the lubricating intervals are long. However, lubricant must always be present in the bearings otherwise their lift may be affected or retarded by injuries which could have easily been avoided. The main functions of lubricant in a bearing are: i.
To provide a separating film between rolling and sliding contacting surfaces, thus pre venting wear.
ii.
To act as a coolant to maintain proper bearing temperature.
iii.
To prevent the bearing from being contaminated by dirt and other foreign matter.
iv.
To prevent corrosion of bearing surfaces.
When the moving parts of a bearing come in contact with grease, a small quantity of oil adheres to the bearing surfaces. Oil is therfore removed from the grease near the rotating parts. The oil that is picked up by the bearing is gradually broken down by oxidation, or lost by centrifugal 7 1610 - 1611 VOL - C1 TAB - 3 - 25
TWO PART BEARING HOUSING
BALL BEARING WITHDRAWAL BALL BEARING REPLACEMENT force, and volatalisation. Bleeding of the Grease therefore takes place to continue the supply of a small quantity of oil, which is usually sufficient for satisfactory operation. Lithium based Multipurpose Grease conforming to Grade 3 of IS 1002-1956 amended upto date, is recommended for all Rotating machines fitted with antifriction bearings. The popular greases are: Shell Alvania (or Multipurpose) Grease 3 Mobilux Grease No.3 Castrol Shperol. AP3 The safe operating temperature range for the above greases is: -130F to 2480F (approx. Value) The quantity of Grease which should be applied to the inside of the bearing when relubricating is, D x B W
= —————— x 28.35 Grams 6000
Where
D = O.D. of the Bearing in mm B = Width of the Bearing in mm W = Weight of grease in gm
Running conditions, especially speed relative to the bearing size determine the permissible relubrication frequencies, provided an approved ball bearing grease is used. Over-lubrication is equally hazardous as under-lubrication. If excess grease is maintained in the race-track under-pressure, excessive friction develops often resulting in the break-down of the grease, which in turn affect the life of the bearing considerably. 3.6
CONTROLLERS, STARTERS AND RHEOSTATS
The contact and insulating parts must be kept thoroughly free from dirt and moisture and there shall be firm metallic connection between fixed and removable contacts when they come together. The covers shall be removed periodically for inspection. Fuse contacts and terminals must be examined periodically for cleanliness and tightness. When a fuse wire or strip has to be renewed, care must be taken that the new is of the correct metal and size. 8 1610 - 1611 VOL - C1 TAB - 3 - 26
3.7
SAFETY DEVICES
Remote tripping devices and limit switches which are provided for safety reasons but which may not be called upon to function under normal operating conditions, shall be checked for operation at regular intervals. Interlocks designed to prevent unsafe operations shall be checked periodically by a deliberate attempt being made by a competent person to perform the operations which the interlocks are designed to prevent. Where an emergency supply is provided, the source of supply and all ancillary apparatus shall be checked periodically. 3.8
CHECK CHART
A check chart should be kept for assistance in the maintenance of the motor. A recommended chart is given in Section 4. All reports and test results shall be recorded in a suitable log book.
4. SI.No.
AC MOTOR CHECK CHART Trouble
Cause
Remedy
01
Hot Bearings General.
Bent or sprung shaft. Excessive belt pull. Pulley too far away. Pulley diameter too small. Misalignment.
Straighten or replace shaft. Decrease belt tension. Move pulley closer to bearing. Use larger pulley. Correct by realignment of drive.
02
Hot Bearings ball or roller.
Insufficient grease.
Maintain proper quantity of grease in bearing.
Deterioration of grease or lubricant contaminated.
Remove old grease, wash bearings thoroughly in kerosene and replace with new grease.
Excess lubricant
Reduce quantity of grease. Bearing should not be more than 1/2 filled.
Heat from hot motor or external source.
Protect bearing reducing motor temperature.
Overloaded bearing. Broken ball or Rough races.
Check alignment, side thrust and end thrust. Replace bearing; first clean housing thoroughly.
Stream of overflow plug not tight.
Remove re-cement threads replace and tighten.
03.
Oil leakage from overflow plugs Cracked or broken overflow plug.
Replace the plug.
Plug cover not tight.
Requires cork gasket or if screw type may be tightened. 9 1610 - 1611 VOL - C1 TAB - 3 - 27
SI.No. 04.
Trouble Motor dirty
Cause
Remedy
Ventilation blocked end winding filled with fine dust or lint.
Rotor winding clogged.
Bearing and brackets coated inside. 05
06.
07.
Motor Wet
Motor stalls
Motor connected but does not start
Clean motor will run 10° to 30°C cooler. Dust may be cement, sawdust, rock dust , grain dust, coal dust and the like.Dismantle entire motor and clean all windings and parts. Clean and grind slip rings. Clean and treat windings with good insulating varnish. Dust and wash with cleaning solvent.
Subject to dripping
Wipe motor and dry by circulating heated air through motor.. Install drip or canopy type covers over motor protection.
Drenched condition.
Motor should be covered to retain heat and the rotor position shifted frequently.
Submerged in flood water.
Dismantle and clean parts. Bake windings in oven at 180°F (82°C) for 24 hours or until resistance to ground is sufficient.
Wrong application.
Change type or size. Consult manufacturer.
Overloaded motor.
Reduce load.
Low motor voltage.
See that nameplate voltage is maintained.
Open circuit.
Fuses blown, check overload relay, starter and pushout.
Incorrect control resistance of wound rotor.
Check control sequence. Replace broken resistors. Repair open circuits.
Mechanical locking in bearings or at air gap.
Dismantle and repair. Clean air gap if choked.
No supply Voltage. One phase open voltage too low.
Check Voltage on each phase.
10 1610 - 1611 VOL - C1 TAB - 3 - 28
SI.No.
08.
09
Trouble
Motor runs and then dies down. (see also SI.No.7).
Motor does not come upto speed.
Cause
Remedy
Motor may be over loaded.
Reduce load or try to start uncoupled from load.
Control gear defective.
Examine each step of the control gear for bad contact or open circuit. Make sure that brushes are making good contact with thering.
Starting torque of load too high.
If of squirrel cage type and with auto-transformer starting change to a higher tap.
Rotor Defective.
If of slip-ring type, lower the starting resistance. Look for broken rings.
Poor stator coil connection.
Remove end belts, locate with test lamp.
Mechanical locking in bearings or at air gap.
Dismantle and repair. Clean air gap if choked.
Power failure.
Check for loose connections to line, to fuses and to control.
Overload.
Examine overload trips. See that they are set correctly to approximately 150 percent full load current. See that the dashpots are filled with correct quantity and grade of oil.
Not applied properly.
Consult supplier for proper type.
Voltage too low at motor terminals because of line drop.
Use higher voltage on transformer terminals or reduce load.
If wound rotor improper control operation of secondary resistance.
Correct secondary control.
Starting load too high.
Check load or motor which is supposed to carry at start.
Check that all brushes are riding on rings.
Check secondary connections Leave no loads poorly connected.
11 1610 - 1611 VOL - C1 TAB - 3 - 29
SI.No.
10.
Trouble
Cause
Remedy
Broken rotor bars.
Look for cracks near the rings. A new rotor may be required as repairs are usually temporary.
Open primary circuit.
Locate fault with testing device and repair.
Motor takes too long to accelerate
Excess loading.
Reduce load. If motor is driving a heavy load or is starting up a long line of shafting start more slowly allowing ample time for acceleration till it overcomes the difficulty.
Poor circuit.
Check for high resistance. Defective squirrel cage rotor.
Replace with new rotor.
Applied voltage too low.
Get power company to increase voltage tap.
11
Wrong rotation. phases.
Wrong sequence of
Reverse connections of motor or at switchboard.
12.
Motor overheats while running underload.
Check for overload.
Reduce load.
Wrong blowers or airshields, may be clogged with dirt and prevent proper ventilation of motor.
Good ventilation is manifest when a continuous stream of air leaves the motor. If not,check with manufactuer
Motor may have one phase open
Check to make sure that all leads are well connected
Grounded coil.
Locate and repair.
Unbalanced terminal voltage.
Check for faulty leads, connections and transformers.
Shorted stator coil.
Repair and then check watt-meter reading.
Faulty connections.
Indicate by high resistance.
12 1610 - 1611 VOL - C1 TAB - 3 - 30
SI.No.
13.
14.
15.
16.
Trouble
Motor vibrates: after corrections have been made.
Unbalance line current on polyphase motors during normal operation.
Scraping noise
Magnetic noise.
Cause
Remedy
High voltage or low voltage
Check terminals of motor with voltmeter.
Rotor rubs stator bore
If not poor machining, replace worn bearings.
Motor misaligned.
Realign.
Weak foundations.
Strengthen base.
Coupling out of balance.
Balance coupling.
Driven equipment unbalanced.
Rebalance driven equipment.
Defective ball or roller bearings.
Replace bearings.
Bearings not in line.
Line up properly.
Balancing weights shifted.
Rebalance rotor.
Wound rotor coils replaced.
Rebalance rotor.
Polyphase motor running single phase.
Check for open circuit.
Excessive end play.
Adjust bearing or add washer.
Unequal terminal volts.
Check leads and connections.
Single phase operation. Poor rotor contacts in control wound rotor resistance.
Check for open contacts. Check control devices.
Brushes not in proper position in wound rotor.
See that brushes are properly seated and shunts in good conditions.
Fan rubbing air shield.
Remove interference.
Fan striking insulation.
Clean the fan.
Loose on bedplate.
Tighten holding bolts.
Air gap not uniform.
Check and correct bracket fits bearing.
13 1610 - 1611 VOL - C1 TAB - 3 - 31
SI.No.
Trouble
Cause
Remedy
Loose bearings.
Correct or renew.
Rotor unbalance.
Rebalance.
NOTE : Certain amount of magnetic noise is inherent in some low speed designs and shouls not cause alarm. 17.
5.
Motor sparking at sliprings.
Motor may be overloaded.
Reduce the load.
Brushes may not be of correct quality and may be sticking in the holders.
Use brushes of the grade recommended.
Brush pressure may be too light or too much.
Adjust the brush pressure correctly.
Sliprings may be tough, dirty or oily.
Clean the sliprings and maintain them smooth glossy and free from oil and dirt.
Sliprings may be ridged or out of truth.
Turn and grind the slipring in a lathe to a smooth finish
MAINTENANCE SCHEDULE The following Maintenance Schedule is suggested as a guide. 5.1
DAILY MAINTENANCE
a.
Examine earth connections and motor leads.
b.
Check motor windings for overheating. (Note that the permissible maximum temperature is above that which can be comfortably felt by hand.)
c.
Examine control equipment.
d.
In the case of oil ring lubricated machines: i.
Examine bearings to see that oil rings are working.
ii.
Note temperature of bearings;
iii.
Add oil if necessary;
iv.
Check and plays 14 1610 - 1611 VOL - C1 TAB - 3 - 32
5.2
WEEKLY MAINTENANCE
a.
Check belt tension. In cases where this is excessive it should immediately be reduced and in the case of sleeve bearing machines the air gap between rotor and stator should be checked.
b.
Blow out windings of protected type motors, situated in dusty locations.
c.
Examine starting equipment for burnt contacts where motor is started and stopped frequently.
d.
Examine oil in the case of oil ring lubricated bearings for contamination by dust, dirt, etc. (This can be roughly ascertained on inspection by the colour of the oil).
5.3
MONTHLY MAINTENANCE
a.
Overhaul Controllers.
b.
Inspect and clean oil circuit breakers.
c.
Renew oil in high speed bearings in damp and dusty locations.
d.
Wipe brush holders and check bedding of brushes of slipring motors.
e.
Check the condition of the grease.
5.4
HALF-YEARLY MAINTENANCE
a.
Clean windings of motors subjected to corrosive or other element. Also bake and varnish if necessary.
b.
In the case of slip-ring motors check slip-rings for grooving on unusual wear.
c.
Renew grease in ball and roller bearings.
d.
Drain all oil bearings, wash with kerosene, flush with lubricating oil and clean oil.
5.5
ANNUAL MAINTENANCE
a.
Check all high speed bearings and renew if necessary.
b.
Blow out all windings of motors thoroughly with clean dry air. Make sure that the pressure is not so high as to damage the insulation.
c.
Clean and varnish dirty and oily windings.
d.
Overhaul motors subject to severe operating conditions.
e.
Renew switch and fuse contacts if badly pitted.
f.
Renew oil in starters subjected to damp or corrosive elements.
g.
Check insulation resistance to earth and between phases of motor windings, control gear and wiring.
h.
Check resistance of earth connections.
i.
Check air gaps.
refill with
15 1610 - 1611 VOL - C1 TAB - 3 - 33
5.6
RECORDS
Maintain a register (as per the specimen shown or enclosed) giving one or more pages for each machine and record therein all important inspections and maintenance works carried out from time to time. These records shall show past performance, normal insulation level, gap measurements, nature of repairs and time between previous repairs and other important information which would be of help for good performance and maintenance.
6.
LIMITS OF TEMPERATURE RISE Permissible maximum temperature rise for class ‘B’ insulation is 120°C Ambient Temperature
....
....
65°C
16 1610 - 1611 VOL - C1 TAB - 3 - 34
DATA SHEET FOR SOOT BLOWER MOTORS
SI. No. 01.
Description
Long Retract
Long Retract
Wall Blower
Wall Blower
Rotary Blower
Application
Long Retract Rotary
Long Retract Traverse
Wall Blower Rotary
Wall Blower Traverse
Rotary Blower Motor
02.
Frame Size
80
80
71
90
71
03.
Flange Type
IS 2223 Type C
IS 2223 Type C
IS 2223 Type C
IS 2223 Type C
IS 2223 Type C
04.
Dimensions( Drg.No)
4--20-20100303
4--20-201-00303
4--20-201-00303
4--20-201-00303
4--20-201-00303
05.
Power in KW
0.45
0.37
0.05
0.56
0.09
06.
Rated Voltage
415
415
415
415
415
07.
No. of Phases & Frequency
3∅ 50 HZ
3∅ 50 HZ
3∅ 50 HZ
3∅ 50 HZ
3∅ 50 HZ
08.
RPM(Approx imate)
1425
1365
1480
1425
1425
09.
Duty
30 minutes
15 minutes
Continous
30 minutes
Continous
10.
Ambient Temperature o C
65
65
65
65
65
11.
Enclosure & Protection
Totally enclosed non ventilated IP 55 protection
Totally enclosed non ventilated IP 55 protection
Totally enclosed non ventilated IP 55 protection
Totally enclosed non ventilated IP 55 protection
Totally enclosed non ventilated IP 55 protection
12.
Class of Institution
B
B
B
B
B
13.
Voltage Variation %
± 10
± 10
± 10
± 10
± 10
14.
Frequency Variation
±5
±5
±5
±5
±5
15.
Combined Voltage & Frequency Variation
± 10
± 10
± 10
± 10
± 10
16.
Starting Torque in kgm.
1.1
0.46
0.245
1.09
0.29
17.
Rated Torque
0.3775
0.264
0.0329
0.382
0.063
17 1610 - 1611 VOL - C1 TAB - 3 - 35
DATA SHEET FOR SOOT BLOWER MOTORS(CONTD.)
SI.N o
D escription
Long Retract
Long Retract
W all Blow er
W all B low er
Rotary Blow er
18.
Breakdow n T orque in kgm.
1.06
0.485
0.265
1.12
0.29
19.
Full load current in A mps.(A pproximat e)
1.26
0.86
0.44
1.36
0.64
20.
N o. of leads
6
6
6
6
6
21.
N ame Plate
Stainless steel
Stainless steel
Stainless steel
Stainless
Stainless steel
22.
Paint
Epoxy grey
Epoxy grey
Epoxy grey
Epoxy grey
Epoxy grey
23.
Conduct size in the T erm inal Box
M 20 x 1.5
M 20 x 1.5
M 20 x 1.5
M 20 x 1.5
M 20 x 1.5
24.
Pow er Factor & Rated Load(A pproximate)
0.68
0.88
0.34
0.78
0.48
25.
Efficiency in Rated Load (A pproximate)
71%
75%
45%
73.5%
44%
26.
M axim um stalling Time (A pproximate)
H ot 20 sec cold 35
H ot 40 sec cold 75
H ot 35 sec cold 65
H ot 30 sec cold 55
H ot 35 sec cold 65
27.
D irection of R otation
Reversibl e
Reversible
Reversible
Reversible
Reversible
28.
O ther Construction al Features
Shaft end w ith oil seal
Shaft end w ith oil seal
Shaft end w ith oil seal
Shaft end w ith oil seal
Shaft end w ith oil seal
29.
W eight of M otor in kg. (A pproximate)
13.5
13.5
13.5
13.5
13.5
30.
G D 2 of M otor in kg.(A pproximate)
0.0073
0.0073
0.0027
0.0112
0.0027
18 1610 - 1611 VOL - C1 TAB - 3 - 36
TAB - 4
INSTRUCTION MANUAL DESCRIPTION, OPERATION AND MAINTANENCE
SOOT BLOWER GENERAL INSTRUCTIONS
Bharat Heavy Electricals Limited Tiruchirapalli PUB.NO.7501
1610 - 1611 VOL - C1 TAB - 4 - 37
CONTENTS INTRODUCTION IMPORTANT INSTRUCTIONS GENERAL INSTRUCTIONS PREVENTING PUFFS AND FURNACE EXPLOSIONS DURING SOOT BLOWING PROCEDURE FOR SETTING BLOWING PRESSURES FOR SOOT BLOWER SYSTEMS SOOT BLOWER CHECK LIST AND RECOMMENDED START-UP PROCEDURE SOOT BLOWER MAINTENANCE RECOMMENDED LUBRICATION CHART FOR SOOT BLOWERS RECOMMENDED QUANTITY OF LUBRICANTS FOR ONE YEAR VALVE SEAT GRINDING FOR SOOT BLOWER VALVE HEADS RECOMMENDED PROCEDURE FOR PACKING INSTALLATION INSTRUCTIONS FOR STORAGE
2 1610 - 1611 VOL - C1 TAB - 4 - 38
INTRODUCTION This general instruction, sets some guidelines in preventing puffs and furnace explosions during soot blowing and outlines the procedure for setting blowing pressures. A check list for operation and a recommended procedure for start-up are given for general care and correct start-up. The section on maintenance gives a detailed glimpse into the maintenance problem. The lubrication schedule helps the maintenance man to choose the correct lubricant and carry out the lubrication plans. No Soot Blower system will operate satisfactorily if it is not properly installed, operated and maintained. It must be recognised that no amount of written instructions can replace intelligent thinking and reasoning on the part of the operators, especially when coping with unforeseen operating conditions. It is the operators’ responsibility to become thoroughly familiar not only with the equipment but also with all pertinent control equipment. The instruction contained in this manual is only an outline of the correct procedures for operation and maintenance. The contents in this manual have been compiled and checked by experts in this field. Every possible care has been taken to ensure the contents are accurate. Suggestions for the improvement of the manual are welcome. If you ever have any query about operation, maintenance or related problems, you are welcome to write to BHEL without obligation.
IMPORTANT INSTRUCTIONS DO’S 1.
CARELESSNESS IN REPAIRING SOOT BLOWING EQUIPMENT CAN CAUSE SERIOUS INJURIES. ACCIDENTS CAN BE PREVENTED BY TAKING SIMPLE PRECAUTIONS.
2.
INCREASE FURNACE DRAFT BY APPROPRIATE ADJUSTMENTS OF THE INDUCED DRAFT FAN TO TAKE CARE OF THE INCREASED FLUE GAS VOLUME DUE TO THE SOOT BLOWING OPERATION. THIS WOULD HELP TO PURGE COMBUSTIBLE GAS POCKETS.
3.
AVOID SOOT BLOWING OPERATION WHEN THE REFRACTORY IS HOT i.e.IMMEDIATELY AFTER STOPPING OR WHEN THE BOILER IS NOT IN SERVICE FOR SOME TIME.
4.
ALL STEAM LEAKS SHOULD BE ATTENDED TO IMMEDIATELY.
5.
AVOID EXCESS BLOWING PRESSURE.
6.
MAIN MEDIUM VALVE SHOULD BE CLOSED IMMEDIATELY AFTER THE COMPLETION OF THE SOOT BLOWING OPERATION.
7.
FOR LUBRICATION, FOLLOW THE LUBRICATION INSTRUCTIONS CAREFULLY.
8.
RETRACT THE LANCE IMMEDIATELY IN THE EVENT OF FAILURE OF POWER TO AVOID DAMAGE TO THE LANCE.
9.
EVEN IF THE BOILER IN OPERATION DOES NOT REQUIRE SOOT BLOWING, KEEP THEM OPERATING AT LEAST ONCE IN A WEEK. THIS WILL HELP IF COAL CHARACTERISTIC CHANGE AT A LATER DATE AND TO KEEP THE SOOT BLOWERS IN ORDER.
10.
ALL THE PEEP HOLES SHOULD BE CLOSED AND LOCKED BEFORE WALL DESLAGERS ARE PUT INTO OPERATION. 3 1610 - 1611 VOL - C1 TAB - 4 - 39
11.
DURING OUTAGES, CHECK THE CLEARANCE BETWEEN THE EDGE OF THE LANCE TUBE AND THE SUPER HEATER, RE-HEATER TUBES. THERE SHOULD BE A MIN. GAP OF 100MM.
12.
THE SOOT BLOWER LINE MUST BE STEAM BLOWN BEFORE THE BLOWERS ARE PUT INTO OPERATION AT THE TIME OF COMMISSIONING.
DON’TS
1.
1.
DO NOT ATTEMPT REPAIRS BEYOND YOUR ABILITIES.
2.
DO NOT OPERATE THE BLOWERS WITH WET STEAM.
3.
DO NOT EXTEND THE LANCE OF LONG RETRACT WITHOUT BLOWING MEDIUM WHEN BOILER IS ‘ON’.
4.
DO NOT OVERTIGHTEN THE PACKING.
5.
DO NOT HAND CRANK THE BLOWERS WHILE THE POWER OR BLOWING MEDIUM IS ‘ON’.
GENERAL INSTRUCTIONS 1.1
Ordering Repair Parts
When ordering repair parts, always give the Name, Part No., Drg. No., as found on the parts lists and Model number as found on the brass name plate. In the case of bearings and elements, swivel tubes or lances refer to Element Location Drawings and give the Drawing No. for the specific piece needed. Elements may vary for different locations. If you have more than one boiler, give the type, size, rating and location of the boiler or boilers for which parts are needed, and the order number under which you purchased the Blowers for which parts are needed. 1.2
A Word of Caution
Carelessness in repairing a blowing equipment can cause serious injuries. Accidents can be prevented by taking simple precautions. Always get permission and clearance from the proper authority before starting to repair any equipment. Use proper lifting equipment for heavy equipment. Do not attempt repairs beyond your ability. Before repairing any equipment operated by steam or air, make sure all supply valves have been closed, tagged or locked and also the electrical connections are cut off. If steam or air supply lines must be energised for purpose of test, use extreme caution.
2.
PREVENTING PUFFS AND FURNACE EXPLOSIONS DURING SOOT BLOWING Explosions, puffs, or blow backs that occur during or as a result of soot blowing operations should be reported to and discussed with the boiler manufacturer. It is impossible to establish a definite procedure to prevent these difficulties because of the variation of fuels and the design and operations of Steam Generating equipment. The start-up or operating engineers working in conjunction with design engineers or boiler manufacturing firms are best qualified to recommend procedures of operation on their particular equipment. The following recommendations are presented for consideration when it is necessary to establish operational procedure to prevent these difficulties. 4 1610 - 1611 VOL - C1 TAB - 4 - 40
(i)
Cleaning Cycle
As a guide line we suggest a soot blowing cycle of once in a day to start with may be established. After watching the performance of the particular coal, oil or any other fuel, with reference to the deposit formation, the blowing cycle can be altered. It is essential to have a satisfactory cycle so that the heat recovery surfaces are kept free of deposits at the same time the tube surfaces are not damaged because of frequent blowing. The life of the soot blower parts will also proportionally decrease with increased frequency. The Boiler operating personnel can establish the optimum blowing cycle depending on the actual furnace conditions. It is impossible to predict the deposit formation since too many factors influence the same. (ii)
When possible, the boiler to be cleaned should be operating at or near the maximum design load.
When soot blowers are operated at low boiler loads, clouds of soot may be blown into the gas stream to form explosive mixtures which may be ignited by the heat from furnace walls or by smoldering soot fires. Soot blower operation at low boiler load, with a resulting colder furnace may also result in some of the unburned combustibles escaping from the furnace and collecting in pockets in back passes. Agitation and ignition of these gas pockets will cause puffs or explosions. All tube surfaces and gas passes, therefore, should be blown with the gas flow at or near maximum to purge the boiler of these possible explosion causes. (iii)
On oil or pulverised fuel fired boilers, soot blowers should be used with the burners operating at the highest possible burning rate, maintaining even stable combustion. Soot blowing schedules should be established to take place during the heaviest load periods, or the burner firing rates should be increased during soot blowing. Burners should be checked during soot blowing for stability.
A high burning rate assures a lower oxygen content in flue gases which eliminate the difficulty as explained in (ii) above. High and stable burning rates also prevent flames from being blown out by small puffs or agitation of the gas flow common while soot blowing. (iv)
Before operating soot blowers the furnace drafts should be increased by opening the boiler outlet damper or by making the appropriate adjustments of the induced draft fan to take care of the increased flue gas volume due to the soot blowing operation. Increased furnace draft helps to purge combustible gas pockets explained in (ii) above.
Increased furnace draft improves cleaning by moving soot particles through gas passes rather than re-depositing them on adjacent surfaces. (v)
Conditions may require the operation of soot blowing equipment with the burners out of service as when cleaning prior to outages to facilitate inspections.This procedure is dangerous. If unavoidable, soot blowing operation should not proceed while the refractory is still hot and there is any possibility of soot fires still smoldering in the setting. Be sure the boiler is cold and inspect the setting for smoldering soot before blowing.
(vi)
The normal sequence of soot blowing is to follow the gas flow through the boiler. The first soot blower to be operated should be the nearest to the burners then each unit in turn along the gas passes to complete the cleaning cycle. This method thoroughly cleans the entire unit by moving along the passes rather than blowing them loose and redepositing them on adjacent surfaces. It may be desirable to reverse this procedure when soot deposits are unusually heavy to avoid plugging and puffs or explosions in the back passes. 5 1610 - 1611 VOL - C1 TAB - 4 - 41
Blowers should then be operated in reverse order from rear to front to rear. This procedure may be desirable during period of low load operation, as when units are banked, or on Marine installations when ships are put out to sea after time spent in port. (vii)
3.
For operating wall deslaggers,operate the row of wall deslaggers at the highest elevation first and then follow downwards, so that, heavy slags dislodged and deposited at lower elevation will be cleared by further soot blowing operation and fall to the ash hopper due to its weight.
PROCEDURE FOR SETTING BLOWING PRESSURES FOR SOOT BLOWER SYSTEMS 3.1
Introduction
All large, high pressure boilers and many medium and small boilers today employ a pressure reducing valve in the steam supply to the soot blower system. This requirement, coupled with the fact that all individual soot blower operating head pressures can be easily adjusted externally while the units operating, permits adjustment of the blowing pressures without internal orifices and at the same time permits operation of the system on a relatively low supply pressure. The reduced supply pressure reduces packing and valve maintenance and makes the system more flexible for pressure adjustment at later dates without the necessity of installing orifices. A step by step procedure is outlined to attain this set up. Use the pressure gauge and the connected fittings issued by us for measuring the blowing pressure. Connect the pressure gauge fittings as shown in the figure. 3.2
Recommended Blowing Pressures
The suggested blowing pressures are listed out in the blowing pressure table, released in 00,076 erection drawing group separately for each contract. When these pressures are not shown on the blowing pressure Table BHEL should be contacted for this information. Request for this information should be complete with blower no. location and the existing blowing pressure. 3.3
Customer Information
It is a most important step that the customer, the operators and the maintenance personnel understand that these Recommended Blowing Pressures are based on past experience with similar fuels, boiler design and firing conditions. The pressures are recommended for trial as a starting point. Blowing pressures are those that are required to clean can only be determined after a period of operation and trial settings with adjustment later, if necessary. 3.4
Set High Pressure First
The unit marked for highest blowing pressure on the Blowing pressure table is set up first. This will usually be a retractable unit in the platen section or in front of the slag screen, (i)
The valve head is designed for high pressure. The valve opening of each blower is adjusted using the setscrew to the required blowing pressure such that the valve dis is opened fully or partially without completely compressing the spring (i.e. spring should not be solid).
(ii)
The steam supply is then turned on and the pressure recommended is set on this high pressure unit from the blowing pressure table by adjusting the supply pressure at the Pressure Reducing Valve. As an example the blowing pressure on this first unit may be 18 Kg./cm2 and the supply pressure may be as low as 21 or 25 kg/cm2 depending on line drop. 6 1610 - 1611 VOL - C1 TAB - 4 - 42
3.5
Set Pressures on Other Models
The next step is to set pressures on one each of the other models in the system – one wall deslagger, one rotary and one air preheater cleaner if they are employed in the particular system. In selecting the one unit of each of these models to be checked, consideration should be given to the highest blowing pressure used on that particular model as well as the unit farthest from the source of steam supply. Line drop will be the only reason for not being able to obtain the recommended pressures. Where pressure cannot be set as high as desired because of line drop on these secondary model settings, it obviously will be necessary to increase the supply pressure through the Pressure Reducing Valve and reduce the pressure on the individual high pressure unit first set up. 3.6
Setting Pressure on all Other Units
From the above procedure we have established the minimum header supply pressure to give the maximum blowing pressure on all of the various soot blower models or types of equipment used in the system. It is now only necessary to set the other pressure by restricting valve opening on other units using lesser pressures. These pressure settings must be made with pressure gauges and the units in actual operation. Measuring the valve opening or using feeler gauges is not reliable since accumulation of tolerances in the valve linkage causes a variation in pressure settings. Normally, no alteration is necessary to the safety valve setting. The seal on safety valves must not be broken or changes made to these safety settings without specific reasons. Safety valves are for the protection of the equipment and system in case of Pressure Reducing Valve failure and their setting does not coincide with this method of pressure setting in any way. PRESSURE SETTING ARRANGEMENT
ITEM NO. OFF NO. 01 1 02 2 03 1 04 1
BPS W. DRG. NO
DESCRIPTION
3.20.998.00796 4.20.998.0 1763 4.20.998.01759 V75 141 0250
CONDENSING LOOP PACKING (COPPER) CONNECTOR PR. GAUGE 150 RANGE 0.70 ata
Safety Valve set pressure Because of the pressure fluctuations occuring in the system when each soot blower valve head is opened and closed the slow reaction of the Pressure Reducing Valve actuator the safety vave is likely to pop or chatter depending on the set pressure. The set pressure can be 7 1610 - 1611 VOL - C1 TAB - 4 - 43
increased if the set pressure is not already in the maximum setting. Normally a set pressure upto 42 Kg./cm2 (g) can be set with a 600 psi rated safety valve. Do not alter the set pressure if the system is stable. With the above procedure of setting pressure we have the maximum valve opening possible on any and all individual soot blower operating heads which reduces valve maintenance. We have the minimum steam pressure on packing, also reducing maintenance. We have a more flexible system in that, if loads are increased or inferior fuels are used for shorter periods where higher blowing pressures are required, one single adjustment can be made at the pressure reducing valve rather than changing and gauging all individual units. When the emergency is past, the original pressures can be restored again with one adjustment at the pressure reducing valve. If there are questions or if difficulties should arise in following this procedure, please contact us for further advice and counsel. Do not set pressure reducing valve supplied systems at 600 psi and reduce blowing pressures with orifices and individual head linkage adjustment. 3.7
Blowing Pressures
When new jobs are commissioned or started up, we can , based on past experience with the type of fuels, firing, boilers and equipment involved, recommend blowing pressures for trial or starting. An operating period then dictates if pressures and operating frequency should be changed.
Pressure Adjustment In Long Retract Observation while the boiler is in operation and inspections at outages are always necessary to see that cleaning is adequate and that tube damage does not result. In order to evaluate either cleaning problems or tube erosion and determine corrective steps to be taken, down steam blowing pressures should be gauged and tabulated along with the operating frequency of the units. Pressure, nozzle size, nozzle angle, drainage of condensate and frequency of operation items that should be reviewed and checked relative to cleaning and erosion conditions. We wish the customer to feel free to call on our service department for advice and counsel which will be based on our past experience in this type of work. 3.8
Inspections
Inspections of all tube surfaces at any scheduled outage, are essential to determine tube damage and cleaning. Wall blower inspection is difficult and costly because of the need of scaffolds or bosunchair, nonetheless inspection is necessary because of the fact that they are hard to see and check while in operation. 8 1610 - 1611 VOL - C1 TAB - 4 - 44
We recommend that inspection be made at every scheduled outage of sufficient length to permit installing a bosunchair or scaffold. We also recommend that inspection be made of all the tube surfaces at each blower location as soon as the boiler is cool enough to enter and before any hand cleaning is accomplished. This early inspection gives true picture of the deposits before they are disturbed and also permits repair during the scheduled outage.
4. SOOT BLOWER CHECK LIST AND RECOMMENDED START-UP PROCEDURE 4.1
Blowing Medium Supply System
(i)
Steam System
(ii)
(a)
Check expansion loops for thermal expansion provision.
(b)
Check for slope or pitch for drainage as called for on drawings.
(c)
Condensate discharge from trap should be led to atmospheric pressure.
(d)
Condensate drain should slope down and away from trap for gravity drain.
Both Air and Steam Systems (a)
Check provisions for boiler expansion Expansion loops provided on steam system Flexible couplings or expansion loops on air system.
(b)
Pipe Hangers Sufficient in number Properly located to eliminate any pipe strain on soot blower inlet flange when system is in hot operating position.
(c)
Blow down either system completely On “Candelabrum” or gradually rising header and branch line systems, it is recommended that all branch lines be blown before inlet flanges of soot blower operating heads are made up. On properly designed drain systems having a drain connected to each operating head, blowing down of construction debris and cleaning lines can be limited to blow down of drain lines and condensate reservoir immediately preceding the drain valve.
(d)
Drains All drain lines must be blown down before final welding in of the drain valve proper. The thermometer or thermocouple should be checked for goodworking conditions.
4.2
Suggested Operation Procedure
(i)
The frequency of soot blower operation depends on the operting conditions, status of the boiler and boiler cleanliness. Some things which may indicate the need for cleaning are; increase in boiler exit gas termperature, decrease in boiler gas flow (assuming constant boiler load) and visual inspection.
(ii)
It is important when starting up a boiler that the soot blowers be used frequently and soon after lighting off. Inefficient combustion in a boiler being started up may result 9 1610 - 1611 VOL - C1 TAB - 4 - 45
in abnormal deposits on the tubes. Unless they are removed frequently, furnace explosions or puffs may result later. It is usually also desirable to use the soot blowers just before taking a boiler out of service. (iii)
When using the soot blowers for the first time, it is advisable to increase the furnace draft as much as possible during the blowing cycle. After several blowing cycles, it will be possible to tell how much the furnace draft shoud be increased for blowing. The furnace draft can be increased by opening the boiler outlet damper wider, in creasing the induced draft fan speed, or opening the induced draft fan damper wider. No increase in forced draft is recommended.
(iv)
When the soot blowers are not being used, the main steam supply valve should always be closed tightly and the drain valves opened wide. The motor equipment for electrically driven blowers is housed in suitable enclosures. For all blowers it is necessary to make the power and control connections from the motor control centres and panel to each blower. There is usually a local starting button for each blower as well as a remote button on the control panel. These buttons are indicated on the wiring diagrams. Suggested Procedures
(v) (a)
Assure that power is available at the proper voltage and frequency as specified on the application drawings.
(b)
Increase the furnace draft as described above.
(c)
For steam blowing systems, open all drain valves wide. If traps are used, be sure isolation valves are open and the by-ass valve is closed.
(d)
Open the main steam or air supply valve slowly until it is wide open. With steam blowing cycle, do not operate any blowers until all the piping has been warmed and drained. Then, if traps are not used, close the drain valve. The hole in the valve seat will serve to keep the lines drained. Never blow with wet steam.
(e)
Operate the blowers in the numerical sequence shown on the general arrangement drawing. There is a panel “start” push button for each blower. The buttons may be included in the automatic sequential operation; they may be individual (buttons for manual operation) therefore, one button must be used to start each blower. Each button should be held in about 5 seconds and then released. The blower will start operating, complete the cycle and this will be indicated in the panel; start the next blower after this blower operation is over.
Pressure Adjustment wall Deslagger 10 1610 - 1611 VOL - C1 TAB - 4 - 46
(f)
Operate each blower in sequence, each may be operated as many times as necessary to clean. (Note: Allow a cooling period of 1 hr. before subsequent operaion of the same blower) NEVER ALLOW A BLOWER TO BLOW UNLESS THE NOZZLE IS ROTATING.
(g)
When the entire blowing cycle is complete, close the main stop valve tightly. Open the drain valves wide if they are closed.
(h)
Adjust the furnace draft to Normal.
(i)
Open the power and control circuit.
(j)
Be sure all blowers have completely retracted and all heads are fully closed.
5. SOOT BLOWER MAINTENANCE 5.1.
Soot blowing, once considered a necessary evil, has become a positive necessity on modern coal and oil-fired boilers. Fuel costs are rising, and heat value per pound of fuel seems to be decreasing. Ash, sulphur and low-fusion-temperature slags cause more trouble with lower Bth. U fuels and demand dependable soot blower operation.
Many cost-conscious engineers are now setting up suitable maintenance programme on soot blowers, and since peculiarities of each boiler plant usually require a programme tailor-made for each plant, it is advisable to enlist the aid of the manufacturer’s field-service engineers in setting up a specific programme. However, the following paragraphs will help to bring light the more important things to be considered. The factors that may cause, or contribute to tube cutting are: (i)
Excessive pressure causing excessive nozzle or jet velocity.
(ii)
Abrasive dust from baffles and sheaves adjacent to blowers entrained in the blowing jet.
(iii)
Condensate in steam, or water in air, whichever is used as the blowing medium.
(iv)
In air heaters or economizers where dew points may be low or boiler gases highly corrosive tube metal may be rusted or eaten away, especially where any condensate or drops of water from blower elements may be deposited on tube surfaces. These rust scales are removed when blowers are operated, thus exposing new metal and the cycle continues until tube failure occurs.
To check tube erosion (a)
Observe, report and record any tube erosion, cutting or polishing that is evident in the slightest degree. The permanent record will help determine on future inspections whether the condition has been corrected.
(b)
Blowing pressures may be reduced on some equipment by adjusting the valve screw, on other equipment by adjustable orifices in still other equipment by a permanent orifice in the line. Manufacturer’s service instructions will indicate the proper procedure. No higher pressure should be used than that needed to clean the boiler. This decreases tube erosion and prevents excessive use of steam or air, thus aiding economy.
(c)
Follow the instructions given under individual blowers.
5.2
External Inspection
(i)
Make sure valve mountings or head supports are secure. Loose mounting permits head and element to move in and out of the wall sleeve, undoing all the careful internal alignment. 11 1610 - 1611 VOL - C1 TAB - 4 - 47
(ii)
Check the operating head and valve to make sure it is functioning properly, mechanically and that it can rotate without undue binding.
(iii)
See that mechanical parts are clean and free from rust. Dirt and rust act as an abrasive, causing moving parts to wear.
(iv)
Remove immediately any and all water pockets in the supply piping system. PROPER DRAINING OF PIPING IS OF PRIME IMPORTANCE. When the blowing medium is steam the supply pipe should have an independent direct connection to the boiler drum, to obtain the direct possible steam at maximum pressure. Stem supply piping should be insulated for safety, and to reduce condensate in the soot blowing system.
(v)
Make sure piping connections to soot blowers are flexible enough that no leakage to abnormal stresses will develop. Proper hangers should be provided for the pipe. Pipe risers should never depend on the soot blower head for any support. This always causes binding when the unit is operated.
(vi)
If condensate traps are used on steam systems, dis-assemble them and clean the screens during outages to make sure they operate properly.If a drain valve with 4mm hole in the seat be used instead of a trap, make sure it is in place and in operating condition.
(vii)
Make sure condensate is drained to atmosphere. If drains are led to blow-down tanks, check valves should be used. If drain systems are connected in series to two or more boilers, check valves should be used to prevent steam from backing up on unused equipment.
5.3
Maintenance
Things listed so far have been inspection points to check during boiler outages. There are other points that can be checked while the boiler is in service. (i)
Operation personnel should be instructed to report immediately to the maintenance personnel any difficulty encountered in operating.
(ii)
Competent maintenance personnel should be required to follow and observe each and every soot blower through its operating cycle on certain definite dates. These inspection periods should be bi-weekly or monthly, depending on the size and importance of the soot blower installation to proper boiler operation.
(iii)
All steam leaks should be corrected immediately.
(iv)
All valves should seat tightly to prevent wire drawing.
(v)
All packing glands should be drawn just tight enough to prevent leakage without binding or breaking down packing fibre by excessive pressure.
(vi)
All cams and moving parts should be cleaned and properly lubricated.
(vii)
Gear boxes should be filled to proper levels with correct gear oils or grease. Greases should be checked regularly to see if they have hardened or separated from their bases because of high ambient temperatures. On outdoor installations, they should be checked when temperatures drop to see if hardening or channelling occurs.
(viii)
Lubrications in air lines to air motors should be checked at least once a week to make sure oil reservoirs are full and feed is correct.
(ix)
With electric motors, insulation, brushes and commutators should be clean and free from oils. General rules for care of electrical equipment and industrial controls should be followed. 12 1610 - 1611 VOL - C1 TAB - 4 - 48
(x)
Where drive chains are used, the chain should be kept as dry as possible.Only enough oil to prevent rust should be applied. Excess oil picks up fly ash and grit to form a cutting abrasive between link connections.
(xi)
With any lubricants, manufacturer’s specifications for correct types, amounts and frequency of application should be closely followed.
5.4
Preparing for outages
Where boilers are subject to extended outages, as in heating plants, maintenance can be reduced by giving proper attention to the equipment before and during the down period. (i)
Moving cams, etc., should be well coated with rust-preventive lubricants.
(ii)
Mechanical units should be covered with canvas, oil cloth or paper for protection against moisture or excessive dust.
(iii)
If operating valves or pistons have rings or parts not made of rust-resistant alloys these parts should be removed. They can be protected by a rust inhibitor by a rust inhibitor or stored until the equipment is required.
(iv)
Where feed lines or telescope tubes are of carbon steel, the units should be extended and rust preventive applied to these parts.
(v)
Inspections and repairs should be made immediately when the boiler is shut down to assure proper operation when the boiler is put back into service.
Care, adjustment and maintenance of automatic control, panels for automatic-sequentital systems are properly entrusted to the instrument personnel. Such systems usually require little care after being placed in service, except to keep all parts thoroughly clean. Generally speaking, they require the same maintenance as any industrial control system except that the loads on relays, indicator lamps and switches are comparatively light, therefore, requiring less attention. Little maintenance trouble is met, if this equipment is kept clean and free from dust and oil. 5.5
Operation
Correct operating procedure will help to minimize maintenance problems. These are important check points. (i)
Drain valve should be fully open, and supply valve opened slowly, during warm-up period. Drain valve should not be closed until the steam leaving the drain is absolutely dry. Drain valves should remain open when units are not operated. These precautions prevent condensate from entering elements to warp or distort them.
(ii)
Rotation of elements should be slow, even and continuous from the time steam flow starts until it is shut off. Should the automatic valve-in-head unit fail to shut off, the entire system should be shut down immediately, and the offending unit be corrected or blanked off before proceeding with the other units in the cleaning cycle. To proceed with the other units after one operating head has failed to shut off would cause tube damage. In addition, there would be reduced blowing pressures to the other elements which would prevent proper boiler cleaning.
(iii)
All units should be kept in operating condition as far as possible. Loss of one unit could cause plugging and thus divert hot gases over an adjacent unit to destroy that element.
(iv)
Blowers should be operated in proper sequence along the gas flow lanes with dampers fully open. This moves soot out, rather than blowing it from one place to another. 13 1610 - 1611 VOL - C1 TAB - 4 - 49
Boiler load should be ¾ to full, if possible to prevent puffs or possible explosions. (v)
Blowers should be operated at proper intervals to reduce temperatures and prevent loss of elements and nozzles. Operating intervals should not be set for certain hours of the day or shift, unless the boiler steams vary evenly and neither soot nor slag conditions are of much concern. Blowing intervals should be adjusted to load, firing and fuel conditions. The guiding rule is that flue gas temperature should not rise more then 20 Deg. C between soot blower operating periods.
Soot blowers should also be operated after any abnormal fuel burner operation resulting in heavy smoke while burning oil. This is especially true if there is an economiser or air heater. Soot blowers are expected to clean efficiently and safely. They are intended to operate on low power and labour cost, and to give long life with minimum maintenance expense. This is possible, even if the equipment be subjected to high temperatures and adverse operating conditions. Soot blowing engineering takes these points into consideration and uses the highest possible engineering standard in design and construction. As a result, blower equipment properly installed and cared for is as trouble-free as possible. To maintain this standard of operation requires only a regular programme of inspection and preventive maintenance.
14 1610 - 1611 VOL - C1 TAB - 4 - 50
6.RECOMMENDED LUBRICATION CHART FOR SOOT BLOWERS 6.1 LRD-IE Long Retractable Soot Blower and LRD-IA Long Retractable Soot Blower (Air -Operated) LUBRICATION POINTS
PART DESCRIPTION
LUBRICANT
FILLING OBSERVATION FREQUENCY FREQUENCY
M ETHOD
OF
APPLICATION
QTY PER BLOWER PER
REMARKS
FILING
1.1
Power Pack (Rotary)
Servosystem Annual 68
3 Months
Fill the reservoir removing vent plug
0.8 litre
See Note 2
1.2
Power Pack (Traverse)
Servosystem Annual 68
3 Months
Fill the reservoir removing vent plug
0.8 litre
Sea Note 2
1.3
Chain
1.4
1,5 1.6
Travelling carriage (Steam Blowing) Travelling carriage (Air Blowing) Air Motor
Servosystem 150 Almasol 1250 or Annual Servogem HTXX
-
-
-
3 Months
Fill in the reservoir
0.6 Kg
Servomesh 28
Annual
3 Months
Fill in the reservoir
0.6 Kg
Servospin 6
2 Months
2 Months
Air line lubrication
I litre
See Note 1
See Note 3
Only for LRD- IA
15 1610 - 1611 VOL - C1 TAB - 4 - 51
NOTE: 1
All the chain and chain links are prelubricated by special treatment by which lubrication is required normally. But as and when sign of rust is identified twofold lubrication is recommended. First the chain is cleaned and trichloroethylene is applied over surfaces. (This is used as a degreasing agent and carrier for penetrating the heavy lubricant. Servosystem 150 is applied as a second cost).
NOTE: 2
Lubricating oil levels should be checked and maintained every month.
NOTE: 3
Almasol 1250 is recommended only when the soot blowing medium temperature exceeds 427’C. For recovery boiler irrespective of temperature Almasol 1250 is recommended.
6.2 RECOMMENDED LUBRICATION CHART FOR LRD-IIE LONG RETRACTABLE SOOT BLOWER
LUBRICATION POINTS
PART DESCRIPTION
LUBRICANT
FILLING OBSERVATION FREQUENCY FREQUENCY
M ETHOD
OF
APPLICATION
QTY PER BLOWER PER
REMARKS
FILING
16
2.1
Travelling carriage (Air Blowing)
Servomesh 28
Annual
3 Months
Fill in the reservoir
0.8 litre
See Note 2 in section 6.1
2.2
Travelling carriage (Steam Blowing)
Almasol 1250 or
Annual
3 Months
Fill in the reservoir
0.6 Kg.
See Note 3 in Section 6.1
2.3
Chain
Servosystem 150
-
-
-
1
See Note 1 in Section 6.1
2.4
Power Pack Rotary and Traverse
Servomesh 28
Annual
3 Months
Fill in the reservoir
0.8 litre
See Note 2 in Section 6.1
1610 - 1611 VOL - C1 TAB - 4 - 52
6.3 RECOMMENDED LUBRICATION CHART FOR RB-IM ROTARY SOOT BLOWERS -MANUAL RB-IE ROTARY SOOT 6 LOWER S-ELECTRICALLY OPERATED RB-IA ROTARY SOOT BLOWERS-AIR-OPERATED
LUBRICATION POINTS
PART D ESCRIPTION
LUBRICANT
FILLING FREQUENCY
OBSERVATION FREQUENCY
M ETHOD
OF
APPLICATION
QTY PER BLOWER PER
REMARKS
FILING
17
3.1
Power Pack
Servosystem 68
Annual
3 Months
Fill in the reservoir
0.5 litre
See Note 2 in Section 6.1
32
Bull gear/(cluster gear of Manuel rotary)
Servogem 3 or Servogem HTXXX
2 Months
1 Month
Apply grease
0. 5 kg
-
3.3
Air motor
Servospin 6
2 Months
2 Months
Air line lubrication
1 litre
O nly for RBlA
1610 - 1611 VOL - C1 TAB - 4 - 53
6.4 RECOMMENDED LUBRICATION CHART OF WB-IE WALL DESLAGGER
LUBRICATION POINTS
PART D ESCRIPTION
LUBRICANT
FILLING FREQUENCY
OBSERVATION FREQUENCY
M ETHOD
OF
APPLICATION
QTY PER BLOWER PER
R EMARKS
FILING
18
4.1
Gear Rack Housing
Servomesh S P 460
Annual
3 Months
Fill in the reservoir
0.5 litre
4.2
Linkage
Servogem 3 or Servogem HTXXX
2 Months
2 Months
Pressure filling
0. 1 kg
4.3
Rotary gear box (steam blowing)
Servomesh S P 460
Annual
3 Months
Fill in the reservoir
0,5 litre
4.4
Rotary gear box
Servorex LO
Annual
3 Months
Fill in the reservoir
0.5 litre
See N ote 2 in Section 6.1
See N ote 2 in Section 6.1
For Air operation only
1610 - 1611 VOL - C1 TAB - 4 - 54
6.5 RECOMMENDED LUBRICATION CHART-FTP-IE FURNACE PROBE AND THE TRAVERSING SOOT BLOWER
LUBRICATION POINTS
5.1
19
5.2
PART DESCRIPTION
Power pack
Chain
FILLING LUBRICANT
FREQUENCY
QTY PER OBSERVATION M ETHOD OF BLOWER PER FREQUENCY APPLICATION
REMARKS
FILING
Servosystem 68
Servosystem 150
Annual
-
3 Months
-
Fill in the reservoir
-
0.8 litre
See Note 2 in Section 6.1
-
See Note 1 in Section 6.1
1610 - 1611 VOL - C1 TAB - 4 - 55
6.6 Comparable Equivalents of international Lubricants Sl. N o.
Indian Oil Corporation
1.
Servosystem 68
2.
Servogem HTXXX or Servogem 3
Hindus tan Pe trole um Enklo 68
-
ESSO Terresso 52 or Nuto 53
-
Pen- o- led EP2
Te xaco and Calte x
Gulf
Thermatex EP- 1
-
Mobil temperature grease 78
Macoma oil 68
Meropa oil N o. 2
-
Mobil Compound BB (Mobil Gear 62.9)
Exxon spartan EP 150
-
-
Mobil compound FF (Mobil gear 634)
Exxon spartan EP 460
Bharat Amocam oil 460
-
Mobilux EPO
Exxon Lidok EPO
-
Bharat Velocite E Exxon Avox EP (gargoyle Arctic Hydrol 15 45 oil light)
Gulf Leymoly
EP Lubricant 65
Macoma oil 78
5.
Servorex LO
Limaplexo
Nebula EPO
Shell Alvania Grease EPO
Texaco Gulf crown Multifak EPO Grease EPO
6.
Servospin 6
Spintek 12
Spinnesso 34 Shell Tellus oil 10 Spintex RS
20
4.
Meropa EP Lubricant lubricant No. 115 5
1610 - 1611 VOL - C1 TAB - 4 - 56
8
Servosystem 150
Yantrol 150
Bharat Pe trole um
Davina Grease N o. 2
Pen- o- led Gervil EP460 EP5
-
Exxon
Mobil Delvac special 1O W30
Sarvomesh S P 460
-
M obil
-
Servomesh 28 Gervil EP15
-
*Lubrication Engine e rs Inc.
Shell Tellus oil 33 Regal oil PC Harmony 61 (R&O )
3.
7
Note 1: Note 2 :
She ll
-
Vitrea 69
-
Texol ' F '
Gulf spin 35
-
Gulf EB 7
Almasol 1250
-
Vactia oil extra heavy
Bharat Extra Motor oil Hydrol 68 1O W- 30
-
-
Bharat MP Grease 3
-
Bharat Hydrol 150
Address of this firm is M/s.Lubrication Engineers Inc., Post Box No. 7128,Forth Worth, Texas 7611, USA. The equivalent lubricants listed above will not have the same characteristics,but they can be used considering the application. names of equivalent lubricant are based on the information available with us.Any revisions in the name of equivalent lubricant may be confirmed with the respective lubricant manufactures.
7.RECOMMENDED QUANTITY OF LUBRICANTS FOR ONE YEAR Sl. N o.
Lubricant
TYPE OF BLOWER
UN IT
1-6
7-12
13-18
19-24
25-30
313-40
40 AN D ABOVE
K g.
6
12
18
24
31
40
-
1.
Almosal 1250 Almosal 1250
2.
Servomesh 28
Long Retractable Model LRD- 1 E (Air Slowing)
Lit.
9
18
27
36
45
54
Servomesh 28
Long Retractable Model LRD- 11 E (Air Blowing)
Lit.
9
18
27
36
45
54
Servomesh 28
Long Retractable Model LRD- 11 E (Steam Blowing)
Lit.
9
18
27
36
45
54
Servosystern 68
Long Retractable Model LRD- 1 E/I A
Lit.
12
24
36
48
60
80
Rotary Blower RB- 1 E
Lit.
4
8
10
12
18
24
Wall Blower WB- l E (Steam Blowing)
Lit.
5
12
18
24
30
40
Wall Slower WB- l E (Air Blowing)
Lit.
3
5
9
12
15
20
Long Retractable LRD- 1 E
K g.
12
24
36
48
60
80
Long Retractable LRD- 11 E
K g.
18
36
54
72
90
120
3
21 4.
5.
Servomesh 60
Servogem HTXXX
Long Retractable Model LRD- I E Long Retractable Model LRD - II E
STEAM BLOWING
1610 - 1611 VOL - C1 TAB - 4 - 57
6.
Servorex LO
Wall Deslagger (Air driven)
Lit.
3
6
9
12
15
20
7.
Servospin 6
All types of air operated Blowers
Lit.
5
10
15
20
25
30
8.
Trichloroethylene
Long Retractable Model LRD (All Types)
Lit.
3
6
9
12
15
30
9.
Servosysterm n 150
Long Retractable Model LRD (All Types)
Lit.
3
6
9
12
15
30
60 30 30 60 40 40
8.
VALVE SEAT GRINDING FOR SOOT BLOWER VALVE HEADS 8.1.
Caution
DO NOT re-grind seats unless absolutely necessary. Every attempt should be made to lap seat and valve into condition without using the re-grinding tool. Only when the normal valve grinding procedure with valve grinding compounds does not remove cuts and wire drawing from the seating surfaces should be grinding tool be resorted to. DO grind very lightly. When the grinding tool is employed only sufficient grinding should be done to remove imperfections. Removing hard stellite face unnecessarily is wasteful and time consuming. DO maintain a 210 angle on the fixed seat in the main body and 19-1/20 angle on valve disc of the valve assembly. It is permissible to be off a few minutes from these angles on both seating surfaces. We endeavour to maintain full width contact for greater life expectancy. This is desirable rather than the “ring” contact which would be present with different angles on the matching seats. The “ring” contact seal cuts through and starts to leak in a relatively short time. 8.2
Disassembly of Operating Heads
All valve heads are stripped down whether removed or still in place on the unit. The valve disc and all packings are removed. The packing gland remains in place. Where packing glands show wear at the valve stem guide area or are to be replaced for any reason, the replacement should be made before re-seating is done. The packing gland is used as a guide for the pilot and the stone sleeve in the re-seating procedure. The packing gland must therefore remain in place after grinding to insure concentricity of the operating parts when the unit is re-assembled. 8.3
Test Checking Valve and Seat
Immediately after dis-assembly an examination of the parts should be made to see that they are not fractured or broken beyond repair that would require replacement. The seating surfaces are then checked. Cracked seat surface in the valve body may require re-stelliting. This is not a recommended field procedure. The valve body with packing gland and valve stem assembly should be returned to our plant for re-stelliting and grinding in the valve. The valve stem assembly may be craked or the valve stem worn or scored requiring replacement. The packing gland may be worn in the valve stem guide area and require replacing. When the body with the final packing gland in place is available the valve assembly is then lapped with fine valve grinding compound. The valve grinding compound should be the water mixed automotive type. The procedure for lapping the valve is comparable to automotive valve grinding using the screwdriver slot in the top of the valve disc to rotate the valve with compound on the seat surface. This light test lapping will indicate the extent of wire drawing, cuts or imperfections in the seating surfaces. From this test lapping, it can be determined if heavy grinding compounds and continued hand grinding with fine lapping compounds used in turn will correct the surfaces or if it will be necessary to resort to the more drastic valve re-grinding. 22 1610 - 1611 VOL - C1 TAB - 4 - 58
8.4
Dressing the Grinding Stone
The stone is installed on the stone sleeve by turning the threaded end of the sleeve into the threaded bushing in the stone. The stone on the sleeve is then installed on the lightly oiled upright stem of the grinder. The sleeve and stone assembly is then rotated with the driver.
Valve Seat Grinding Tool set 1.Drive RPM of Drive Shaft = 12000 4. Stone Sleeve 2.valve Body
5. Stone (Norton ME 105420 or Equivalent)
3.Pilot The cutting angle of the diamond point “dresser” should be set on the angle indicator to 210. The dressing of the stone should be with very slow feeds of the micrometer adjustment in the diamond feed screw to avoid waste and damage to the stone. 8.5
The Pilot
The pilot is then installed in the soot blower head from the stuffing box side. Pilot “plug” should enter and fit snugly in the packing box of the packing gland in order to insure concentricity of the newly made seat with the guide of the packing gland. 8.6
The Stone Sleeve and Stone Assembly
The sleeve and stone assembly is then inserted in the operating head from the opposite side of the packing gland. The stem on the pilot entering into the sleeve should be lightly oiled. A minimum amount of oil should be used to avoid oil loading of the grinding stone. 8.7
The Driver
The driving head is then fitted into the sleeve. The stone should be off the seat and ride on the pilot stem only as driver is started. The driver with sleeve and stone assembly is advanced slowly until the seat surface is contacted only very lightly. The driver is then withdrawn very slowly. Cutting on these seats is extremely rapid because of the angle, therefore, we repeat, proceed slowly in removing metal. A slight check after the first touch will indicate if additional grinding is required. 8.8
Valve Stem Assembly
The valve disc of the valve stem assembly may be cut or wire drawn with marks too deep to remove by compounds and hand work. These assemblies can be dressed to the 20 Deg. with a grinder in a lathe or a regular automotive valve grinder. Extreme care should be exercised where the disc seating surface of the valve stem assembly is ground or refinished that excessive metal is not removed. 23 1610 - 1611 VOL - C1 TAB - 4 - 59
Never more than a total of 0.25mm should be removed from the face of the disc on the valve stem assembly as it is received from the factory. Removing excessive metal by this grinding of the disc on the valve stem assembly will reduce the diameter and thin the seating wall of the valve disc permitting it to be driven through the fixed seat. This is not dangerous to personnel but does impose a more expensive maintenance problem. We recommend replacement of the valve stem assembly when the seat surface is damaged. 8.9
Check for Mating Seat Angle
When both seating surfaces have been regrouped the mating angles can be checked by the use of Prussian Blue. With blue applied to the seating surface a light turn of the valve assembly will indicate not only imperfections but will determine if the angles of both seat and valve are identical in the lapped area. The fixed seat in the body should show full width contact on the valve disc rather than “ring” contact. If “ring” contact is apparent the angle on the grinding stone may require a slight correction in the “dressing” angle. 8.10
Re-dressing the Grinding Stone
The grinding stone should not be permitted to develop a ring or groove between ‘dressing. The side angle of the stone should remain straight and flat. “Dressing” is also essential to prevent oil carbon loading. 8.11
Lapping after Grinding
When seats have been reground the valve should be hand lapped with very fine lapping compound. This procedure again is very very light. Only sufficient pressure is applied with a very few turns so that a fine “frosted” surface appears on the newly polished ground parts. Actually this lapping procedure should be more of a check to see that surfaces properly made on both parts. Figures show a hand tool suggested for this purpose. 8.12
Re-Assembly
The re-assembly of the operating head is of course in the reverse order of dis-assembly. Where the operating heads are rotary soot blower, heads, care should be exercised when the head is reinstalled that element flange is registered properly on the operating head. If some marks or care is exercised in this respect it will save resetting the blowing cams in order to correct the blowing arc. Blowing arcs should be double checked on all rotaries after replacement to avoid cutting tube destroying baffles or inducing improper cleaning that would be encountered if the blowing arc were established in the improper segment or if the element is improperly moved end ways. Note: We recommend that the SB valve assembly to be sent to the factory for re-conditioning rather than the customer trying to recondition the valve since special care should be taken in repairing this valve.
9.
RECOMMENDED PROCEDURE FOR PACKING INSTALLATION The useful life of packing is dependent on the method of installation. Poor installation can cause the best packing to fail prematurely. The methods in this procedure, if followed, will lead to better sealing and longer life. These packing method apply both to installing packing in new equipment and replacing packing in equipment that is in service.
24 1610 - 1611 VOL - C1 TAB - 4 - 60
9.1
Installation method
Clean out the old packing. Flexible packing hooks are available for removing the packing. Inspect the feed pipe stem for wear or damage. Remove any raised metal that projects above the normal surface. Do not try to file out depressions or scratches. Raised metal will tear packing. Any reworking of scratches will only worsen the condition. Keep the new packing clean during installation. Grit or other hard foreign matter that is installed with the packing may score the feed pipe causing an early failure of the packing. Install all packing rings so that the joints are staggered and kept approximately 90 Deg. apart. Spot the joints in clockwise direction to facilitate locating them when removing the packing. 9.2
Install the rings one at a time
Each ring must be set firmly into place with either the gland or a tamping tool as shown in figure. After each ring is installed, the ring must be compressed with approximately the same force that it will have with the final gland force. Each ring should be equally compressed when the entire set is installed. If this is not done, only the last ring will do the sealing and will wear quickly.
Install each ring as per the figure. Bevelled packing is to be installed with the bevel lip on the shaft pointing toward the pressure. One end of the tamping tool is angled for bevelled packing. Fit the bevel on the packing to the bevel on the tool see figure. Oil or grease may be applied to the outside of braided asbestor packing to help in installing it in the stuffing box. Tighten the gland follower, sufficiently tight, after the packing has been installed to insure final seating of the packing. The nuts should be backed off two or three turns to relieve excessive pressure. Adjust packing to operating conditions. Allow packing to leak a small amount, if possible, when starting newly packed equipment. Tighten the gland slowly as the packing seats. Do not be afraid to let packing leak a small amount. It is good assurance that packing is not too tight and the liquid usually has some lubricating qualities. When renewing packing, use all new clean packing. Worn packings are dry, highly compressed, have high friction and may develop scoring. Remember packing is relatively cheap. Labour and materials necessary to replace worn feed pipes are expensive and critical commodities. The most expensive seal is a seal that fails. Light gland pressure should be maintained at all times. Too much pressure will cause binding, scoring of the shaft and force the lubricant out the packing. Too little gland pressure will allow excessive leakage and washing out of the packing. When the packing has been compressed to less than ¾ of its original height, it should be replaced. The loss of height in packing may indicate a loss of essential lubricant.
25 1610 - 1611 VOL - C1 TAB - 4 - 61
lAPPING TOOL
9.3
Packing
Keep packing glands just tight enough to prevent leakage : Do not overtighten them. Replace packing that leaks excessively. Refer to instruction ‘Recommended Procedure for Packing Installation’.
10.
INSTRUCTIONS FOR STORAGE All the Soot Blowers, though designed for outdoor applications, require special care during storage before erection and commissioning. These instructions may please be taken seriously to avoid costly replacements or breakdowns at a later date. (i)
On receipt of the Soot Blowers, carefully check for any damage of the components. List out the damaged components with reference to the item no. in the concerned assembly drawings to BHEL, Tiruchirapalli for further action.
(ii)
See the Soot Blower assemblies are shipped completely covered with waterproof coverings. Unless the blowers are taken for immediate erection please do not disturb the coverings. Coverings are to be replaced wherever damaged.
(iii) Some assemblies like Wall Deslaggers and Rotary heads are shipped with temporary wooden platforms to prevent parts getting damaged during erection. These need not be removed till the blowers are erected. 26 1610 - 1611 VOL - C1 TAB - 4 - 62
(iv) All the electrical items are to be covered with waterproof and dust proof coverings. Nozzle and valve openings are shipped covered. This may be checked and covered wherever necessary. (v)
Normally storage under covered roof is not necessary for Soot Blowers when the waterproof covers are not removed. Wall Deslaggers and Rotary Soot Blower heads can be stored under covered roof if the interval between Soot Blower erection and receipt is more than two months.
(vi) Always use the lifting lugs or hooks provided to avoid damage to the connected parts. Similarly avoid hitting the assembly against structures or other boiler components while the Soot Blowers are being lifted. (vii) The above instructions are for guidelines only and the concerned persons may use their own discretion’s knowing well that these are electro-mechanical components.
27 1610 - 1611 VOL - C1 TAB - 4 - 63
TAB - 5
INSTRUCTIONAL MANUAL WALL DESLAGGER MODEL-WB IE
Bharat Heavy Electricals Limited Tiruchirapalli
PUB.NO.7503
1610 - 1611 VOL - C1 TAB - 5 - 64
CONTENTS INTRODUCTION IMPORTANT INSTRUCTIONS FOR ERECTION,START-UP & OPERATION DESCRIPTION WALL DESLAGGER BASIC ASSY. (REF. DRG. 0-00-073-60026) INSTALLATION
CHECK LIST AND ADJUSTMENTS CHECK LIST ADJUSTMENTS
START UP CHECKS OPERATION OPERATIONAL PROBLEMS AND MAINTENANCE MAINTENANCE AND LUBRICATION RECOMMENDED SPARES
2 1610 - 1611 VOL - C1 TAB - 5 - 65
Wall Deslagger LIST OF DRGS INCLUDED IN THE MANUAL 1.
0-00-073-60026
WALL DESLAGGER BASIC ASSY.
2.
0-00-073-60027
SWITCH BOX ASSY.
3.
1-00-073-60003.
SBV HEAD ASSEMBLY
4.
1-00-073-60109
RACK GEAR HOUSING ASSY.
5.
1-00-076-60110
ROTARY GEAR BOX ASSY.
6.
2-00-073-60088
WALL DESLAGGER MAIN ASSY.
7.
3-00-073-60008
CAM ASSY. (TERMINAL BOX)
8.
3-00-073-60105
CLEVIS BRACKET ASSY.
9.
3-00-073-60006
WALL BLOWER WIRINGDIAGRAM
10.
3-00-073-60106
RACK CAM ASSEMBLY
11.
4-00-073-60165
SPECIAL ALLEN KEY
12.
4-00-073-60166
SPECIAL SQUARE KEY
13.
4-00-073-60167
VALVE SPRING TOOL
3 1610 - 1611 VOL - C1 TAB - 5 - 66
INTRODUCTION The coal fired boilers demand the maximum in effective Furnace wall slag control. Effective deslagging entails- high striking power combined with barest minimum “dead time” between blowings. WBIE Wall Deslagger is designed to efficiently meet these needs. No soot blower system will operate satisfactorily if it is not properly installed, operated and maintained. It must be recognised that no amount of written instructions can replace intelligent thinking and reasoning on the part of the operators, especially when coping with unforeseen operating conditions. It is the operator’s responsibility to become thoroughly familiar not only with the equipment but also with all pertinent control equipment. The instruction gives the general description of the wall deslagger and its installation procedures. Details of the, adjustments of blowing speed, valve stroke and nozzle are outlined. The operation, maintenance and lubrication details are also given. The contents in the manual have been compiled and checked by experts in the field. Every possible care has been taken to ensure the contents are accurate. However, it must be understood that the manual is not a contract document. If you ever have any query about operation, maintenance or related problems, you are welcome to write to us without obligation. BHARAT HEAVY ELECTRICALS LTD. BOILER PLANT - TIRUCHIRAPPALLI.
4 1610 - 1611 VOL - C1 TAB - 5 - 67
WALL DESLAGGERS IMPORTANT INSTRUCTIONS FOR ERECTION,START-UP & OPERATION DO’S ERECTION 1
Check the opening in the boiler wall. It shall be minimum 75 mm through.
2.
Check the wall sleeve for perpendicularity and concentricity.
3.
Check blower number with reference to location drawing.
4.
Check the ACCESSIBILITY FOR HAND CRANK and the Switch box assembly.
5.
Check whether the WALL DESLAGGER is PERPENDICULAR after mounting.
6.
Check the PROJECTION OF NOZZLE INTO THE WALL.
7.
Support the SOOT BLOWER piping on the Boiler STEEL such as BUCK STAYS, FURNACE GUIDES etc.
8.
After the nozzle setting, PUNCH MARK on the alignment plate.
BEFORE START-UP 1.
FLUSH the gear boxes thoroughly with ‘SERVOMESH 60’ and fill the gear boxes with the lubricants as recommended.
2.
Make sure the DRAIN HOLES in the MOTOR FRAMES point downwards and are open.
3.
Check the direction of rotation of both the MOTORS.
4.
Make sure that the stop nuts are in place on the rods.
5.
Check whether covers are put on the blower.
6.
Check the perpendicularity of the blower when the blower is working.
START-UP AND OPERATION 1.
Check Lubricating oil levels frequently.
2.
Ensure all the interlocks are in use.
3.
Ensure availability of hand cranks for immediate use.
4.
Set the Blowing as per recommendation.
5.
Ensure proper valve opening and close during operation.
6.
Ensure the blowers are at home position after cycle completion.
7.
Ensure a gap of 3-6mm between rotary gear box and rack gear guide rod boss at the extended position.
8.
Attend steam leakage immediately.
9.
In case off emergency alarm due to elapsed timer, Low header pressure, No blowing medium, A/C supply failure, interlocks, etc., immediately withdraw the swivel tube using emergency hand cranks, after switching off the Power Supply.
10.
Pay immediate attention of rectifying the mechanical and electrical faults.
11.
Observe all the safety practices. 5 1610 - 1611 VOL - C1 TAB - 5 - 68
DONTS ERECTION 1.
Do not place heavy Loads on wall deslagger.
2.
Do not use the blowers as welding platform.
3.
Do not remove the wooden supporting planks until soot. blower is firmly fixed to wall.
4.
Do not leave the swivel tube at extended position.
START-UP AND OPERATION
1.
1.
Do not operate wall deslagger with wet steam.
2.
Do not operate the blower without blowing during boiler operation.
3
Do not attend any maintanence work on soot blowers when power and /or steam supply is ‘ON’.
4.
Do not operate the blower with excessive steam leakage through packing.
5.
Do not use hand crank lever for retract when power is ‘ON’.
6.
Do not stand near peepholes when the blower is operating.
DESCRIPTION 1.1
Wall Deslagger Basic Assy. (Ref. DRg. 0-00-073-60026)
The deslagger consists of a stationary body (item 10) and rack gear housing (item 2) and a rotary gear box assy. (item 3) to which the swivel tube assy. (item 5) is attached. The swivel tube assy, is supported by Bushing (item 17) at each end of the body casting. The horizontal guide rods (item No. 09 of Drg. No. 1- 00-073-60109) are used to assure proper alignment of the relay gear box assy. A stationary electric motor (item 59) is situated on the right side of the. blower. This motor, through a Rack gear housing Assy. operates a pinion which drives a horizontal rack assembly, (item 11) the outer end of which is fastened to the rotary gear box Assy. (item 3). When the Rotary gear box approaches the fully extended position a ramp cam (item 2) attached to the free end of the rack (item No. 01, 3-00-073-60106) contacts a bearing surface, which is a part of the clevis bracket Assy. (item 6) and pushes the valve stem assy. (item No.02 of drg. No. 1-00-073-60003), admitting the steam to the swivel tube. When the blower is started the rack pinion moves the rack (item 11) and rotary gear box towards the boiler. Operation of the Rack gear housing causes rotation of a shaft extending out -from the rack gear housing into a switch box Refer Drg. No. 0-00-073-60027. Located in this switch box are two cam actuated limit switches. One cam holds limit switch LSTE in the open position when the blower is fully retracted. Extending of the blower moves the cam allowing LSTE to close. The blower is then under its own control. Near the fully - extended position, the ramp cam strikes the lever that open the SBV head valve. The second limit switch cam strikes the LSTS limit switch, which opens the circuit to the traverse motor (item No. 59) and closes the circuit to the rotary motor (item 60). The rotary motor is attached to the rotary gear box assy. When LSTS closes, the motor rotates the swivel tube through a gear train. When the blowing sweep is finished the cam assy. (item 7) on the swivel tube contacts and rotates the arm on the limit switch LSTR. The traverse motor begins to retract the blower. Near the fully retracted position the cam again opens the switch LSTE to haet the blower. 6 1610 - 1611 VOL - C1 TAB - 5 - 69
CAUTION : Care should be exercised when operating the WB-IE with its guard assy. (item 9)and its holding nuts (item 30) removed. If, for any reason, the stop limit switch. (LSTE) is not actuated during the retract portion of the operating cycle, it is possible for the rotary gear box to overtravel and drop off the end of the guide rods. If the rack should come free of the gear rack pinion drive, the cams for the limit switches will require resetting. The end of the worm shaft (item 7 Drg.No. 1-00-073-60109) is slotted so that a hand crank can be inserted to allow manual operation of the blower. Be sure the power circuits are deenergized before using this crank. 1.2
INSTALLATION
i.
Wall Deslagger Sleeves A wall blower is supported by four studs attached to the flange of a sleeve or wall box inserted in the boiler wall.
ii.
For steel - cased wall: Install sleeve as shown on application drawing. Be sure elevation and vertical location are exactly as shown in the relevant contract drawing.
Sleeves are usual ly attached to waterwall tubes to maintain proper distance between the fully extended nozzles and the tube surfaces. Application drawings show how to allow for movement of a sleeve relative to the boiler wall. Cut the proper size hole in the casing panel or plate. With sleeve and panel or plate positioned, build wall around it as shown in the drawing. If the sleeve flange is shown welded to the panel or plate, tack welds will be sufficient if they are one inch apart on each of the four sides iii.
Erecting the Soot Blower
With sleeve properly installed, lift the blower into position. Make sure there are no obstructions in the path of the rotary gear box. Slide blower forward, so that the four M20 studs on the sleeve flange fit into the four holes on the boiler end of the blower body. Screw one jam nut tightly against each side of each hole to give the blower firm’ support. Unless otherwise specified on the job drawings, no other support is needed. iv.
Adjusting the Blower Position
The blower must be positioned so the relationship between the fully extended nozzle and the boiler wall (or the waterwall tubes) is correct. In the absence of a specific dimension on the drawings, set the centre line of the back nozzle 38 mm from the face of the wall tubes. Adjust the blower in or out of the boiler by turning the stud nuts on the sleeve plate. To check the location of the nozzle, the swivel tube and nozzle should be extended fully into the boiler. The blower is completely assembled and if clear, is ready to operate once the power has been connected properly. For directions on making the electrical connections and setting switches, see the instructions below. Before extending the swivel tube and nozzle, make sure there are no obstructions in the path of the rotary gear box. V.
Erection of Piping
When the piping is erected, great care should be taken to make up the inlet flanged joint properly. No piping should be supported by the blower. 7 1610 - 1611 VOL - C1 TAB - 5 - 70
Proper piping supports and guides should be used to prevent piping strain. When the companion flange is attached to the pipe correctly and the gasket is intalled, the flange should match property. Then add the flanges, studs and nuts. When the nuts and studs are removed, the flanges should not spring apart or to either side, nor should the pipe exert an upward force on the head. Whenver wall boxes are attached to waterwall tubes (as is usually the case) the blower will move with the tubes when the boiler expands and contracts. All piping and electrical connections should be sufficiently flexible and have expansion loops, etc., to allow for this movement and prevent severe strains from being exerted on the blower. Refer to the application drawings for the amount and direction of any movement of the blower. CAUTION : Switch Box Assy. Refer Drg. 0-00-073-60027 When adjusting limit switches, power to the unit must be turned off to avoid injury of the operator. Operation of the unit should be by means of the hand crank (item 11) provided. The operation of the deslagger is controlled by three limit switches. Two of these (LSTE & LSTS) are located inside the switch Box enclosure, mounted on the right side of the blower. The thi rd switch (LSTR) is situated below the swivel tube and is operated by a split cam (item 9) on the tube. The setting of switches LSTE and LSTS are shown in the drawing referred above. The cams operating the switches are set at the factory. Minor adjustment may be necessary. The inner cam operates the LSTS switch, which starts the rotary motor. Ensure the Rotary gear box stops 3 to 8 mm before the guide bar bush ( without ramming against the boss). The outer cam operates stop switch LSTE and must be set to trip LSTE, and hold it open when the gear box is 8 to 10 mm from the fully retracted or park position. When first operating the blower, check this carefully. It must be so set to allow for drift after motor is shut off. The inner switch cam for LSTS, must be set to trip the switch when the travelling gear box is in between 3-6 mm from the fully extended position. This also should be checked when running the blower for the first time. Since packing friction affects the amount of drift, care must be taken to avoid ramming the rotary gear box against the stops in either directions. vi.
Electric Connections WIRING DIAGRAMS: Refer Drg. 3-00-073-60006
The electrical connections can now be made as shown on the application drawings. For Blowers with integral terminal box, all wiring connections are made to the terminal box. For blowers without integral terminal boxes all connections are still made to one point - the small cast box on the top of the blower. The number of connections to be made are shown on the wiring diagrams. Before operating any blower, make sure the drain holes in the motor frames point downward and are open. Add the proper quantity of oil to the two gear boxes (rotary and traversing) and assure that the vents point up and are open.
8 1610 - 1611 VOL - C1 TAB - 5 - 71
2.
CHECK LIST AND ADJUSTMENTS 2.1
Check List
i.
Lubrication a.
Rotary gear box
b.
Traverse gear box
ii.
External Electrical connections
iii.
Nozzel position adjustment
iv.
Perpendicularity of swivel tube with respect to furnace wall.
v.
Pressure setting a.
Initial setting
b.
Final setting
vi.
Limit switch adjustment for rotary gear box travel
vii.
Removal of SBV head NRV plug.
2.2
Adjustments
i.
Adjustment of Blowing Sweep
The sweep of some wall blowers is restricted because of their proximity to corners or burners. Refer to the application drawings to determine sweep. It is important that the sweep be set as closely as possible to that shown on the application drawings, otherwise damage to the boiler may result. The nozzle opening position is indicated by a mark on the swivel tube or by the key slot in the swivel tube which can be seen by, removing the guard and the nut and washer at the end of the swivel tube. To adjust the sweep, remove the sheet metal guard. If it is convenient to operate the blower with electrical power use the “local start” push button station. The swivel tube and rotary gear box extend rapidly; be sure there are no obstructions in the path of the rotary gear box. To stop the swivel tube rotation and retract the tube and gear box, rotate the lever on the reverse limit switch operated by the split cam on the swivel tube. This will retract the blower rapidly. Make sure there are no obstructions in the path of the rotary gear box On standard wall blowers there is one stop collar or split cam on the swivel tube, (item 7) adjacent to the rotary gear box (item 3). This collar contacts the lever of the reverse limit switch to retract the blower at the end of its sweep. On wall blowers with restricted sweeps there are two cams. One cam contacts the limit switch to reverse the swivel tube at the end of the sweep, while the other retracts the swivel tube and rotary gear box at the end of the blowing sweep. Loosen the set screws in these cams and assure that they are loose on the swivel tube before adjusting the sweep. To adjust the sweep, start the blower and allow the swivel tube to rotate until it is in the proper position for the end of the blowing sweep. Retract the swivel tube, using the reverse limit switch. Set the reverse limit switch stop collar so that the side of the collar will just contact the side of the reverse limit switch lever. Tighten the setscrew. With all adjustments completed, operate the blower and check the sweep for correctness, preferably from inside the boiler. Replace the guard (item 9). 9 1610 - 1611 VOL - C1 TAB - 5 - 72
ii).
Valve Stroke Adjustment
SBV HEAD ASSY: Refer Drg. 1-00-073-60003 The SBV head allows the blowing pressure of the blower to be adjusted by limiting the stroke of the head valve. Where it is necessary to reduce pressure greatly, a fixed orifice may be installed in the head inlet flanges. The stroke of the head valve is governed by adjustment of the drive screw which contacts the head valve stem. In the closed position, a minimum clearance of 1 mm must be maintained between adjusting screw and valve stem, to assure tight valve seating. In general, slag removal will necessitate blowing pressure of 10-14 kg/sq cm. Soot and fly ash will need 10-18 kg/sq cm and dust removal pressure may be as low as 7 kg/sq cm. Always consult the General Arrangement Drawing for recommended blowing pressure. The stroke of the head valve is governed by adjustment of the drive screw which contacts the head valve stem. Maximum stroke of the valve is 14.5 mm. If this maximum stroke is desired adjust the valve drive screw so the screw begins to depress the valve stem when the pad on the rotary gear box is 38 mm from the rack housing pad. When these two pads touch, the rotary gear box is fully extended. Extending the screw through the lever increase valve opening and blowing pressure. In the closed position, a minimum clearance of 0.8 mm must be maintained between the drive screw and the valve stem, to assure tight valve seating. When proper pressure has been established, by gauge reading, lock the drive screw in place with lock nut. iii.
Nozzle Adjustment
Nozzle alignment should be made from inside the furnace, referencing the centreline of the nozzle and wall tube surface, with the nozzle opening parallel to the wall tubes. If the units are set from outside the boiler, they should be checked inside at the first opportunity. After the unit is installed, it should be checked to make sure that it is perpendicular with the boiler wall, to insure cleaning through the full blowing arc. The sweep should then be set, if possible, so that the nozzle is pointing down or in the 6 O’clock position, when the head opens. This helps to prevent tube cutting from condensate since the nozzle blows parallel with the tube when the head first opens and condensate is blown off before the jet sweeps across tubes.
3.
START UP CHECKS For detailed Start up checks
4.
a.
Check the blower numbers and their location.
b.
Check the perpendicularity of the wall sleeve with reference to water wall
c.
Check the mounting of the blower for perpendicularity to the water wall.
d.
Ensure the nozzle projection inside the boiler. (Normally the nozzle centre line should be 38 mm from water tube).
e.
Check the free manual movement.
f.
Check whether all the blowers are in the initial position.
OPERATION When just putting the blower into service, start it locally so that the operation of all parts can be observed. It is advisable to check the blowing pressure, using an auxiliary gauge. Start the 10 1610 - 1611 VOL - C1 TAB - 5 - 73
unit and observe to confirm that the blowing steam comes on at the proper time. If not, hand operate the blower reversing switch LSTR. If the boiler is in operation do not allow the blower extended for any length of time as the swivel tube may get damaged. If the valve head has failed to open, retract the blower before examining the head. There is a panel start push button for each blower. Each button should be held in about three seconds, then released. The blower then extends, open the head, completes a blowing cycle, closes the head and retracts. Operate each Push button once for each blowing cycle.
5.
OPERATIONAL PROBLEMS AND MAINTENANCE Problem
Causes
Suggested Remedy
1.Steam leakage through
1. Improper tightening swivel tube gland packing
Tighten the glands (Do not over tighten)
2. Excessive wear on the glands
Replace the glands with packings
3. Scratch marks, dents for surfaces defect on the swivel tube
In case excessive surface defect change the swivel tube
4. Defective packing or poor quality of packing
Replace the defective packing
1. Physical obstruction to gear box assy.
Observe for any obstruction and clean
2. Dust deposition on swivel tube, guide rods
Clear the dust and debris using compressed air
3. Overtightened gland packing
Maintain proper tightness of packing rings
1. Overtightening of swivel tube packing
A slight amount of steam passing is advisable for ensuring proper tightness
2. Defective surface
Replace the swivel tube condition of swivel tube
3. Valve stem seizure
Service the valve head adjust valve stem packing tightness
2. Traverse Motor over loading
2. (a) Gear box assy. not moving
2. (b) Motor over loading at 1. Limit switch LSTS extended position improper setting
3. Steam leakage through valve stem
Reset the cam in limit switch box
2. Improper setting of O/L relay at MCC
Check the setting and do the connection
3. Accumulation of slag inside the sleeve tube.
Clear the slag accumulation
1. Poor defective packing
Use good quality packing
11 1610 - 1611 VOL - C1 TAB - 5 - 74
Problem
Causes
Suggested Remedy
2. Defective surface condition of valve stem/gland bushing
Check the condition of valve stem and gland bushing and replace the defective one
3. Inadequate tightening of packing rings
Tighten the packing rings (Do not over-tighten the packing)
4. Valve passing: (through 1. Gland packing over bushing seat) tightened 2. Insufficient lapping or improper lapping or damaged valve disc
3. Foreign material trapped in between disc and seat
6.
Slightly loosen the gland so that the stem is not tightly held by the packing Dismantle the valve Disc and seat using lapping tool (As suggested in Pub. No. 7501) for severe damages either in disc or seat replace the damaged part. This will be cleared when the valve is wide opened.
MAINTENANCE AND LUBRICATION 1.
General
Soot blowers, nozzles and swivel tubes are continuously subjected to high temperatures and dirty atmosphere. Therefore, proper maintenance is necessary to keep this equipment as trouble - free as possible. To assure efficient operation and long life, attention must be given to the item below a.
Cleanliness
To assure long life and good performance of soot blowers, the outer surfaces should be cleaned of dirt and rust periodically. If allowed to accumulate, dirt and rust will enter the operating mechanism, prevent proper operation and cause excessive wear on moving parts. If a blower is not to be used for appreciable time, coat all exposed surfaces with a good grade of grease. b.
Equipment Inspection
A regular check, at least every six months should be made for wall deslaggers while the boiler is on service to ensure that the wall blowers remain perpendicular to the boiler wall. Pipe strain and boiler movement can after the position of these units in such a manner that, the swivel tube is not perpendicular to the surfaces of the wall being cleaned. This check is necessary to prevent tube erosion and it can be made visually or by placing a spirit level on the rack of swivel tube. Correction is accomplished by adjusting the nuts on the studs of the wall box adaptor where the stud passes through wall deslagger steam chest mounting flange. Check the distance from the centre line nozzle to the surfaces to be cleaned. This distance should be given in arrangement drawing issued for the relevant contract. Normally the distance will be 38 mm. Mounting : Check the soot blower mounting periodically to make sure the blower is securely mounted and properly adjusted. The mounting position is adjusted by means of the stud nuts on the sleeve. Be sure each nut on each side, of the blower body flange is tight. Loose mounting 12 1610 - 1611 VOL - C1 TAB - 5 - 75
or improper adjustment may result in misdirection of the blowing medium and possible poor cleaning or boiler damage. Piping : Check the external piping periodically for leaks. Tighten fittings to stop leaks or replace faulty fittings and connections. Be sure the piping places no strain on any blower. Swivel Tube Nozzle : At every boiler outage an inspection should be made of each swivel tube nozzle. If a nozzle is split or cracked, it should be replaced. Blowing Sweep : Any blower with a sweep of less than 360 deg. should be checked periodically for adjustment. The sweep should be kept the same as that on the application drawings. It is also advisable to check adjacent boiler tubes and walls for any possible damage. ii.
Lubrication
a.
Rack Gear Box : Every six months remove the inspection plug and make an inspection for sufficient lubrication of the gears. Apply the lubricant directly to the gear box. Use 0.6 lit. of Servomesh 60 or equivalent poured through the inspection opening. The oil level plug is small brass pipe plug on the front of the box about 50 mm from the bottom.
b.
Rotary Gear Box : Every six months make an inspection for sufficient lubrication of the gears at the combination inspection and filler fitting. The lubricant is Servomesh 60 added through the combination filler and level elbow on the side of the box. For detailed lubrication instruction refer to “Lubrication Chart and “Recommended quantity of Lubricants per annum” in the publication No. 7501 : Soot Blower General Instructions.
iii.
Packing
See Recommended Procedure for Packing Installation in the Publication No. 7501 Soot Blower: General Instructions. iv.
Swivel Tube Removal
Removal of swivel tube will be necessary because of: a.
Cracked or damaged nozzle.
b.
Persistent steam leakage even with new packing set due to swivel tube surface defects.
In order to remove the swivel tube, the main guard (item 9 of Drg. 0-00-073-60026) and the rotary gear box are the only part that have to be removed. These two parts can be dismantled without distrubing the Wall Deslagger assembly or any other pressure parts. To dismantle the rotary gear box, the lock huts (item Nos.30,35 of Drg. No. 0-00-073-60026) fixing the rack and ~the swivel tube to the rotary gear box should be removed and then the gear box can be dismantled. After removing the rotary gear box the swivel tube assembly can be pulled out of the Wall Deslagger body. The limit switch cam assembly shall be removed so that it can be reused in the swivel tube assembly. The procedure has to be followed in the reverse order for the assembly of new swivel tube. For the Wall Deslagger with long extended swivel tube, the full assembly itself should be removed from the mounting sleeve. V.
Spares
While ordering spares, indicate Item No., Drg. No., BPS No. as found in Bill of materials in addition to the old contract No. etc. for early delivery. In the enclosed drawings spares that are recommended for stock bytheuser are marked by “S”. Section 7 gives the recommended List of Standard Spares. 13 1610 - 1611 VOL - C1 TAB - 5 - 76
7.
LIST OF RECOMMENDED SPARES FOR WALL DESLAGGER WB - 1 E NOTE The list of spares under is to aid the selection of the required item.The editing and deletion of number of pieces solely lie on the user.
Sl.No Description No
Item
Assembly
No
Drawing No.
Part Material
No. of WB - IE
Code
1-6
7 - 16 17 - 24 25 - 40 over 40
1.
Valve gland Packing set
12
2-00-073-60088 963533150000
4
8
12
16
20
2.
* Packing set (Steam)
11
2-00-073-60088 9653533180000
4
8
12
16
20
3.
Gland
16
0-00-073-60026 160133990000
3
6
9
12
20
4.
Bushing
17
0-00-073-60026 160134080000
3
6
9
12
20
5.
Bearing SKF 6205 2RS
45
1-00-073-60109 55/119/0620500
2
4
6
8
10
SKF 6204
46
1-00-073-60209 55/111/0620400
2
4
6
8
10
Mc Gill CYR 13/8
12
3-00-073-60105 97/353/3130000
2
4
6
8
10
SKF 51101
31
1-00-073-60110 55/211/5110100
2
4
6
8
10
SKF 51102
32
1-00-073-60110 55/211/5110200
2
4
6
8
10
6.
Motor (Rotary)
60
0-00-073-60026 962720730000
1
2
3
4
5
7.
Motor (Traverse)
59
0-00-073-60026 962720050000
1
2
3
4
5
B.
SBV Head Assy.
01
0-00-073-60026 84202010010
1
2
3
4
5
9.
Oil Seal
17
0-00-073-60027 96/353/0830000
2
3
6
7
8
10.
Oil Seal
37
1-00-073-60109 96/353/0820000
2
3
6
7
8
11.
Limit Switch Heavy duty
18
0-00-073-60027 963582820000
2
3
6
7
8
12.
Limit Switch (Micro)
03
0-00-073-60027 96/362/0640000
2
3
6
7
8
13.
Limit Switch (Micro)
03
0-00-073-60027 96/362/0630000
2
3
6
7
8
14.
Gaskets 18
0-00-073-60026 963533590000
1
2
3
4
5
TVA5
Element Gasket
Sl.
Description
Item No
No
Assembly
Part Material
No. of WB - IE
Motor Gasket
49
Drawing No. 0-00-073-60026
Code 96/353/113
1-6 1
Cover Gasket Gasket Gasket Cover Gasket Gasket Gasket Gasket 15. Swivel tube Assy.
42 50 43 12 05 09 09 05
1-00-073-60109 0-00-073-60026 1-00-073-60109 0-00-073-60027 1-00-073-60003 1-00-073-60110 2-00-073-60088 0-00-073-60026
96/353/046 96/353/047 963530540000 96/353/112 22/021/303 96/353/044 22/021/269 842020125500
1 1 1 1 1 1 1 -
7 - 16 17 - 24 2 3 2 2 2 2 2 2 2 1
3 3 3 3 3 3 4 1
25 - 40 4
Over 40 5
4 4 4 4 4 4 6 2
5 5 5 5 5 5 8 2
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TAB - 6
FURNACE TEMPERATURE PROBE MODEL FTP IE & IIE
Bharat Heavy Electricals Limited Tiruchirapalli
PUB. NO. 7505 1610 - 1611 VOL - C1 TAB - 6 - 92
CONTENTS INTRODUCTION GENERAL GENERAL DESCRIPTION GENERAL DETAILED DESCRIPTION POWER PACK ASSEMBLY THE TRAVELLING CARRIAGE LANCE ASSEMBLY POSITION INDICATOR CONTROL CIRCUITRY INSTRUCTIONS FOR INSTALLATIONS INSPECTION CHECK LIST INSTRUMENTATION WIRING OPERATION THREE PUSH BUTTON OPERATION (LOCAL AND REMOTE) EMERGENCY RETRACTION REMOTE POSITION INDICATOR MAINTENANCE INSTRUCTIONS LUBRICATION REPLACEMENT THERMOCOUPLE REPLACEMENT POTENTIOMETER REPLACEMENT RECOMMENDED LIST OF SPARES FOR TEMPERATURE PROBE REQUIRED TOOLS FOR TEMPERATURE PROBE RECOMMENDED LUBRICATION CHART
2 1610 - 1611 VOL - C1 TAB - 6 - 93
LIST OF DRAWINGS (WITHOUT AIR COOLING) 0-00-073-60028
FURNACE TEMPERATURE PROBE BASIC ASSY.
0-00-073-60004
POWER PACK ASSEMBLY - TRAVERSE
1-00-073-60112
LANCE BEARING ASSEMBLY
2-00-073-60006
WIRING DIAGRAM
2-00-073-60092
TRAVELLING CARRIAGE HOUSING ASSEMBLY
2-00-073-60091
FURNANCE TEMP. PROBE MAIN ASSY.
2-00-073-60093
STOP LIMIT SWITCH ASSEMBLY
2-00-073-60094
REVERSE LIMIT SWITCH ASSEMBLY
3-00-073-60107
LANCE ASSY.
3-00-073-60108
DRIVE JACK SHAFT BEARING ASSEMBLY
3-00-073-60109
IDLER JACK SHAFT BEARING ASSEMBLY
3-00-073-60110
POTENTIOMETER ASSEMBLY
3-00-073 60001
THERMOCOUPLE ASSEMBLY
4-00-073-60005
TRAVERSE CHAIN ASSEMBLY
4-20-001-00523
CHAIN ADJUSTMENT
4-00-073-60110
REQUIRED TOOLS FOR FURNACE TEMPERATURE PROBE
3 1610 - 1611 VOL - C1 TAB - 6 - 94
LIST OF DRAWINGS (WITH AIR COOLING) 0-00-073-60029
POWER TRACK FURNACE PROBE ASSY. (WITH AIR COOLING)
1-00-073-60128
B.O.M. FOR FURNACE TEMP. PROBE BASIC ASSY.
0-00-073-60004
POWER PACK ASSEMBLY - TRAVERSE
1-00-073-60112
LANCE BEARING ASSEMBLY (FOR 76mm O.D. LANCE ONLY)
2-00-073-60096
SOLENOID VALVE ASSEMBLY
2-00-073-60097
LANCE ASSEMBLY
2-00-073-60098
TRAVELLING CARRIAGE HOUSING ASSEMBLY
2-00-073-60093
STOP LIMIT SWITCH ASSEMBLY
2-00-073-60094
REVERSE LIMIT SWITCH ASSEMBLY
3-00-073-60123
COOLING AIR LIMIT SWITCH ASSEMBLY
3-00-073-60124
CYCLING LIMIT SWITCH ASSEMBLY
3-00-073-60108
DRIVE JACK SHAFT BEARING ASSEMBLY
3-00-073-60109
IDLER JACK SHAFT BEARING ASSEMBLY
3-00-073-60110
POTENTIOMETER ASSEMBLY
3-00-073 60001
THERMOCOUPLE ASSEMBLY
3-00-073-60125
PUSH BUTTON ASSEMBLY
4-00-073-60005
TRAVERSE CHAIN ASSEMBLY
4-20-001-00523
CHAIN ADJUSTMENT
2-00-073-60099
PHYSICAL WIRING DIAGRAM
3-00-073-60127
SCHEMATIC WIRING DIAGRAM
4 1610 - 1611 VOL - C1 TAB - 6 - 95
INTRODUCTION The Furnace temperature probe installed in various power station installations is manufactured by BHEL with its Engineering know-how and the sum of the experience gained on many new installations in India. The BHEL Furnace probe gives the reach needed for a constant check on gas temperatures in critical boiler start-up phases and provide an extra measure of protection during periods when boiler equipment is subject to the most hazard. The temperature measurement system will function satisfactorily with a little attention to installation, operation and maintenance. It must be recognised that no amount of written instructions can replace intelligent thinking and reasoning on the part of the operators, especially when coping with unforeseen operating conditions. It is the operators responsibility to become thoroughly familiar not only with the equipment but also with all pertinent control equipment. The instruction contained in this manual is only an outline of the correct procedures for installation, operation and maintenance. The contents in the manual have been compiled and checked by experts in the field. Every possible care has been taken to ensure the contents are accurate. However, it must be understood that the manual is not a contract document. If you ever have any query about operation, maintenance or related problems you are welcome to write to us without obligation.
5 1610 - 1611 VOL - C1 TAB - 6 - 96
GENERAL This standard BHEL furnace probe is equipped with chromel alumel thermocouple installed in a lance tube. Air cooling for the lance tube is also available for special applications. Model FTP-IE for travels from 1.5 metre to 7.3 metre, has a 76mm O.D. lance. Model FTP-IIE for travels from 7.4 metre to 12.2 metre has a 108mm O.D. lance. In both the models, probes are available with or without air cooling. The probe may be operated in furnace gas temperature upto 537°C (100°F) and for very short period of time in gas temperature as high as 565° C (1050°F) without air cooling. The temperature probe can be used to measure furnace gas temperature upto max. 815°C (1500°F) with the lance cooled by air. This standard equipment will be limited to monitoring furnace temperatures upto, but not exceeding 815°C (1500°F) during boiler start-up. While using for temperature above 565°C (1050°F), air cooling of the lance probe must be used. Cooling air requirement for the temperature probe is determined by the diameter of the lance, length of travel and the temperature of the area in which the probe is expected to operate. Operators are requested to observe four important limiting factors in the operation of standard furnace temperature probes. i.
Never exceed 537°C (1000°F) without cooling air for continuous operation.
ii.
Never exceed 565°C (1050°F) for short intermittent periods without cooling air.
iii.
Never exceed 815°C (1500°F) with arrangement for cooling air.
iv.
Ensure availability of sufficient cooling air.
Contact Engineering Division of Bharat Heavy Electricals Limited, Trichy for information concerning specific applications and operations.
6 1610 - 1611 VOL - C1 TAB - 6 - 97
2.
GENERAL DESCRIPTION 2.1
GENERAL
The BHEL Furnace temperature probe is an electro-mechanical equipment for positioning a thermocouple element in the furnace gas stream for temperature measurement. The thermocouple is fixed to the tip of a lance tube which travels into and out of the gas passage. The lance travels approximately two metres per minute while extending and retracting. The thermocouple can be retracted manually in case of emergency. Gas temperatures in the area just before the superheater elements at the exit of the furnace, can be critical during boiler start- up, before steam circulation for the cooling of the superheater/reheater tube material is sufficiently established. The furnace temperature probe, by permitting continuous measurement of the gas temperatures, helps to reduce the danger of heat damage to the tubes. For this reason, such probes are also known as basic start-up probes. The furnace temperature probe can also be used to obtain gas temperatures during the low load operation of the boiler. 2.2
DETAILED DESCRIPTION
Ref. Assembly drawing of temperature probe: (Drg.No.0-00-073- 60028 & 0-00-073-60029) i. Probe Housing (Item No. O1/03 of Main assembly drawing as above. The housing of the temperature probe is a pressed steel section and it covers all the moving parts. The lips are cut off from the outboard end to a distance of approximately 750 mm to facilitate removal of travelling carriage. Angle tracks are welding on either side of the casing to guide the travelling carriage. The rods are provided at the bottom to hold the open ends of the housing. At the front end a wall plate is welded on to the casing, to which the lance bearing assembly is fixed. The lance bearing assembly carries an hour glass shapped roller for supporting the lance tube and a plain cylindrical roller on top for guiding the lance. The mechanical stop for the carriage is also welded to the housing top in the front. The stop at the outboard end is adjustable and is provided in the side of the housing. The jack shaft bearing assembly which is fixed to the housing provides for the adjustment of the tension in the traversing chain.4 A cable carrier drag chain (Item No. 42/36 of Drg.No. 0-00-073- 60028 & 0-00-07360029 respectively) is attached with travelling carriage, by the driving end and the fixed end of the drag chain is connected with a mounting bracket assembly on the middle bottom of the housing. This drag chain is supported by the track covers hanging from the housing on both right and left side and guided by two angle plates on the bottom cover. The thermocouple lead wire is taken through the drag chain support plates and connected to the terminal head near the mounting bracket assembly. When provision for air cooling of the lance tube is made, an air hose is also taken through the support plates of drag chain from the mounting bracket assembly to the travelling carriage housing and it is connected with connectors at the both ends. A ball valve with pneumatic actuator and a solenoid valve is mounted near the mounting bracket assembly with a pressure switch. The hose pipe is connected to the outlet side of ball valve and inlet side is the customer air connection (7 Kg/Cm²(g)). Lifting eyes for sling attachment are welded to the side of the housing at convenient places, to facilitate lifting. The probe is supported at two places. The boiler end is supported in the wall box through two shoulder bolts which allow the probe to move when the wall moves. The outboard end again is hinged support and is fixed to the boiler structures.
7 1610 - 1611 VOL - C1 TAB - 6 - 98
ii.
POWER PACK ASSEMBLY (01 of assembly Drawing No. 0-00-073- 60004)
The main prime mover for the probe is a fractional horse power motor. A reduction gear box attached to the motor has an output speed of 9.2 rpm. The motor with the reducer is fixed on top of the housing at the front end. The reducer output shaft drives the jack shaft through a set of sprockets and an endless chain. The jack shaft transmits the rotary motion to a long chain for the entire length of the probe, the ends of which anchored to the travelling carriage, through another jack shaft and idler sprocket at the other end of the housing. The idler jack shaft is provided with adjusting screws for keeping the chain in the right tension. iii.
The Travelling Carriage. (Drg.No. 2-00-073-60092 and 2-00- 073-60098)
The travelling carriage of the probe is a cast iron housing to which the lance tube is bolted. The carriage assembly has two wheels which are guided by the inner side of the housing and the top of guide angles. Two rollers on the sides of the travelling carriage prevent the sideways movements. The travelling carriage guide rollers at the side also operate the arms of the terminal limit switches of the heavy duty type which are fixed to the sides of the housing. Removal of the travelling carriage assembly is achieved by unscrewing the removable portion of the angle guide track at the outboard end and slipping the assembly down carefully without causing damage to the thermocouple at the lance head. In case of air cooled temperature probe, the travelling carriage is made, up cast steel/Ductile iron in order to maintain pressurised chamber and a hose connector is screwed on the carriage to couple the hose with it. (Ref.Drg.No. 1, 2-00-073-60098) iv.
Lance Assembly (Drg.No. 3-00-073-60107 & 2-00-073-60097)
The lance tube Assembly is bolted to the travelling carriage and the lance is a alloy steel tube. The lance tube is not normally air cooled, when the probe is used for gas temperatures upto 537°C (1000°F). If air cooling is provided, the air house is connected to a coupling at the travelling carriage end of the lance tube. The thermocouple is normally of the grounded chromel alumel type enclosed in a stainless steel sheath. It is fixed to the end of the lance tube, by means of a threaded coupling. The thermocouple extends through the lance tube to the terminal coupling at the carriage end where a female connector for the lead wires is provided. The corresponding male connector is connected to the thermocouple lead wire which terminates at the thermocouple terminal head, fixed on the housing, through cable drag chain. The probe has to be connected to a suitable temperature indicator which will show the gas temperature. For preventing any damage to the thermocouple head a cage type protective shield is provided, and this will allow free access of flue gases to the tip of thermo couple during operation. In case of air cooled probe, an inner S.S.tube called lance liner tube is supported by equidistant lugs as shown in the drawing 2-00-073- 60097 at various intervals inside the lance tube and two straight bore nozzles are provided to expand the entering air pressure to furnace pressure. The air enters through the annular space between liner tube and lance tube and enter the liner tube through the gap provided at the front end to reach the nozzles thereby it maintains the cooling effect on the surface of the lance. V.
Position Indicator (see assembly drawing)
In order to know the position of the lance tube, corresponding the gas temperature, a position indicator is normally provided with the temperature probe. The position indicator is a voltmeter calibrated to continuously indicate the position of the thermocouple in. The voltmeter is connected in parallel with a linear, ten turn helipot potentiometer (variable resistor) which is driven by a no slip belt drive on the jack shaft. The mechanical arrangement of the potentiometer drive is illustrated in Drg. 3-00-073-60109 and 3-00-073-60110. 8 1610 - 1611 VOL - C1 TAB - 6 - 99
The details of the electrical wiring for the probe without air cooling are illustrated in the Drg. 2-00-073-60006 and for the probe with air cooling refer drawing 2-00073-60099 and 3-00-07360127. A 0-10 voltmeter calibrated in percentage of travel and at toroidal type 12k ohm. 50 watts variable resistor are supplied loose, as position indicating instruments along with the probe. The voltmeter and the variable resistor are to be mounted in the control cubicles and wired to the helipot poten tiometer by the customer. The variable resistor is to be used for calibrating the travel indicated by the voltmeter. The calibration of the position indicator is to be done during commissioning of the temperature probe. 110V single phase 50 cycle is recommended for this circuit. Vi.
Control Circuitry
The control circuitry on the temperature probe is designed as per the requirement. All electrical hardwares for control and indication are subject to the customer’s option. For this reason, control arrangements are presented in detail by specific contract circuit descriptions and contract drawings.
3.
INSTRUCTIONS FOR INSTALLATIONS 3.1
Inspection check list
i.
Check the thermocouple tip for any damage from handling or shipment, after removing the shield for the thermocouple.
ii.
Check all control and power wiring for loose terminals, proper connections etc.,
iii.
Check connection of motor for proper direction of rotation.
iv.
Check all thermocouple junctions for tight terminal connections.
V.
Check the limit switch actuating arms to see that they are in correct operating positions.
vi.
Check alignment of frame structure, track and sheave wheel track, particularly for any bend, twist or other distortions.
vii.
Check roller chain sprockets for correct engagement with the chains.
viii.
Check alignment of the roller bearing for the lance tube and adjust only, if required.
ix.
Check lubrication of roller chains, sprockets bearings, wheels, rollers, etc., and fill in oil for the reduction gear of the power pack.
x.
Check for pressure tightness of the air hose reel, if the probe is provided with air cooling arrangement.
3.2
Instrumentation wiring
The thermocouple lead wires are internally connected to the fixed terminal head on the probe during manufacture. The extension wire should be taken from the terminal head. Ensure the use of the correct compensating cable corresponding to chromel/Alumel thermocouple, the leads connecting to the indicating instrument should be connected to the junction head according to the polarity indicated by the marking of the terminals and the code markings on the leads. Ensure that all connections are tight and firm. A potentiometer type instrument is recommended as the temperature indicating device. NOTE : Check connections of measuring instrument, position transmitter etc., for proper polarity.
4.
OPERATION Refer to the contract circuit diagram for the correct operating description. 4.1
Three push button operation (local and remote)
This push button station has ‘Extend’, ‘Retract’ and ‘Stop’ push buttons. By operating the ‘Extend’ push button the forward contacts of the drive motor will be energised and the probe will move 9 1610 - 1611 VOL - C1 TAB - 6 - 100
forward. Normally, approximately 35 seconds lag is expected between the thermocouple position and the corresponding thermocouple temperature. If multipoint recorder is used, the lag will increase. If the temperature registered by the probe is below 538°C it is expected to be within approximately 50C to the actual temperature measured at the location. The position transmitter will indicate to the operator the travel of the probe in percentage of full travel. At the end of the travel, the travelling carriage side thrust roller will actuate the reverse limit switch and then the ‘reverse’ contactor will be energised to reverse the drive motor and retract the probe. An indicating ‘red’ light may be connected in the panel which will momentarily indicate when the reverse limit switch is actuated. If required with a change in the circuit the probe may be stopped at the full extended position when the reverse limit switch is actuated. Indicating light can be suitably connected to indicate full extended position as red light in the panel. When the ‘reverse’ push button is operated the probe reverses from any position and when the stop limit switch is actuated the probe stops at the fully retracted position and a green light will come on the panel. In the intermediate position both lights will be off. By utilizing the ‘STOP’ push button, the probe lance can be stopped at any desired location. This will enable the operator to check and concentrate on any hot spots in the furnace. A remote contact on the temperature recorder which will close when the temperature measured is +300C more than the maximum 538°C is necessary to give an alarm; and the same time the probe can be retracted. A parallel push button station in the panel will be necessary for remote operation. 4.2
Please refer to application and wiring diagrams (Drg.No. 3-00-073-60127)
This BHEL Furnace Temperature Probe is equipped with a duplex Chromel-Alumel Thermocouple either duplex or simplex. The equipment is limited to monitoring furnace temperatures upto, but not exceeding 1000°F without cooling air; and up to, but not exceeding 1500°F with cooling air. Confirm that sufficient cooling air is available. Operators must observe the temperature limitations to avoid damage to, or loss of, the lance. Contacts (RC) on the customer’s recorder are to close when the temperature reaches 1500°F, energizing the RA relay which will cause the probe to retract to its AT REST position and bring in the customer’s alarm. The temperature probe controls include PARK, EXTEND, RETRACT and STOP push buttons, a solenoid valve SV, pressure switch PS (opens on flow), timer T, alarm relay RA and relay P. (Please note the following are not by PS 20 Group; Alarm relay RA, and Relay P). Solenoid Valve SV and timer T will be energized when the blower moves away from its PARK position and actuate Limit Switch LS-4. SV, PS and timer T form the cooling air supply interlock. If cooling air is not sensed within the time relay period (10 seconds), relay RA will be energized to bring in the alarm. The probe will be caused to retract to its PARK position. Loss of cooling air during operation will also energize the alarm relay. The control push button function as follows: EXTEND -
Depress this push button to cause the probe to extend into the boiler.As the probe moves away from its AT REST position, it will trip LS-3 and LS-4 limit switches. When the probe reaches its fully extended position, it will momentarily trip limit switch LS-1 causing the probe to retract. This circuit will be through closed RET and LS 3 contacts to the RET motor starter.
RETRACT Depress this pushbutton to cause the probe to retract to its fully retracted position. The probe will not remain in its fully retracted position, but will be caused to extend as it momentarily 10 1610 - 1611 VOL - C1 TAB - 6 - 101
trips limit switch LS-2, creating a circuit to the EXT motor starter. STOP
PARK
4.3
-
Depress this pushbutton to stop the probe, at any position, on the EXTEND or RETRACT cycle, to take a reading to continue the EXTEND or RETRACT cycle, depress the desired pushbutton to reinstate the circuit. -
Depress the pushbutton to cause the probe to return to the fully retracted position and stop. The probe will also be caused to PARK if the RA alarm is brought in.
Emergency Retraction
Using a hand crank, the lance can be retracted manually in case of emergency. Before using the hand crank the power supply to the drive motor should be disconnected and the drive should be declutched. For declutching pull out the coupling item 05 of Drg. 3-00-073- 60108 and turn about 900 clockwise thereby the spring lock provided will lock the coupling in the declutched position. For clutching just turn the coupling lock 900 anticlockwise which will keep the coupling engaged with sprocket. A slight adjustment of the sprocket may be necessary in some cases to align the clutch jaws with the sprocket. 4.4
Remote Position Indicator
Setting and Installation Instructions for the slidewire Type position Indicator. CAUTION: The voltmeter indicator is built to accept a maximum of ten (10) volts only. Therefore, it will be necessary to use a separate test voltmeter with a scale suitable for the maximum incoming control voltage. i.
Refer to BHEL Wiring Diagram.
ii.
Mount the adjustable resistor as near as possible to the voltmeter indicator.
iii.
WITH POWER OFF connect all wires as shown on the W/D except the two on the voltmeter indicator; connect these two to the test meter, (see caution above).
iv.
Move the slider of the adjustable resistor to the extreme opposite end of the resistor from the power connection.
v.
Position Probe to a fully Retracted position. Turn the zero screw on the indicator face to zero meter.
vi.
Rotate helipot shaft to the zero degree position and recouple shaft.
vii.
Turn POWER ON. Test meter should now read ‘zero’ or almost zero.
viii.
Run or crank the unit to the fully extended position.
ix.
Move the adjustable resistor slider towards the power connected end until the test meter reads ten (10) volts.
x.
TURN POWER OFF - Disconnect the test meter and connect the leaders to the voltmeter indicator.
xi.
TURN POWER ON - Indicator should now read 100%.
xii.
Final adjustment may be necessary. If indicator reads less than full open move the adjustable resistor slider ahead slightly being careful not to exceed full 100% on the scale. If meter reads more than zero, when unit is fully closed repeat setting starting with step 6.
xiii.
After setting indicator, lock adjustable resistor slider in place. 11 1610 - 1611 VOL - C1 TAB - 6 - 102
5.
MAINTENANCE INSTRUCTIONS 5.1
Lubrication
Refer to the lubrication chart. The drive chains are prelubricated in the manufacturing stage itself and normally we do not recommend any lubrication. Any grease if applied will only attract fly ash accumulation and will result in the loss of articulation of the chain links. Periodically inspect the chain for any rusting or loss of articulation. If severe damage is noticed degrease the chains and apply a thin coat of oil equivalent to Grade SAE 30 with a brush so that all the parts will be covered. 5.2
Replacement
A. Thermocouple Replacement i.
Before replacing the thermocouple, the following checks are recommended to insure that the replacement is necessary: a.
Check all the wiring for breaks and insure that all electrical connections are tight.
b.
With the boiler operating run the probe tube forward approximately 300 mm to place the tip in the higher gas temperature. The temperature read out device should indicate an increase in temperature if the thermocouple is operating satisfactorily.
c.
An alternate method will be to apply heat to the thermocouple and observe the thermocouple output using a portable potentiometer.
d.
If no change in temperature is indicated from the above check, disconnect the read out device and monitor the thermocouple signal with a suitable test device to insure that the read out device is operating satisfactorily. Before proceeding further, disconnect the motor and control power supply.
ii.
Remove the housing cover in the out board end and the travelling carriage cover to have an access to the thermocouple disconnecting plugs. Disconnect the thermocouple extension wire from the compensating cable.
iii.
Pull back the travelling carriage to the extreme out board end and support the lance tube at two places so that it will not damage to compensating cables. Disconnect the lance flange from the travelling carriage.
iv.
Push the lance inside to some distance so that the thermocouple extension wire is out of the travelling carriage and remove the lance by tilting and pulling back from the boiler.
v.
Loosen the S.S. compression fitting which fixes the thermocouple to the lance and the thermocouple guide. Pull out the thermocouple from the flange side after attaching a wire or string to the thermocouple.
vi. B.
Follow the above procedure in reverse for assembling the new thermocouple. Use high temperature antiseize thread compound in all the threads for easy removal. Potentiometer Replacement:
The variable potentiometer used in the position transmitters assembly is limited mechanically to a maximum of 10 revolutions of the input drive shaft. Eventhough the maximum possible travel of the probe utilizes only about 8 revolutions, in order to safeguard the potentiometer at either end of the 10 turn range, proper care should be taken during installation. When replacing the potentiometer, turn the potentiometer shaft clockwise to the full 10 turn and then turn counter clockwise half turn before mounting the unit. The position is corresponding to the fully retracted position of the probe.
12 1610 - 1611 VOL - C1 TAB - 6 - 103
RECOMMENDED LIST OF SPARES FOR TEMPERATURE PROBE SI.No.
Description
Drg.No./Code No.
Qty./Probe
01.
Lance Flange Gasket
4-20-791-00389
1
02.
STOP Switch Assembly
2-00-073-60093
1
03.
Reverse Switch Assembly
2-00-073-60094
04.
Chain Traverse 11/2"P
97-366-023
1.5m
05.
Connector Link 11/2"
97-366-025
1
06.
Offset Link 11/2"
97-377-024
1
07.
Cycling Switch Assembly
3-00-073-60124
1
08.
Cooling Air Switch Assembly
3-00-073-60123
1
09.
Potentiometre Assembly
3-00-073-00110
1
10.
Roller Chain3/4"P
97-366-026
0.5m
11.
Connector Link3/4"P
97-366-028
1
12.
Offset Link3/4"P
97-366-027
1
13.
No Slip Pulley 32T
97-366-154
1
14.
Bearing 6208 2 RS
55-119-06208
2
15.
Gasket (Power Pack)
96-353-052
1
16.
Gasket (Travelling carriage)
17.
Thermocouple Asse mbly
Per order
1
18.
Airvent
4-20-201-01540
1
19.
Gasket
4-20-952-01535
1
20.
Bearing 6209 2 RS
55-119-06209
2
21.
Bearing 6208 2 RS
55-119-06208
2
22.
SPRING
96-353-058
1
23.
Motor 0.37 KW
96-272-004
1
24.
No slip belt
97-366-153
1
1
* Only for air cooled Temperature probe
REQUIRED TOOLS FOR TEMPERATURE PROBE Spanner
Allen Key
Circlip Pliers
13 1610 - 1611 VOL - C1 TAB - 6 - 104
RECOMMENDED LUBRICATION CHART SI.No
01.
02.
Equipment Description
Recommended Lubricant IOC HP
Power pack
Servosystem 68 system 68
Chain See Note: 2
NOTE.-1
Servo
Enklo 68
Enklo 150
BP
Bharat Hydrol 68
Bharat Hydro 150
Method of Filling
Reservoir
By Brush
Frequency of Change
Annual
...
Frequency of Observation
Quantity/ probe (Annual)
3 Months (See Note:8)
1 Litre
...
1 Litre
Lubricant oil level must be checked and maintained every month.
14
NOTE.-2 All the Chain and Chain links are prelubricated by a special treatment by which no lubrication is required normally but as and when sign of rust is identified two fold lubrication is recommended First the chain is cleaned and then Trichloroethylene is applied over the surfaces. Servoline 150 Enklo 150 Bharat Hydrol 150 is applied as a second coat by brush.
1610 - 1611 VOL - C1 TAB - 6 - 105
ESTIMATED TOTAL QUANTITY OF EACH LUBRICANT ANNUAL REQUIREMENT PER PROBE Servosystem 68 (IOC) or Enklo 68 (HP) or Bharat Hydrol 68 (BP) Servosystern 150 (IOC) or Enklo 150 (HP) or Bharat Hydrol 150 (BP)
- 0.6kg - 1.6 litres
15 1610 - 1611 VOL - C1 TAB - 6 - 106
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TAB - 7
INSTRUCTION MANUAL LRD IIE LONG RETRACTABLE SOOT BLOWER
PUB.NO.7514
1610 - 1611 VOL - C1 TAB - 7 - 132
CONTENTS GENERAL INFORMATION LONG RETRACTABLE SOOT BLOWER MODEL LRD-IIE GENERAL DESCRIPTION (REFER DRG. NO. 0-00-073-60024) SBV HEAD (DRG. NO. 1-00-073-60003) INSTZLLATION INSTRUCTION INSTALLATION INSTRUCTIONS GENERAL PIPING WIRING ERECTION CHECKS START UP CHECKS SOOT BLOWER OPERATION CHECK LIST OPERATION EMERGENCY OPERATION OF SOOT BLOWER TROUBLE SHOOTING AND MAINTENANCE PREVENTIVE MAINTENANCE CHECK LIST INTERNAL INSPECTIONS EXTERNAL INSPECTION-LONG RETRACT LUBRICATION PROCEDURE FOR LANCE AND FEED TUBE REMOVAL PACKING INSTALLATION CHAIN TENSION ADJUSTMENT (DRG. NO. 4-20-001-00523) RECOMMENDED LUBRICATION CHART FOR LRD IIE LONG RETRACTABLE SOOT BLOWER OPERATIONAL PROBLEMS AND MAINTENANCE
2 1610 - 1611 VOL - C1 TAB - 7 - 133
RECOMMENDED SPARES FOR LONG RETRACTABLE SOOT BLOWER(MODEL LRD IIE) ASPIRATING AND SEALING AIR FOR LONG RETRACTABLE BLOWERS WITH SINGLE SCRAPER PLATE SINGLE SCRAPER PLATE AIR SEAL ASPIRATOR AIR SEAL SCRAPER PLATE FORCED PRESSURE AIR VALVE
3 1610 - 1611 VOL - C1 TAB - 7 - 134
LIST OF DRAWINGS FOR LONG RETRACTABLE SOOT BLOWER MODEL T 30 LRD - IIE SI No
Drawing No.
Description LRSB T 30 M ark II-E
LRSB T 30 M ark II-E Special
1.
LRSB M ain Assembly
2-00-073-60080
2-00-073-60084
2.
General Arrangement
0-00-073-60024
0-00-073-60025
3.
Bill of M aterial
1-00-073-60098
1-00-073-60099
4.
M ain Gear Box Assembly (Traverse)
0-00-073-60022
5.
M ain Gear Box Assembly(Rotary)
0-00-073-60023
6.
Carriage Housing Assembly
0-00-073-60021
7.
SBV Head Assembly
8.
D.A. Head Main Assembly
_
1-00-073-60100
9.
Basic Head Assembly
_
1-00-073-60101
10.
Adjustable Bearing Assembly
2-00-073-60078
11.
Stop Switch Assembly
2-00-073-60079
12.
Reverse Switch Assembly
2-00-073-60079
13.
W all Blowing limit switch
_
2-00-073-60082
14.
Control circuit for combination long Retract and W all blower
_
2-00-073-60083
15.
W iring diagram
16.
Chain Tightener(Traverse)
3-00-073-60093
17.
Chain Tightener(Rotary)
3-00-073-60094
18.
Traverse Chain Assembly
3-00-073-60095
19.
Rotary Chain Assembly
3-00-073-60096
20.
3-00-073-60097
21.
Jackshaft Bearing Assembly (Traverse) Jackshaft Bearing Assembly (Rotary)
22.
Tools Chart for LRSB
3-00-073-60099
23.
Valve Lapping Tool
3-00-073-60094
24.
Valve Spring Tool
4-00-073-60157
25.
Valve Tamping Tool
4-00-073-60155
26.
W rench
4-00-073-60156
27.
Valve Spring Tool Assembly
4-00-073-60158
28.
Chain Adjustment
4-00-073-00523
1-00-073-600003
3-00-073-60004
_
3-00-073-60100
3-00-073-60098
FOR DETAILED ERECTION AND START-UP INSTRUCTIONS REFER M ETHODS AND PROCEDURS FOR INSTALLATION OF SOOT BLOW ERS. PUBLICATION No.7508-78
4 1610 - 1611 VOL - C1 TAB - 7 - 135
GENERAL INFORMATION The Long Retractable Soot Blowers are designed and manufactured with a view to keep the boiler operating efficiently. Because of their exclusive dual motor drive, they assure optimum cleaning of all heating surfaces. BHEL’s Soot Blowers are installed in various power stations in India and abroad and the sum of the experience gained on many new installations goes long way in continuous perfection of the equipment. The equipment will function satisfactorily with a little proper attention to installation, operation and maintenance. It must be recognized that no amount of written instructions can replace intelligent thinking and reasoning on the part of the operators, especially when coping with unforeseen operating conditions. It is the operators’ responsibility to become thoroughly familiar not only with the equipment but also with all pertinent control equipment. The instruction contained in this manual is only an outline of the correct procedures for installation, operation and maintenance. The contents in the manual have been compiled and checked by experts in the field. Every possible care has been taken to ensure the contents are accurate. However, it must be understood that the manual is not a contract document. If you ever have any query about operation, maintenance or related problems, you are welcome to write to us without obligation.
5 1610 - 1611 VOL - C1 TAB - 7 - 136
SAFETY NOTICE PROPER SERVICE & REPAIR IS IMPORTANT TO THE SAFE AND RELIABLE OPERATION OF SOOT BLOWERS. THE SERVICE PROCEDURES DESCRIBED IN THIS MANUAL INSURING ACCURATE AND PREDICTABLE PRODUCT PERFORMANCE ARE EFFECTIVE METHODS OF OPERATIONS. THE SPECIAL TOOLS RECOMMENDED BY BHEL SHOULD BE USED IN SOME OF, THESE SERVICE OPERATIONS. IT IS IMPORTANT TO NOTE THAT THIS MANUAL CONTAINS VARIOUS WARNINGS AND CAUTIONS WHICH SHOULD BE CAREFULLY READ AND FOLLOWED TO AVOID THE RISK OF PERSONNEL INJURY OR DAMAGE OF THE EQUIPMENT. ANY ONE WHO USES, A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY BHEL MUST SATISFY HIMSELF THOROUGHLY THAT NEITHER HIS SAFETY NOR THE EQUIPMENT SAFETY, WILL BE JEOPARDIZED BY THE SERVICE METHOD HE SELECTS. EVERY PRECAUTION SHOULD BE TAKEN TO PREVENT INJURY, TO PERSONNEL DURING -THE PERFORMANCE OF ANY TEST, INSTALLATION OR REMOVAL. BHEL COULD NOT POSSIBLY EVALUATE ALL CONDITIONS THAT COULD INJURE PERSONNEL OR EQUIPMENT, BUT DOES OFFER THESE SAFETY PRECAUTIONS AS AN ASSISTANCE ONLY. Important instruction for erection, start-up & operation of long retractable soot blowers DOS ERECTION 1.
CHECK THE BLOWER NUMBERS BEFORE ERECTION.
2.
USE ONLY THE LIFTING LUGS FOR HANDLING THE BLOWERS.
3.
CHECK THE SQUARENESS AND CONCENTRICITY OF THE WALL BOX.
4.
OPERATE THE BLOWER MANUALLY FOR CHECKING THE CLEARANCE INSIDE THE BOILER.
5.
CHECK FOR ACCESSIBILITY FOR THE HAND CRANK FOR MANUAL OPERATION.
6.
COVER THE JUNCTION BOXES AND CABLE OPENING TO PREVENT WATER ENTRY.
BEFORE START-UP 1.
FLUSH THE GEAR BOXES WITH ‘SERVO MESH 28’ AND FILL THEM WITH THE LUBRICANTS AS RECOMMENDED.
2.
CHECK THE DIRECTION OF ROTATION OF BOTH THE MOTORS.
3.
CHECK WHETHER ALL COVERS ARE PUT ON THE BLOWER.
4.
CHECK THE OPERATION OF THE STOP AND REVERSE LIMIT SWITCHES.
5.
OBSERVE ALL SAFETY PRACTICES.
6.
CHECK WHETHER THE CORRECT BLOWER IS INSTALLED IN THE CORRECT LOCATION.
7.
CHECK THE LANCE DROOP AT FULLY EXTENDED CONDITION AND MAKE SURE THAT THERE IS A SURFACE TO SURFACE CLEARANCE OF 100 mm TO 150 mm BETWEEN TOP BOILER TUBES AND LANCE TUBE. IF 6 1610 - 1611 VOL - C1 TAB - 7 - 137
THE CLEARANCE IS LESS, PROVIDE SHIELDING AS INDICATED IN DRAWING. 8.
IN THE SIMILAR WAY, CHECK THE SIDE CLEARANCE IN THE HORIZONTAL PASS.CREDIT SHOULD BE TAKEN FOR PROVISION OF HORIZONTAL EXPANSION.
START-UP & OPERATION 1.
CHECK LUBRICATING OIL LEVELS FREQUENTLY. FOLLOW THE LUBRICATION SCHEDULE.
2.
OBSERVE ALL SAFETY PRACTICES IN USE.
3.
ENSURE THAT ALL INTERLOCKS ARE IN OPERATING CONDITION.
4.
CHECK WHETHER HAND CRANKS ARE AVAILABLE AT EACH ELEVATION.
5.
INSPECT PERIODICALLY FOR THE FOLLOWING (a)
PACKING WEAR (SHOWED BY STEAM LEAKAGE).
(b)
RUSTING OF CHAINS.
(c)
GASKET LEAKAGE.
(d)
CHAIN TENSION.
6.
SET THE BLOWING PRESSURE AS PER RECOMMENDED VALUE. ENSURE THAT THE VALVE GETS COMPLETELY CLOSED AFTER SETTING.
7.
ENSURE THE BLOWER LANCES ARE IN HOME POSITION BEFORE AND AFTER THE SOOT BLOWING CYCLE.
8.
WHEN AN ALARM IS SOUNDED DUE TO ELAPSED TIMER, LOW HEADER PRESSURE, NO BLOWING MEDIUM INTERLOCKS, MAKE SURE THE LANCE IS WITHDRAWN IMMEDIATELY.
9.
IMMEDIATELY ATTEND TO ANY LEAKAGE CAUSED DUE TO: (a)
VALVE LEAKAGE.
(b)
FLANGE LEAKAGE.
10.
MAKE SURE THE VALVE OPENING LINKAGES ARE IN GOOD WORKING CONDITION AND THE OPERATION IS SMOOTH.
11.
QUICKLY RECTIFY THE TROUBLES WHEN MALFUNCTION IS INDICATED IN THE PANEL.
12.
WHEN THE BLOWERS ARE OPERATED FROM PANEL, KEEP ONE MAN NEAR TO OBSERVE THE OPERATION.
DONT’S ERECTION 1.
DO NOT MIX UP THE BLOWERS.
2.
DO NOT LIFT/HANDLE THE BLOWER WITH ROPE/CHAIN WRAPPED AROUND.
3.
DO NOT USE THE HOUSING AS THE WELDING PLATFORM.
4.
DO NOT PLACE HEAVY LOADS ON THE BLOWER.
5.
DO NOT PLACE THE BLOWER ON THE PLATFORM WITHOUT PROPER SUPPORT. 7 1610 - 1611 VOL - C1 TAB - 7 - 138
6.
DO NOT LEAVE THE LANCE AT EXTENDED POSITION.
START-UP & OPERATION
1.
1.
DO NOT OPERATE THE SLOWER WITH WET STEAM.
2.
DO NOT OPERATE WITHOUT BLOWING MEDIUM DURING BOILER OPERATION.
3.
DO NOT ATTEMPT MAINTENANCE WORK WHEN POWER AND BLOWING MEDIUM ARE NOT CUT OFF.
4.
DO NOT CRANK THE LANCE MANUALLY WITH STEAM SUPPLY ‘ON’.
5.
DO NOT OPERATE THE SOOT BLOWER WITH EXCESSIVE STEAM LEAKAGE THROUGH PACKING.
6.
DO NOT OPERATE THE BLOWER IN QUICK SUCCESSION. MINIMUM ONE HOUR COOLING PERIOD BEFORE SUBSEQUENT OPERATION IS A MUST TO AVOID ANY DAMAGE TO MOTOR WINDINGS.
7.
DO NOT OVERTIGHTEN THE DRIVE CHAINS (NOISY RUNNING IS O.K. SILENT RUNNING IS NOT ADVISABLE).
8.
DO NOT LEAVE THE LANCE FOR A LONG TIME WITH BLOWING MEDIUM INSIDE THE BOILER. (IT WILL DAMAGE THE BOILER TUBES, IF KEPT INSIDE WITH BLOWING MEDIUM).
LONG RETRACTABLE SOOT BLOWER MODEL LRD-IIE 1.1
General Description (Refer Drg. No. 0-00-073-60024)
The LRD-IIE model Soot Blower is a boiler cleaning device in which a rotating lance extends into and retracts from the boiler to make sure that the cleaning medium-steam air-directed through the nozzles, removes the deposits from tube or wall surfaces. The lance (item 07) is attached to a carriage housing (item 5) which runs on tracks inside the blower housing. The carriage and lance are moved by means of a traversing chain (item 15) operated by a 0.56 kW electric power pack (item 2). Rotary motion is applied to the lance through the travelling carriage by a second chain (item 16) driven by a separate 0.75 kW electric power pack (item 3). Control movement is by a stop limit switch and a reverse limit switch (items 11 and 12). The unit can be supplied with different traversing and rotating speeds. Standard traversing speeds are available in various increments from 1.25 to 3.65 m. per minute. Standard rotating speeds are available in various increments from 4.25 rpm to 7.75 rpm. These speed variations are accomplished by changing the power pack and jack shaft drive sprockets. Other speeds are possible for special application by the use of special sprockets. Normally the blowers will be supplied with 1.65 m/min and 5.92 rpm. Flow of blowing medium through the retractable soot blower is controlled by the valve (item 4 detailed description is given under the head “ SBV head -) mounted at the rear end of the blower. The feed pipe item no. 08 is attached to the outlet of this valve head. This feed pipe passes through packing gland in the traveling carriage and lies inside the lance tube (item 07) extending to almost the entire length of the blower. The wheels on the travelling carriage run on tracks welded to the inside of the blower housing (item 1). Sideways motion is limited by a roller on each side of the carriage which use the housing sides as guides. 8 1610 - 1611 VOL - C1 TAB - 7 - 139
The ends of traversing chain are connected to each end of the carriage (3-00-073-60095). The rotary chain is continuous (3-00-073-60096). It passes over sprockets on the carriage and causes rotation through a gear train. The lance is flanged to the carriage and supported on the boiler end by bearing and yoke plate. (item 6) The electric gear box on the right side is for traversing and the electric gear box on the left side is for rotation when viewed from the rear end of the blower. Motion is transmitted from the gear boxes to jack shafts on each side of the blower. Tension on the internal chains are adjusted by adjusting the screws on chain tighteners which hold the idler sprockets on the outboard end of the unit. The housing completely covers the blower except the traversing and rotating gear boxes. The housing is open at the bottom except for tie bars at intervals. A section of the top of the housing near the rear end of the blower is cut away to, allow access to the travelling carriage. The access areas have removable cover. A short section of the track at the rear is removable to permit removing the travelling carriage for major maintenance. The soot blower valve head item No. 04 is operated by a trip pin (item No. 18 of (0-00-073-60021) on the top of the travelling carriage which engage a trip cam item No. 27 and through the trip rod item No. 30 linkage and valve lever item No. 25 causes the head valve to open or close. The stroke of the head valve is governed by the length of the trip rod. To change the valve stroke, loosen the jam nuts where it screws into the rod connection and turn the rod. One end of the rod has a right hand thread, the other end in left hand. When the desired length is attained tighten the join nuts. The spring on the trip rod should be adjusted to eliminate all looseness in the assembly. 1.2
SBV Head (Drg. No. 1-00-073-60003)
The Soot Blower Valve head allows the blowing pressure of the blower to beadjusted by limiting the stroke of the valve. Where it is necessary to reduce the pressure greatly, a fixed orifice may be installed in the head inlet flange. The stroke of the head valve is governed by adjustment of the drive screw which contacts the head valve stem. In the closed position, a minimum clearance of 1mm must be maintained between adjusting screw and valve stem, to assure tight valve seating. In general, slag removal will necessitate blowing pressure of 10-16 kg./cm². Soot and fly ash will need 8-15 kg/cm² and for dust removal, pressure may be as low as 7 kg/cm². In locations of high gas temperatures, the flow from the lance is determined by cooling requirements of the lance and may exceed 75 cubic metres per min. of air or 4,500 kg per hour of steam. This cooling requirement is determined by the furnace gas temperature in which the blower is operating and the number of square inches of lance surface exposed to these furnace temperatures. Obviously a 6 metre lance requires a higher flow of blowing medium to keep it cool than a 3 metre lance. Likewise a 3 metre lance of 76.1 O.D. requires less cooling than a 3 metre lance of 108 O.D. Always refer to the general arrangement drawing (refer General Instructions) for a recommended blowing pressure. CAUTION : DO NOT ADJUST THE VALVE ADJUSTMENT SCREW SO THAT EVEN IN COMPLETELY RETRACTED POSITION THE VALVE IS KEPT IN OPEN CONDITION. 9 1610 - 1611 VOL - C1 TAB - 7 - 140
2.
INSTZLLATION INSTRUCTION
2.
INSTALLATION INSTRUCTIONS 2.1
GENERAL
A wall sleeve and lance scraper plate are provided with each soot blower. The scraper plate usually just floats on the lance. In cases where tube and wall movement are identical the sleeve is Welded to both and the retractable unit is hinged to the sleeve. The outboard mounting is from auxiliary., steel. via a -hinge hanger arrangement which allows the boiler end to move with the walls. For particular information regarding any installation, refer to job drawings. For either type installation, support members must be installed to avoid interfering with travelling carriage operation. All supports should be securely made to prevent vibration, which could subject the supply piping to fatigue strain. 2.2
PIPING
A companion flange, complete with gaskets and fasteners is supplied with each unit. This flange is to be attached to the blowing medium supply piping. The piping must be free of strain and have flexibility to allow the blower to move. 2.3
WIRING
Refer to wiring diagrams 3-00-073-60004 for full information on power and control wiring integral with the blower.
3. ERECTION CHECKS Ref. Installation Manual Pub. No. 7508-78 for detailed instructions.
4.
(a)
The blower should be supported in suck a way that it normally sloped towards the boiler when the boiler is steaming Please ref. manual Pub. No. 7508-78.
(b)
Do not place heavy loading on the blowers. They are not designed for taking, such heavy loads.
(c)
Ensure a minimum surface to surface clearance of 100 mm between boiler tubes and lance tube at the extended condition of th a lance tube.
(d)
Ensure a minimum clearance of 100 mm between the top surface of the boiler tube and the lowest surface of the lance tubes.
(e)
If the clearance is not achieved, the boiler tubes shall be shielded.
(f)
Cover all the sliding and electrical parts to prevent accumulation of filth, debris and water. Make sure all the openings and cover in the junction boxes are, completely closed during and after field cable connections.
(g)
The soot blowers are like precision machines and hence to be handled with care. Use the lifting lugs and skids to prevent damage to the housing electrical cables and other parts.
(h)
Make sure sufficient number of hand cranks are available at each elevations.
START UP CHECKS For detailed start up checks. (See Pub. No. 7508.) (a)
Check the blower numbers and their location. 10 1610 - 1611 VOL - C1 TAB - 7 - 141
5.
(b)
Check the chain tension.
(c)
Check the position of valve opening cam. (See Pub. NOL. 7508 for details.)
(d)
Check all the cable connections.
(e)
Check lubrication in the gear box.
(f)
Check for free manual movement.
(g)
Check the lance/boiler tube clearances.
(h)
Check the clearances for manual hand cranking.
(i)
Check whether all the blowers are in the initial position.
SOOT BLOWER OPERATION 5.1
CHECK LIST
For Long Retractable Soot Blower (LRD-IIE) the following items are to be checked carefully before initial operation of the blower: (i)
(ii)
(iii)
(iv)
Lubrication level (a)
Travelling carriage.
(b)
Rotary Gear box.
(c)
Traverse Gear box.
Chain Tension (a)
Rotary side.
(b)
Traverse side.
Blowing Pressure (a)
Initial setting.
(b)
Final setting.
SBV Head Air Valve (Non-return valve)
Plug is to be removed and the air valve to be installed only in case of forced draft furnace. 11 1610 - 1611 VOL - C1 TAB - 7 - 142
(v)
Motor Rotation (a)
(vi)
(vii)
(viii)
Rotary drive motor should run-top rotary chain to rear and bottom rotary chain towards the furnace unless specified.
Installation of Air Vents (a)
Rotary Gear box.
(b)
Traverse Gear box.
(c)
Travelling carriage.
Interference (a)
External interference.
(b)
Internal tube (clearance and alignment)
Pecking Tightness
To be tightened slightly for minimum leakage during operation. (ix)
External Power and Control cable connections. CONTROL PANEL FULLY OPERATIONAL WITH ALL THE INTERLOCKS IN OPERATING CONDITION.
CAUTION:
DO NOT OPERATE THE BLOWER IN QUICK SUCCESSION. MINIMUM I HOUR COOLING PERIOD BEFORE SUBSEQUENT OPERATION IS A MUST To AVOID ANY DAMAGE TO MOTOR WINDINGS.
5.2
OPERATION
i)
General
As the start button is pressed the unit begins to extend and rotate. As the nozzles clear the boiler Wall the carriage strikes the cam, opening the head and blowing commences. At the fully extended position the travelling carriage strikes the reverse limit switch, (item No. 12 of main assembly) which closes. momentarily to reverse the unit. As the carriage retracts, it again strikes the cam closing the - SBV head. The travelling carriage continues its rearward travel until the cleaning nozzle is retracted into the protection of the wall box at which time the stop limit switch (item No. 11 in the main assembly) is struck to stop the unit. (ii)
Frequency
The frequency of Soot Blower operation depends on the operating conditions of the boiler and boiler cleanliness. Some events which may indicate the need for cleaning are, increase in boiler exit gas temperature, increase in gas pressure loss across the boiler (assuming constant boiler load) and visual inspection. It is important when starting up a boiler that the soot blowers be used frequently, and soon after lighting off. Inefficient combustion in a boiler during start up may result in abnormal deposits on the tubes. Unless these are removed frequently, furnace explosions or puffs may result later. It is usually also desirable to use the soot blowers just before taking a boiler out of service. Care must be taken to avoid extending the lance into the boiler without flow of blowing medium, or in subjecting the lance to temperatures in excess of 550°C. If the lance becomes stalled when partially extended, allow blowing to continue in order to cool the lance until manual emergency retract Procedure is taken up. When first placing the 12 1610 - 1611 VOL - C1 TAB - 7 - 143
blower in service make sure it is in good mechanical condition and that flow of blowing medium is established properly. When the soot blowers are not being used, the main blowing medium valve should be closed tightly. 5.3
EMERGENCY OPERATION OF SOOT BLOWER
(i)
To put the soot blower on manual operation.
(ii)
(a)
Switch off power and control supply.
(b)
Close the main stop valve of soot blower system to shut off steam/air supply.
(c)
Insert the handcrank on the worm shaft and rotate until the blower reaches starting position.
Warning (a)
No soot blower should be operated for a second time within one hour interval to avoid damage to motor windings.
(b)
No soot blower should be operated without blowing medium when the boiler is ‘on‘.
(c)
Soot blower should never be manually operated with steam. At the time of any failure of power or control supply during operation of soot blower, the blower should be immediately brought to its starting position to avoid any possible damage to heating surfaces or lance tube. At the end of the traversing gear box, a slotted stub shaft is provided for hand cranking. After removing the cap, a hand crank can be engaged to move the lance manually. One hand crank is normally furnished with each blower. It is also possible to move the gear box with a portable air motor. (SPEC: ½” Pneumatic drill suitable adopter for stubbed shaft; SPEED 275 to 300 rpm)
6.
(d)
No soot blower lance should be left with blowing medium inside the boiler for a long time. Failure of bringing the lance to the start position will lead to damage boiler tubes and the lance.
(e)
In compliance with transportation codes, blowers must be shipped with dry gear boxes. Before operating the blowers fill the power packs with recommended lubricants.
TROUBLE SHOOTING AND MAINTENANCE Unless soot blowers are properly operated and maintained, there can be lengthy and costly outages, and need for more expensive replacement of boiler equipments. Preventive Maintenance Check List The following is a suggested maintenance schedule. Establish a regular maintenance programme compatible with conditions at installation. 6.1
At one week intervals
Check for steam leakage in the travelling carriage gland packing. Aslightamount of leakage is required and permitted. If leakage is excessive change the packing. The entire packing set should be changed at one time. Follow the instructions for changing the packing. Check for scoring marks on the feed tube.
13 1610 - 1611 VOL - C1 TAB - 7 - 144
6.2
At one month intervals
(a)
Check the travelling carriage and valve for steam leakage. If steam leakage is noticed tighten the glands and watch the performance during the next Operation.
(b)
Check for the steam leak through valve seat. A HOT lance tube (when the line is charged with steam) is the indication of steam leak through seat, if it is supported by the hissing noise of steam leakage.
(c)
Check the presence of ‘Stop pin‘ on the cam bracket.
(d)
Check the angle tracks and chain. If ash building is noticed, clean them.
6.3
At 6 month intervals
(a)
Check chain tension of both rotary drive and traversing drive chain. These chains should be adjusted to ride on the upper angle iron track and on the lower turned edge of the main housing. The chain should be supported and carried free from either the driver or the idler end sprockets, or both, for a minimum distance of 750 mm and a maximum distance of 1 metre. Refer Drg. 4-20-001-00523.
(b)
Check chain tension of both jack shaft drive chain. The jack shaft drive chains should be tightened so that normal hand pressure will depress either side of the chain at the mid point approximately 25 mm.
(c)
Chains subjected to caustic or corrosive atmosphere or extremely high temperatures may require re-lubrication. Lubricate chains as soon as they show signs of rust on any of the external parts. Replace any chain that is badly rusted or corroded and has lost articulation. Refer to LUBRICATION SECTION of General Instructions for recommended lubricants and lubrication procedure. (Pub. No. 7501-79)
(d)
Check both “ Stop “ and “ Reverse “ limit switches. The actuating arms should be tight and secure on the switch pivots. The pivots should be free of paints or oil so that no hinderance or binding of movement occurs. The actuating arm should be correctly adjusted so as to pass freely through the slots in the housing and be properly engaged by the travelling carriage slide roller.
6.4
At one year intervals
(a)
Check gaskets at travelling and rotary gear box covers. (Gaskets may have. dried and shrunk permitting oil seepage). Cap screws on covers should be. tightened. Replace gaskets if seepage is excessive.
(b)
Check oil level in travelling carriage gear boxes. Add recommended lubricant, if necessary. Refer to LUBRICATION SECTION of General Instructions. (Pub. No. 7501)
(c)
Check oil in the reduction gear boxes on the traversing and rotary power packs. Add recommended lubricant, if necessary. Refer to Lubrication Section of General Instructions.
(d)
Check complete assembly. Tighten loose bolts, nuts and cap screws. Replace missing cotter pins and springs.
(e)
Change motor bearings, if required.
(f)
Coat the threaded components with Molyka or antiseize compound so that the rusting will be prevented.
(g)
Check the valve stem assembly for pitting and if pitting is severe replace the stem with a new one. Apply Molyka on the stem while assembly. 14 1610 - 1611 VOL - C1 TAB - 7 - 145
(h)
Check the mountings and hanger supports of blower. The hinge pin should be secured by cotter pins. Lock clamp washers are required to secure mounting shoulder bolts.
(i)
Test, Operate each individual blower
Using the local start button with the blowing medium of the unit under normal operating conditions, test, operate each individual blower. Along with the mechanical operation of each blower the blowing pressure also should be checked by using pressure gauge, in the SBV operating head. The recommended blowing pressure is shown on the general arrangement drawings Blowing pressure chart. This manual check is essential to assure that excessive blowing pressures are not incurred what would cause boiler tube wastage. 6.5
Shut-down checks
In addition to the annual checks as in 6.4 the following checks are to be carried out : (a)
Check whether the boiler tubes have eroded. If thickness is reduced to a very low value provide of shielding.
(b)
Check the gap between the lance tube and the boiler tube. The gap should be kept min. of 100 mm. For the blowers located in the second pass, the gap between the lance tube, (at the extended condition) and the coil edge is to be checked. The minimum distance of 100 mm is to be maintained.
(c)
Paint the blowers once in two years.
6.6
Periodical check determined by installation conditions
(a)
Check motor starter cabinets. Cabinets should be kept securely closed and gaskets should be in place to prevent contamination. If cabinets have been opened for servicing, carefully blow surfaces free of dust or foreign material with tight air pressure from a dry, clean air supply. Position gasketand secure cover.
(b)
Packing on the feed tube in the travelling carriage and the valve stem in the SBV operating head should be tightened. When packing glands are fully down and leakage is still present, the units should be marked for repacking after the blowing medium is turned off and the header secured and tagged.
(c)
Scraper plates should be inspected for wear as a regular maintenance procedure. Immediately following start-up, routine examination should begin and should be scheduled for two month intervals. After completing several bimonthly checks, the frequency of these inspections may be altered by increasing or decreasing the time interval between checks (to be determined by the wear pattern)
(d)
Internal Inspections
(i)
Check to see that nozzles are not worn, cracked or split. Examine inner wall sleeve edges to make sleeves are not breaking down under heat and thus failing to protect nozzle heads when they are retracted. See that nozzles are properly retracted for protection.
(ii)
Examine thoroughly all tubes cleaned by these units by rubbing the hands over them to determine if there are any grooves or flat spots indicating erosion or cutting. Tube 15 1610 - 1611 VOL - C1 TAB - 7 - 146
erosion or cutting with Retractable Units is invariably due to excessive blowing pressure. This pressure should be controlled to avoid the damage. On Long Retract able Units be careful not to reduce pressure to a point where the volume of steam.passing through the lance will be insufficient for cooling the lance when fully extended. (iii)
Space between Water wall tubes where these lances enter is sometimes limited by boiler construction. Check to see that lances enter the centre of the operating without striking the boiler tube which could thus be damaged.
(iv)
Lances should be straight and true. Straightening procedures as outlined for Rotary Equipment can be followed.
(e) External Inspection-Long Retract (i)
For general instructions refer Section 5.2-EXTERNAL INSPECTION of Publication No. 7501.
(ii)
Take care when mounting long retractables. Where outboard bearing or boiler end of the unit is supported and attached to the boiler, the other point should be attached to structural steel. The boiler will move under heat and load. Thus if more than one point is attached to steel structures, twisting and bending of the unit will occur with boiler load changes.
(iii)
All units of this type have some sort of the telescoping tube or feed tube running through a packing gland. Surfaces passing through these glands should be clean, smooth and free from burrs, cuts of scoring. If they cannot be cleaned, they should be replaced to prevent excessive packing replacement or damage to mating parts.
(iv)
It is sometimes necessary to relocate soot blower units or add additional equipment to relieve troubles or reduce maintenance. This, as well as a question of change in design should be deferred until all possible sources of trouble have been eliminated.
6.7
Lubrication
The capacity of the travelling carriage is 1 litre of gear oil. We recommend SERVOMESH 28 for air blowing and 0.6 kg of SERVOGEM HTXX for steam blowing. Where SERVOGEM HTXX or equivalent is used in the travelling carriage, the grease, after it has been run through a few operations will find its own level. The volume of this grease should be approximately half-way on the hollow spindle as a maximum, minimum should be upto the oil level plug. (if temperatures of blowing steam exceeds 427°C use Almasol 1250). The reduction gear boxes on the motor power packs have a capacity of 0.75 litre each. Also the recommended lubricant is SERVOMESH 28. Replace the pipe plugs in the highest opening in the box with air vents provided loose. Should the chains be subject to caustic or corrosive atmosphere or extremely high humidity conditions they may require lubrication. Failure to properly tighten and constantly maintain packing in the travelling carriage of steam blowing installations will rapidly deplete lubrication on the drive chains. Chains should be lubricated as soon as they show signs of rust or any of the external parts. Should chains be badly rusted and corroded in the pins and rollers and the movement (or articulation) lost, no amount of penetrating oil or lubrication will free those parts which have seized up. Two-fold lubrication is recommended, when required: For the first step of the chain lubrication procedure, a light body penetrating fluid should be applied not only to wash out rust, fly ash, and debris but also to act as a carrier to help the heavier, lasting lubricant enter the close clearances between pins and rollers. 16 1610 - 1611 VOL - C1 TAB - 7 - 147
We recommend for the first coat Trichloroethylene. Since this penetrating spray must be thin, it will volatilize and evaporate rather quickly. The application of a heavier more permanent lube must follow immediately while the penetrating oil is still present, to carry the heavy lube to the working parts. We recommend for the second coat, Light oil to the grade of SAE-30. The second coat, should be applied as a thin coat with brush so as to cover and penetrate the bearing areas. Too much of the lubricant will trap the flyash and will make the chain stiff and loose the articulation. The Indian Oil grade of SAE-30 will be SERVOLINE-140. 6.8
Procedure for Lance and Feed Tube Removal
The lance tube and feed tube can be removed from the bottom of the blower. For their removal proceed as follows : (i)
Remove M20 nuts attaching the SBV valve head to the blower and remove the head.
(ii)
Loosen the packings on the travelling carriage.
(iii)
Slide the feed tube out of several centimeters and remove two feed pipe retainer ring halves.
(iv)
Disconnect the lance flange from the travelling carriage. Slide the feed tube into the lance several centimeters. The lance should be supported by a sling through the housing.
(v)
Remove tie bars from the bottom of housing at the head end to allow the lance to be dropped.
(vi)
Lower the end of the lance and feed pipe and pull the lance out of the roller bearing at the boiler end of the blower and slide it out of the blower housing.
(vii)
To reassemble the lance and feed pipe, follow the steps in reverse order.
6.9
Packing Installation
(i)
The travelling carriage utilizes a formed packing set. The packing gland nuts should be drawn up tight enough to effect a seal but not excessive enough to restrict the travel of the carriage.
(ii)
Recommended procedure for Packing Installation
(a)
The useful life of packing is dependent on the method of installation. Poor installation can cause the best packing tofail prematurely. The methods in this procedure, if followed, will lead to better sealing and longer life. These packing methods apply both to installing packing in new equipment and replacing packing in equipment that is in service.
(b)
Installation Method (Travelling Carriage Assembly) Clean out the old packing. Flexible packing hooks are available for removing the packing. Inspect the feed pipe for wear or damage. Remove any raised metal that projects above the normal surface. Do not try to file out depressions or scratches. Raised metal will tear packing. Any reworking of scratches will only worsen the condition. Keep the new packing clean during installation. Grit or other hard foreign matter that is installed with the packing may score the feed pipe causing an early failure of the packing. Install all packing rings so that the joints are staggered and kept approximately 90° 17 1610 - 1611 VOL - C1 TAB - 7 - 148
apart. Spot the joints in clockwise direction to facilitate locating them when removing and packing. Install the rings one at a time. Each ring must be set firmly into place with either the gland or a tamping tool as shown in Drg. 4-20-996-01241. After each ring is installed, the ring must be compressed with approximately the same force that it will have with the final gland force. Each ring should be equally compressed when the entire set is installed. If this is not done, only the last ring will do the sealing and will wear quickly. Bevelled packing is to be installed with the bevel lip on the shaft pointing toward the pressure. One end of the tamping tool is angled for bevelled packing. Fit the bevel on the packing to the bevel on the tool. Oil or grease may be applied to the outside of braided asbestos packing to help in installing it in the stuffing box. Tighten the gland follower, sufficiently tight, after the packing has been installed to insure final seating of the packing. The nuts should be backed off two or three turns to relieve excessive pressure. Adjust packing to operating conditions. Allow packing to leak a small amount, if possible, when starting newly packed equipment. Tighten the gland slowly as the packing seats. Do not be afraid to let packing leak a small amount. It is good assurance that packing is not too tight and the liquid usually has some lubricating qualities. (c)
Installation Method (SBV Head Assembly)
The new packings on the soot blower valve head assembly can be easily assembled removing the valve from the soot blower. If packings are installed with the valve mounted on the blower, care should be taken to see the valve stem assembly does not fall in the soot blower pipe line. Install the rings one at a time. Each ring must be set firmly into place using the gland bushing. Follow the Installation procedwe as suggested in 6.7 (b). For assembling the spring retainer of the valve (item 08 of 1-00-073-60003), use the spring tool as suggested in the drawing 4-00-073-60158. When renewing packing, use all new clean packing. Worn packings are dry, highly compressed, have high friction and may develop scoring. Remember packing is relatively cheap. Labour and materials necessary to replace worn valve stems are expensive and critical commodities. The most expensive seal is a seal that fails. Light gland pressure should be maintained at all times. Too much pressure will cause binding, scoring of the shaft and force the lubricant out the packing. Too little gland pressure will allow excessive leakage and washing out of the packing. When the packing has been compressed to less than 3/4 of its original height, it should be replaced. The loss of height in packing may indicate a loss of essential lubricant. 6.10 Chain Tension Adjustment (Drg. No. 4-20-001-00523) The chain must ride on the upper angle iron track and on the lower turned edge of the main housing. Under no circumstances can the chain be so tight that it will be supported only by the drive and idler sheave sprockets. When the chain is being adjusted, the chain should be supported and carried free from either or both end sprockets, that is either the driver or the idler for a minimum distance of 750 mm and a maximum of 1000 mm from the sprocket to the track. 18 1610 - 1611 VOL - C1 TAB - 7 - 149
The mid-point of the chain from 750to 1000 mm of the driver and 750 to 1000 mm of the idler must ride on the lower rail. 6.11 Spares In the enclosed drawings spares that are recommended for stock by the user, are marked by ’S’. While ordering spares the item number and drawing number as found in the Bill of material and details furnished in the soot blower name plate must be indicated for quick supply of these items. Section 10 gives the recommended list of standard spares.
7.
RECOMMENDED LUBRICATION CHART FOR LRD IIE LONG RETRACTABLE SOOT BLOWER
Lubrication Points
Part Description
Lubricant
Filling frequency
Observation Method of frequency application
Qty. per Blower per Filling
2.1
Travelling carriage (Air blowing)
Gervil EP 2 of HPC or Servomesh 28
Annual
3 Months
Fill in the reservoir
0.8 litre
2.2
Travelling carriage (Steam Blowing)
Trisona 2 of H PC or Almasol 1250 or Servogem HTXX
Annual
3 Months
Fill in the reservoir
0.6 Kg.
2.3
Chain
Servoline 140 or Enklo 65 of HPC
-
-
2.4
Power PackRotary and Traverse
Servomesh 28 or Enklo 53 of HPC
Annual
3 Months
-
-
Fill in the reservoir
0.8 litre
Remarks See Note 2
See Note 3
See Note I
See Note 2
19 1610 - 1611 VOL - C1 TAB - 7 - 150
8.
OPERATIONAL PROBLEMS AND MAINTENANCE
Problem 1.Overheating of the lance tube
Probable Cause No steam flow/less steam flow (a) (b) (c)
(d) (e)
3 Steam leakage through valve stem
Insufficient blowing pressure Valve stem doesn’t move valve stem
Increase the blowing pressure Dismantle and clean the
Increase in flue gas temp. than the designed value Absence of valve opening screw
Check the boiler parameters Assemble the valve openingscrew
Slipping of ‘valve opening lever‘ from ‘Tripping Lever’ Selection of nozzle size
Adjust the pull rod to have proper engagement
(g)
Keeping the lance without the blowing medium lance is bent, straighten
Retract the lance immediately as soon as noticed. If
(a)
Poor quality of packing recommended used for use
Use packing
(b)
Further compression impossible as the packings become solid
Use new packings
(c)
Inadequate tightening (Caution : Do not overtighten the packings)
Tighten the packings:
(d)
Excessive wear of glands new glands
Replace the packing with
(e)
Scratch marks, dents or other surface defect on the feed pipe
If excessive scratch marks are noticed, change the feed pipe
(a)
Poor quality of packing used recommended
Use the quality packing
(b)
Further compression impossible as the packings become solid
Use new packings
(c)
Inadequate tightening (Caution : Do not overtighten) 20
Tighten the packings
(f)
2 Steam Leakage through travelling carriage
Suggested Remedy
Refer with BHEL (T) and change the nozzle head
1610 - 1611 VOL - C1 TAB - 7 - 151
Problem 4. Chain failure
Probable Cause (a)
Rusting of the chain and loss of articulation Assambly of commercial chains and links These chains will fail frequently. Install spl. quality chains only
Install new chain
(c)
Mounting of wrong motor on the traverse power pack and wrong setting of thermal overload relay
Check the installation of correct motor. Check and set the O/L relay as per recommendation
(d)
Improper assembly of connector links
Assemble connector links properly
(e)
Wearing of chain links and rivets worn out links
Protect chains from ash build up or change the
(a)
Bent lance due to overheating
Remove and straighten the lance tube
(b)
Wrong setting of O/L relay
Set the O/L relay as per recommendation
(c)
Accumulation of ash build up over angle tracks
Clean the angle tracks periodically
(d)
Overtightened gland packings in the travelling carriage
Do not tighten the packing too much Profuse leakage will not harm any parts
(e)
Slag build up in wall sleeve or physical obstruction
Clean the sleeve or adjust the SB alignment
(f)
Shifting of super heater reheater tubes
(g)
Housing Damage during Erection
During shut-down or align boiler tubes so that a min. 100-150 mm. of gap is ensured Rectify the housing so that the travelling carriage moves freely
(h)
Valve opening cam in wrong direction or valve opening cam placed at wrong position ensured
Reposition the cam so that smooth engagement with blowing adjustment bar is
(i)
Earthing of cable at any point
Find out the cable and replace the damaged cable with a new one
(j)
Rusting of terminals which will be indicated by chattering of contacts 21
Replace the terminals with new ones
(b)
5 Motor overload
Suggested Remedy
Commercial chains are having low breaking load.
1610 - 1611 VOL - C1 TAB - 7 - 152
Problem
6 Limit Switch Failure
Probable Cause (k)
Supply voltage low correct voltage
Ensure the availability of
(l)
Gear box jammed or no lubricant
Service the gear box or fill in the recommend lubricant
(a)
Sticking of contacts due to damage, or due to poor quality contact material or due to underrating of contacts
Replace the limit switch with new ones
(b)
Failure of internal parts, springs, locking notches etc.
Replace the limit switch With new ones
(c)
Build up of foreign particles on limit switch which may result in breakage of operating arm Wrong assembly of limit switch
Replace the broken switch arm with a new one
(d)
7 Valve seat leakage
Suggested Remedy
Reassemble the limit switch so that the overtravel is restricted to within 50° Correct the directions of the actuation
(e)
Wrong direction of L.S. actuation
(a)
Gland packings overtightened
Loose the gland packings so that the valve stem closes properly
(b)
Insufficient lapping or damage to the valve disc
(c)
Valve opening setscrew pressing the valve stem while the travelling carriage is in the home
Dismantle the valve and lap the valve stem disc with the use of seat with the hand lapping tool(as suggested in 7501) Adjust the valve opening setscrew so that a min. gap of 1 mm is maintained position
(d)
Valve stem corrosion. replace the valve stem
If the corrosion is excessive,
(e)
Likely small particles trapped between seat and disc.
This can be avoided by tapping the valve through a lever
22 1610 - 1611 VOL - C1 TAB - 7 - 153
S. COMBINATION LONG RETRACT AND WALL BLOWER Please refer to. the T 30 MK II-E Installation Instructions for general installation and maintenance information. The specific assembly drawings for this combination retract-wall blower follow this description of the blower operation. The Assembly drawing and description of the ‘ DA ‘head furnished on this blower are also included. Description of Operation (Refer Drg. 0-00-073-60025 and 2-00-073-70083) Blower operation is initiated by depressing the “ Panel start - or the “ Local start push button. This creates the circuit to energize the “ CRO - relay and thus starts the rotary motor, causing the lance to rotate. This “ EXT - relay will be energized through closed centrifugal contacts on the rotary motor or through ‘ CRO ‘ contact and the limit switch LS1 thus causing the traverse motor starts, causing the lance to extend from initial position. The circuit will be locked by limit switch LS2 is tripped. After a pre-determined travel, limit switch LS3 will be tripped energizing the latching solenoid valve SV that -controls the DA head, permitting the blowing medium to be admitted to the lance. The blower will continue to rotate and. extend until the limit switch LS1 is momentarily tripped, breaking the circuit to “ EXT” and bringing in “ RET “ to cause the lance to retract. The circuit will be locked by 101 R contacts. The lance will retract until limit switch LS3 is tripped energizing the timer T and R2 through closed R1 contacts. This causes the blower to stop, rotate and blow in position until timer ‘T’times out. When timer ‘T’ times out, 101 R2 will be do-energized. The circuit will be created through closed R1 and R2 contacts to permit the blower to continue toretract. When timer T times out. energizing releasing solenoid valve SV to close the DA head and blowing will Stop. Limit switch LS2 will be stroked causing the blower to atop at its “.REST “ position. diaphragm Operated ‘ DA’ Head Assembly Drawing 1-00-073-60100. The ‘DA’ Head is a diaphragm operated valve which controls the flow of blowing medium to the blower. This head has a poppet type valve, which is stroked by the interaction of the diaphragm plate, spindle and a lever. The 40 square inch operator requires air loading pressure in the range of 40 to 80 psi. When air is supplied to diaphragm it moves up racking lever No. 21 causing adjusting screw No.* 26 to stroke the head poppet valve. There must be a back lash of at least 1- 16" between adjusting screw No. 26 and poppet valve stem. Increasing. this backlash reduces blowing pressure. A number 60 drill blood hole is required in the tubing fitting in stalled in the diaphragm chamber while the vent port is open to atmosphere.
23 1610 - 1611 VOL - C1 TAB - 7 - 154
10. RECOMMENDED SPARES FOR LONG RETRACTABLE SOOT BLOWER (MODEL LRD IIE)
S 1. N o. 1.
Ite m N o.
De s cription Valve Gland Packing
..
As s e mbly Drawing No
Part Drawing No
04
2- 00- 073- 60080
-
09
1- 00- 073- 60101
-
Part M ate rial Code
1- 6
7- 12
96/353/365
4
8
12
16
4
8
12
16
MARK No. Off T 30 M ark II-EII - E
13- 19 Over 20
24 1610 - 1611 VOL - C1 TAB - 7 - 155
2.
Packing (Travelling Carriage).
41
0 - 0 0 - 0 7 3 - 6 0 0 21
-
97/366/141
3.
Chain 2- Pitch ..
04
3- 00- 073- 60095
-
97/366/125
4.
Connector Link 2- Pitch ..
01
3 - 0 0 - 0 7 3 - 6 0 0 95
-
97/366/126
2
4
6
8
5.
Offset Link 2- Pitch
02
3- 00- 073- 60095
-
97/366/127
2
4
6
8
6.
Chain 3/4- Pitch ..
04
3- 00- 073- 60096
-
97/366/026
7.
Connector Link 3/4" Pitch
01
3 - 0 0 - 0 7 3 - 6 0 0 96
-
97/366/028
2
4
6
8
8.
Offset Link 3/4" Pitch
02
3- 00- 073- 60096
-
97/366/027
2
4
6
8
9.
SBV Head Assembly
04
0- 00- 073- 60024
1- 0 0 - 0 7 3 - 6 0 0 0 3
-
1
2
3
4
18
0 - 0 0 - 0 7 3 - 6 0 0 23
-
96/353/066
4
6
8
12
13
0 - 0 0 - 0 7 3 - 6 0 0 22
-
Oil Seal
39
0 - 0 0 - 0 7 3 - 6 0 0 21
-
96/353/310
4
6
8
12
12. Oil Seal
40
0- 00- 073- 60021
-
96/353/311
4
6
8
12
10. Oil Seal BSI
11.
..
One blower requirement length varies contract to contract
One blower requirement length varies contract to contract
S 1. N o.
De s cription
Ite m N o.
As s e mbly Drawing No
Part Drawing No
Part M ate rial Code
-
-
M ark II-EII - E No. Off T 30 MARK 13- 19 Over 20
1- 6
7- 12
22/021/303
1
2
3
4
22/021/610
1
2
3
4
GASKET 13 .
Spiral Wound Gasket
55
0- 00- 073- 60024
14 .
Gasket
05
1- 00- 073- 60003
11
1- 00- 073- 60101
12
0 - 0 0 - 0 7 3 - 6 0 0 23
16
0 - 0 0 - 0 7 3 - 6 0 0 22
25
0- 00- 073- 60023
-
52
0- 00- 073- 60022
-
22/021/619
1
2
3
4
15.
16.
Gasket
Motor Gasket
25 1610 - 1611 VOL - C1 TAB - 7 - 156
17 .
Cover Gasket
15
0 - 0 0 - 0 7 3 - 6 0 0 22
-
22/021/609
1
2
3
4
18 .
Gear Box Cover Gasket
17
0 - 0 0 - 0 7 3 - 6 0 0 22
-
22/021/615
1
2
3
4
19.
Gasket
4,2-
0 - 0 0 - 0 7 3 - 6 0 0 21
-
22/021/611
1
2
3
4
20.
Gasket
-
22/021/612
1
2
3
4
21.
Bearing Housing Gasket
14
0 - 0 0 - 0 7 3 - 6 0 0 22
-
22/021/613
1
2
3
4
22.
Motor 1 hp
03
0- 00- 073- 60023
-
-
1
1
2
2
23.
Motor 3/4 hp
03
0- 00- 073- 60022
-
-
1
1
2
2
43
0- 00- 073- 60021
BEARINIGS 24.
Bearing SKF 6210 2RS
06
3- 00- 073- 60097
-
55/119/06210
1
1
2
2
25.
Bearing SKF 6206 2RS
06
3- 00- 073- 60098
-
55/119/06206
1
1
2
2
S 1. N o. 26.
De s cription Guide Roll Bearing
Ite m N o.
As s e mbly Drawing No
Part Drawing No
05
3- 00- 073- 60093
-
05
3- 00- 073- 60094
-
No. Off T 30 M ark II-E
Part M ate rial Code
1- 6
7- 12
13- 19
Over 20
97/366/124
1
1
2
2
27.
Ball Bearing
07
2- 00- 073- 60078
-
96/353/305
1
1
2
2
28.
Ball Bearing SKF 6309
10
0 - 0 0 - 0 7 3 - 6 0 0 22
-
55/111/06309
1
1
2
2
03
' 0 - 0 0 - 0 7 3 - 6 0 0 23
26
29.
Ball Bearing SKF 6204
11
0 - 0 0 - 0 7 3 - 6 0 0 22
-
55/111/06204
1
1
2
2
30.
Ball Bearing SKF 6202
12
0 - 0 0 - 0 7 3 - 6 0 0 22
-
55/111/06202
1
1
2
2
31.
Ball Bearing SKF 6021 ' C4
33
0 - 0 0 - 0 7 3 - 6 0 0 21
-
55/111/06021
1
1
2
2
32,
Ball Bearing SKF 6020 ' C4
34
0 - 0 0 - 0 7 3 - 6 0 0 21
-
55/111/06020
1
1
2
2
33.
Ball Bearing SKF 6209 2RS.
35
0 - 0 0 - 0 7 3 - 6 0 0 21
-
55/119/06209
1
1
2
2
34.
Ball Bearing SKF 6205 213S.
36
0 - 0 0 - 0 7 3 - 6 0 0 21
-
55/119/06205
1
1
2
2
35.
Ball Bearing SKF 6305 . .
-
55/111/06305
1
1
2
2
37
0- 00- 073- 60021
1610 - 1611 VOL - C1 TAB - 7 - 157
36.- Ball Bearing SKF 6005 2RS
38
0 - 0 0 - 0 7 3 - 6 0 0 21
-
55/119/06005
1
1
21
37.
02
1- 00- 073- 60101
-
-
2
4
6
02
1- 00- 073- 60003
-
-
Valve Stem Assy.
2 8
38.
Gland
11
0- 00- 073- 60021
4 - 2 0 - 2 0 1, 0 0 2 2 9
-
1
2
3
4
39.
Bushing
10
0- 00- 073- 60021
4 - 2 0 - 2 0 1- 0 0 0 7 5
-
1
2
3
4
40.
Lance Tube Assy.
07
0- 00- 073- 60024
-
-
-
1
1
-
-
-
-
1
1
0- 00- 073- 60025 41.
Feed Tube Assy.
08
0- 00- 073- 60024
42.
Umit Switch
09
2- 00- 073- 60079
-
97/353/900
2
4,
6
8
43.
Limit Switch
03
2- 00- 073- 60008
-
97/353/021
2
4
6
8
0- 00- 073- 60025
RECOMMENDED SPARES FOR (SPECIAL) COMBINATION LONG RETRACTABLE AND WALL BLOWER
Sl. no
Description
Item
Assembly
Part
No.
Drawing number
Drawing number
Part
No. off T 30 Mark II – E
Material code
1-6
7-12 13-19 over 20
27
01
DA Head valve assembly
01
1-00-073-60100
1-00-073-60101
-
1
1
2
2
02
Gasket
10
1-00-073-60101
-
-
1
2
3
4
03
Gasket
19
1-00-073-60100
-
22/021/617
1
2
3
4
04
‘O’ Ring
22
1-00-073-60100
-
96/353/307
1
2
3
4
05
Solenoid valve
42
0-00-073-60025
-
97/366/129
1
1
2
2
06
Exhaust valve
43
0-00-073-60025
-
97/366/130
1
1
2
2
1610 - 1611 VOL - C1 TAB - 7 - 158
11.
ASPIRATING AND SEALING AIR FOR LONG RETRACTABLE BLOWERS WITH SINGLE SCRAPER PLATE (Applicable for Pressurised Furnace) Single Scraper Plate Air Seal When soot blowers are used on boilers with positive furnace pressures, it is necessary to use air seal aspirators with the soot blower sleeves. The air seal sleeve is used to prevent escape of furnace gases from around the lance. The use of an aspirator, while not mandatory with air seal sleeves, permits removal of a lance with the boiler in operation, without danger of escape of furnace gases. The air seal and aspirator are attached to the soot blower sleeve. Aspirator The aspirator consists of a cylindrical annular air chamber, into which high pressure air is admitted. The lance passes through the central portion of the aspirator. In the cylinder forming the inner wall of the aspirator chamber, there are a series of nozzles drilled on an angle so that discharge of air through them forms a cone with the base at the aspirator and the apex several inches forward of the lance tip. When air is admitted to the aspirator the cone of air prevents flow of furnace gases back through the aspirator and allows removal of the lance or scraper plate. Air Seal The air seal is located directly behind the aspirator. The lance scraper plate forms the rear wall of this chamber. Low pressure air is introduced into the chamber at a pressure greater than furnace, and due to small clearance between outside diameter of lance and inside diameter of the scraper plate, an effective seal is formed against furnace pressure. Scraper Plate The scraper plate is held in position by a horizontal spring through which the lance passes. The scraper plate is hardened, and in addition to sealing, will remove deposits on the lance. When air is admitted to the air seal, an effective seal is made at the lance outside diameter so furnace gas cannot escape from the boiler. The lance is positioned so that both nozzles lie behind the air seal in the fully retracted position, thus the nozzles.are outside the seal, away from furnace gas, which prevents damage from corrosion caused by boiler gases in the lance. Air at some pressure (see contract drawings) above furnace pressure must be provided at the inlet to the air seal chamber to effect a proper seal, seal air should be ON whenever the boiler is in service, with the lance in place. If the lance is removed, the opening must be covered and the seal air shut off. Aspirating air must be ON when removing or installing the lance or scraper plate. Aspirator air pressure is determined by lance size (see contract drawings). Permanent air connections for aspirating air are not required. Quick disconnect fittings for air hook up are desirable to speed hook up for maintenance. The manifold valve must be in “seal” - position when the boiler is in operation. Aspirating air is supplied (only for short periods) when repairs or replacements are being made with the boiler in operation. Before attempting scraper plate maintenance, make sure the aspirating air is ‘ ON’ by placing the manifold in the ‘aspirate ‘ position. If the seal is to be opened for an extended time, cover the open end of the aspirator and reduce the aspirator air flow to that necessary to keep the sleeve cool. 28 1610 - 1611 VOL - C1 TAB - 7 - 159
Never allow the aspirator or air seal to be open ended when the boiler is in service without having aspirating air ‘ ON’. The air seal should be reassembled by reversing the above procedure. Determine, that the nozzle head is in the proper position. When the air seal chamber is secured the aspirating air should be turned OFF and the seal air should be ON. NOTE:
NOZZLES ARE TO BE ON THE OUTBOARD SIDE OF THE SCRAPER PLATE WHEN THE BLOWER IS FULLY RETRACTED AND IN THE ‘AT REST’ POSITION.
The proper location of these soot blower nozzles should be checked prior to start-up and at every outage. Should nozzle openings straddle the scraper plate or be on the inboard side, the seal will be lost and furnace gas will escape which will destroy the lance tip. Where design dictates that the blower lance be extra, long, so as to extend any blowing nozzle beyond this air seal (or where half tract blowers are employed) with nozzles on the furnace side of the scraper plate, while the blower is ‘at rest‘ special provisions are made to seal or purge furnace gases from the blower. Forced Pressure Air Valve For those installations where nozzles are on furnace side of seal air chamber, a forced pressure air valve is located on the soot blower valve. Seal air is supplied to the forced pressure air valve, by tubing connected to the seal air header. The forced pressure air valve acts as a check valve to retain high pressure steam in the operating head valve while blowing. After blowing has been completed, a small spring opens the check to admit seal air to the blower lance and drive out furnace gases. Check contract drawings and specifications to determine aspirator and seal air volume required. This will vary, depending on furnace pressure; there of, specifications on contract drawings should be checked and followed. Seal air pressure differential can be checked by extending the retracted soot blower nozzles to the furnace side of the seal air chamber and through the wall sleeve into the furnace cavity several inches. The blower is extended as far as possible without actuating the blowing valve linkage. This will place the blowing nozzles in the furnace area, which will allow furnace pressure into the lanceand back to the soot blower valve. CAUTION:
SECURE BOTH BLOWING MEDIUM AND ELECTRIC DRIVE CIRCUITS BEFORE EXTENDING THE LANCE FOR THESE READINGS TO AVOID INJURY TO PERSONS TAKING THE READINGS.
The furnace pressure reading can then be obtained on this individual soot blower by installing a manometer in the 3/8 inch tap on the soot blower valve normally used to measure blowing pressures. The seal air pressure should be measured as close as possible to the inlet to the’air seal downstream of all air hose fittings and branch line connections. This usually requires a tap in the last fitting to the air seal manifold valve. The tap can be 1/8 or 1/4 inch pipe thread and a standard pipe plug used to close the opening when readings have been completed. With the lance extended and one leg of a “ U “ tube manometer connected to the soot blower valve tap and the other leg of the manometer to the seal air supply (as described above) the differential pressure between seal air supply and furnace presssure may be read directly on the “ U “ tube. 29 1610 - 1611 VOL - C1 TAB - 7 - 160
At least two readings should be taken under two or more boiler load conditions. Readings are desirable at nominal or high boiler loads and at relatively low boiler loads. These readings should be checked against contract data to insure adequate seal air pressure and flow are available. Cover Along with the air seal and aspirator assembly a cover is supplied separately for covering the furnace opening, in case the seal is to be kept opened for extended period.
30 1610 - 1611 VOL - C1 TAB - 7 - 161
31 1610 - 1611 VOL - C1 TAB - 7 - 162
32 1610 - 1611 VOL - C1 TAB - 7 - 163
33 1610 - 1611 VOL - C1 TAB - 7 - 164
34 1610 - 1611 VOL - C1 TAB - 7 - 165
35 1610 - 1611 VOL - C1 TAB - 7 - 166
36 1610 - 1611 VOL - C1 TAB - 7 - 167
37 1610 - 1611 VOL - C1 TAB - 7 - 168
38 1610 - 1611 VOL - C1 TAB - 7 - 169
39 1610 - 1611 VOL - C1 TAB - 7 - 170
40 1610 - 1611 VOL - C1 TAB - 7 - 171
41 1610 - 1611 VOL - C1 TAB - 7 - 172
42 1610 - 1611 VOL - C1 TAB - 7 - 173
43 1610 - 1611 VOL - C1 TAB - 7 - 174
44 1610 - 1611 VOL - C1 TAB - 7 - 175
45 1610 - 1611 VOL - C1 TAB - 7 - 176
46 1610 - 1611 VOL - C1 TAB - 7 - 177
47 1610 - 1611 VOL - C1 TAB - 7 - 178
48
LRD IIE
1610 - 1611 VOL - C1 TAB - 7 - 179
49 1610 - 1611 VOL - C1 TAB - 7 - 180
50 1610 - 1611 VOL - C1 TAB - 7 - 181
51 1610 - 1611 VOL - C1 TAB - 7 - 182
52 1610 - 1611 VOL - C1 TAB - 7 - 183
53 1610 - 1611 VOL - C1 TAB - 7 - 184
54 1610 - 1611 VOL - C1 TAB - 7 - 185
55 1610 - 1611 VOL - C1 TAB - 7 - 186
56 1610 - 1611 VOL - C1 TAB - 7 - 187
57 1610 - 1611 VOL - C1 TAB - 7 - 188
58 1610 - 1611 VOL - C1 TAB - 7 - 189
59 1610 - 1611 VOL - C1 TAB - 7 - 190
60 1610 - 1611 VOL - C1 TAB - 7 - 191
61 1610 - 1611 VOL - C1 TAB - 7 - 192
62 1610 - 1611 VOL - C1 TAB - 7 - 193
TAB - 8
METHODS AND PROCEDURES FOR INSTALLATION SOOT BLOWERS
Bharat Heavy Electricals Limited Tiruchirapalli
PUB.NO.7508
1610 - 1611 VOL - C1 TAB - 8 - 194
CONTENTS INTRODUCTION PRECAUTIONS FOR SOOT BLOWER ERECTION IMPORTANT INSTRUCTIONS ERECTION AND START-UP-LONG RETRACTABLE SOOT BLOWERS IMPORTANT INSTRUCTIONS ERECTION AND START -UP-WALLDESLAGGER IMPORTANT INSTRUCTIONS - ERECTION AND START-UP-ROTARY SOOT BLOWER LIST OF DRAWINGS PREPARATION ERECTION INSTRUCTIONS : LONG RECTRACTABLE SOOT BLOWER ERECTION INSTRUCTIONS : WALL DESLAGGER ROTARY SOOT BLOWER FURNANCE TEMPERATURE PROBE ERECTION INSTRUCTIONS : HALF RETRACTABLE SOOT BLOWER ERECTION INSTRUCTIONS : TEH BLOWERS FOR AIR HEATERS START UP CHECKS ERECTION INSTRUMENTATIONS : SOOT BLOWER PIPING START-UP CHECKS - PIPING THERMAL OVERLOAD RELAY SETTING FOR SOOT BLOWER MOTOR PROTECTION CHECK SHEETS
2 1610 - 1611 VOL - C1 TAB - 8 - 195
INTRODUCTION The following pages contain a recommended procedure for the erection and start-up of all types of Soot Blowers and Furnace Temperature Probe manufactured by Bharat Heavy Electricals Limited, Tiruchirapalli. Detailed operation and maintenance instructions are dealt in separate manuals. The contents are compiled from the expertise available with us. Sufficient care has been taken to include salient points on erection and commissioning based on the observations made at site as well as on the feed back available from site. Every possible care has been taken to ensure- the contents are accurate. Generally the procedure has been profusely illustrated. It must be recognized that no amount of written instructions can replace intelligent thinking and reasoning on the part of the erectors, especially when coping with individual site conditions. Suggestions for the improvement of the manual would be welcome. BHARAT HEAVY ELECTRICALS LIMITED BOILER PLANT - TIRUCHIRAPALLI
3 1610 - 1611 VOL - C1 TAB - 8 - 196
PRECAUTIONS FOR SOOT BLOWER ERECTION STORE THE SOOT BLOWER COMPONENTS PROPERLY UNDER COVERED ROOF. BLOWERS SHOULD BE LIFTED USING THE LIFTING LUGS/EYE BOLTS. EXTRA CARE YOU TAKE DURING ERECTIONWILL ENSURE TROUBLE FREE OPERATION. REFER TO ENGINEERING DEPARTMENT FOR ANY DOUBTS/DEVIATIONS IN THE DRAWINGS. ENSURE ALL ERECTION WELDING IS DONE BY A CERTI FIED/QUALIFIED WELDER ONLY. CHECK THE BLOWER NOS. BEFORE INSTALLATION. TONNAGE AND QUALITY ERECTION SHOULD GO HAND IN HAND. INSPECT THE SQUARENESS AND CONCENTRICITY OF WALL BOX WITH RESPECT TO OPENING. OPERATE THE SOOT BLOWERS MANUALLY TO CHECK THE INTERFERENCE AFTER INSTALLATION. NEVER USE THE SOOT BLOWERS AS WELDING PLATFORM.
IMPORTANT INSTRUCTIONS ERECTION AND START-UP-LONG RETRACTABLE SOOT BLOWERS DO’S ERECTION 1.
Look for Blower Numbers on the name plates before erection.
2.
Operate the blower manually for checking the clearance inside.
3.
Check the squareness and concentricity of the wall box.
4.
Check for accessibility for the hand crank for manual operation.
5.
Use lifting lugs for lifting.
BEFORE START-UP 1.
Flush the power packs with ‘SERVO SYSTEM 68’ and fill them with the lubricants as recommended.
2.
Check the DIRECTION OF ROTATION of both the MOTORS.
3.
Check whether all covers are put on the blower.
4.
Check the OPERATION of the STOP AND REVERSE LIMIT SWITCHES.
5.
Observe all safety practises.
6.
Check whether the correct blower is installed in the correct location.
7.
For air operated blowers: (i)
Install lubricator and filter near the blower and adjust the lubricator..
(ii)
Ensure sufficient compressed air pressure at the inlet.
(iii)
Ensure sufficient quantity lubricant in the lubricator periodically.
ADDITIONAL INSTRUCTIONS FOR HALF RETRACTABLE SOOT BLOWERS AND THE BLOWERS FOR AIR HEATERS.ERECTION 4 1610 - 1611 VOL - C1 TAB - 8 - 197
1.
USE CORRECT ELECTRODE FOR WELDING THE LANCE/BLOWING ARM.
2.
Check for Alignment of support bearings in the case of half retracts and ‘support channels in the case of LRNR-IE blowers for Air Heaters.
NOTE: FOR IMPORTANT INSTRUCTIONS ON START-UP, SHUT-DOWN AND MAINTENANCE REF. INSTRUCTIONS MANUAL PUB. No. 7502 LONG RETRACTABLE SOOT BLOWER. DON’TS ERECTION 1.
Do not MIX UP the blowers.
2.
Do not use the housing as the welding platform.
3.
Do not place HEAVY LOADS on the blower.
4.
Do not place the blower on the platform without PROPER SUPPORT.
5.
Do not leave the lance at extended position.
BEFORE START-UP 1.
Do not operate the blower WITH WET STEAM..
2.
Do not operate WITHOUT BLOWING MEDIUM during boiler operation.
3.
DO NOT attempt maintenance WORK when POWER AND BLOWING medium are ‘ON’.
4.
DO NOT crank the lance manually with STEAM SUPPLY ‘ON’.
5.
Do not operate the soot blower with excessive steam leakage through packing.
6.
Do not operate the blower in quick succession. MINIMUM ONE HOUR COOLING PERIOD before subsequent operation is a must to avoid any damage to motor windings.
7.
For air operated soot blowers: DO NOT OPERATE the blower WITHOUT LUBRICATOR AND FILTER.
8.
Do not over tighten the drive chains ‘Noisy running is O.K., silent running is NOT Allowed.’
NOTE: LONG RETRACTABLE SOOT BLOWER MODEL LRD-11E SHOULD HAVE STEAM SUPPLY DURING ‘EMERGENCY’ RETRACT.
IMPORTANT INSTRUCTIONS ERECTION AND START -UP-WALL-DESLAGGER DO’S ERECTION 1.
Before erecting the blower, check the opening in the boiler wall. It shall be MINIMUM 80 MM through out.
2.
Before erecting the wall deslagger, check the wall sleeve for perpendicularity and concentricity. Check the blower number with reference to location drawing.
3.
Check the ACCESSIBILITY FOR HAND CRANK and the switch box assembly.
4.
Check whether the WALL DESLAGGER IS PERPENDICULAR after mounting.
5.
Check the PROJECTION OF NOZZLE INTO THE WALL.
6.
Support the soot blower piping on the BOILER STEEL SUCH AS BUCK STAYS, FURNACE GUIDES etc. 5 1610 - 1611 VOL - C1 TAB - 8 - 198
7.
Check and mark up those units where nozzle is not pointing downwards.
BEFORE START-UP 1.
FLUSH the gear boxes thoroughly with ‘SERVOM ESH SP460’ and fill the gear boxes with the lubricants as recommended.
2.
Make sure the DRAIN HOLES in the MOTOR FRAMES point DOWNWARDS and are open.
3.
Check the DIRECTION of rotation of both the MOTORS.
4.
Make sure that the stop nuts are in place on the GUIDE RODS.
5.
Check whether the COVERS are put on the blower.
6.
Check the perpendicularity of the blower when the boiler is working.
NOTE: FOR IMPORTANT INSTRUCIONS ON START- UP, SHUT-DOWN AND MAINTENANCE.REFER INSTRUCTION MANUAL PUB. No. 7503 WALL DESLAGGER. DON’TS ERECTION 1.
DO NOT SUPPORT the blower separately unless otherwise specified.
2.
Do not use the blower as a platform/ladder.
3.
Do not support the soot blower piping from boiler columns and platforms.
4.
Do not place the blowers on the platform without proper support.
BEFORE START-UP 1.
DO NOT operate the blower with WET STEAM.
2.
Do not set the cam for Micro Limit Switches with ‘POWER’ ON.
3.
Do not operate the blowers under low boiler loads without trial operation.
4.
Do not hand crank with power and/or steam ‘ON’.
IMPORTANT INSTRUCTIONS - ERECTION AND START-UP-ROTARY SOOT BLOWER DO’S ERECTION 1.
Erect the correct Blower in the correct location. (Look for the BLOWER NUMBER on the reaction plate).
2.
Check for the ALIGNMENT of the SUPPORT BEARING of the blowing element.
3.
Look for the CORRECT BLOWING ELEMENTS as per the blower number given on the element.
4.
Adjust the nozzle position as per requirement.
BEFORE START-UP 1.
FLUSH the power pack thoroughly with ‘SERVO SYSTEM 68’ and fill the same with the lubricant recommended.
2.
Check whether the SWITCH BOX COVER is put on the blower. 6 1610 - 1611 VOL - C1 TAB - 8 - 199
3.
Check the DIRECTION OF ROTATION of the motor and blowing element.
4.
Check whether the CORRECT BSLOWER is installed IN THE CORRECT LOCATION.
5.
For air operated blowers: (i)
Install the LUBRICATOR AND FILTER near the blower and adjust the lubricator.
(ii)
Ensure SUFFICIENT COMPRESSED AIR PRESSURE at the inlet.
(iii)
Ensure SUFFICIENT QUANTITY OF LUBRICANT in the lubricator periodically.
NOTE:
FOR IMPORTANT INSTRUCTIONS ON START-UP, SHUT-DOWN AND MAINTENANCE.REFER INSTRUCTIONS MANUAL PUB. No. 7504 ROTARY SOOT BLOWER.
DON’TS ERECTION 1.
DO NOT MIX UP the blower.
2.
Do not SUPPORT the blower EXTERNALLY unless otherwise specified.
3.
Do NOT USE the blower as the PLATFORM.
4.
Do not connect the seal air piping rigid. Connect it with a FLEXIBLE hose
5.
DO NOT MIX UP the blowing elements.
BEFORE START-UP 1.
Do not operate the blower with wet steam.
2.
Do not admit steam into the blower when the blowing element is stationary.
3.
Do not attend to any repair work with STEAM/POWER ‘ON’.
4.
Do not attempt manual rotation when power is ‘ON’.
5.
For air operated blowers:
DO NOT OPERATE THE BLOWER WITHOUT THE LUBRICATOR AND FILTER. LIST OF DRAWINGS (1)
4-00-073-60085
Long Retractable Soot Blower.
(2)
4-00-073-60086
Wall Deslagger.
(3)
4-00-073-60087
Rotary Soot Blower.
(4)
1-00-073-60059
Seal Air Connection for LRSB.
(5)
3-00-073-60039
Important of Blower Location.
(6)
3-00-073-60040
Typical Alignment of Blowing Element -(Rotary Blower).
(7)
3-00-073-60041
Erection of Wall Blower.
(8)
3-00-073-60044
Location of Filter & Lubricator.
(9)
3-00-073-60045
Erection of LRSB.
(10)
3-00-073-60046
Erection of LRSB. 7 1610 - 1611 VOL - C1 TAB - 8 - 200
(11)
3-00-073-60047
Supporting the Wall Deslagger on the Platform.
(12)
3-00-073-60049
Welding of Wall Sleeve.
(13)
3-00-073-60050
Supporting Rotary Soot Blower on the Platform.
(14)
4-00-073-60013
Flange Tightening Sequence.
(15)
4-00-073-60014
Lifting the Rotary Soot Blower.
(16)
4-00-073-60015
Piping Insulation (upto Valve Flange).
(17)
4-00-073-60016
LRSB Support.
(18)
4-00-073-60017
Supporting of Soot Blower Piping (WB-IE).
(19)
4-00-073-60057
Nozzle Adjustment.
(20)
4-00-073-60058
Supporting Long Retractable Soot Blower on the Platform.
(21)
4-00-073-60059
Alignment of Rotary Blower Element.
(22)
4-00-073-60060
Manual Operation of Rotary Blower.
(23)
4-00-073-60062
Alignment of Swivel Tube.
(24)
4-00-073-60063
Position of LRSB.
(25)
4-00-073-60064
Arrangement of the Valve during Steam Blowing.
(26)
4-00-073-60070
Setting of Wall Deslagger Control Cams.
(27)
4-00-073-60071
Draining Arrangement.
(28)
4-00-073-60072
Clearance Space around LRSB.
(29)
4-00-073-60073
Clearance Space around WB-IE.
(30)
4-00-073-60074
Clearance Space around RB-IE.
(31)
4-00-073-60075
Clearance Space around FTP-IE.
(32)
4-00-073-60076
Sealing Air Connection for RB-IE.
(33)
4-00-073-60088
LRD - I - Point Loading - Motors Rear Top Mounted.
(34)
4-00-073-60089
Furnace Temperature Probe - Support Point Loading.
(35)
4-00-073-60090
Seal Air Requirement Chart.
(36)
4-00-073-60091
Aspirating Air Requirements. LEGEND
LRSB
-
Long Retractable Soot Blower
WB-IE
-
Wall Deslagger
RB-IE/RB-IA/RBIM -
Rotary Soot Blower
FTP-IE
Furnace Temperature Probe
-
8 1610 - 1611 VOL - C1 TAB - 8 - 201
LIST OF ERECTION DRAWINGS BOILER
: ....................................................................................
CUSTOMER NO : .................................................................................... A.
LONG RETRACTABLE SOOT BLOWERS:
(i)
LRD-I Soot Blower Views.
(ii)
LRD-I Long Retrac: Sleeve Views.
B. (i) C.
WALL DESLAGGER: WB-IE Soot Blower Views. ROTARY BLOWERS:
(i)
Rotary Blower Views.
(ii)
Blowing Element.
(iii)
Blowing Element.
(iv)
Blowing Element.
D.
FURNACE TEMPERATURE PROBE:
(i)
Furnace Temperature Probe Erection Views.
(ii)
Furnace Temperature Probe Sleeve Views.
E.
HALF RETRACTABLE SOOT BLOWER:
(i)
LRD-1 Half Retract Views.
(ii)
LRD-I Half Retract sleeve view
F.
TEH BLOWERS FOR AIR HEATERS:
(i)
LRNR-I Non Rotating Soot Blower Views.
(ii)
LRNR-I Non Rotating Soot Blower Sleeve Views.
G. (i)
OTHERS: Soot Blower Arrangement.
(ii) (iii) (iv) (v) (vi)
9 1610 - 1611 VOL - C1 TAB - 8 - 202
H.
SOOT BLOWER PIPING:
(i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) (x) 1.
PREPARATION
(i)
Inventory the shipment and immediately report shortages.
(ii)
List out the damaged components with reference to the item number in the concerned assembly drawings and report to Bharat Heavy Electricals Limited, Tiruchirapalli. Refer the following manuals for the concerned assembly drawings.
(iii)
(a)
Pub. No. 7502: Long Retractable Soot Blowers - LRD-IE.
(b)
Pub. No. 7503: Wall Deslagger - WB-IE.
(c)
Pub. No. 7504: Rotary Soot Blower - RB-IE.
(d)
Pub. No. 7505: Furnace Temperature Probe - FTP-IE.
(e)
Pub. No. 7507: Long Retractable Soot Blower Air Operated - LRD-IA,
(f )
Pub. No. 7509: Long Retractable Soot Blower Model LRNR-IE.
(g)
Pub. No. 7511: Manual Rotary Soot Blower - Model RB-IM.
(h)
Pub. No. 7512: Rotary Soot Blower - Air operated - RB-IA.
(i)
Pub. No. 7513: Pneumatic Control Panel - CPP.
(j)
Pub. No. 7514: Long Retractable Soot Blower - LRD-11E..
Check Blower number ,as given in the shipping list/location drawings.
NOTE: ALL BLOWERS ARE NOT IDENTICAL (iv)
Plan for tools, tackles, rigging and handling facilities required for the installation of the Blowers.
(v)
Ensure that all documents like Erection Manuals, Erection Drawings and other relevant documents are available before commencement of the erection. If not contact BHEL, Tiruchy for complete documents.
(vi)
Programme a sequence of erection in relation to the type of the blowers being erected. Economics and safety are equally important while erecting the blowers.
(i)
Transport
The soot blower assemblies are shipped completely covered with water proof coverings. UNLESS THE BLOWERS ARE TAKEN FOR IMMEDIATE ERECTION, DO NOT DISTURB THE 10 1610 - 1611 VOL - C1 TAB - 8 - 203
COVERINGS. Replace the damaged covers wherever required. Some assemblies like wall deslaggers; and rotary blowers are shipped with temporary wooden platforms to prevent parts getting damaged during erection. THESE ARE NOT TO BE REMOVED TILL THE BLOWERS ARE ERECTED. This will ensure that the parts are not damaged during handling. Cover all the electrical items with water proof and dust proof coverings. Nozzle and valve openings are shipped covered. If any damages are noticed to the covering take necessary actions to rectify it. (ii)
Storage
Normally storage under covered roof is not necessary for soot blowers. When the water proof covers are removed, wall deslaggers; and rotary blowers must be stored under covered roof if the interval between soot blower erection and receipt is more than one month. Always use the lifting lugs or hooks provided to avoid damage to the connected parts Similarly avoid hitting the assembly against the structures or other boiler components while the soot blowers are being lifted. Ensure that the air vent plug in the gear boxes are in place. Avoid leaving open holes in the gear boxes. IF THE STORAGE PERIOD IS LIKELY TO EXCEED 2 MONTHS FILL THE GEAR BOXES WITH OIL FOR PROTECTION. Support the blowers properly during storage. Avoid stacking the blower or placing heavy weights on the blowers. (iii)
Weight
(a)
LongRetract: The weight varies with the travel. For actual values refer 4-00-073-60088.
(b)
Wall Deslagger: 150 Kg per blower.
(c)
Rotary Soot Blower: 90 Kg per blower.
(d)
Furnace Temperature Probe: The weight varies with travel. For actual weight refer 4-00-073-60089.
ERECTION INSTRUCTIONS : LONG RECTRACTABLE SOOT BLOWER (i )
Supports
The long retractable soot blowers are to be supported at both boiler and rear ends. Unless otherwise indicated in the drawing, the boiler end shall not be supported in the platforms. (Refer Drg. 4-00-073-60016). Long retracts are normally slopped towards the boiler when the unit is working. To achieve this, while erecting due consideration shall be given to the boiler expansion so that at boiler hot conditions the blower will be slopping towards the boiler. This is to aid condensate drainage into the boiler after the blowing operation is over. (Refer Drgs. 3-00-073-60045, 3-00-073-60046 & 4-00-073-60063). The retractable soot blowers are also to be erected inclined considering the horizontal expansion, so that when the boiler is working the blower will be perpendicular to the wall in the horizontal plane. The expansion values at different soot blower points are given in the soot blower piping drawings. NOTE: THIS SLOPE WILL NOT BE APPLICABLE TO HALF RETRACTS AND TUBULAR AIR HEATER CLEANERS. (ii)
Lifting
While lifting the long retractable soot blower take care to see that no damage is caused to the wiring and other components by hitting with other structures. Use only the lifting lugs. It is suggested to have wooden blocks on the sides of the housing so that the slings will not damage the electrical wiring while lifting. 11 1610 - 1611 VOL - C1 TAB - 8 - 204
CAUTION: DO NOT REMOVE THE WOODEN GUARDS (Refer Drg. 4-00-073-60058). (iii) (a) (b)
General Ensure adequate clearance for the lance removal. Weld the wall boxes with the seal box in such away that the wall box centre line is perpendicular to the water wall and concentric to the opening (Refer Drgs. 3-00-073-60045 & 3-00-073-60046).
If the lance does not travel perpendicular to the water wall, at the end of forward travel, the gap between the lance and the nearby tube will be very small. This may lead to erosion and damage to boiler tubes. (c)
The mounting lugs should be kept horizontal (Refer Drg. 3-00-073-60049) while welding the wall sleeve assembly.
(d)
IMPORTANT: Ensure that the correct blower is erected at the correct location. (Refer Drg. 3-00-073-60039). The blower number on the name plate should correspond to the location number in the drawing. All the long retractable blowers are not identical. For example the size, shape, and position of the nozzle, the material composition of the lance etc., will be different. Interchanging of the blower will result in damage of the lance tube. Record the blower Number in 13A Check Sheet Blower Number.
(e)
After erecting the long retracts, move the lance forward and backward to check whether the gap between the lance edge and the boiler tubes is uniform after considering the allowance kept for horizontal vertical expansion.
(f )
After the electrical connections have been completed, close the terminal box with the terminal box cover. The cover should be tightened with all screws and gaskets to make the terminal box weather proof. The incoming cables should be flexible to take up blower movements and the connections should be properly sealed.
(g)
Check whether the scraper plate in the blower assembly rides on the lance loosely. There should not be any binding.
(h)
In the case of pressurised boiler ensure that the nozzle does not lie in the seal chamber (Refer Drg. 1-00-073-60059).
(i)
Do not remove the flange protection plate and the wooden block attached to the blower near the boiler end, till, the blower is installed. These will protect the blower parts and the sealing face of the flange.
(j)
While erecting the blower ensure that the minimum access is available for maintenanc.Refer Drg. 4-00-073-60072. It is not possible to alter the soot blower locations, since these are linked up with the boiler tubes inside. Modification can be only on the structures and platforms wherever required.
(k)
Do not place any heavy objects on the blowers. They are not designed for taking such heavy loads.
(l)
For Air Operated Long Retracts, install the lubricator and filter very close to the blower (Refer Drg. 3-00-073-60044).
(m)
Do not use the blower as the welding platform
IMPORTANT: THE AIR INLET CONNECTIONS SHALL BE KEPT COVERED TILL THE AIR PIPING IS CONNECTED. 12 1610 - 1611 VOL - C1 TAB - 8 - 205
ERECTION INSTRUCTIONS : WALL DESLAGGER (i)
Supports
The wall deslaggers are not to be separately supported unles otherwise specified. The wall deslagger along with its wall box should be welded with the seal box (Refer Drg. 3-00-073-60041). (ii)
Lifting
Use the eye bolt provided for lifting the wall deslagger see Fig. Since some of the components like gear housing etc., are made of aluminium, care should be taken while lifting the blowers so that these parts will not get damaged. IMPORTANT: Careless handling will break the casting connecting the switch box. DO NOT REMOVE THE WOODEN PLATFORMS TILL THE BLOWER IS ERECTED. (Refer Drg. 3-00-073-60047) (iii)
General
(a)
Ensure adequate clearance for access to the.switch box and hand cranking (Refer Drg. 4-00-073-60073).
(b)
IMPORTANT: WELD THE WALL BOX WITH THE SEAL BOX IN SOCH A WAY THAT THE WALL BOX CENTRE LINE IS PERPENDICULAR TO THE WATER WALL. IF THIS IS KEPT UP, THE NOZZLE CENTRE LINE WILL AUTOMATICALLY BE PARALLEL TO THEWATERWALL. WALL BOX SLEEVE ALSO SHOULD BE CONCENTRIC TO THE SLEEVE BOX OTHERWISE INTERFERENCE OF THE SWIVEL TUBE WITH THE WATER WALL WILL RESULT (Refer Drgs. 3-00-073-60041 & 4-00-073-60062).
(c)
Check all wall daslaggers for the following :
-
Axis of swivel tube is to be perpendicular to plane of boiler wall tubes. NO DEVIA. TION CAN BE ALLOWED!
-
Distance of centre line of clearing nozzle to face the boiler tubes to be cleaned must be 38 mm. (Refer Drg. 4-00-073-60057). This should be set from inside the furnace only. After this is set by mounting studs and nuts, punch mark the setting on the alignment plate, taking the wall box flange as the reference. This will be helpful for quick adjustment for setting, if blowers are dismantled and re-erected for detailed instructions see (iv) “Nozzle adjustment”.
(d)
Ensure the incoming cables to the switch box are flexible and supported externally. Connections shall be sealed water tight.
(e)
The piping for wall blower should always be supported on the buckstays, furnace guides etc., and never on the supporting structures of platform (Refer Drg. 4-00-073-60017).
(f )
Never allow anybody to stand on the wall deslaggers. This will damage the components and also whatever adjustment done earlier will be lost. See Fig. 8. NEGLIGENCE OF THIS WILL RESULT IN TUBE FAILURE.
(g)
Ensure the blower with the correct blower number is erected at the correct location. Some wall deslaggers may have limited angle blowing arrangement.
(h)
Do not place any heavy load on the blower especially on the switch box. If this is NOT FOLLOWED THE SWITCH MOUNT CONNECTOR WILL BREAK.
(i)
Before erection, verify whether the nozzle is pointing downwards. If not mark up those units for adjustments during start up. 13 1610 - 1611 VOL - C1 TAB - 8 - 206
(iv)
Nozzle adjustment
Nozzle alignment should be made from inside the furnace, referencing the centre line of the nozzle and wall tube surface, with the nozzle opening parallel to the wall tubes. If the units are set from outside the boiler through expediency, they should be checked from inside at the first opportunity. A tool (gauge) for checking the 38 mm nozzle position is supplied in PGMA 20-998 and this could be used for setting the nozzle position properly thig method of checking from inside is preferred. Since it is not always possible or practical to check and adjust the location of the wall blower nozzle from inside the boiler, the following procedure can be used for determining the nozzle location from outside the boiler, with blower removed. Care must be taken to make sure the proper ‘A’ dimension is established between the centre line of the nozzle and the face of the tube (usually 38 mm). Refer to job drawings for the proper dimensions. The swivel tube should be fully extended with the hand crank and a measurement taken from the centreline of the nozzle to the face to steam chest flange. This is shown as dimension ‘B’ on Drg. 4-00-073-60057. A rod of sufficient length to reach through the boiler wall, with 76 mm hook bend at 900 to its longitudinal axis is used, as shown in the drawing, to establish the location of the inside adjustment nuts on the mounting studs in relation to the tube. This is shown as dimension ‘C’. (This is to be carried out before mounting the blower.) Dimension ‘C’is equal to dimension ‘B’minus dimension ‘A’. The length ‘Co should then be marked on the rod and the adjusting nuts set to this dimension.Otten the unit is installed, it should be checked to make sure that it is prependicular with the boiler wall, to ensure cleaning through the full blowing arc. The sweep should then be set, if possible, so that the nozzle is pointing down, or in the 6 O’clock position, when the head opens. This helps to prevent tube cutting from condensate since the nozzle blows parallel with the tube when the head first opens and condensate is blown of before the jet sweeps across tubes (Refer Drg. 4-00-073-60057).
5.
ROTARY SOOT BLOWER (i)
Supports
The rotary blowers need not be externally supported unless otherwise specified. The rotary blower along with its wall sleeves should be either welded of fastened as the case may be. (ii)
Lifting
Use the eye bolt provided on the blower for lifting. Since some of the components like reaction plate, switch box are made of aluminium, care should be taken (Refer Drg. 4-00-073-60014) while lifting to avoid damage to these parts. (iii)
General
(a)
Ensure adequate clearance for the access to switch box and hand cranking (Refer Drg 4-00-073-60074).
(b)
Weld the wall boxes with the seal box in such a way that the wall box centre line is perpendicular to the wall and also concentric. If this is kept up the nozzle centre line will come parallel to tube lanes (Refer Drg. 3-00-073-60040).
(c)
Align the supports for blowing element properly. If this is not carried out correctly, blowing element may fail or motor may get overloaded (Refer Drg. 4-00-073-60059)
(d)
Unless otherwise indicated, keep the nozzle position of the blowing element downwards at rest (Refer Drg. 3-00-073-60040). Punch rmarks on element indicate nozzle position 14 1610 - 1611 VOL - C1 TAB - 8 - 207
(See Fig.).
7.
(e)
Do not allow the men to stand or place heavy weight on rotary blowers, this will damage the components and dislocate the alignment.
(f)
Ensure the incoming power and control cables are flexible and supported externally The connections shall be leak tight.
(g)
After the installation check the nozzle position for correctness. The nozzle position should be always as indicated in drg.
(h)
Ensure proper element is kept at proper location. The position numbers are usually punched/stencilled at shop (Refer the concerned erection drg.). Element for high temperature areas will be stainless steel or chrome plated. ALL ELEMENTS ARE NOT IDENTICAL.
(i)
Install the correct blower in the correct location. There may be variation in the angle of blowing and the direction of rotation. ALL ROTARY HEADS ARE NOT SAME.
(j)
DO NOT REMOVE THE WOODEN PLATFORMS TILL THE BLOWER IS ERECTED (Refer Drg. 3-00-073-60050).
(k)
or detailed instructions on setting the blowing sweep refer to Pub, No. 7504-00, Rotary Soot Blower, Section 4.
FURNANCE TEMPERATURE PROBE (i)
Supports
The Furnace Temperature Probe is to be supported at both boiler and rear ends. Unless otherwise indicated in the drg., the boiler end shall not be supported in the platforms. While erecting due consideration shall be given to the boiler expansion so that at hot boiler conditions the probe will be horizontal and perpendicular to the plane of water wall. ii)
Lifting
Refer to Section 3 (ii) Long Retractable Soot Blower. iii)
General
(a)
Before installation, the thermocouple head should be checked.
(b)
Weld the wall box on the seal box so that the wall box centre line is perpendicular to the water wall and concentric to the opening.
Eye hangers are provided for lifiting.Use them.DO not wrap around the wall deslagger for lifting. 15 1610 - 1611 VOL - C1 TAB - 8 - 208
(c)
Ensure adequate clearance for hand cranking and accessibility to other parts (Refer drg. 4-00-0173-00075).
ERECTION INSTRUCTIONS : HALF RETRACTABLE SOOT BLOWER (i)
Supports
Half retract shall be horizontal when the Boiler is steaming. While erecting consider the boiler expansion for mounting the Half retract. Refer the relevant contract drgs. for expansion values. Blower should be supported at both boiler and rear ends as indicated for long retractable soot blower. (ii)
Lifting
Refer to Section 3 (ii) of Long Retract. (iii)
Alignment of Supports
The lance extension requires support inside the boiler. This support is to be correctly aligned with the soot blower opening. If it is not done, motor will get overloaded and/or lance will break (iv)
Alignment of Lance
The lance extension is to be welded with the lance tube in the field. The lance after welding shall be horizontal. Check the same in different planes using the spirit level. (v)
Welding of Lance
Material of the lance, may be carbon or alloy steel, hence correct electrodes to be used for this weld. If in doubt, please get the confirmation. This weld is a pressure containing weld and shall be tested by Radiography. (vi)
Lance Supports
After welding the lance check whether the lance rests on the supports. Extend the lance using the hand crank and check whether there is any bending.
ERECTION INSTRUCTIONS : TEH BLOWERS FOR AIR HEATERS (i)
Supports
Supports to be provided at (a) Wall box (b) at the rear end. The blower shall be horizontal during erection. (ii)
General
(a)
Alignment of the cross arm to the lance tube to be correctly carried out to prevent binding of the lance.
(b)
The weld between the cross arm and the lance tube is a pressure weld, and this is to be done by a high pressure welder.
(c)
Use the correct electrode for this joint. If in doubt get the confirmation.
(d)
Before welding the cross arm, move the cross arm to the full length along the guide channels. It shall move smoothly.
(e)
After welding, extend the lance and check whether the movement is smooth. Take corrective action if the movement is tight.
(f)
Check the level of the support channel before welding the cross arm.
9. START UP:START UP CHECKS 9.1
Long Retractable Soot Blower
(i)
Correct blower at correct location. 16 1610 - 1611 VOL - C1 TAB - 8 - 209
(ii)
Check the retract slope.
(iii)
Check the chain tightness, if loose tighten the adjusting screws provided on the jack shaft bearing as per the requirement. See Fig. 12 and refer the Instructions Manual Pub. No. 7502: Long Retractable Soot Blower.
(iv)
Check whether stop pin is present on the cam bracket.
(v)
Check the operation of the limit switches.
vi)
Check whether the clutch is engaged.
(vii)
Check the direction of rotation of the lance tube (Rotation should be counter-clockwise viewing from the rear and of the blower.)
(viii)
Check whether the proper lubricants are filled up in the gear box and travelling carriage.
(ix)
Check the position of the valve opening cam.
(x)
Extend the lance manually to check the clearance on the sides. Power shall be off during manual operation. For manual operation, declutch.
(xi)
Close the terminal box with all screws after power and control wiring.
(xii)
Check for the smooth operation of the valve opening linkages. Jerky operations must be corrected.
CAUTION:
DO NOT OPERATE MANUALLY WHILE BLOWING MEDIUM IS ON.
9.2
Wall Deslaggers
(i)
Extend the swivel tube manually to see whether it interferes with the water wall tube.
(ii)
Check the nozzle at the extended portion. The nozzle shall be pointing down at the start of the cycle.
(iii)
Check operation of the micro limit switches and set the same by operating the manual crank - For setting Limit Switches Refer Detailed Drg. 4-00-073-60070.
(iv)
Check whether the cable to rotary gear box is cleared while the gear box is advancing.
(v)
Check the direction of rotation of swivel tube. Usually it will be clockwise viewing from the rear end of the blower.
(vi)
Check whether the switch box is tightly closed.
(vii)
Check whether the lubricants are filled in the gear boxes.
(viii)
Check whether the limit switch operating cam on the swivel tube is correctly positioned.
(ix)
Check whether the nuts on the guide rods are present. If not, do not operate till they are placed.
CAUTION:
DO NOT OPERATE MANUALLY WHILE POWER IS ON.
17 1610 - 1611 VOL - C1 TAB - 8 - 210
9.3
Rotary Soot Blower
(i)
Disengage the coupling and check the rotation of the blowing element with a spanner (Refer Drg. 4-00-073-60060).
(ii)
Check the starting position of the blowing, the direction, angle of blowing, and the nozzle position.
(iii)
Check the operation of the valve opening and closing mechanism.
(iv)
Check whether the switch box cover is closed tightly.
(v)
Check whether the correct blowing element is erected at the correct location.
(vi)
Check whether the proper lubricants are filled in the gear box.
9.4
Half Retractable Soot Blower
(i)
Check the points (i) to (xi) given under 9.1.
(ii)
Operate the blower, during the hot boiler condition and check whether motors draw more current than the rated.
CAUTION: DO NOT OPERATE THE BLOWER IN DECLUTCHED CONDITION WITH STEAM. 9.5
T.E.H. Blowers or Air Heaters
(i)
Check the points (i) to (xi) given under Section 9.1.,
(ii)
Operate the blower during the hot boiler condition and check whether the motor draws more current than the rated.
CAUTION: DO NOT OPERATE THE BLOWER IN DECLUTCHED CONDITION WITH STEAM. 9.6
Air Operated Long Retractable and Rotary Soot Blowers
(i)
Check whether the lubricator and filter are in the compressed air line and fill the lubricator and adjust the same for 5 drops/mt.
(ii)
Check the pressure of the compressed air. It should be min. of 80 PSIG at the Soot Blower.
(iii)
Check for air leakages in the power and control air lines.
9.7
Furnace Temperature Probe
(i)
Check the chain tightness and presence of rusting.
(ii)
Check the operation of the Limit Switch.
(iii)
Check whether the proper lubricant is filled in the gear box.
(iv)
Check all thermocouple junction for tight terminal connections.
(v)
Check for pressure tightness of the air hose if the probe is provided with air cooling arrangement and the required air pressure. 18 1610 - 1611 VOL - C1 TAB - 8 - 211
(vi)
Use the Rheostat for adjusting position indicator.
(vii)
Check whether the temperature Indicating/recording circuit is provided with temp high retract interlock.
9.8
General
(i)
All the gear box should be checked for lubricant at required quantity and topped up if necessary. All the air vents should be in place
(ii)
Check all the valve operating linkages, the valve opening setscrew should project sufficiently to open the valve.
(iii)
Check the IR value of the motors. Normally all motors will be alright, since all are weather proof.
(iv)
If boiler is not working all the blower can be electrically operated with local push button stations without steam. Check the correct directions of rotation/operation.
(v)
When the soot blower is in operation observe the smoothness of valve opening and closing, the operation should be smooth without any jerks. Check whether retract lance is rotating while advancing.
(vi)
Check the electrical overload relays and thermal relays for proper matching with the soot blower motor particulars.
(vii)
If orifice is indicated in the valve head, check whether this is installed.
(viii)
Check before operating on steam whether the valve opening screws will open the valve.
(ix)
If the furnace is pressurized check whether seal and aspirating air have been connected properly and required pressure is available.
(x)
Check whether lubricator and filter are provided in air line for AIR OPERATED SOOT BLOWER, and proper lubricant with sufficient quantity is available.
(xi)
Follow the commissioning procedures for commissioning the soot blowers as indicated in Pub. No. 7501 Soot Blower: General Instructions.
(xii)
Set the blowing pressures on all blowers as per the chart given in General Instruction 7501 (or concerned contract drg.) Follow the procedure as indicated in General Instruction 7501 and record in “13-B Check Sheet: Blowing Pressure”.
NOTE: IN CASE THE CONTROL PANEL AS WELL AS MOTOR CONTROL CENTRE ARE NOT READY, PRE-COMMISSIONING OF SOOT BLOWERS CAN BE CARRIED OUT USING A TEST CONTROL BOX. FOR THE DETAILED INFORMATION ON THIS, CONTACT BHEL, TIRUCHY.
ERECTION INSTRUMENTATIONS : SOOT BLOWER PIPING 10.1
SOOT BLOWER PIPING
(i)
Routing
Routing of the pipe line shown in the concerned contract drawing is suggestive. Carry out the final routing suitably considering the following points. (a)
Easy accessibility for operation and maintenance of valves and fittings.
(b)
Adequate head room wherever the tubes are crossing walkways and platforms.
(c)
Enough clearance for pipe from structural members. 19 1610 - 1611 VOL - C1 TAB - 8 - 212
(d)
Adequate flexibility to absorb differential expansion.
(e)
Clearance from approach to doors and other apertures.
(ii)
Drain
Erect the piping with adequate slope (5to 15°) so that the drain canflow away promptly. Avoid horizontal pipe arrangement. If unavoidable provide suitable drain piping to the vertical header. iii)
Support the pipe line with eye hooks (eye hangers) as indicated in the concerned contract drawing.
iv)
Support the pipe line to wall deslaggers to boiler steel such as buck stays, furnace guides instead of supporting on structural steel.
(v)
Provide the expansion loops as indicated in the concerned contract drawing.
(vi)
Insulate the soot blower piping upto the valve head mating flange as shown in Drg. No. 4-00-073-60015.
vii)
Tubes, angles, channels are issued in running meters and to be cut for the required lengths at site.
viii)
Prepare the edge preparations for the tubes as per standard edge preparation.
(ix)
Carry out the welding with the certified welders.
(x)
Do not,support the piping on the soot blower valve.
(xi)
Support,the safety valve exhaust pipe as indicated in the concerned contract drawing.
xii)
Use pipe anchors and pipe guides as suggested in the contract drawing.
xiii)
Follow the sequence of tightening of the soot blower companion flange and the valve head as indicated in Drg. No. 4-00-073-60013.
10.2
SEAL AIR PIPING - ERECTION
Seal air piping is provided to prevent the flue gases escaping through the wall openings in the case of pressurised furnace. Normally seal air is taken from forced draft fan outlet. (i)
Avoid sharp bends in the air line.
(ii)
Avoid rigid connections to the blower and use flexible rubber hoses in between the air line header and the blower to prevent the boiler expansion stressing the seal air piping.
(iii)
See that all the connections are air tight.
(iv)
Connect the seal air line to the points indicated in the respective soot blowers. These will normally be indicated in the contract drawings (Refer Drg. 1-00-073-60059 4-00-073-60076).
10.3
ASPIRATING AIR PIPING-ERECTION
Aspirating air is provided in the pressurised wall boxes of long retracts and furnace probes to facililate their removal while the boiler is working. This line taken from the plant compressed air system, and will be having a pressure of minimum 5 Kg/cm2 g. (i)
Avoid sharp bends.
(ii)
All joints shall be pressure tight.
(iii)
Provide an orifice to reduce to the required pressure.
(iv)
Isolating valves are to be provided for each air connection to the blowers.
20 1610 - 1611 VOL - C1 TAB - 8 - 213
11.
START-UP CHECKS - PIPING (i)
Soot Blower Piping (Steam)
(a)
Check expansion loops for thermal expansion provision.
(b)
Check for slope drainage.
(c)
Condensate drainage shall be from trap to atmospheric pressure.
(d)
Condensate drainage through permanent leak off valve shall be to blowdown tank.
(e)
Check whether the piping is supported with sufficient pipe hangers.
(f )
Check whether the piping at the wall blower locations are supported at the buck stays or furnace guides etc.
(g)
Carry out the hydraulic test at the pressure of 70 Kg/cm2 g in the piping. While doing so check whether all the flanges are blanked with blank flange supplied in P.G. 21. The soot blower valve heads are not to be included. DO NOT PRESSURIZE THE VALVE MORE THAN THE T.C. VALVE
(h)
Blow off the piping with steam as suggested below:
The practice of steam blowing the main line (main vertical header) through the drain valve will result in incomplete cleaning of the branch line, which may lead to valve failure and Scoring of the finely ground feed tube and swivel tube. TO AVOID THIS, BLOW THE INDIVIDUAL LINES TO SOOT BLOWER SEPARATELY. During steam blowing protect the valve internals. Use a flat sheet to cover the valve flange and tie it with the flange, as shown in Drg. 4-00-073-60064. The pressure of steam blowing should be minimum 15 Kg/cm2g. At this time keep the control valve, full open and drain valve closed. Repeat the blow 3 or 4 times for each branch. (i)
Check and record the warming up time required for the piping. Identify the branches where water hammer is present. Additional drain connections may be required in these lines, since the slope is not sufficient for draining the condensate (Refer Drg. 4-00-073-60071).
(j)
Check the function of the control valve. Control valve shall be in operation before commencing the soot blower operation. Check control valve function when the soot blower is in operation. Safety valves will not open if the control valves are acting fast enough.
(k)
Check for leakages and binding in the aspirating and seal air lines.
(l)
Check the differential pressure of seal air when the seal air is on. This check will ensure adequate seal air pressure for each opening (Refer Drg. 1-00-073-60059). Check whether the measured pressure is correct as given in 4-00-073-60090 (for Retracts and Probe).
(m)
Check the function of the aspirating arrangement for proper working.
(n)
Check pressurized furnace seal air systems.
(o)
Check the aspirating air pressure on all blowers and check for correctness as given in 4-00-073-60091 (for Retracts and Probe).
21 1610 - 1611 VOL - C1 TAB - 8 - 214
(ii)
Pressurized Furnace Seal Air Systems
A.
Retracts
(a)
Check all nozzles to see that all parts of nozzles are within two scraper plates that form the seal air void in the case of two scraper plate design. This should be checked and inspected before boiler operation.
(b)
Follow the instructions of extending blowing nozzles into furnace and reading seal air pressure differential against dynamic seal air supply pressure where it enters the manifold valve on the air seal aspirator assembly.
(c)
Where nozzles are extended beyond seal air void, as on short stroked or extended lances on half retracts and air preheater cleaners, see that the forced pressure air valves are properly installed and properly supplied with seal air.
(d)
Make certain all manifold valves are correctly positioned to deliver seal air when boiler is under load and being fired.
B.
Wall Deslagger
(a)
Follow instructions on extending blowing nozzles into furnace and reading sealair pressure differential against dynamic seal air supply pressure where it entres wall box adoptor.
(b)
Check all wall deslaggers to see they are properly equipped with forced pressure air valves are properly tubed and supplied with seal air so as to purge blower internals.
(c)
Make certain that all 3 way supply valves on the seal air aspirator combined supply line are correctly positioned to supply seal air when the boiler is fired.
22 1610 - 1611 VOL - C1 TAB - 8 - 215
23 1610 - 1611 VOL - C1 TAB - 8 - 216
13-A CHECK SHEET: BLOWER NUMBER
S 1. N o.
Type of Soot Blowe r
Blowe r No.
As in Contractdrg. drg
As e re cte d
S 1.N o.
Type of Soot Blowe r
Blowe r No.
As in Contract drg.
As e re cte d
24 1610 - 1611 VOL - C1 TAB - 8 - 217
13-A CHECK SHEET: BLOWER NUMBER
S 1. N o.
Type of Soot Blowe r
Blowe r No.
As in Contractddrg rg.
As e re cte d
S 1.N o.
Type of Soot Blowe r
Blowe r No.
As in Contract drg.
As e re cte d
25 1610 - 1611 VOL - C1 TAB - 8 - 218
13-A CHECK SHEET: BLOWER NUMBER
S 1. N o.
Type of Soot Blowe r
Blowe r No.
As in Contractddrg rg.
As e re cte d
S 1.N o.
Type of Soot Blowe r
Blowe r No.
As in Contract drg.
As e re cte d
26 1610 - 1611 VOL - C1 TAB - 8 - 219
13-A CHECK SHEET: BLOWER NUMBER
S 1. N o.
Type of Soot Blowe r
Blowe r No.
As in Contractddrg rg. As e re cte d
S 1.N o.
Type of Soot Blowe r
Blowe r No.
As in Contract drg.
As e re cte d
27 1610 - 1611 VOL - C1 TAB - 8 - 220
13-B CHECK SHEET: BLOWING PRESSURE TIME FOR WARM UP : IN MINUTES Blowing pre s s ure S 1.N o.
Type of Soot Blowe r -
Blowe rNo.
As in Contract drg.in kg/cm2(g)
As me as ure d in kg/cm2(g)
Blowing pre s s ure S 1.N o.
Type of Soot Blowe r
Blowe rNo.
As in Contract drg.in kg/cm2(g)
As me as ure d in kg/cm2((g) g)
28 1610 - 1611 VOL - C1 TAB - 8 - 221
13-B CHECK SHEET: BLOWING PRESSURE TIME FOR WARM UP : IN MINUTES Blowing pre s s ure S 1.N o.
Type of Soot Blowe r -
Blowe rNo.
As in Contract drg.in kg/cm2(g)
As me as ure d in kg/cm2(g)
Blowing pre s s ure S 1.N o.
Type of Soot Blowe r
Blowe rNo.
As in Contract drg.in kg/cm2(g)
As me as ure d in kg/cm 2(g(g) )
29 1610 - 1611 VOL - C1 TAB - 8 - 222
13-B CHECK SHEET: BLOWING PRESSURE TIME FOR WARM UP : IN MINUTES Blowing pre s s ure S 1.N o.
Type of Soot Blowe r -
Blowe rNo.
As in Contract drg.in kg/cm2(g)
As me as ure d in kg/cm2(g)
Blowing pre s s ure S 1.N o.
Type of Soot Blowe r
Blowe rNo.
As in Contract drg.in kg/cm2(g)
As me as ure d in 2 kg/cm ((g) g)
30 1610 - 1611 VOL - C1 TAB - 8 - 223
13-B CHECK SHEET: BLOWING PRESSURE TIME FOR WARM UP : IN MINUTES Blowing pre s s ure S 1.N o.
Type of Soot Blowe r -
Blowe rNo.
As in Contract drg.in kg/cm2(g)
As me as ure d in kg/cm2(g)
Blowing pre s s ure S 1.N o.
Type of Soot Blowe r
Blowe rNo.
As in Contract drg.in kg/cm2(g)
As me as ure d in kg/cm2((g) g)
31 1610 - 1611 VOL - C1 TAB - 8 - 224
13-C CHECK SHEET: SEAL AIR PRESSURE FOR PRESSURISED BOILERS
S 1.N o.
Type of s oot Blowe r
Blowe r No.
Se al Air Pre s s ure
As in. Contract drg.in mm of Wate r Column
As me as ure d in mm of Wate r Column
Sl. No.
Type of Soot Blowe r
Blowe r No.
Se al Air Pre s s ure
As in Contract drg. in mm of Wate r Column
As me as ure d in mm of Wate r Column
32 1610 - 1611 VOL - C1 TAB - 8 - 225
13-C CHECK SHEET: SEAL AIR PRESSURE FOR PRESSURISED BOILERS
S 1.N o.
Type of s oot Blowe r
Blowe r No.
Se al Air Pre s s ure
As in. Contract drg.in mm of Wate r Column
As me as ure d in mm of Wate r Column
Sl. No.
Type of Soot Blowe r
Blowe r No.
Se al Air Pre s s ure
As in Contract drg. in mm of Wate r Column
As me as ure d in mm of Wate r Column
33 1610 - 1611 VOL - C1 TAB - 8 - 226
13-C CHECK SHEET: SEAL AIR PRESSURE FOR PRESSURISED BOILERS
S 1.N o.
Type of s oot Blowe r
Blowe r No.
Se al Air Pre s s ure
As in. Contract drg.in mm of Wate r Column
As me as ure d in mm of Wate r Column
Sl. No.
Type of Soot Blowe r
Blowe r No.
Se al Air Pre s s ure
As in Contract drg. in mm of Wate r Column
As me as ure d in mm of Wate r Column
34 1610 - 1611 VOL - C1 TAB - 8 - 227
13-C CHECK SHEET: SEAL AIR PRESSURE FOR PRESSURISED BOILERS
S 1.N o.
Type of s oot Blowe r
Blowe r No.
Se al Air Pre s s ure
As in. Contract drg.in mm of Wate r Column
As me as ure d in mm of Wate r Column
Sl. No.
Type of Soot Blowe r
Blowe r No.
Se al Air Pre s s ure
As in Contract drg. in mm of Wate r Column
As me as ure d in mm of Wate r Column
35 1610 - 1611 VOL - C1 TAB - 8 - 228
13-D CHECK SHEET: WALL DESLAGGER NOZZEL SETTING
S 1.N o.
Blowe r.No.
Dime ns ions in mm 'A'
'B'
'C'
SI. No. Blowe r.No 'B-C'
Dime ns ions in mm 'A'
'B'
'C'
'B-C'
36 1610 - 1611 VOL - C1 TAB - 8 - 229
13-D CHECK SHEET: WALL DESLAGGER NOZZEL SETTING
S 1.N o.
Blowe r.No.
Dime ns ions in mm 'A'
'B'
'C'
SI. No. Blowe r.No 'B-C'
Dime ns ions in mm 'A'
'B'
'C'
'B-C'
37 1610 - 1611 VOL - C1 TAB - 8 - 230
13-D CHECK SHEET: WALL DESLAGGER NOZZEL SETTING
S 1.N o.
Blowe r.N o.
D ime ns ions in mm 'A'
'B'
'C'
SI. N o. Blowe r.N o 'B-C'
D ime ns ions in mm 'A'
'B'
'C'
'B-C'
38 1610 - 1611 VOL - C1 TAB - 8 - 231
13-D CHECK SHEET: WALL DESLAGGER NOZZEL SETTING
S 1.N o.
Blowe r.No.
D ime ns ions in mm 'A'
'B'
'C'
SI. No. Blowe r.No 'B-C'
D ime ns ions in mm 'A'
'B'
'C'
'B-C'
39 1610 - 1611 VOL - C1 TAB - 8 - 232
40 1610 - 1611 VOL - C1 TAB - 8 - 233
41 1610 - 1611 VOL - C1 TAB - 8 - 234
42 1610 - 1611 VOL - C1 TAB - 8 - 235
43 1610 - 1611 VOL - C1 TAB - 8 - 236
44 1610 - 1611 VOL - C1 TAB - 8 - 237
45 1610 - 1611 VOL - C1 TAB - 8 - 238
46 1610 - 1611 VOL - C1 TAB - 8 - 239
47 1610 - 1611 VOL - C1 TAB - 8 - 240
48 1610 - 1611 VOL - C1 TAB - 8 - 241
49 1610 - 1611 VOL - C1 TAB - 8 - 242
50 1610 - 1611 VOL - C1 TAB - 8 - 243
51 1610 - 1611 VOL - C1 TAB - 8 - 244
52 1610 - 1611 VOL - C1 TAB - 8 - 245
53 1610 - 1611 VOL - C1 TAB - 8 - 246
54 1610 - 1611 VOL - C1 TAB - 8 - 247
55 1610 - 1611 VOL - C1 TAB - 8 - 248
56 1610 - 1611 VOL - C1 TAB - 8 - 249
57 1610 - 1611 VOL - C1 TAB - 8 - 250
58 1610 - 1611 VOL - C1 TAB - 8 - 251
59 1610 - 1611 VOL - C1 TAB - 8 - 252
60 1610 - 1611 VOL - C1 TAB - 8 - 253
61 1610 - 1611 VOL - C1 TAB - 8 - 254
62 1610 - 1611 VOL - C1 TAB - 8 - 255
63 1610 - 1611 VOL - C1 TAB - 8 - 256
64 1610 - 1611 VOL - C1 TAB - 8 - 257
65 1610 - 1611 VOL - C1 TAB - 8 - 258
66 1610 - 1611 VOL - C1 TAB - 8 - 259
67 1610 - 1611 VOL - C1 TAB - 8 - 260
68 1610 - 1611 VOL - C1 TAB - 8 - 261
69 1610 - 1611 VOL - C1 TAB - 8 - 262
70 1610 - 1611 VOL - C1 TAB - 8 - 263
71 1610 - 1611 VOL - C1 TAB - 8 - 264
72 1610 - 1611 VOL - C1 TAB - 8 - 265
73 1610 - 1611 VOL - C1 TAB - 8 - 266
74 1610 - 1611 VOL - C1 TAB - 8 - 267
75 1610 - 1611 VOL - C1 TAB - 8 - 268
TAB - 9
1610 - 1611 VOL - C1 TAB - 9 - 269
