soot blower.pdf

1

IK545 CONTENTS

SECTION

TITLE

PAGE

1 1.1 1.2 1.3 1.4 1.5 1.6

GENERAL DESCRIPTION General Opening Controls Application Cleaning Principle Operating Cycle Identification

19 19 19 19 19 20 20

2 2.1 2.1.1 2.1.2 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.3 2.3.1 2.3.2 2.3.3 2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.5 2.5.1 2.6 2.6.1

COMPONENT DESCRIPTION ELECTRICAL Electrical Components Function MOUNTING Beam Front Support Plate Wallbox Pressure Regulating Valve (When Applicable) Rear Support Auxiliary Support MECHANICAL Carriage Electric Drive Motor Expanda Cable BLOWING MEDIUM Poppet Valve Poppet Valve Operation Air Relief Valve Feed Tube Lance Tube Nozzle OPERATING SWITCHES Limit Switches / Pressure Switch MANUAL OPERATION Emergency Retract Air Tool

21 21 21 21 23 23 23 24 24 25 26 26 26 27 27 28 28 29 30 30 31 31 32 32 33 33

3 3.1 3.2 3.3 3.4 3.5 3.6 3.7

INSTALLATION INSTRUCTION Location Mounting Lifting the Sootblower Blowing Medium Supply Pipework Scavenging Air Lubrication Electrical Connections

34 34 34 34 34 34 35 35

2

IK545 CONTENTS (Continued)

SECTION

TITLE

PAGE

4 4.1 4.2 4.3

COMMISSIONING Stage 1 - Inspection Stage 2 - Functional Checks Stage 3 - Pre-Operational Checks

36 36 36 36

5 5.1 5.2

OPERATION INSTRUCTIONS Operation Precautions Blowing Schedule

38 38 38

6 6.1 6.2 6.3 6.4 6.5

MAINTENANCE INSTRUCTIONS Operational Checks Periodic Inspection Annual Maintenance Major Overhaul Manual Operation

39 39 39 39 40 40

7 7.1 7.2 7.2.1 7.3 7.4 7.4.1 7.4.2 7.5

LUBRICATION Initial Operation Carriage Assembly Gearbox Lance Hub General Lubrication Grease Fittings Bolt Heads and Threads List of Recommended Lubricants

41 41 41 41 41 41 41 41 41

8 8.1 8.2 8.3 8.4

MAINTENANCE SCHEDULE Operational Checks Periodic Inspection Routine Maintenance Major Overhaul

43 43 43 43 44

9

OPTIONAL TOOLS

45

10

PARTS IDENTIFICATION

55

11

RECOMMENDED SPARES LIST

97

12

JOB SHEETS

101

13

FAULT FINDING

160

3

IK545 CONTENTS (Continued)

SECTION 14 14.1 14.1.1 14.1.2 14.1.3 14.2 14.2.1 14.2.2 14.3 14.3.1 14.3.2

TITLE STORAGE, HANDLING, & INSPECTION DURING STORAGE STORAGE Initial Receipt At Site Stacking Sootblowers Feed Tube and Poppet Valve Packing HANDLING Handling Packed Equipment Handling Unpacked Equipment INSPECTION DURING STRAGE Frequency Protective Lubrication

PAGE 163 163 163 163 163 163 163 164 164 164 164

4

IK545 ILLUSTRATIONS

FIGURE 1 2 3 4 5 5A 6 7 8 9 10 11 12 12A 13 14 15 16 17

TITLE IK - 545B Sootblower - Overall View Nozzle Cleaning Pattern Electrical Components - Schematic Diagram Front Support Roller Arrangement Wallbox Sealing Air Connection (Positive Pressure) Rear Support Arrangement Auxiliary Support Carriage Operation Expanda Cable Operation Poppet Valve Popper Valve Linkage Air Relief Valve Feed Tube Packing Arrangement Operating Switches Emergency Retract Air Tool Checking the Blowing Pressure Location of Square Tang for Manual Operation Typical Slinging Arrangement

PAGE 18 19 21 23 24 24 25 26 26 27 28 29 30 30 32 33 37 40 164

5

IK1M CONTENTS

SECTION

TITLE

PAGE

1 1.1 1.2 1.3 1.4 1.5 1.6

GENERAL DESCRIPTION General Operating Controls Application Cleaning Principle Operating Cycle Identification

174 174 174 175 175 175 175

2 2.1 2.1.1 2.1.2 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.3 2.3.1 2.3.2 2.3.3 2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.4.7 2.5 2.5.1 2.6

COMPONENT DESCRIPTION ELECTRICAL Electrical Components Function MOUNTING Beam Front Support Wallbox Rear Support MECHANICAL Carriage and Drive Mechanism Guide Assembly Leadscrew BLOWING MEDIUM Poppet Valve Poppet Valve Operation Air Relief Valve Feed Tube Lance Tube Lance Tube Support Element / Nozzle / Rake Arrg’t OPERATING SWITCHES Limit Switches MANUAL OPERATION

176 176 176 176 178 178 178 178 179 180 180 180 181 182 182 183 183 184 184 185 185 186 186 186

3 3.1 3.2 3.3 3.4 3.5 3.6

INSTALLATION INSTRUCTION Location Mounting Lifting the Sootblower Blowing Medium Supply Pipework Lubrication Electrical

187 187 187 187 187 187 187

6

IK1M CONTENTS (Continued)

SECTION

TITLE

PAGE

4 4.1 4.2 4.3

COMMISSIONING Stage 1 - Inspection Stage 2 - Functional Checks Stage 3 - Pre-Operational Checks

188 188 188 188

5 5.1 5.2

OPERATION INSTRUCTIONS Operating Precautions Blowing Schedule

190 190 190

6 6.1 6.2 6.3 6.4 6.5

MAINTENANCE INSTRUCTIONS Operational Checks Periodic Inspection Annual Maintenance Major Overhaul Manual Operation

191 191 191 191 192 192

7 7.1 7.2 7.3 7.4

LUBRICATION Carriage Drive Chain Leadscrew and Square Shaft General Lubrication

193 193 193 193 193

8 8.1 8.2 8.3 8.4

MAINTENANCE SCHEDULE Operational Checks Periodic Inspection Routine Maintenance Major Overhaul

195 195 195 195 196

9

OPTIONAL TOOLS

197

10

PARTS IDENTIFICATION

205

11

RECOMMENDED SPARES LIST

231

12

JOB SHEETS

234

13

FAULT FINDING

279

7

IK1M CONTENTS (Continued)

SECTION 14 14.1 14.1.1 14.1.2 14.1.3 14.2 14.2.1 14.2.2 14.3 14.3.1

TITLE STORAGE, HANDLING, & INSPECTION DURING STORAGE STORAGE Initial Receipt At Site Stacking Sootblowers Feed Tube and Poppet Valve Packing HANDLING Handling Packed Equipment Handling Unpacked Equipment INSPECTION DURING STORAGE Frequency

PAGE 282 282 282 282 282 282 282 283 283 283

8

IK1M ILLUSTRATIONS

FIGURE 1 2 3 4 5 5A 5B 6 7 8 9 10 11 12 13 14 15 16 17 18

TITLE IK1M Sootblower - Overall View View on Rear of IK1M looking towards Boiler Cleaning Pattern Electrical Components-Schematic Diagram Front Support Arrangement Scavenging Air Arrangement Adjustable Rear Support Drive Arrangement Guide Assembly Leadscrew Arrangement Sectional View of Popper Valve Poppet Valve Linkage Air Relief Valve Feed Tube and Packing Lance Tube Support Limit Switch Operation Square Tang for Manual Operation Checking the Blowing Pressure Manual Operation Typical Slinging Arrangement

PAGE 173 174 175 176 178 179 179 180 181 181 182 183 183 184 185 186 186 189 182 283

9

INSTRUCTION MANUAL

DIAMOND IK-545B SOOTBLOWER ELECTRIC MOTOR DRIVEN (Customised to suit) Contract No. N10865 IM123

Diamond Power Specialty Limited

Glasgow Road Dumbarton Scotland G82 1ES Tel: Dumbarton (01389) 744000

Fax: Dumbarton (01389) 762669

FORM 14164

10

EQUIPMENT IDENTIFICATION FORM

N10865

Diamond Contract No :-

07461-49100-A610-00

Customer Order No :-

12.9 kg/cm2 (2nd SH Inlet)) 12.6 kg/cm2 (2nd SH (HT) Outlet) 10.0 kg/cm2 (2nd SH (LT) Outlet)

Blowing Pressure :-

Equipment Supplied :-

Site :-

27 - Diamond IK545B (Electric Motor Driven) Long Retractable Sootblower.

Rabigh, Saudi Arabia

POSITION No LSB A LSB B LSB C

SERIAL No B66494 B66495 B66496

UNIT No 1 1 1

CUSTOMER TAG No B1HCB01AN301 B1HCB01AN302 B1HCB01AN303

LSB A LSB B LSB C

B66501 B66502 B66503

2 2 2

B2HCB01AN301 B2HCB01AN302 B2HCB01AN303

LSB A LSB B LSB C

B66508 B66509 B66510

3 3 3

B3HCB01AN301 B3HCB01AN302 B3HCB01AN303

LSB A LSB B LSB C

B66515 B66516 B66517

4 4 4

B4HCB01AN301 B4HCB01AN302 B4HCB01AN303

LSB A LSB B LSB C

B66522 B66523 B66524

5 5 5

B5HCB01AN301 B5HCB01AN302 B5HCB01AN303

NOTE When ordering Instruction Manuals for the above equipment please quote the Diamond Contract number and the following I.M. number:-123 (PAGE 1 of 2)

FORM 13519

11

EQUIPMENT IDENTIFICATION FORM

N10865

Diamond Contract No :-

07461-49100-A610-00

Customer Order No :-

12.9 kg/cm2 (2nd SH Inlet)) 12.6 kg/cm2 (2nd SH (HT) Outlet) 10.0 kg/cm2 (2nd SH (LT) Outlet)

Blowing Pressure :-

Equipment Supplied :-

Site :-

27 - Diamond IK545B (Electric Motor Driven) Long Retractable Sootblower.

Rabigh, Saudi Arabia

POSITION No LSB A LSB B LSB C

SERIAL No B66529 B66530 B66531

UNIT No 6 6 6

CUSTOMER TAG No B6HCB01AN301 B6HCB01AN302 B6HCB01AN303

LSB A LSB B LSB C

B66536 B66537 B66538

7 7 7

B7HCB01AN301 B7HCB01AN302 B7HCB01AN303

LSB A LSB B LSB C

B66543 B66544 B66545

8 8 8

B8HCB01AN301 B8HCB01AN302 B8HCB01AN303

LSB A LSB B LSB C

B66550 B66551 B66552

9 9 9

B9HCB01AN301 B9HCB01AN302 B9HCB01AN303

NOTE When ordering Instruction Manuals for the above equipment please quote the Diamond Contract number and the following I.M. number:-123 (PAGE 2 of 2)

FORM 13519

12

------ IMPORTANT -----READ THIS MANUAL BEFORE COMMISSIONING INSTALLING

OPERATING MAINTAINING

THIS EQUIPMENT WARNING This equipment may be operated by remote control WARNING Isolate from power and blowing medium supply before working on equipment WARNING To avoid personal injury or damage to equipment during installation, commissioning, operation or maintenance, follow the instructions given on the Job Sheets.These instructions are of a general nature and do not cover every circumstance. WARNING To maintain the safety and efficiency of the equipment, follow the maintenance schedule instructions and use only Diamond Spare Parts as described in the Parts Identification and Recommended Spares sections of the manual.

OCTOBER 1993

FORM 14148

13

CONTENTS

SECTION

TITLE

1 1.1 1.2 1.3 1.4 1.5 1.6

GENERAL DESCRIPTION General Operating Controls Application Cleaning Principle Operating Cycle Identification

2 2.1 2.1.1 2.1.2 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.3 2.3.1 2.3.2 2.3.3 2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.5 2.5.1 2.6 2.6.1

COMPONENT DESCRIPTION ELECTRICAL Electrical Components Function MOUNTING Beam Front Support Plate Wallbox Pressure Regulating Valve (When Applicable) Rear Support Auxiliary Support MECHANICAL Carriage Electric Drive Motor Expanda Cable BLOWING MEDIUM Poppet Valve Poppet Valve Operation Air Relief Valve Feed Tube Lance Tube Nozzle OPERATING SWITCHES Limit Switches / Pressure Switch MANUAL OPERATION Emergency Retract Air Tool

3 3.1 3.2 3.3 3.4 3.5 3.6 3.7

INSTALLATION INSTRUCTIONS Location Mounting Lifting the Sootblower Blowing Medium Supply Pipework Scavenging Air Lubrication Electrical Connections

OCTOBER 2002

(PAGE 1 OF 3)

FORM 14274

14

CONTENTS (Continued)

SECTION

TITLE

4 4.1 4.2 4.3

COMMISSIONING Stage 1 - Inspection Stage 2 - Functional Checks Stage 3 - Pre-Operational Checks

5 5.1 5.2

OPERATING INSTRUCTIONS Operating Precautions Blowing Schedule

6 6.1 6.2 6.3 6.4 6.5

MAINTENANCE INSTRUCTIONS Operational Checks Periodic Inspection Annual Maintenance Major Overhaul Manual Operation

7 7.1 7.2 7.2.1 7.3 7.4 7.4.1 7.4.2 7.5

LUBRICATION Initial Operation Carriage Assembly Gearbox Lance Hub General Lubrication Grease Fittings Bolt Heads and Threads List of Recommended Lubricants

8 8.1 8.2 8.3 8.4

MAINTENANCE SCHEDULE Operational Checks Periodic Inspection Routine Maintenance Major Overhaul

9

OPTIONAL TOOLS

10

PARTS IDENTIFICATION

11

RECOMMENDED SPARES LIST

12

JOB SHEETS

13

FAULT FINDING

OCTOBER 2002

(PAGE 2 OF 3)

FORM 14274

15

CONTENTS (Continued)

SECTION 14 14.1 14.1.1 14.1.2 14.1.3 14.2 14.2.1 14.2.2 14.3 14.3.1 14.3.2

OCTOBER 2002

TITLE STORAGE, HANDLING, & INSPECTION DURING STORAGE STORAGE Initial Receipt At Site Stacking Sootblowers Feed Tube and Poppet Valve Packing HANDLING Handling Packed Equipment Handling Unpacked Equipment INSPECTION DURING STORAGE Frequency Protective Lubrication

(PAGE 3 OF 3)

FORM 14274

16

ILLUSTRATIONS

FIGURE 1 2 3 4 5 5A 6 7 8 9 10 11 12 12A 13 14 15 16 17

NOVEMBER 1999

TITLE IK-545B Sootblower - Overall View Nozzle Cleaning Pattern Electrical Components - Schematic Diagram Front Support Roller Arrangement Wallbox Sealing Air Connection (Positive Pressure) Rear Support Arrangement Auxiliary Support Carriage Operation Expanda Cable Operation Poppet Valve Poppet Valve Linkage Air Relief Valve Feed Tube Packing Arrangement Operating Switches Emergency Retract Air Tool Checking the Blowing Pressure Location of Square Tang for Manual Operation Typical Slinging Arrangement

FORM 14275

17

SECTION 1

FORM 15018/1

JULY 1999

18

SECTION 1

SECTION 1 GENERAL DESCRIPTION Introduction This instruction manual covers the IK-545B long retractable sootblower supplied by Diamond Power Specialty Limited; the main features are illustrated in Fig.1. 1.1

General The IK-545B is a fully-retractable sootblower incorporating a travelling carriage and dual rack-and-pinion drive. Power is transmitted, through an expanding cable arrangement, from a fixed power connection on the beam to an electric motor on the carriage. The motor moves the carriage to project a cleaning nozzle into the boiler. Blowing medium flow is controlled by an integral poppet valve, which is mechanically operated by the carriage.

1.2

Operating Controls The IK-545B sootblower is normally operated from a remote control panel or from an individual starter box. Alternative controls are available to suit specific applications. Upon completion of the cleaning cycle, the controls automatically reset ready for the next cycle. No further action is required by the operator unless a fault develops. A manual override allows the sootblower to be retracted at any point in its forward travel. Additional information on the operating controls is given in Section 2.

1.3

Application The IK-545B is designed for cleaning the heating surfaces of the boilers fired with ash-producing fuels, and is used principally to remove slag and ash deposits from slag screens, superheaters, reheaters, and economisers. It is also used to clean deposits from the underside of furnace arches. The Model IK-525B is supplied for travels over 7.6m (25ft) and up to 13.7m (45ft)

1.4

Cleaning Principle (Fig.2) The basic function of the sootblower is to clean the heating surfaces of the boiler by the impact energy of high-pressure air, or steam, which is delivered from two opposing nozzle openings located at the end of a translating and rotating lance tube.

FIG.2 CLEANING PRINCIPLE The lance tube advances on a 100 mm (4 in.) helix; therefore, the opposing nozzle openings provide cleaning at 50 mm (2 in.) intervals. OCTOBER 2000

FORM 14729

19

SECTION 1 1.4

Cleaning Principle (Fig.2) (Continued) A 25 mm (1 in.) shift of blowing pattern for reverse travel bisects the blowing pattern for forward travel, thus producing a cleaning helix every 25 mm (1 in. ) Other helices are available for specific applications.

1.5

Operating Cycle The operating cycle begins with the unit in the retracted position. When power is applied to the electric motor, the carriage moves forward by rack-and-pinion drive to project the lance tube into the boiler. When the nozzle is inside the boiler, the carriage operates a cam which, in turn, opens the blowing medium valve to start the cleaning operation. The carriage then continues to project the rotating lance tube into the boiler until it reaches its extreme forward travel. At this point, the carriage reverses its direction and, at the same time, indexes the lance tube to return on a different nozzle path. The carriage continues to retract until the nozzle is near the boiler wall, at which point the blowing medium is shut off. The operating cycle is completed when the carriage returns to its retracted position.

1.6

Identification Each sootblower in an installation is identified by a serial number and a position number, both of which are marked on the sootblower nameplate. A list of the serial numbers of the sootblowers in the installation is given on the Equipment Identification Form; the position of each sootblower is indicated against the relevant serial number. Any features which vary from sootblower to sootblower are also indicated against the serial number. A more detailed specification of the equipment covered is given on the Equipment Identification Form at the front of this manual.

FORM 14729

OCTOBER 2000

20

SECTION 2

SECTION 2 COMPONENT DESCRIPTION General The IK-545B sootblower comprises a number of sub-assembly components. This Section describes the function of these components and their relationship to each other. A comprehensive breakdown of the components is given in Section10 ('Parts Identification'). 2.1

ELECTRICAL

2.1.1 Electrical Components (Fig.3) Electrical components on the sootblower comprise a drive motor, forward and reset limit switches and terminal box containing start and reverse pushbuttons. The wiring between the drive motor, limit switches and terminal box is part of Diamond Power supply. The interconnecting wiring from the sootblower to the electric control panel is not part of Diamond Power supply. To complete the electrical link up between the sootblower and the control panel a typical or customised interconnecting schematic diagram is normally supplied by Diamond Power for this purpose. 2.1.2 Function When the drive motor is energised from the control panel or local start push-button it drives the carriage forward. As the carriage approaches the limit of its forward travel, a limit switch trip arrangement on the carriage, makes contact with the forward limit switch. This action reverses the drive motor

FIG.3 ELECTRICAL COMPONENTS - SCHEMATIC DIAGRAM

As the carriage approaches its fully retracted position, the limit switch trip arrangement again makes contact, this time with the reset limit switch. This action stops the drive motor. The sootblower can also be retracted at any point during forward travel by pressing the local retract push-button.

JULY 2005

FORM 14332/2

21

4

3

2

1

$ )

) $

A

5

6

> A ? >)A ? > A ?

A

(

=

(

(

)

)

A2 ) $

DP

LF

) $

'

> ?

H1 CAUTION * ISOLATE ELSEWHERE BEFORE ACCESSING ANY TERMINALS * SOOTBLOWER MAY START UNEXPECTEDLY

(

=

+# B B

'

'

) )

) $

' )

> A ?

(

) $

> A ?

' ) )

) $

)

( I

1

' 20

NOTES 1. EARTHING BY CUSTOMER TO MEET LOCAL AND GOVERNMENT REGULATIONS AN EARTH CONNECTION IS PROVIDED INSIDE THE TERMINAL BOX FOR CONNECTION OF EARTH CORES IN MULTI-CORE INTERCONNECTING CABLES.

) $

2. A CABLE HELIX OR OTHER MEANS OF CABLE MOVEMENT MUST BE ALLOWED BETWEEN STANDING STEELWORK AND SOOTBLOWER TO ALLOW FOR BOILER EXPANSION.

( 28 '

3. ANY CABLE VOLTAGES SHOWN ARE ACTUAL VOLTS CARRIED BY CORES, THEY DO NOT SHOW SIZE OR RATING OF CABLES. 4. SOOTBLOWER IS SHOWN IN REST POSITION WITH LSR ACTUATED.

31 32

5. INTERNAL WIRING ON SOOTBLOWER IS BY DPSL. INTERCONNECTING CABLE AND GLANDS TO SOOTBLOWER IS NOT BY D.P.S.L. &

!"

) 941

'

) %

I I

I # #

1 1 4

' ) % ' ($ % ' B B B B B B 841420-0002 841420-0001 879011-3200 )( %' ' () % ) ) % ) ) % (

,05 ' ')'%

:& ) )

%

;

0C 2" + @ #$? 071 @10/ ?

V

W

A2 DP D

G1 G

G

H

LF LF H1

H1 -% A A

171"& 4 171" ! )-B -)/7-1. 5 7 .7"C& ,171"& $ /60 =0/.;& $& C01. A .7"C& $#8,, ;-/ )0 /"/.) 510 >B 1" $? 8 8 % (' 1)D .37& $& C01. 8'$ % '8' /60 & ,171"& 8%)1" 8 8 $% -,-7 4+-7)5& 100 " "/.D & "4) & A .7"C& 8 %'( 8 ",-./0 "144 1.. )71"& +/CB 1" 8& E ($ (% )" +& $2 # % 8 =& 1) /; (' % /45 "& ""/7 ;& $ A /-0 A -2-.=4 A .7"C& #8,, ;-/ )0 /"/.) 510 >B 1" * = #$? 8 8 % ( /60 =0/.;& & C01. 8 8 % ( 1)D .37& & C01. 8 8 8% 8 /60 & 0-,-7 4+-7)5& %)1" & -%7 ,! 4-0-)1. 8 8 8% $ /60 & 0-,-7 4+-7)5& $%)1" & -%7 ,! 4-0-)1. ' ($ % ' /".-.= /6 0& H7 /, 117601+ "H A .7"C& 88,, ;-/ )0 /"/.) 510 A /60 0/.; A 1)D .37 A .7"C& ',, ;-/ )0 /"/.) 510 A /60 0/.; A 1)D .37 8( %' 1/, F3/" & 1""14-1. "17 )7-1. ' 8 % ",-./0 612 /44C& & $& -77/0& +-75 B -2-.=4 ' (8 % ",-./0 01)D 44C 8 8 % 34563771. 44C& 7/"7& 8 8 % 3456371. 44C& "4 & 8 8 % 34563771. .4 "7& 8 8 % 34563771. .4 "7& ! " " # $" %& '( $") * *# %& +" , 8 8

8 $ #

,

(

<

'

'

'

(

8 8

-=57 5/.; > ? 4117601+ " 451+.& 4117601+ " .17 / /-0/60 #

8 $

8

> @ ?

(

CAUTION * ISOLATE ELSEWHERE BEFORE ACCESSING ANY TERMINALS * SOOTBLOWER MAY START UNEXPECTEDLY

> @ ?

8 $

8

( '

NOTES 1. EARTHING BY CUSTOMER TO MEET LOCAL AND GOVERNMENT REGULATIONS AN EARTH CONNECTION IS PROVIDED INSIDE THE TERMINAL BOX FOR CONNECTION OF EARTH CORES IN MULTI-CORE INTERCONNECTING CABLES.

8 $

2. A CABLE HELIX OR OTHER MEANS OF CABLE MOVEMENT MUST BE ALLOWED BETWEEN STANDING STEELWORK AND SOOTBLOWER TO ALLOW FOR BOILER EXPANSION.

(

3. ANY CABLE VOLTAGES SHOWN ARE ACTUAL VOLTS CARRIED BY CORES, THEY DO NOT SHOW SIZE OR RATING OF CABLES.

'

4. SOOTBLOWER IS SHOWN IN REST POSITION WITH LSR ACTUATED. 5. INTERNAL WIRING ON SOOTBLOWER IS BY DPSL. INTERCONNECTING CABLE AND GLANDS TO SOOTBLOWER IS NOT BY D.P.S.L. &

!"

8 930

'

8 %

'

+/4 '((( %

I I I I I I

%

A 451+. B 1" " B1.0C

(

:

B -2-.= B -2-.= B -2-.= B -2-.=

0 .=75 /4 " FG ; 0 .=75 /4 " FG ;

6C175 "4 6C175 "4 6C175 "4 6C175 "4 B -7 6 B 1" 45-!!-.= 7 ",-./04 /4 " FG ;

/44C1BI !/"74 1.0C

% (

& 8 8

%

:

/;; ;

!"

# # #

#

#

)*+

#

1

2

3

",-./0 12& 34563771. 4

$% % 5

6

177

SECTION 2 2.2

MOUNTING

2.2.1 Beam (Fig.1) The beam is a fabricated assembly comprising a pressed-steel canopy with front and rear bulkhead plates. It provides support and protection for the sootblower mechanism. Lugs, welded to the canopy, provide lifting points and can also be used to support the rear end of the sootblower in service. The front end is supported via the front bulkhead. A stop bar (Fig.5) is welded to the underside of the beam interior near the front bulkhead to bring the carriage to a halt should malfunctioning of the front limit switch occur. 2.2.2 Front Support (Fig.5) The IK-lM is supported at the front (boiler end) via a mounting flange welded, on site, to a wallsleeve (provided by the customer) in the boiler wall. The arrangement is shown below.

FIG.5 FRONT SUPPORT ARRANGEMENT The mounting flange is supplied as part of the sootblower assembly and is bolted to the sootblower front bulkhead via a wallbox arrangement. 2.2.3 Wallbox (Fig.5) The wallbox, in addition to providing a front mounting point for the sootblower, forms a seal around the lance tube via rear and front seal plates contained within the wallbox to prevent leakage of boiler gases. JUNE 1997

FORM 14863

178

SECTION 2 2.2.3.1 Scavenging Air (Fig.5A) Boiler gases are prevented from escaping to atmosphere by pressurising the wallbox. A hand-operated gate valve is provided at the sealing air entry to the wallbox. The valve is connected to the sealing air line and adjusted to maintain adequate sealing air within the wallbox. A connection on the sealing air line runs to the air relief valve to provide a scavenging function.

FIG. 5A SCAVENGING AIR ARRG'T 2.2.4

Rear Support (Fig.5B) The sootblower is supported at the rear by a support bar, screwed rod and support plate arrangement assembled, on-site, to the structural steelwork. The rear support consists of a support bar which is secured between two side plates welded to the sides of the beam.

FIG.5B ADJUSTABLE REAR SUPPORT Screwed rods located within the support bar are assembled onto the structural steelwork to allow for vertical adjustment as required. The side plates incorporate an elongated hole to assist positioning and to allow for boiler expansion in the horizontal plane. The side plates also incorporate a circular hole for use during the handling process. The supporting steelwork is not supplied by Diamond Power, but design information is given on the Installation drawing. FORM 14335/1

AUGUST 2005

179

SECTION 2 2.3

MECHANICAL

2.3.1 Carriage and Drive Mechanism (Fig.6) The IK-lM is driven by a totally-enclosed 0.55 kW (3/4hp) electric motor, using a drop-cord as the power supply. The motor is flange-mounted to the carriage housing and drives the carriage via a worm reduction gear and drive nut arrangement housed within the carriage.

FIG. 6 DRIVE ARRANGEMENT The drive nut traverses a stationary leadscrew as it rotates and thus propels the carriage. Direction and extent of travel are controlled by limit switches, as described in paragraph 2.5. The lance hub forms part of the carriage assembly. The lance tube is flange-mounted to the hub and travels with it. Where the element has to be rotated as it travels, a chain and sprocket drive arrangement is used to rotate the lance hub. Where the element is of the non-rotating type, the hub drive arrangement is omitted. 2.3.2 Guide Assembly (Fig.7) A guide assembly, comprising a mounting plate and two guide blocks, is bolted to the carriage housing. A guide tube which runs the length of the beam, is located at one end in the front bulkhead. The opposite end of the guide tube is retained by two cotter pins on either side of the rear bulkhead.

FORM 14309

JANUARY 2000

180

SECTION 2 2.3.2 Guide Assembly (Fig.7) (Cont’d) As the carriage travels forward, the guide assembly slides along the supporting guide tube. A trip bracket, bolted to the forward guide block, actuates the limit switches which control the travel of the sootblower.

FIG.7 GUIDE ASSEMBLY 2.3.3 Leadscrew (Fig.8) The leadscrew is supported by the front and rear bulkheads. Under normal operating conditions, the leadscrew is prevented from rotating by a locking pin which passes through the right hand pillow block of the poppet valve mechanism. As the carriage drive nut rotates, it traverses the stationary leadscrew.

FIG.8 LEADSCREW ARRANGEMENT When the locking pin is removed, the leadscrew can be rotated to drive the carriage manually. A square tang is provided on the end of the leadscrew for attaching a ratchet wrench. Collars, pinned to the leadscrew prevent axial movement of the leadscrew during forward and reverse travel. SEPTEMBER 2005

FORM 14310

181

SECTION 2 2.4

BLOWING MEDIUM

2.4.1 Poppet Valve (Fig.9) The poppet valve controls the flow of blowing medium to the element and is operated automatically by a cam and trigger, as described in paragraph 2.4.2. It is connected to the blowing medium supply by a companion flange designed to suit the blowing medium pipework. The valve is flange-mounted to the sootblower rear bulkhead by four studs and nuts which also connect it to the feed tube (paragraph 2.4.4), as shown in Figure 12. The IKlM may be fitted with a 40, 60, or 120 bar poppet valve, depending upon the pressure of the blowing medium. The valve body is supplied in carbon steel for standard applications, and in a chrome molybdenum alloy for higher ternperature applications. The arrangement of components within the valve body is shown in Figure 9 below

FIG.9 SECTIONAL VIEW OF POPPET VALVE The valve seat is of flexible construction to allow for thermal expansion. The stem and disc assembly in the valve comprises a stem and a flexible valve disc. On 40 and 60 bar applications, the valve disc is loosely attached to the stem by a screwed retainer and lockwasher. On 120 bar poppet valves, the disc is retained on the valve stem by a welded plug. A slight play, in both cases, ensures positive sealing of the disc on the seat. The sealing face of the valve has a hard deposited surface to minimise wear. The valve stem is positioned by a guide which is screwed into the valve body. An adjustable pressure control disc is screwed onto the lower part of the guide and is held in position by a lock pin. The upper part of the stem guide contains the valve stem packing which seals around the stem to prevent leakage of the blowing medium. A packing nut, screwed onto the stem guide, compresses the packing through a packing washer. The packing nut also supports the valve spring which acts on the stem through a valve yoke. The valve yoke secures the spring retainer and is located in a groove on the upper part of the stem. The poppet valve inlet, outlet, stem guide, and lock pin are fitted with gaskets to prevent leakage of blowing medium. FORM 13246

JULY 1996

182

SECTION 2 2.4.2 Poppet Valve Operation (Fig.10) The poppet valve is operated automatically via a cam and offset trigger arrangement. As the carriage moves forward, a trip pin mounted on the side of the carriage, actuates the cam, thus pulling the valve trigger forward. The trigger pivots on bearings in each of two pillow blocks bolted to the rear bulkhead. Movement of the trigger depresses the valve stem, thus opening the valve and admitting blowing medium to the feed tube.

FIG.10 POPPET VALVE LINKAGE The position of the trip pin on the carriage can be altered to vary the valve-opening position. Provision is made, also, for adjusting the engagement of the pin with the cam by increasing or decreasing the length of the linkage operating arm. 2.4.3 Air Relief Valve (Fig.11) The poppet valve is fitted with an air relief valve which screws into the poppet valve body. The air relief valve allows air to be drawn into the poppet valve between blowing cycles, thus preventing corrosive gases from being drawn into the poppet valve, feed tube, and lance tube as the blowing medium condenses.

FIG.11 AIR RELIEF VALVE When the poppet valve is operated to admit blowing medium to the feed tube, the air relief valve closes to prevent escape of blowing medium. AUGUST 2003

FORM 13839/1

183

SECTION 2 2.4.4 Feed Tube (Fig.12) Blowing medium is admitted to the feed tube when the poppet valve opens at the start of the cleaning cycle and passes through it into the lance tube. The feed tube is telescoped inside the lance tube in the fully-retracted position; the blowing medium is sealed by packing in a gland in the carriage hub. The outside diameter of the feed tube is highly-polished to minimise packing wear as the lance hub slides over it during the cleaning cycle.

FIG.12 FEED TUBE AND PACKING The feed tube is made of stainless steel, hence no maintenance is required. The end of the feed tube is sealed against the gasket in the poppet valve outlet by a clamping plate which also secures the valve to the rear bulkhead. 2.4.5 Lance Tube The lance tube directs the flow of blowing medium to the element. The flanged end of the lance tube is bolted to the hub on the carriage, as shown in Figure 12, and moves with it. The other end of the lance tube is generally supplied prepared for welding to the element on-site; a screwed adapter may be fitted where required. Once connected to the lance tube, the element moves with it.

FORM 13247

JULY 1996

184

SECTION 2 2.4.6 Lance Tube Support (Fig.13) The lance tube normally rotates as it travels and is supported by rollers mounted on shafts welded to the front bulkhead. The roller shafts are angled to ensure that full rolling contact is made between the rollers and the lance tube as it travels.

FIG.13 LANCE TUBE SUPPORT Where the IK-lM is used to drive a rake-type (non-rotating) element, a single or double profile roller is required. 2.4.7 Element (Fig.3) The element is designed to clean the heating surface using a series of nozzles arranged to suit the particular operation. The size and number of nozzles are determined by the cleaning requirement. Normally, the element is welded to the end of the lance tube on site. Blowing medium is directed at the area to be cleaned by the nozzles as the element traverses the boiler tubes. This action removes slag, ash, or any other deposits from the area to be cleaned. Suitable supports should be provided for the cleaning element, as illustrated on the Installation Drawings.

SEPTEMBER 2005

FORM 13248/1

185

SECTION 2 2.5

OPERATING SWITCHES

2.5.1 Limit Switches (Fig.14) Limit/Proximity switches, one directly mounted on the sootblower beam and one mounted on a rail, control forward and reverse travel. The front switch (LSF) reverses the sootblower at full extension, while the rear switch (LSR) stops the sootblower in the reset position.

FIG.14 LIMIT/PROXIMITY SWITCH OPERATION A sequence switch, when fitted, operates the next sootblower in turn. Travel limits can be altered by adjusting the position of the switches on the mounting rail. The switches are actuated by a trip bracket on the guide assembly fitted onto the carriage (Fig.7). 2.6

MANUAL OPERATION (Fig.15) For maintenance purposes, or in an emergency, the sootblower carriage can be operated manually by turning the square tang on the end of the leadscrew. During normal operation, the leadscrew is locked to prevent rotation but can be released by removing the securing nut and locking pin. Once the securing nut is removed and the locking pin withdrawn from the leadscrew, the square tang can be turned with a ratchet wrench.

BALL / POPPET VALVE

FIG.15 SQUARE TANG FOR MANUAL OPERATION Turning the square tang counter-clockwise, results in the carriage travelling forward; conversely, turning the square tang clockwise, results in the carriage returning towards the normal fully-retracted position. FORM 14827

JANUARY 2006

186

SECTION 3

SECTION 3 INSTALLATION INSTRUCTIONS General Installation drawings are supplied with each set of sootblowers; these drawings generally show the location of the sootblowers, overall dimensions, method of mounting, extent of Diamond Power supply, and connections to be made. Reference should be made to the Job Sheets (Section 12) for step-by-step installation instructions. 3.1

Location Each sootblower is identified on the appropriate installation drawing by a serial number; this number is marked on the sootblower nameplate. Care must be taken to ensure that each sootblower is installed in its correct location, by referring to the relevant drawing.

3.2

Mounting The IK-lM is supplied complete with a mounting flange which must be welded onsite to a sleeve in the boiler wall. It must also be supported at the rear via the lifting lugs. Reference should be made to the relevant installation drawings for full mounting details.

3.3

Lifting the Sootblower When lifting the sootblower into position, the lifting lugs on the beam should be used (Section 14). NOTE: Do not use a sling around the beam or the protruding lance tube, as this may cause damage and subsequent malfunctioning.

3.4

Blowing Medium Supply Pipework The IK-lM is normally supplied complete with a companion flange prepared for welding on-site to the blowing medium supply pipework. The pipework is not normally supplied by Diamond Power but must conform to any specification laid down in the contract paperwork. The basic requirements are that it must be designed and installed to avoid straining the sootblower and have a drainage slope of at least 1 in 25 downwards from the companion flange. The supply pipework must be blown out to remove all scale, weld bead, etc., upon completion of installation work. A sheet metal deflector must be inserted between the sootblower poppet valve inlet and the companion flange before this operation to ensure that debris does not reach the valve seat.

3.5

Lubrication Reference should be made to the Lubrication Chart in Section 7.

3.6

Electrical Power and control connections must be made to the terminal box. Reference should be made to the electrical control details in Section 2 for the connections required.

MAY 1998

FORM 13249

187

SECTION 4

SECTION 4 COMMISSIONING

General Commissioning should be carried out in three stages: (1) Inspection; (2) Functional Checks; and (3) Pre-Operational Checks as briefly described in the following paragraphs. Reference should be made to the Job Sheets at the back of this manual for more detailed instructions, and to the commissioning check list for a summary and further references. 4.1

Stage 1 - Inspection Immediately prior to operating the sootblower for the first time, an inspection should be made to ensure that it has been properly installed, that all connections (electrical, steam, and air, where appropriate) have been made, that it has been lubricated as specified in the installation instructions, and that it has not sustained any damage since installation. Once the above inspection has been made and any further work required completed, the sootblower can be operated as described in paragraph 4.2.

4.2

Stage 2 - Functional Checks Functional checks should be made before the furnace comes on-load (i.e. without blowing medium) to ensure that the sootblower mechanism is operating correctly. The sootblower should initially be operated manually to check for freedom of movement and correct functioning of the mechanism, as described in Job Sheet 7. Where the sootblower is an electrically-driven model, it should be operated from the local control to check for correct direction of motor rotation and correct operation of limit switches. Power consumption should also be compared (where possible) with the normal starting and full load current, as stated on the motor rating plate. The sootblower is now ready to be checked with the furnace on-load, as described in the following paragraph.

4.3

Stage 3 - Pre-Operational Checks (Fig.16) The final stage in commissioning involves checking for blowing medium leakage, setting the blowing pressure, and setting the wallbox sealing pressure, where applicable. This can only be carried out with the furnace on-load and all services available (i.e. power, blowing medium, and sealing air). The check for leakage is particularly important where superheated steam is used as the blowing medium. and should be made before, and during, initial operation of the sootblower. Any leakage must be eliminated before moving to the next stage of commissioning. The recommended blowing pressure is given on the Equipment Identification Form at the front of this manual.

MAY 1998

FORM 13840

188

SECTION 4

4.3

Stage 3 - Pre-Operational Checks (Fig.16) (Cont’d) The actual blowing pressure must be checked under normal operating conditions, i.e. with blowing medium available at normal pressure and temperature, nozzle in place, and the air relief valve in good working order. Blowing pressure can be checked by connecting a suitable pressure gauge to the air relief valve, as shown below.

FIG.16 CHECKING THE BLOWING PRESSURE The blowing pressure is controlled by raising or lowering the pressure control disc, thus increasing or decreasing the gap between the valve seat and the disc; the gap is set at approximately 2.5 mm (0.1in) on assembly. Adjustment is made by disconnecting the air relief valve and removing the lock pin coupling, and then rotating the pressure control disc. The pressure control disc must be locked in position after adjustment by replacing the lock pin coupling. The lock pin should engage one of the deep grooves in the pressure control disc; each groove represents approximately 0.2 mm (0.08 in) vertical movement of the pressure control disc. The sootblower should be operated through several complete cycles, with steam on, to check that it is functioning correctly before finally putting it into service.

FORM 13840

MAY 1998

189

SECTION 5

SECTION 5 OPERATING INSTRUCTIONS General The IK1M Sootblower can be operated from a remote panel or from push-buttons mounted on the sootblower terminal box or an individual starter box. Once started, the sootblower automatically completes its operating cycle and returns to the rest position ready for a further cycle. Provision is made, also, for manual operation (Section 6.) 5.1

Operating Precautions When the sootblowers are installed on a small boiler, the steaming capacity should be maintained at over 50% and the draft fans should be operating at a high rate of flow during the sootblowing period. This ensures that the amount of cleaning medium blown in is small compared to the amount of gases passing through the boiler, and also that the deposits removed by the sootblowers are carried through the boiler. If the firing rate is low, the sootblowing may agitate combustibles in the furnace and cause puffing. On larger boilers, these precautions are not normally necessary, as the amount of cleaning medium blown in is usually small compared to the amount of gases passing through.

5.2

Blowing Schedule When a steam generator is first placed into service, the tube surfaces have an immunity to ash and slag adherence. Consequently, it will appear, at first, that the recommended blowing pressures are higher than required. During this period, lasting for a few weeks, it may not be necessary to operate the sootblower very often. Later, after the tube surfaces have acquired a coating of residual slag, the deposits of slag and ash will be more difficult to clean and the recommended pressures will be more than likely required. Before commencing blowing, reference should be made to the operating precautions given in paragraph 5.1. Normal recommended practice is to clean the boiler in the direction of the gas flow. The units nearest to the furnace operate first, followed by the superheater and economiser units. If heavy accumulations are to be removed, a few of the units in the rear passes of the boiler should be operated interchangeably with those in the first pass. This eliminates a heavy accumulation in the boiler output area. If a 'straight-through' schedule is employed, it is possible that accumulation removed from the superheater region will pile up in the economiser area. These recommendations are general ones, operating experience with the individual boiler is the most accurate guide.

JULY 1996

FORM 13251

190

SECTION 6

SECTION 6 MAINTENANCE INSTRUCTIONS General Maintenance instructions in this Section are grouped under the following headings for convenience: Operational Checks; Periodic Inspection; Annual Maintenance; and Major Overhaul. A maintenance schedule for each group is provided in Section 8, and Job Sheets, detailing the action to be taken, are provided in Section 12. Lubricants, which should be kept readily available for maintenance purposes, are listed in Section 7. 6.1

Operational Checks Checks should be made when the sootblower is operating to detect malfunctioning or blowing medium leakage. With the exception of blowing medium leakage, these checks are normally made by the operator.

6.2

Periodic Inspection The sootblower should be inspected periodically to ensure that :(a) All mechanisms are functioning correctly. (b) All moving parts are adequately lubricated. (c) Blowing medium is not leaking. (d) Feed tube surface is in good condition. (e) Lance tube/Element/Rake Arrg't surfaces are in good condition. (f) Blowing pressure is correct. The frequency of inspection will depend on operating conditions, but should be at least once per month.

6.3

Annual Maintenance The IK1M Sootblower should be inspected annually for deterioration of all critical parts; these should be renewed, where necessary. Packing and lubricants should be renewed and mechanisms checked and adjusted, where necessary. NOTE: Components on the carriage assembly which are sealed for life, should only be re-lubricated if dismantling has taken place. This does not apply to bearings and similar parts, which should be discarded and renewed. Critical parts include the following:(a) Poppet Valve, including Air Relief Valve. (b) Feed Tube. (c) Lance Tube, Element or Rake Arrg't. (d) Front Support Rollers. (e) Limit Switches. (f) Drive Nut. (g) Guide Nuts

JULY 1996

FORM 13252

191

SECTION 6 6.4

Major Overhaul The IK1M Sootblower should be dismantled every three years for inspection and renewal of all wearing parts. Seals, packing and lubricants should be renewed at this overhaul. Wall sleeves and supporting steelwork should also be checked, and renewed if unserviceable. NOTE Components on the carriage assembly which are sealed for life should only be re-lubricated if dismantling has taken place. This does not apply to bearings and similar parts, which should be discarded and renewed.

6.5

Manual Operation (Fig.17) During maintenance, or in an emergency, the Sootblower carriage can be operated manually by using the retraction handle. After first removing the protective cap on the end of the gear reducer, the drive pin can next be removed and the square tang can now be turned with the handle. With the drive motor thus disconnected, turning the square tang clockwise results in the carriage travelling forward and the lance tube going into the boiler. Conversely, turning the square tang counterclockwise results in the carriage returning towards the fully-retracted position.

FIG.17 LOCATION OF SQUARE TANG FOR MANUAL OPERATION

The following important information should also be noted:(a) The blowing medium pressure should be 'On' when the sootblower is operated manually to cool the lance tube until it is retracted. (b) The sootblower must always be returned to the retracted position after manual operation to re-set the limit switches.

FORM 13252

JULY 1996

192

SECTION 7

SECTION 7 LUBRICATION

General To maintain the efficiency of the IK-1M Sootblower, it is essential that periodic checks are carried out at the lubrication points listed in this Section. 7.1

Carriage The worm set cavity of the carriage, is factory-lubricated and sealed for life. When the carriage requires dismantling, the lubricant should be renewed as follows :Carriage:- Worm Set Cavity – 385 – 400g (13.6 - 14.fl.oz.) of Tivela GL 00 or Rocol “Sapphire Extreme”. Moving components of the Carriage run in sealed bearings and therefore do not require lubrication.

7.2

Drive Chain The drive chain should be lubricated at least once a year with light machine oil.

7.3

Leadscrew The ends, only, of the leadscrew should be lubricated annually to prevent corrosion. On no account should the surfaces on which the drive nut and guide assembly travel be lubricated; these components do not require lubrication and may be harmed by grit or ash adhering to any lubricant applied.

7.4

General Lubrication The general lubrication points are illustrated below. Bolt Heads and Threads: ------------------Molykote Thred-Gard, or any other suitable anti-seize Compound.

LUBRICATION POINTS - IK1M SOOTBLOWERS

FEBRUARY 2006

FORM 13253/4

193

SECTION 7

IK1M LUBRICATION CHART

COMPONENT

LOCATION

LUBRICATION

PART TO BE

POINT

LUBRICATED

Carriage

(1) Under Sootblower Beam

Worm Gear and Shaft Cavity

Gearing

Drive Chain

(2) At Rear of Carriage

Chain Links

Chain

Leadscrew

(3) Rotates through Carriage

Ends only of Leadscrew

Ends only of Leadscrew

FEBRUARY 2006

FREQUENCY

Sealed for Life

Annually

MEANS OF

LUBRICANT

LUBRICANT

LUBRICATION

ROCOL

SHELL

Fill with 385 - 400g (13.6 – 14.0.fl. oz)

Sapphire Extreme

Tivela GL 00

Spray or Brush

Light Machine Oil

Light Machine Oil

Brush

Light Machine Oil

Light Machine Oil

FORM 14535/4

194

SECTION 8

SECTION 8 MAINTENANCE SCHEDULE

General Sootblower controls are normally arranged to protect the plant and the sootblower from damage in the event of a fault developing, by rendering the sootblower inoperative until the fault is rectified. The Maintenance Schedule, in the following paragraphs, is designed to minimise loss of use of the sootblower by forming the basis of a system of preventive maintenance which identifies parts of the sootblower requiring attention before they deteriorate to such an extent as to render the sootblower inoperative. Action to be taken in the event of a fault developing is given against each item, either directly, or by reference to a Job Sheet. 8.1

Operational Checks Points to be checked are as follows:1. Check the amperage as each sootblower operates and compare the readings obtained with the full load current as shown on motor rating plate. Excessive current consumption, or fluctuating readings, indicates a sootblower fault, which should be investigated as soon as possible. 2. Check that the sootblower operates through its full cycle - failure to do so may be due to either a mechanical fault in the sootblower itself, or an external fault, such as inadequate blowing medium supply.

8.2

Periodic Inspection Frequency of this inspection will depend on operating conditions, but should not be less than once per month. Points to be checked are: 1. All mechanisms are functioning as described in Section 2. 2. Blowing pressure is correct; refer to Job Sheet 4. 3. Blowing medium is not leaking; refer to Job Sheet 5. 4. All moving parts are adequately lubricated; refer to Section 7.

8.3

Routine Maintenance Routine maintenance should be carried out annually, with the sootblower in situ and all services connected, but isolated as specified on the relevant Job Sheet. The IK1M Sootblower should be inspected and dismantled as required for renewal, if necessary. As a preliminary to this operation, the sootblower should be run and checked for any malfunctioning, as described in paragraphs 8.1 and 8.2. Dismantling and Reassembly instructions are given on the relevant Job Sheets in Section 12. Gaskets and packing seals should be renewed at this stage. Reference should be made to Section 7 for details of lubrication required.

APRIL 1998

FORM 13254

195

SECTION 8

8.3

Routine Maintenance (Cont’d) Critical parts, which should be examined in more detail at this overhaul, are as follows: 1. Lance Tube - Check for corrosion, surface damage, and straightness. 2. Element / Rake Arrg't - Check for cracking and corrosion. 3. Feed Tube - Check for corrosion, surface damage, and straightness. 4. Carriage - Check for overheating and noisy running. 5. Guide Assembly - Examine for damage and wear. 6. Poppet Valve - Dismantle. A. Valve Stem and Disc Assembly - Check for wear and renew if necessary. B. Valve Seat - Check for wear and lap if necessary. C. Reassemble using new packing and gaskets. 7. Air Relief Valve - Pressure Test. Ensure that the disc, spring and seat are in good condition 8. Limit Switches - Check for correct operation (Section 12). 9. Motor - Check for overheating and freedom of movement. 10. Drive Nut - Check for wear; renew if necessary. Upon completion of Routine Maintenance, decommissioned as described in Section 4.

8.4

the

sootblower

should

be

Major Overhaul The IK1M Sootblower should be inspected every three years and dismantled for renewal of all wearing parts, if necessary. As a preliminary to this operation, the sootblower should be run and checked for any malfunctioning, as described in paragraphs 8.1 and 8.2. Dismantling and Reassembly instructions are given on the relevant Job Sheets in Section 12. Gaskets, packing, seals, and lubricants, when required should be renewed at this stage. The procedure for examining critical parts is similar to that given for Routine Maintenance. Upon completion of a Major Overhaul, the sootblower should be recommissioned as described in Section 4.

FORM 13254

APRIL 1998

196

SECTION 9

SECTION 9 OPTIONAL TOOLS

Certain jobs described in the Maintenance Section can best be accomplished using tools developed for the job. These tools are listed below and are available from Diamond Power. To order, quote the revelant part number and quantity required.

Lapping Equipment for Poppet Valve Valve Seat Protector Assembly Poppet Valve Maintenance Tool (Spanner) Poppet Valve Maintenance Tool (Depressing Tool) Feed Tube Packing Tool Assembly Wrench for Manual Operation Test Pressure Gauge Assembly

FEBRUARY 1999

FORM 13225

197

SECTION 9

LAPPING EQUIPMENT FOR POPPET VALVE

Item No.

Part No.

Description

1

395111-1123

Wobble Stick

1

2

313641-1125 314718-1121 392442-1120

Lapping Disc, Serrated Face (Series 40) Lapping Disc, Serrated Face (Series 60) Lapping Disc, Serrated Face (Series 120)

1 1 1

3

313641-2123 314718-2129 392442-2128

Lapping Disc, Plain Face (Series 40) Lapping Disc, Plain Face (Series 60) Lapping Disc, Plain Face (Series 120)

1 1 1

OCTOBER 1994

No. Off

FORM 11827

198

SECTION 9

VALVE SEAT PROTECTOR ASSEMBLY (PART No. 310925-1029 - SERIES 40) (PART No. 310925-2026 - SERIES 60) (PART No. 392443-1129 - SERIES 120)

Item No.

Part No.

Description

1

863015-2800

Nut

1

2

311938-1113

Stem

1

3

311936-1115 311936-2113 393444-1128

Spacer (Series 40) Spacer (Series 60) Spacer (Series 120)

1 1 1

4

311937-1114 311937-2112 Not Applicable

Disc (Series 40) Disc (Series 60) Disc (Series 120)

1 1 -

AUGUST 1996

No. Off

FORM 11828

199

SECTION 9

POPPET VALVE MAINTENANCE TOOL (SPANNER)

Item No. 1

NOVEMBER 2000

Part No.

Description

312227-1129

Valve Packing Nut Spanner

No. Off 1

FORM 10658

200

SECTION 9

POPPET VALVE MAINTENANCE TOOL (DEPRESSING TOOL)

Item No. 1

NOVEMBER 1994

Part No.

Description

307025-1024

Valve Spring Depressing Tool

No. Off 1

FORM 12974

201

SECTION 9

FEED TUBE PACKING TOOL ASSEMBLY (Part No. 308191-1012 - Graphite Foil Packing) (Part No. 308191-2010 - Teflon Packing

Item No.

Part No.

Description

1

307762-0114

Spring Clip (2-3/8"in o/d Feed Tube)

1

2 3

306761-0117 327425-1127

Body (Graphite Foil Packing) Body (Teflon Packing)

1 1

MARCH 1995

No. Off

FORM 12720

202

SECTION 9

WRENCH FOR MANUAL OPERATION

Item No. 1 2

AUGUST 1996

Part No.

Description

909305-0017 901412-0006

Ratchet Wrench Socket Extension (Not Illustrated)

No. Off 1 1

FORM 13760

203

SECTION 9

TEST PRESSURE GAUGE ASSEMBLY

Item No. 1

Part No.

Description

398023-000A

Pressure Gauge

FEBRUARY 1999

No. Off 1

FORM 15164

204

SECTION 10

SECTION 10 PARTS IDENTIFICATION Part Numbers for spares ordering purposes can be identified by referring to the Parts Identification pages in this Section. The contract number and the sootblower serial number should be quoted when ordering spares. The main assemblies and sub-assemblies of the Parts Lists are arranged in the following order: IK-lM Main Assembly. Carriage Assembly. Lance Joint and Packing Assembly. Blowing Medium Turn-on Assembly. Poppet Valve Assembly. Air Relief Valve Assembly. Electric Control Assembly. Electric Control/Wiring Assembly. Terminal Box Assembly. (As Required) Front Bulkhead/Roller Assembly. (As Required) Guide Assembly. Low Noise Wallbox Assembly c/w Adaptor. (As Required) Wallbox/Seal Plate Assembly. (As Required) Wallbox and Scavenge Line Assembly. (As Required) Scavenging Air Line and Piping Assembly (As Required) Scavenging Air Assembly. (As Required) Piping Assembly. (As Required) Guard Assembly. (As Required) Acoustic Cover Assembly (As Required) Rear Support Assembly. (As Required)

FEBRUARY 2005

FORM 13202/3

205

SECTION 10 PARTS IDENTIFICATION (CUSTOMISED) CONTRACT No.N10865 Assy Desc / Part No IK1M-TE MAIN ASSEMBLY 398742-0043

JET TUBE ELEMENT MAT’L: Low Alloy

CARRIAGE ASSEMBLY 398271-ASRBYT

Item No 1 2 2A 3 4 4A 5 6 7 8 8A 9 10 10A 10B 10C 11 12 13 28 29 30 31 32 33 36 37 38

SECTION 10

Part No

Form No

398299-000A 398271-ASRBYT N10865-861 FF1DA0-0133 M3000E-0132 JE528 398339-A000 397218-010A 397247-A100 397769-0001 N10865-2-613 398565-1C00 395635-1039 907923-0003 Not Applicable Not Applicable 397257-000B 397243-010D 395608-4044 398535-000A 397802-R2A2 397556-DDN1 350256-010A 397473-J120 (6-off) 397474-010A (12-off) Not Applicable 398496-000A Not Applicable

15442 " " " " " " " " " " " " " " " " " " " " " " " " " " "

395595-1128 395596-1127 395602-1145 395586-1020 395589-1126 396337-000A 397197-010A 875603-3215 875005-4030 Not Applicable 395585-1146 398336-010A Not Applicable

15327 " " " " " " " " " " " "

22 23 24 25 26 27 28 29 30 31 32 33 35-39 ( PAGE 1 of 3 )

FORM 14017

206

SECTION 10 PARTS IDENTIFICATION (CUSTOMISED) CONTRACT No.N10865

SECTION 10

Assy Desc / Part No

Item No

Part No

Form No

CARRIAGE ASSEMBLY (Cont’d) 398271-ASRBYT

40 41 42

0903-801 (Tivela) 395598-1034 879006-3502

15327 " "

LANCE JOINT & PACKING ASSY 395608-4044

10

346160-1134

13205

BLOWING MEDIUM TURN-ON ASSY 398339-A000

39

398305-0400

15376

POPPET VALVE ASSEMBLY 397802-R2A2 * (Welded with Item 1) * (Fitted with Item 1)

1 2 3 4 11 22 23 25 26

*398580-RAA0 344381-1033 309786-1128 394197-1123 393802-1122 397474-010A 397473-J090 398325-010A Not Applicable

14895/1 " " " " " " " "

AIR RELIEF VALVE ASSY 397257-000B

1 2

Not Applicable 941402-0001

14302 "

ELECTRIC CONTROL ASSEMBLY 397769-0001 *Refer to Wiring Diagram

1 5&6 7 8 - 11 12 13 14 15 16 19 20 22 23 - 25 26 27 - 38

398348-S0002 * 398494-A1500 * 875608-3216-(2-off) 398360-010A (4-off) 879016-3200 (6-off) 875611-3237 (4-off) 398360-010B (6-off) * 849515-8909 879006-4002 * 849534-8903 *

14864 " " " " " " " " " " " " " "

TERMINAL BOX ASSEMBLY 398348-S0002

1 2 3 6

875003-3525 875003-3530 Not Applicable Not Applicable

15486 " " "

( PAGE 2 of 3 )

FORM 14017

207

SECTION 10

SECTION 10 PARTS IDENTIFICATION (CUSTOMISED) CONTRACT No.N10865 Assy Desc / Part No

Item No

Part No

Form No

FRONT BULKHEAD ASSEMBLY 398535-000A

2

395570-1135 (2-off)

15479

FRONT ROLLER ASSEMBLY 395635-1039

1

395636-1137

13210

GUIDE ASSEMBLY 397247-A100

1 2

397235-000A 397242-010A

14304 "

WALLBOX & SCAVENGE LINE ASSY 398565-1C00

1 2 3 17

397704-010A 396940-010C 397448-000D RT012709CA (1900mm)

15417 " " "

( PAGE 3 of 3 )

FORM 14017

208

IK1M MAIN ASSEMBLY

AUGUST 2005

SECTION 10 DRG. NO. 398742-0043 PART. NO.

FORM 15442

209

SECTION 10 IK1M MAIN ASSEMBLY Item No. 1 2 2A 3 4 4A 5 6 7 8 8A 9 10 10A 10B 10C 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 * 30 * 31 * 32 * 33 * 34 * 35 36 37 38

Part No.

Description

873607-4841 397243-010A 397245-010A 873651-4042 398704-010A 391750-1128 398695-010A 864501-8903 875005-4016 879016-4000 398553-010A 398252-000A 871014-4841 873013-4800

909305-0017 901412-0006

* Items Supplied Loose

FORM 15442

DRG. NO. 398742-0043 PART. NO. No. Off

Beam Arrg't 1 Carriage Assembly 1 Motor 1 Feed Tube 1 Lance Tube 1 Steam / Air Lance / Rake Extension (Not Illustrated)1 Blowing Medium Turn- On Assembly 1 Leadscrew 1 Guide Assembly 1 Electric Control Assembly 1 Electric Control / Wiring Assembly (Not Illustrated) 1 Mounting Flange / Wallbox Assembly) 1 Roller, Front Support As Req’d Circlip (Not Illustrated) As Req’d Shaft, Front Support (Not Illustrated) 1 Set Screw (Not Illustrated) 1 A.R.V/ Pressure Switch / Gauge Mounting Assy 1 Locating Collar, Lead Screw 1 Lance Joint and Packing Assembly 1 Cotter Pin 2 Locating Collar, Lead Screw 1 Locking Pin, Lead Screw 1 Roll Pin 1 Emblem 2 Warning Tag 1 Nameplate 1 Gripnail 4 Screw, Hex Hd M8 x1.5 – 16 lg 4 Lockwasher, Split Type M8 4 Top Cover Plate 1 Leadscrew Clamp Assy 1 Bolt, Hex Hd M12 x 1.75 – 65 lg 1 Nut, Nylock M12 x 1.75 1 Bulkhead Assy, Bolt-On 1 Poppet Valve Assembly 1 Companion Flange (Not Illustrated) 1 Gasket (Not Illustrated) 1 Stud (Not Illustrated) As Req’d Nut (Not Illustrated) As Req’d Ratchet Wrench (Not Illustrated)** 1 Socket Extension (Not Illustrated)** 1 Guard Assembly (Not Illustrated) 1 Rear Support Assembly (Not Illustrated) 1 Scavenging Air Assy (Not Illustrated) 1

Item 37 fitted to rear lifting lugs at site

** Per Boiler Set

AUGUST 2005

210

CARRIAGE ASSEMBLY

APRIL 2002

SECTION 10 DRG. NO. 398271-0042 PART. NO.

FORM 15327

211

SECTION 10 CARRIAGE ASSEMBLY

Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

FORM 15327

Part. No. 395658-1148 395590-1123 395591-3128 395591-4126 343831-1130 395648-1133 395647-2124 907923-0016 901110-0040 901110-0125 901110-0105 907923-0001 907923-0012 907655-0007 875005-4430 879016-4400 344093-4135 875005-3520 879016-3500 395603-1128 901416-8900

941401-0009

DRG. NO. 398271-0042 PART. NO.

Description Housing Bearing Carrier Gasket, Bearing Carrier Gasket, Bearing Carrier Gasket, Motor Flange Collar,Motor Shaft Key Retaining Ring Ball Bearing Ball Bearing Ball Bearing Retaining Ring Retaining Ring Expansion Plug Hex Hd Screw Lockwasher Key Hex Hd Screw Lockwasher Key Seal Worm Gear Worm Shaft Drive Nut Sprocket Arrg't Sprocket 18T Chain Arrg't Locking Plate Screw Hex Hd Screw Hub, Sprocket Lance Hub Trip Pin Pipe Plug Hub Arrg’t Rotary Union Nipple Coupling Torque Bracket Arrg’t Lubrication Chain Guard Arrg’t Plain Washer

No. Off 1 1 1 As Req'd 1 1 1 2 2 2 1 2 1 1 4 4 1 8 8 1 1 1 1 1 1 1 1 1 2 8 1 1 1 As Req’d 1 1 1 1 1 As Req’d 1 2

APRIL 2002

212

SECTION 10 LANCE JOINT AND PACKING ASSEMBLY

Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13

DRG. NO. 395608-1040 PART. NO.

Part No.

Description

395647-1126 395609-1122 907923-0016 395610-1137 395638-1135 873015-4400 873008-4400 879006-4400 395615-1124

Key 8 x 8 x 19 Flange Retaining Ring, External Gasket, Lance Tube Bushing, Front Nut, Hex M10 x 1.5 Nut, Hex, Locknut M10 Washer, Form A, M10 Stud, Gland Packing Packing Packing Gland Arrg't Lockwasher, Split Type M10 Screw, Hex Hd M10 x 1.5 – 45Lg

395611-1037 879016-4400 875005-4437

FEBRUARY 2005

No. Off 1 1 1 1 1 2 2 2 2 1 1 6 6

FORM 13205

213

SECTION 10 BLOWING MEDIUM TURN-ON ASSEMBLY

OCTOBER 2006

DRG. NO. 398339-0042 PART. NO.

FORM 15376

214

SECTION 10 BLOWING MEDIUM TURN-ON ASSEMBLY

Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

FORM 15376

DRG. NO. 398339-0042 PART. NO.

Part No.

Description

No. Off

907948-8901 907948-8900 869068-0012 398333-000A 398646-000A 901118-0054 398301-010B 871014-4840 879006-4802 873651-3233 879006-4800 879016-4800 875005-4836 397729-000A 873024-5200 398649-010A 398334-000A 869006-8904 398301-010A 876004-8904 879006-5200 873015-5200 398302-010A 907920-9005 907920-9010 304634-0117 907920-0113 395875-1129 879016-4400 875005-4433 873015-4800 301235-0116 863603-1716 875007-3516 873651-4042 876006-4410 398651-010A 398804-010A

Rod End Rod End Washer, 1.5 x 0.75 x 16G Cam Arrg't Mounting Arrg’t Oilite Bearing Spacer, Poppet Valve Trigger Hex Hd Bolt M12 x 1.75 x 60 lg ‘C’ Washer M12 Roll Pin ø5 x 35 lg Washer Form-A M12 Lockwasher, Split Type M12 Hex Hd Screw M12 x 1.75 X 40 lg Trigger Shaft Arrg't Aerotight Hex Nut M16 x 2.0 Bearing Retainer, Poppet Valve Mounting Pivot Block Arrg’t Washer 30 OD x 22 ID x 16G Spacer, Poppet Valve Trigger Hex Hd Bolt M16 x 2.0 x 90 lg Washer, Form-A M16 Hex Nut M16 x 2.0 Spacer, Poppet Valve Cam External Retaining Ring External Retaining Ring Gasket, Feed Tube External Retaining Ring Clamping Plate, Feed Tube Lockwasher, Split Type M10 Hex Hd Screw M10 x 1.5 – 35 lg Hex Nut M12 x 1.75 Pin, Poppet Valve Yoke Cotter Pin, Split Ø2 x 15 Screw, M6 1.0 x 16 Lg Roll Pin, Ø8 x 70 Lg Grub Screw, M10 x 1.5 x 10 Lg Plate, Lead Screw Locking Bracket Block, Lead Screw Locking Adjusting Rod

1 1 1 1 1 2 1 4 8 2 2 12 8 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 2 2 4 1 1 3 1 4 1 1 1

OCTOBER 2006

215

SECTION 10 BLOWING MEDIUM TURN-ON ASSEMBLY

DRG. NO. 398339-0042 PART. NO.

NOTES 1. Assemble adjusting rod and rod ends with equal thread engagement at each end. For reference the nominal engagement will be 23mm. 2. Adjustment at final assembly is achieved by loosening the locking nut and rotating the adjusting rod. Re-tighten the locking nut when adjustment is correct. 3. Apply Molykote Gn+ to threads and head of screws and torque to 41Nm (30 lb.ft) 4. Apply Molykote Gn+ to threads and faces of poppet valve nuts and torque to 75Nm (55 lb.ft). For each nut, bend up only ONE tab of the locking washer. 5. When poppet valve is correctly aligned with the feed tube, drill Ø5 through the bulkhead (via existing Ø5 holes in mounting plate) and fit Ø5 roll pins. NOTE: It is possible that misalignment / distortion of the rear bulkhead will cause the lance to lose contact with the front rollers when the poppet valve mounting is tightened. If this is the case then adjust the four M10 grub screws to compensate. 6. Assemble all threads with Molykote Gn+. 7. Assemble rod ends with Molykote Gn+ on the bores. 8. Install Oilite Bearing flush with inside surface of Poppet Valve Mounting. 9. Install Oilite Bearing flush with small diameter face of Bearing Retainer. 10. The Trigger Assembly should be fitted by inserting the non-lever end through the larger hole in the Poppet Valve Mounting Bracket as shown. Then fit a washer (detail 3) before inserting the lever end into the Oilite Bearing within the smaller hole of the Poppet Valve Mounting Bracket. Finally fit the bearing retainer c/w Oilite Bearing. 11. When the valve is fully open ensure there is a minimum gap of 0.25mm between the valve spring coils.

OCTOBER 2006

FORM 15376

216

POPPET VALVE ASSEMBLY (IR2G) / (IK1M) / (DOPV)

OCTOBER 2006

SECTION 10 DRG. NO. 397802-0042 PART. NO.

FORM 14895/1

217

SECTION 10 POPPET VALVE ASSEMBLY (IR2G) / (IK1M) / (DOPV) Item No. 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Part No.

Not Not Not Not Not

Applicable Applicable Applicable Applicable Applicable

930711-9034 301142-0118 301808-0113 302051-0115 302032-0119 302027-0116 398443-010A 342928-1136 301167-2114 396774-0121 Not Applicable

DRG. NO. 397802-0042 PART. NO.

Description.

No. Off

Valve Body Valve Stem and Disc Arrg't Flexible Valve Seat Pressure Control Disc Trigger Arrg’t Valve Yoke Pin Cotter Pin Trigger Pin Cotter Pin Lock Pin Plug Copper Washer Valve Yoke Valve Spring Retainer Valve Spring Packing Nut Packing Washer Valve Stem Packing Valve Stem Guide Valve Stem Washer Adjustable Pressure Tag Nut Stud / Hex Soc Hd Screw Adaptor Locking Washer, Poppet Valve Nut Plug, G3/4

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 1 2 1

NOTES: 1. Valve Stem Guide, Lock Pin and Plug threads to be coated with ‘Molykote Gn Plus’ (907145-0002) 2. Torque Valve Stem Guide to 80Nm (60lb.ft) 3. Valves to be hydro tested to procedure – QA 002 6. This clearance dimension should be set between the bottom face of the packing nut hex and the top face of the valve stem guide hex. Increasing this dimension above 8mm can cause the spring to hard stop when the valve is fully open. Decreasing this dimension below 3.5mm may cause problems with the valve stem packing. 7. Ensure valve stem packing rings are assembled as shown.

FORM 14895/1

OCTOBER 2006

218

SECTION 10 AIR RELIEF VALVE ASSEMBLY

Item No. 1 2 3 4 5 6 7 8 9 10

DRG. NO. 397257-0034 PART. NO.

Part No.

Description

341245-1027 935923-8400 937817-8400 936220-8400 935924-8461 349569-010D 930711-9034 396774-0121

Street Elbow Male Stud Coupling Air Relief Valve Arrg't Nipple Tee Piece Plug Nipple Adaptor Copper Washer Adjustable Pressure Control Tag

DECEMBER 1996

No. Off 1 1 1 1 1 1 1 1 1 1

FORM 14302

219

ELECTRIC CONTROL ASSEMBLY

NOVEMBER 2004

SECTION 10 DRG. NO. 397769-0043 PART. NO.

FORM 14864

220

SECTION 10 ELECTRIC CONTROL ASSEMBLY Item No. 1 5 6 7 8 9 10 11 12 13 14 15 16 19 20 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

FORM 14864

Part No.

DRG. NO. 397769-0043 PART. NO. Description

No. Off

Terminal Box/Assembly Cable Gland Pg13.5 Limit Switch Mounting Rail Cable 3-core (Length as req’d) As Cable 5-core (Length as req’d) As Cable Gland Pg16 Cable Looped 4-core (Length as req’d) Screw M5 0.8 x 16 lg Nut As Lockwasher M5 As Screw M5 x 0.8 – 45 lg Nut Nut M6 Cable Clip Washer M8 Proximity Switch (Rear) (IFM) Adaptor, Motor M20 x Pg16 Proximity Switch (Front) (IFM) Grommet Strip Screw M6 x 1.0 x 35 lg Washer M6 As Screw, Hex Hd M6 x 1.0 x 16 lg Screw M5 x 0.8 – 30 lg Proximity Switch (Front) (Telemechanique) Gland M20 Gasket Proximity Switch (Rear) (Siemens) Proximity Switch (Front) (Siemens) Proximity Switch (Front & Rear) (Namur) Proximity Switch (Front & Rear) (Ersce) Proximity Switch (Front & Rear) (Siemens)

1 2 2 1 Req’d Req’d 2 1 2 Req’d Req’d 4 6 2 1 4 1 1 1 4 4 Req’d 1 2 1 2 2 1 1 2 2 2

NOVEMBER 2004

221

ELECTRIC CONTROL / WIRING ASSEMBLY

SEPTEMBER 2006

SECTION 10 PART. NO. N10865-2-613 (REV B) DRG. NO. 396600-1723

(CONTRACT N10865)

222

SECTION 10 ELECTRIC CONTROL / WIRING ASSEMBLY

Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27# 28# 29# 30# 31# 32#

Part No. * * 841402-0071 * 841402-0079 849518-8949 841405-0116 * 848300-9784 875007-3236 879011-3200 * * * 841402-0067 841402-0078 841404-0014 841404-0015 907506-8901 * * * * * * 847313-9208 398348-S0002 398743-AA10 841420-0002 841420-0001 841420-0010 841420-0011

PART. NO. N10865-2-613 (REV B) DRG. NO. 396600-1723

Description

Qty.

Electric Motor 1 Entry, Motor, M25 Cable Gland M25 2 Entry 25.4 mm dia clearance hole (for M25) Locknut M25 1 Cable, Motor, 4-core Limit Switch, LSR & LSF - Ersce 2 Entry M20 Terminal Cross Connector, 3 way 1 Screw, M5 x 0.8 – 40 lg Soc Hd 4 Washer, M5 Serrated 4 CP20 Rail CP20 Fixings Entry 20.4mm dia clearance hole (for M20/Pg13.5) Cable Gland M20 2 Locknut M20 2 Cable, Limit Switch, 3-core, Hi-temp silicon 1 Cable, Limit Switch, 5-core, Hi-temp silicon 1 Warning Label, “Steam Sootblower” 1 Entry 44mm dia clearance hole Cable Gland By others Locknut By others Entry 29mm dia clearance hole Cable Gland By others Locknut By others VCI Foam Square, Corrosion Protection 2 Terminal Box Assembly, RH 1 Terminal Block Assembly 1 Pushbutton Assy, Start, RED 1 Pushbutton Assy, Reverse, GREEN 1 Pushbutton Insert, RED 1 Pushbutton Insert GREEN 1

N10865-2-613 Electrical Parts Assembly, RH Sootblower N10865TB Terminal Box Assembly, populated Assy of # parts only * Shown for reference only

(CONTRACT N10865)

SEPTEMBER 2006

223

SECTION 10 TERMINAL BOX ASSEMBLY (RITTAL)

Item No. 1 2 3 4 5 6 7 8

JUNE 2006

DRG. NO. 398348-0140 PART. NO.

Part No.

Description

873015-3500 879016-3500

Screw, Slt Hd Csk M6 x 1.0 - 25lg Screw, Slt Hd Csk M6 x 1.0 - 30lg Screw, Slt Hd Csk M6 x 1.0 - 45lg Hex Nut M6 Lockwasher, Split Type M6 Nylon Spacer Washer, Form A, M6 Terminal Box

875006-3500 841406-0009

No. Off As Req’d 1 4 8 4 4 4 1

FORM 15486

224

SECTION 10 FRONT BULKHEAD ASSEMBLY.

Item No. 1 2

AUGUST 2005

DRG. NO. 398535-0028 PART. NO.

Part No.

Description.

398389-010A 395570-1135

Front Bulkhead Plate (Bolt-on) Shaft

No. Off 1 As Req’d

FORM 15479

225

SECTION 10 FRONT ROLLER ASSEMBLY

Item No. 1 2 3

JULY 1997

DRG. NO. 395635-1039 PART. NO.

Part No.

Description

901110-0058 907923-0005

Roller Ball Bearing Retaining Ring

No. Off 1 1 2

FORM 13210

226

SECTION 10 GUIDE ASSEMBLY

Item No. 1 2 3 4 5 6

DRG. NO. 397247-0037 PART. NO.

Part No.

Description

875005-4425 879016-4400 873651-8900 873607-4841

Guide Block Arrg't Guide Tube Screw Lockwasher Roll Pin Cotter Pin

NOVEMBER 2001

No. Off 1 1 2 2 2 2

FORM 14304

227

WALLBOX AND SCAVENGE LINE ASSEMBLY

SEPTEMBER 2003

SECTION 10 DRG. NO. 398565-0047 PART. NO.

FORM 15417

228

SECTION 10 WALLBOX AND SCAVENGE LINE ASSEMBLY Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

FORM 15417

Part No.

397703-010A 875005-4444 871014-4852 873015-4800 879016-4800 941414-0010 932500-8902 902210-8903 931403-0012 841414-0067 941416-0015 941401-0012 931403-0005 902225-0005 873015-3200 879016-3200 875005-3220 941406-0001 873651-3220

DRG. NO. 398565-0047 PART. NO.

Description.

No. Off

Wallbox Housing Seal Plate Seal Arrg’t Wallbox Flange Hex Hd Screw M10 x 1.50 – 80 lg Hex Hd Bolt M12 x 1.75 –120 lg Hex Nut M12 x 1.75 Lockwasher, Split Type M12 Reducing Tee Hosetail ½”BSPT Hose Clip 90° Elbow Adapter Nipple Plug Rubber Hose (Cut to suit) Copper Tube (Cut to suit) Clamp, Copper Tube Hex Nut Lockwasher Hex Hd Screw M5 x 0.8 – 20 lg 90° Elbow ½” x ½” Roll Pin 0.5 x 20 lg

1 1 1 1 4 4 8 8 1 1 2 1 1 1 1 As Req’d As Req’d 1 1 1 1 1 1

SEPTEMBER 2003

229

SECTION 10 REAR SUPPORT ASSEMBLY

Item No. 1 2 3 4 5 6

MARCH 2003

DRG. NO. 398496-0025 PART. NO. 398496-000A

Part No.

Description

398496-010A RZ240130KC-0250 873015-6000 879006-6000 863607-2240 869006-3600

Rear Support Bar Screwed Rod Hex Nut M24 Washer M24 Cotter Pin 3/16”x 2” lg Plain Washer

No. Off 1 2 4 4 2 2

FORM 15382

230

SECTION 11

SECTION 11 RECOMMENDED SPARES LIST

It is recommended that stocks of the items listed in this Section be maintained as follows: 1. Running Maintenance Quantities shown in column 1 should be regarded as a minimum initial stock level until actual usage is established through operating experience. 2. Incurred Maintenance Diamond sootblowers are designed to operate for long periods with the minimum of maintenance and spares usage; component parts do not normally require replacement unless a breakdown occurs due to accident or misuse. It is recommended, however, that a stock of the items listed be maintained to minimise downtime should a breakdown occur, recommended quantities are shown in column 2.

3. Major Overhaul When the boiler is off-load for a major overhaul, sootblowers should be inspected for wear or damage as indicated in Section 8, and parts replaced as necessary. Items which are normally replaced at this stage are indicated by a quantity in column 3.

The items listed in this Section should be adequate for normal use but the quantities stocked may have to be adjusted to take account of severe usage or delays in obtaining replacements . The assembly headings indicate where the items listed are used. Since headings and items appear in the same order as shown in the Parts Identification Section of the Instruction Manual, part numbers of related items can be readily identified. The quantities recommended have been calculated per ten sootblowers. These quantities may require to be adjusted to correspond with the actual number of sootblowers in use.

SEPTEMBER 1984

FORM 12996

231

SECTION 11

RECOMMENDED SPARES LIST ( Per 10 Sootblowers ) EQUIPMENT TYPE :CONTRACT No :-

IK1MTE SOOTBLOWER (Positive Pressure) N10865

DESCRIPTION

1. Running Maintenance 2. Incurred Maintenance 3. Major Overhaul

PART NO

QUANTITY 1

2

3

-

1 1 1 1 2

10

395591-3128 395591-4126 343831-1130 395647-2124 901110-0040 901110-0125 901110-0105 344093-4135 395603-1128 901416-8900 395595-1128 395596-1127

-

1 1 1 1 2 2 1 1 1 1 1 1

-

LANCE JOINT & PACKING ASSY Bushing Packing (Solid Ring) Packing (Split Ring) Gland Key Gasket

395608-4044 395638-1135 346160-1134 396741-010A 395611-1037 395647-1126 395610-1137

10 -

1 10 1 1 1

10 10 10 10 10

BLOWING MEDIUM TURN-ON ASSY External Retaining Ring External Retaining Ring Gasket, Feed Tube External Retaining Ring

398339-A000 907920-9005 907920-9010 304634-0117 907920-0113

-

1 1 1 1

-

MAIN ASSEMBLY Electric Motor Feed Tube Lance Tube Element: Mat’l: Low Alloy Gasket (Companion Flange) CARRIAGE ASSEMBLY Gasket, Bearing Carrier Gasket, Bearing Carrier Gasket, Motor Flange Key Ball Bearing Ball Bearing Ball Bearing Key Key Seal Worm Gear Worm Shaft

398742-0043 N10865-861 FF1DA0-0133 M3000E-0132 JE528 350256-010A 398271-ASRBYT

(Page 1 of 2)

FORM 13218

232

SECTION 11

RECOMMENDED SPARES LIST ( Per 10 Sootblowers ) EQUIPMENT TYPE :CONTRACT No :-

IK1MTE SOOTBLOWER (Positive Pressure) N10865

DESCRIPTION

1. Running Maintenance 2. Incurred Maintenance 3. Major Overhaul

PART NO

QUANTITY 1

2

3

POPPET VALVE ASSEMBLY Valve Stem and Disc Arrg't Flexible Valve Seat Pressure Control Disc Lock Pin Plug Lock Pin Washer Valve Yoke Valve Spring Retainer Valve Spring Packing Nut Packing Washer Valve Stem Packing Valve Stem Guide Valve Guide Washer Nut Stud Locking Washer

397802-R2A2 344381-1033 309786-1128 394197-1123 393802-1122 930711-9034 301142-0118 301808-0113 302051-0115 302032-0119 302027-0116 398443-010A 342928-1136 301167-2114 397474-010A 397473-J090 398325-010A

10 -

2 2 2 2 2 2 2 2 2 2 10 2 2 4 4 2

5 10 10 10 10 10 10 -

AIR RELIEF VALVE ASSEMBLY Air Relief Valve Copper Washer

397257-000B 341245-1027 930711-9034

-

2 1

10

(REF) ELECTRIC CONTROL ASSEMBLY Limit Switch (Forward) Limit Switch (Reverse)

397769-0001 841405-0116 841405-0116

FRONT ROLLER ASSEMBLY

20

(Per Wiring Diagram N10856-2-613)

-

1 1

-

Roller Bearing

395635-1039 395636-1137 901110-0058

-

2 2

20 20

WALLBOX & SCAVENGE LINE ASSY Seal Plate

398565-1C00 396940-010C

-

1

-

FORM 13218

(Page 2 of 2)

233

SECTION 12

SECTION 12 JOB SHEETS

JOB SHEET NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

SEPTEMBER 1995

TITLE

IK1MTE Installation Procedure. Commissioning Check List. Blowing Medium Turn-On Linkage - Adjusting Procedure. Poppet Valve - Checking / Setting the Blowing Pressure. Pressure Sealing Points - Checking Procedure. Limit Switches - Renewal and Adjustment. Checking the Electrical Operation. Manual Operation. Feed Tube Packing - Split Ring : Adjusting the Packing Gland. Feed Tube Packing - Split Ring : Renewal. Poppet Valve - Removal from Sootblower. Poppet Valve - Dismantling. Poppet Valve - Valve Stem Packing : Adjusting Procedure. Poppet Valve - Valve Stem Packing : Renewal. Poppet Valve - Tools and Equipment for Lapping the Valve Seat. Poppet Valve - Valve Seat Lapping Procedure. Poppet Valve - Seat Renewal. Poppet Valve - Reassembly Procedure. Poppet Valve - Replacing on the Sootblower. Lance Tube Gasket - Adjusting Procedure. Lance Tube Flange Gasket - Renewal. Lance and Feed Tube - Removal. Carriage - Removal and Replacement. Carriage - Dismantling and Reassembly. Wallbox - Dismantling.

FORM 13286

234

JOB SHEETS The information within the job sheets are of a general nature and are not intended to cover every individual sootblower system.

WARNING Before all adjustments, repairs and tests are undertaken the control room should be notified. The appropriate local permits should be taken out and all safety precautions taken.

NOTE Refer to the yellow coloured warning sheet at the front of the Instruction manual for general information regarding important Installation, Commissioning, Operating and Maintenance instructions.

FORM 15325

235

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : JOB SHEET TITLE : STEP

IK1M INSTALLATION PROCEDURE ACTION

No.1 SHEET 1 of 3 REF./INFO.

1.

Remove all straps and packing from the sootblower.

2.

Inspect the sootblower for possible damage from shipment or storage.

3.

Check that the sootblower is complete.

4.

Determine the location and mounting position of the sootblower in the installation.

Inst. Drg

5.

Position and weld the wallsleeve to the boiler wall..

Inst. Drg

6.

Bolt the mounting flange to the front bulkhead.

7.

Lift the sootblower into position using the lifting lugs provided on top of the beam.

8.

Position the sootblower with the wall sleeve located in the mounting flange recess.

9.

Position and bolt the rear support to the supporting steelwork.

10.

Weld the mounting flange to the wall sleeve.

11.

Connect the blowing medium supply pipework to the sootblower. NOTE The supply pipework is not provided by Diamond Power and must be carefully installed to prevent undue stress on the sootblower. To ensure correct drainage of condensate, refer to the installation drawing.

12.

Bolt the companion flange to the poppet valve inlet flange.

13.

Position and weld the blowing medium supply pipework to the companion flange.

14.

Unbolt the companion flange from the poppet valve flange.

OCTOBER 2000

Packing List

FORM 13256

236

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : JOB SHEET TITLE :

IK1M INSTALLATION PROCEDURE

STEP

ACTION

15.

Insert a sheet metal deflector between the companion flange and the sootblower.

16.

Blow out the blowing medium supply pipework to remove all scale, weld bead, etc.

17.

Remove the deflector and insert the companion flange gasket.

18.

Bolt the companion flange to the sootblower valve inlet flange, compressing the gasket evenly between the flanges. Tighten the studs in the sequence shown in the following illustration. NOTE The use of a torque wrench is not manditory but the approximate torque value of a properly tightened stud is as follows:80 - 100 Nm for M20 studs (40 and 60 Bar Valves) 125 – 140 Nm for M24 studs (120 Bar Valves)

No.1 SHEET 2 of 3 REF./INFO.

STUD TIGHTENING SEQUENCE NOTE Series 60 and 120 poppet valve installations have eight flange studs. 19.

Observe the alignment of the beam assembly; check for any bends, twists, or other distortions.

20.

Connect the element (normally supplied loose) to the lance and check for straightness.

FORM 13256

Inst Drg

OCTOBER 2000

237

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : JOB SHEET TITLE :

IK1M INSTALLATION PROCEDURE

No.1 SHEET 3 of 3

STEP

ACTION

REF./INFO.

21.

Make the power and control connections to the sootblower terminal box; ensure there are no loose terminals or wiring.

Section 2

22.

Leave the sootblower ready for commissioning, with the power off and the blowing medium supply isolated.

FORM 13256

OCTOBER 2000

238

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : IK1M SERIES JOB SHEET TITLE : COMMISSIONING

No.2 SHEET 1 of 2

STEP

ACTION

1.

Isolate the sootblower from the blowing medium and power supply.

2.

Inspect the sootblower to ensure that installation work has been done as specified on the Installation Job Sheet, that power and blowing medium is available, and that any lubrication required has been carried out.

3.

Check that the sootblower can be operated safely without affecting any other equipment, and obtain any permit required.

4.

Arrange the sootblower for manual operation and ensure that the carriage is fully retracted.

Job Sheet 8

5.

Check the position of the limit switch arms; they should be at right angles to the centre line of the sootblower except when in contact with the trip bar; adjust if necessary.

Job Sheet 6

6.

Ensure that all moving parts of the sootblower are free to move, particularly the leadscrew, guide bar, and front support rollers, if fitted.

7.

Move the carriage forward until the integral trip pin engages the blowing medium turn-on linkage and adjust if necessary.

Job Sheet 3

8.

Move the carriage forward until it contacts the front limit switch. Check the travel against that specified on the Installation Drawing and adjust the limit switch position if necessary. Retract the sootblower fully on completion of this step.

Job Sheet 6

9.

Turn on the blowing medium supply and check for leakage and correct as necessary.

Job Sheet 5

Check the blowing pressure and adjust if necessary.

Job Sheet 4

10.

AUGUST 1996

REF./INFO.

FORM 13257

239

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : IK1M SERIES JOB SHEET TITLE : COMMISSIONING STEP

ACTION

11.

Check the electrical operation.

12.

Run the sootblower through a complete cycle and check:-

No.2 SHEET 2 of 2 REF./INFO. Job Sheet 7

(1) That it reverses automatically when the front limit switch is tripped. (2) That it stops when the rear limit switch is tripped. (3) That the poppet valve operates satisfactorily. 13.

Isolate the sootblower from the blowing medium and power supply and leave it ready for operation.

FORM 13257

AUGUST 1996

240

SECTION 12

DIAMOND POWER JOB SHEET

No.3

SOOTBLOWER TYPE : IK1M BLOWING MEDIUM TURN-ON LINKAGE JOB SHEET TITLE :

SHEET

ADJUSTING PROCEDURE

STEP

ACTION

1 of 1 REF./INFO.

CAUTION Do not operate the blowing medium turn-on linkage by hand with the poppet valve under pressure. 1.

Isolate the sootblower from the blowing medium and power supply.

2.

Move the carriage forward manually and note the position of the cam as the trip pin engages. The correct position is shown below.

3.

If the cam engagement position is incorrect, adjust it by shortening or lengthening the poppet valve adjusting rod.

4.

To adjust the length of the adjusting rod, loosen the locking nut and rotate the adjusting rod. Re-tighten the locking nut when the adjustment is correct.

5.

Re-connect the blowing medium and power supply.

AUGUST 2003

FORM 13258/1

241

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : JOB SHEET TITLE : STEP

No.4 SHEET

IK1M POPPET VALVE (CHECKING/SETTING THE BLOWING PRESSURE)

ACTION

1 of 2 REF./INFO.

NOTE The Blowing pressure can only be set under normal working conditions, i.e. with blowing medium available. 1.

Check that the sootblower is in the fully-retracted position.

2.

Check that the poppet valve is in the closed position.

3.

Isolate the poppet valve from the blowing medium supply.

4.

Isolate the sootblower from the power supply.

5.

Determine the blowing pressure.

6.

Remove the 3/8"in BSPT blanking plug from the air relief valve.

7.

Connect a suitable pressure gauge to the air relief valve outlet.

8.

Remove the lock pin plug from the poppet valve, and coat the threads with an anti-seize compound, replace the lock pin.

9.

Turn on the blowing medium supply.

MAY 1998

Section 4

FORM 14306

242

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : JOB SHEET TITLE :

SHEET

IK1M POPPET VALVE (CHECKING/SETTING THE BLOWING PRESSURE)

STEP

ACTION

10.

Open the poppet valve by running the sootblower carriage forward manually, and note the pressure gauge reading.

11.

Run the sootblower back manually to the fully-retracted position, ensuring that the poppet valve closes.

12.

Remove the lock pin plug.

13.

Using a screwdriver inserted through the tapped lock pin side hole, rotate the pressure control disc clockwise to lower or anti-clockwise to raise, thus decreasing or increasing the blowing pressure between the valve seat and the valve disc.

14

Replace the lock pin plug after adjustment has been completed, ensuring that it seats in one of the deep flutes in the disc.

15.

Repeat steps10-14 until the recommended blowing pressure is obtained.

16.

Isolate the poppet valve from the blowing medium supply.

17.

Remove the pressure gauge.

18.

Replace the blanking plug.

19.

Turn on the blowing medium supply

20.

Reconnect the power supply.

21.

Test run the sootblower.

FORM 14306

No.4 2 of 2 REF./INFO.

MAY 1998

243

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : JOB SHEET TITLE : STEP

IK1M PRESSURE SEALING POINTS (CHECKING PROCEDURE)

ACTION

No.5 SHEET 1 of 1 REF./INFO.

NOTE A check should be made for leakage at the pressure sealing points listed below. This should be carried out by operating the sootblower with the blowing medium on. 1.

Poppet Valve to Companion Flange : Tighten the gasket - if leakage persists, remove the poppet valve and renew the gasket.

Job Sheet 12

2.

Feed Tube to Poppet Valve : Tighten the gasket - if leakage persists, remove the poppet valve and renew the gasket.

Job Sheet 12

3.

Lance Tube : If leakage is detected, tighten the retaining bolts which secures the lance tube flange to the lance hub. If leakage persists after further tightening, renew the gasket.

Job Sheets 21 and 22

4.

Feed Tube Packing : Check for leakage. If leakage is detected, tighten the packing gland to eliminate the leakage. This should be carried out when the feed tube is at its hottest condition. Do not tighten the packing gland more than is necessary as this will shorten the packing life and increase the load on the motor. If the leakage persists, renew the packing.

5.

Poppet Valve Stem Packing : Check for leakage. If leakage is detected, tighten the brass packing nut beneath the valve spring by turning it in a clockwise direction until the leakage has been eliminated. If the leakage persists, renew the packing.

JULY 1996

Job Sheet 11

Job Sheet 15

FORM 13261

244

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : JOB SHEET TITLE : STEP

IK1M LIMIT SWITCHES: RENEWAL AND ADJUSTMENT

ACTION

1.

Isolate the sootblower from the power supply.

2.

Shut off the blowing medium supply.

3.

Unscrew the cable gland and connecting cable from the faulty limit switch, noting the correct wire termination points.

4.

Remove the two mounting screws, lockwashers, and nuts which secure the faulty limit switch to the mounting rail; remove the limit switch from the mounting rail. NOTE

No.6 SHEET 1 of 2 REF./INFO.

Before removing the faulty limit switch, mark its position on the mounting rail. When replacing the rear limit switch, it is important that it cannot be overrun by the trip bracket on the guide assembly fitted to the carriage.

5.

Select a new limit switch and install it in the reverse order to that given for removal. Ensure that the wires are fitted to the same termination points and that the switch is positioned within the marking points on the mounting rail.

FEBRUARY 2006

FORM 13262

245

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : JOB SHEET TITLE :

IK1M LIMIT SWITCHES: RENEWAL AND ADJUSTMENT

STEP 6.

ACTION

No.6 SHEET 2 of 2 REF./INFO.

Adjustment Procedure

6.1

Check that the contact roller engages correctly with the trip bracket on the carriage. The angular position of the roller crank can be altered by loosening the adjusting screw, turning the crank until the roller makes contact, and then tightening the screw.

6.2

Check for correct travel by ensuring that the limit switch (front or rear) is located the correct distance along the mounting rail. The switch can be adjusted by loosening the two mounting screws and moving the limit switch towards the front or rear of the sootblower.

Inst. Drg.

6.3

Operate the sootblower manually to check that the limit switches operate correctly when actuated by the carriage trip bracket. Care must be taken to ensure that the trip bracket does not overrun the rear limit switch.

Job Sheet 8

7.

Reconnect the power supply and test-run the sootblower

8.

Reconnect the blowing medium supply.

FORM 13262

FEBRUARY 2006

246

SECTION 12

DIAMOND POWER JOB SHEET

No.7

SOOTBLOWER TYPE : IK1M SERIES JOB SHEET TITLE : CHECKING THE ELECTRICAL OPERATION

SHEET

STEP

ACTION

1.

Switch on the power supply.

2.

Run the sootblower forward, manually, for a short distance but not far enough to clear the rear limit switch.

3.

Depress the ‘START’ push-button on the control panel.

4.

Check the motor rotation, the sootblower should travel forward. If the motor rotation is wrong, correct it as follows

4.1

Switch off the power supply.

4.2

Remove the terminal box cover.

4.3

Change over the power wires.

4.4

Replace the terminal box cover.

4.5

Switch on the power supply.

4.6

Depress the 'START' push-button again, and re-check as in Step 4.

5.

Run the sootblower forward through its complete cycle.

6.

At the end of the cycle, check that the sootblower is in the retracted position, with the blowing medium and power supply disconnected.

AUGUST 1996

1 of 1 REF./INFO.

Job Sheet 8

FORM 13263

247

SECTION 12

DIAMOND POWER JOB SHEET

No.8

SOOTBLOWER TYPE : IK1M SERIES JOB SHEET TITLE : MANUAL OPERATION STEP

SHEET 1 of 2

ACTION NOTE Each sootblower can be operated maintenance or in an emergency.

REF./INFO. manually

during

If a fault develops with a set of sootbiowers during automatic sequential operation, those in use should retract automatically. If they fail to do so for any reason, such as power failure, motor stalled, etc.; immediate action must be taken to manually withdraw the sootblowers involved. This is carried out by attaching a ratchet wrench to the square tang on the rear bulkhead

Section 9.

Manual operation is as follows: 1.

Isolate the sootblower from the power supply.

2.

Unscrew the securing nut and withdraw the locking pin from the leadscrew collar; this action disconnects the drive.

3.

Attach a ratchet wrench to the square tang. Turning the square tang clockwise results in the carriage returning towards the normally fully-retracted position. Conversely, turning the square tang counter-clockwise results in the carriage travelling forward and the lance tube going into the boiler.

AUGUST 1996

FORM 13264

248

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : IK1M SERIES JOB SHEET TITLE : MANUAL OPERATION STEP

ACTION

3. Cont’d

NOTE: (a) The sootblower must always be returned to the retracted position after manual operation, to reset the limit switches.

4. 5.

No.8 SHEET 2 of 2 REF./INFO.

(b) If the poppet valve is ‘ON’, blowing medium pressure will prevent easy removal of the locking pin on the leadscrew collar. In this case, the wrench should be used to turn the square tang and apply pressure in a clock-wise direction; this will then allow removal of the pin. Do not apply more than 75 NM (55 lbs.ft.) of torque to the square tang. After retraction has been completed, replace the locking pin in the collar, securing it with the nut. Re-connect the power supply.

FORM 13264

AUGUST 1996

249

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : IK1M SERIES FEED TUBE PACKING:- (SPLIT RING) JOB SHEET TITLE : ADJUSTING THE PACKING GLAND.

STEP

ACTION

1.

Isolate the sootblower from the power supply.

2.

Shut off the blowing medium supply.

3.

Tighten the two packing gland nuts, just enough to prevent leakage. The position of the packing gland nuts is shown in the illustration below. NOTE The feed tube packing, which provides a seal between the stationary feed tube and the translational lance hub, is compressed in the stuffing box by the adjustable packing gland surrounding the feed tube. The gland can be tightened until the gland shoulder butts against the end of the lance hub.

No.9 SHEET 1 of 2 REF./INFO.

On applications where superheated steam is used as the blowing medium, tighten the packing gland when the feed tube is at its hottest condition, as described in Step 3. This procedure will increase the life of the packing and prevent over-tightening due to thermal expansion. 4.

If persistant leakage occurs, and further tightening does not stop it, add additional packing up to a maximum of three rings.

AUGUST 1996

FORM 13265

250

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : IK1M SERIES FEED TUBE PACKING:- (SPLIT RING) JOB SHEET TITLE : ADJUSTING THE PACKING GLAND.

STEP 5.

ACTION

No.9 SHEET 2 of 2 REF./INFO.

Adding Additional Packing

5.1

Remove the nuts which secure the packing gland to the lance hub. Slide the packing gland towards the rear bulkhead.

5.2

Fit new additional split-ring packing into the stuffing box, using the optional packing tool.

5.3

Replace the packing gland.

5.4

Replace the packing gland nuts, and hand-tighten them only.

6.

Turn on the blowing medium supply.

7.

Reconnect the power supply.

8.

Test-run the sootblower.

9.

Adjust the packing gland, if necessary, to ensure a tight seal, by tightening the nuts evenly.

FORM 13265

Section 9

AUGUST 1996

251

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : IK1M SERIES FEED TUBE PACKING:- (SPLIT RING) JOB SHEET TITLE : RENEWAL

STEP

ACTION

1.

Isolate the sootblower from the power supply.

2.

Shut off the blowing medium supply.

3.

Move the carriage forward, manually, a short distance, to obtain working clearance.

4.

Remove the two packing gland nuts and two locknuts which hold the packing gland in position.

5.

Slide the packing gland to the rear of the feed tube.

6.

Remove the old packing rings with a flexible packing hook. Direct the hook at the bore of the stuffing box to avoid damaging the feed tube.

7.

Carefully clean the carriage hub stuffing box, packing gland, and all components. A solvent may be required to remove any traces of gum.

8.

Inspect the feed tube and stuffing box for scratches, nicks, or wear.

9.

Repair or renew any damaged parts.

AUGUST 1996

No.10 SHEET 1 of 2 REF./INFO.

Job Sheet 8

FORM 13266

252

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : IK1M SERIES FEED TUBE PACKING:- (SPLIT RING) JOB SHEET TITLE : RENEWAL

STEP

ACTION

10.

Lay out each packing ring in the correct sequence and direction for installation.

11.

Using both hands, and with the diagonal cut held upward, fit the first packing ring on the feed tube.

12.

Gently insert the packing ring into the stutting box.

13.

Clamp a feed tube packing tool around the feed tube, with the bevelled end towards the stuffing box; gently press the packing ring into place.

14.

Repeat the procedure with the remaining packing rings, indexing each diagonal cut 90° with the preceding ring.

15.

Insert the last packing ring, and reverse the packing tool, placing the square end towards the stuffing box; firmly press the packing ring into position.

16.

Remove the packing tool and slide the packing gland into position.

17.

Tighten the gland nuts evenly until the packing is slightly compressed; maximum torque is 10 NM (7 lbs.ft.).

18.

Turn on the blowing medium supply.

19.

Reconnect the power supply.

20.

Test-run the sootblower.

21.

Adjust the packing gland, if necessary.

FORM 13266

No.10 SHEET 2 of 2 REF./INFO.

Section 9.

AUGUST 1996

253

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : IK1M SERIES POPPET VALVE:JOB SHEET TITLE :

REMOVAL FROM SOOTBLOWER.

STEP

ACTION

1.

Isolate the sootblower from the power supply to prevent automatic operation of the unit.

2.

Shut off the blowing medium supply.

3.

Disconnect the air relief valve from the scavenging air line (if fitted).

4.

Remove the yoke cotter pin and withdraw the valve yoke pin from the yoke.

5.

Disconnect the poppet valve at the companion flange.

6.

Disconnect the poppet valve at the valve outlet flange.

7.

Remove the poppet valve from the sootblower.

AUGUST 2003

No.11C SHEET 1 of 1 REF./INFO.

FORM 14858/2

254

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : IK1M SERIES POPPET VALVE:- DISMANTLING JOB SHEET TITLE : STEP

ACTION

No.12 SHEET 1 of 1 REF./INFO.

NOTE This Job Sheet covers partial dismantling of the poppet valve in preparation for valve seat lapping or renewal. Dismantling procedure is as follows. 1.

Remove the poppet valve from the sootblower.

2.

Depress the valve spring just enough to allow removal of the yoke .

3. 4. 5. 6. 7.

Job Sheet 11

Remove the yoke and release the spring tension. Lift off the valve spring retainer and the valve spring. Remove the valve stem and disc assembly. Remove the packing nut and packing washer.

Job Sheet 13 Section 9

Remove the packing from the valve stem.

AUGUST 1996

FORM 13268

255

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : JOB SHEET TITLE : STEP

No.13

IK1M SERIES

SHEET

POPPET VALVE :

1 of 2

(Valve Stem Packing Adjustment Procedure)

ACTION

REF./INFO.

NOTE If leakage occurs at the valve stem at the top of the poppet valve body, this is an indication that the valve stem packing nut requires tightening, or that the valve stem packing should be renewed. 1.

Using the valve packing spanner, turn the brass packing nut beneath the valve spring in a clockwise direction, tightening just enough to prevent leakage. Overtightening will shorten the packing life and may cause the valve stem to bind. The packing nut should be torqued to 23 NM (17 lbs.ft.) maximum. Refer also to note 6.

Section 9

2.

If persistant leakage occurs, and further tightening does not stop it, renew the packing.

Job Sheet 14

OCTOBER 2006

FORM 14307

256

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : JOB SHEET TITLE : STEP

No.13

IK1M SERIES

SHEET

POPPET VALVE :

2 of 2

(Valve Stem Packing Adjustment Procedure)

ACTION

REF./INFO.

NOTES: 1. Valve Stem Guide, Lock Pin and Plug threads to be coated with ‘Molykote Gn Plus’.(907145-0002) 2. Torque Valve Stem Guide to 80Nm (60lb.ft) 6. This clearance dimension should be set between the bottom face of the packing nut hex and the top face of the valve stem guide hex. Increasing this dimension above 8mm can cause the spring to hard stop when the valve is fully open. Decreasing this dimension below 3.5mm may cause problems with the valve stem packing. 7. Ensure valve stem packing rings are assembled as shown.

OCTOBER 2006

FORM 14307

257

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : JOB SHEET TITLE :

IK1M SERIES POPPET VALVE : (Valve Stem Packing Renewal)

No.14 SHEET 1 of 2

STEP

ACTION

1.

Isolate the sootblower from the power supply to prevent the automatic operation of the sootblower.

2.

Shut off the blowing medium supply.

3.

Remove the poppet valve from the sootblower. NOTE To prevent the valve stem and disc assembly from falling into the poppet valve, the valve stem should be held up during this operation.

5.

Remove the yoke and release the spring tension.

6.

Lift off the spring retainer and the spring; then remove the packing nut, packing washer, and old packing from the valve stem.

Job Sheet 13

7.

Insert the new packing, staggering the splits in the rings by 90°. Use only the packing specified in the Parts list.

Sections 10 and 11

8.

Seat each ring separately.

9.

Reassemble the poppet valve in the reverse order to that given for dismantling. CAUTION Tighten the packing just enough to ensure that the spring is not coil bound when the valve is fully open. A valve packing spanner, for turning the packing nut, is available for this operation. The packing nut should be torqued to 23 NM (17 lb.ft) maximum. Refer also to note 6.

OCTOBER 2006

REF./INFO.

Job Sheet 11

Job Sheet 18 Job Sheet 13

FORM 13270

258

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : JOB SHEET TITLE : STEP

IK1M SERIES POPPET VALVE : (Valve Stem Packing Renewal)

ACTION

No.14 SHEET 2 of 2 REF./INFO.

NOTES: 1. Valve Stem Guide, Lock Pin and Plug threads to be coated with ‘Molykote Gn Plus’.(907145-0002) 2. Torque Valve Stem Guide to 80Nm (60lb.ft) 6. This clearance dimension should be set between the bottom face of the packing nut hex and the top face of the valve stem guide hex. Increasing this dimension above 8mm can cause the spring to hard stop when the valve is fully open. Decreasing this dimension below 3.5mm may cause problems with the valve stem packing. 7. Ensure valve stem packing rings are assembled as shown.

OCTOBER 2006

FORM 13270

259

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : IK1M Series POPPET VALVE : Tools and Equipment JOB SHEET TITLE : Needed for Lapping the Valve Seat.

STEP

ACTION

No.15 SHEET 1 of 1 REF./INFO.

NOTE The tools and equipment required for lapping are as follows:1.

One disc is serrated, for rough lapping, and the other disc is plain, for finishing and burnishing. The surfaces of both discs must must be kept lapped flat; a lapping machine, or surface plate , can be used to maintain the disc surfaces.

2.

Lapping Compounds:Diamond Compound, Hyprez 45. Diamond Compound, Hyprez 14. Diamond Compound, Hyprez 3.

Section 9

3.

Lapping Equipment:Wobble stick, manually-operated valve grinder, or small capacity air motor with flexible shaft.

Section 9

4.

Inspection Equipment:Blue block - for checking flatness. An unused lapping disc, which is absolutely flat, can also be used. Prussian blue - to determine high and low markings.

JULY 1996

FORM 13271

260

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : IK1M SERIES POPPET VALVE : JOB SHEET TITLE :

VALVE SEAT LAPPING PROCEDURE

STEP

ACTION

1.

Dismantle the poppet valve.

2.

Charge an unused serrated lapping disc with Hyprez 45 compound.

3.

Rough-lap for two five-minute cycles, checking the valve seat surface at the end of each cycle.

4.

Clean off any traces of compound from the seat.

5.

Charge an unused plain lapping disc with Hyprez 14 compound.

6.

Finish lap for two-five minute cycles, checking the valve seat surfaces at the end of each cycle.

7.

Clean off any traces of compound from the seat.

8.

Charge the plain lapping disc with Hyprez 3 compound

9.

Burnish-lap for five minutes.

10.

Clean off any traces of compound from the seat.

11.

Cover the surface of a blue block with a very thin uniform coating of Prussian blue.

12.

Place the blue block carefully on the lapped seat.

13.

Applying finger pressure only, move the blue block back and forth slightly.

14.

Carefully remove the blue block.

15.

Inspect the lapped seat. If the dye transfer is uniform, the seat is satisfactory; if not uniform, then the seat is not flat and the complete lapping procedure must be repeated.

16.

After the lapping procedure is completed, clean the valve body with white spirit, using a small bristle brush.

JULY 1996

No.16 SHEET 1 of 2 REF./INFO. Job Sheet 12 Section 9

Section 9

FORM 13272

261

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : IK1M SERIES POPPET VALVE : JOB SHEET TITLE :

VALVE SEAT LAPPING PROCEDURE

STEP

ACTION

17.

Dry the body with air, or by wiping. Special care should be taken to remove all minute particles of fuzz and paper shreds.

18.

Reassemble the valve in the reverse order to that given for dismantling.

FORM 13272

No.16 SHEET 2 of 2 REF./INFO.

Job Sheet 18

JULY 1996

262

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : JOB SHEET TITLE : STEP

IK1M SERIES POPPET VALVE : SEAT RENEWAL

ACTION

No.17 SHEET 1 of 2 REF./INFO.

1.

Dismantle the poppet valve.

Job Sheet 12

2.

Remove the old seat by machining the weld away. Avoid removing material from the shoulder under the seat, as this shoulder positions the new seat to the correct depth in the body.

Poppet Valve Assembly. Section 10

3.

Assemble and position the new seat into the body, using a seat protector. The protector, in addition to preventing injurious material from reaching the seat, locates the seat correctly in relation to the valve stem guide. Care should be taken to ensure that the pressure control disc is correctly orientated. Tighten the locknut finger-tight to hold down the seat during welding.

Section 9

4.

Select an approved welding rod and hold it at approximately 85°, to deposit more metal on the seat than on the body. Two 2.4mm (3/32”in) diameter rods should be used per seat. * Equivalent to AWS 5.18 Class ER-70s-G or BS2901 Part1(1970) A18. * Equivalent to AWS E7028 or BS639 (1976) E5144H.

5.

*MIG wire * Welding Rod

Using D.C. welding equipment set at 82-92 amperes (reverse polarity), start welding at 90° from the point of least clearance between the body and the seat. Make a single pass weld only, with no initial tacking. Proceed towards the point of least clearance.

NOVEMBER 2004

FORM 13273

263

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : JOB SHEET TITLE :

IK1M SERIES POPPET VALVE : SEAT RENEWAL

No.17 SHEET 2 of 2

STEP

ACTION

6.

Overlap 13-19mm (1/2”in - 3/4”in) between rod applications. Clean the slag from the welded area between applications.

7.

Upon completion of welding, chip off any remaining slag from the weld.

8.

Ensuring that the sealing surfaces are protected, carefully wire brush the valve body.

9.

Laap the valve seat to ensure a flat surface.

Job Sheet 16

Reasemble the valve in the reverse order to that given for dismantling.

Job Sheet 18

10.

FORM 13273

REF./INFO.

NOVEMBER 2004

264

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : IK1M SERIES POPPET VALVE : JOB SHEET TITLE :

REASSEMBLY PROCEDURE

STEP

ACTION

No.18 SHEET 1 of 1 REF./INFO.

NOTE This procedure covers reassembly after partial dismantling for seat-lapping or renewal. The valve should be reassembled in clean conditions to reduce the possibility of grit being trapped between the sealing faces. The reassembly procedure is as follows : 1.

Place the poppet valve on its side.

2.

Install the stem and disc assembly, taking care to ensure that the sealing faces are clean and undamaged. NOTE Maintain firm contact between the sealing faces during the subsequent steps.

3.

Insert the new valve stem packing, staggering the splits in the rings by 90°; seat each ring separately.

4.

Replace the packing washer.

5.

Replace the packing nut and screw it down hand tight only; adjust on assembly.

6.

Place the valve body in an upright position.

7.

Replace the valve spring, valve spring retainer and valve yoke. NOTE If the valve is not to be put into service immediately, the inlet and outlet should be sealed to protect the internals.

10.

Replace the poppet valve on the sootblower.

JULY 1996

Job Sheet 19

FORM 13274

265

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : IK1M SERIES POPPET VALVE:JOB SHEET TITLE :

REPLACING ON THE SOOTBLOWER.

STEP

ACTION

1.

Ensure that the sootblower is isolated from the power supply and that the blowing medium supply is shut off.

2.

Ensure that the valve inlet and outlet sealing surfaces are clean and undamaged.

3.

Fit a new feed tube gasket to the valve outlet flange.

4.

Position the poppet valve on the sootblower with the four studs projecting through the rear bulkhead.

5.

Ensure that the feed tube retaining ring groove is clean and the edges free from burrs.

6.

Ensure retaining ring is fully seated in the groove with the sharpest edge of the retaining ring installed towards the rear bulkhead.

7.

Push the feed tube through the rear bulkhead until it makes contact with the feed tube gasket.

8.

Slide the feed tube clamping plate along the feed tube ensuring that the counter bore in the clamping plate engages squarely over the retaining ring.

NOVEMBER 2001

No.19B SHEET 1 of 2 REF./INFO.

FORM 14859/1

266

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : IK1M SERIES POPPET VALVE:JOB SHEET TITLE :

REPLACING ON THE SOOTBLOWER.

STEP

ACTION

9.

Loosely fit the locking washers and securing nuts which retains the poppet valve to the mounting and clamping plates via the rear bulkhead.

10.

Locate and tighten the two screws of the clamping plate in turn by torquing them in small increments to 41 Nm (30 lb.ft.) maximum. This procedure will ensure that the clamping plate is pulled squarely on to the retaining ring compressing the feed gasket between the poppet valve and the end of the feed tube.

11.

Tighten the poppet valve locking washers and securing nuts in turn by torquing them in small increments to 75 Nm (55 lb. ft) maximum. For each nut, bend up only one tab of the locking washer.

12.

Re-connect the poppet valve trigger to the yoke with the pin and cotter pin.

13.

Fit a new companion flange gasket.

14.

Re-connect the companion flange to the poppet valve.

15.

Re-connect the scavenging air line to the air relief valve.

16.

Re-connect the blowing medium and power supply.

17.

Test-run the sootblower, checking for leaks.

18.

Reset the blowing pressure.

FORM 14859/1

No.19B SHEET 2 of 2 REF./INFO.

(if fitted)

Section 4

NOVEMBER 2001

267

SECTION 12

DIAMOND POWER JOB SHEET

No.20

SOOTBLOWER TYPE : IK1M SERIES JOB SHEET TITLE : LANCE TUBE FLANGE GASKETADJUSTING PROCEDURE

SHEET

STEP

ACTION

1 of 1 REF./INFO.

NOTE The lance tube flange gasket is compressed between the lance hub and the lance tube flange by tightening the retaining bolts as follows:1.

Tighten the six bolts in the sequence shown in the illustration below. The bolts should be torqued to 23 Nm (17 ft. lbs.) NOTE The torque figure given applies to bolts coated with antiseize compound. Higher torque may be necessary when retightening in service.

2.

Section 7

If persistant leakage occurs and further tightening does not stop it, renew the gasket.

AUGUST 1996

FORM 13278

268

SECTION 2

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : JOB SHEET TITLE : STEP

IK1M SERIES LANCE TUBE FLANGE GASKET :RENEWAL

ACTION

1.

Ensure that the carriage is in the fully-retracted position.

2.

Isolate the sootblower from the power supply.

3.

Shut off the blowing medium supply.

4.

Remove the four nuts which secure the poppet valve to the rear bulkhead; remove the poppet valve.

5.

Remove the feed tube retaining ring.

6.

Slide the feed tube to the rear of the sootblower, ensuring that the feed tube and lance tube are supported securely.

7.

Remove the six bolts and lockwashers which secure the lance tube flange to the lance hub flange.

8.

Move the lance tube forward far enough to clear the carriage hub.

9.

Remove the existing lance tube flange gasket.

10.

No.21 SHEET 1 of 2 REF./INFO.

Examine the locating face at the lance hub and lance tube flange.

AUGUST 1996

FORM 13279

269

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : JOB SHEET TITLE :

No.21

IK1M SERIES

SHEET

LANCE TUBE FLANGE GASKET :RENEWAL

2 of 2

STEP

ACTION

11.

Clean and remove any loose particles of dirt or existing gasket, as applicable.

12.

Install the new gasket.

13.

Reasemble in dismantling.

the

reverse

order

REF./INFO.

to

that

given

for

NOTE Coat the threads of the six lance hub flange bolts with anti-seize compound before reassembly, and torque to 23 NM (17 lb/ft). The torque figure given applies to bolts coated with antiseize compound. Higher torque may be necessary when retightening in service.

FORM 13279

AUGUST 1996

270

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : JOB SHEET TITLE : STEP

IK1M SERIES LANCE AND FEED TUBE :REMOVAL ACTION

No.22A SHEET 1 of 2 REF./INFO.

NOTE This Job Sheet should be used in conjunction with Job Sheet No.23 Carriage Removal and Replacement. 1.

Isolate the sootblower from the power supply.

2.

Shut off the blowing medium supply.

3.

Remove one of the front support rollers.

4.

Move the carriage forward manually to obtain sufficient access to feed tube clamping bolts and nuts.

5.

Remove the four nuts which clamp the feed tube to the poppet valve via the mounting plate and slide the clamping plate forward.

6.

Remove the feed tube retaining ring.

7.

Push the feed tube forward and remove the clamping plate.

8.

Disconnect the air relief valve from the scavenging air line.

9.

Remove the yoke cotter pin and withdraw the valve yoke pin from the yoke.

10.

Fig 13 Job Sheet 8

Job Sheet 11

Remove and aside the poppet valve assembly.

APRIL 1997

FORM 14857

271

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : JOB SHEET TITLE :

IK1M SERIES LANCE AND FEED TUBE :REMOVAL

STEP

ACTION

11.

Withdraw the feed tube via the rear bulkhead plate.

12.

Support the lance tube.

13.

Remove the six bolts and lockwashers from the lance hub flange.

14.

Withdraw the lance tube via the rear bulkhead plate.

15.

Inspect the lance and feed tube, repair or renew as required.

16.

Reassemble in the reverse order to that given for dismantling again in conjunction with Job Sheet 23.

No.22A SHEET 2 of 2 REF./INFO.

NOTE Coat the threads of the six lance hub flange bolts with anti-seize compound before reassembly, and torque to 23 NM (17 lb/ft). The torque figure given applies to bolts coated with antiseize compound. Higher torque may be necessary when retightening in service. 17.

Re-connect the blowing medium supply.

18.

Re-connect the power supply.

19.

Test-run the sootblower.

FORM 14857

APRIL 1997

272

SECTION 12

DIAMOND POWER JOB SHEET

No.23A

SOOTBLOWER TYPE : IK1M SERIES JOB SHEET TITLE : CARRIAGE :REMOVAL AND REPLACEMENT

SHEET

STEP

ACTION

1 of 2 REF./INFO.

NOTE This Job Sheet covers the removal of the carriage from the sootblower for inspection and overhaul, or for the replacement of a spare carriage. Dismantling for overhaul is covered by Job Sheet 24. 1.

Isolate the sootblower from the blowing medium and power supply.

2.

Disconnect the power supply cable from the motor.

3.

After disconnection, arrange slings to support the lance and carriage.

4.

Tension the slings to take the weight of the carriage.

5.

Remove the two roll pins at the rear bulkhead and withdraw the guide tube.

6.

Remove the screw from the leadscrew support tube at the rear bulkhead.

7.

Remove the roll pin which secures the collar to the leadscrew.

8.

Withdraw the leadscrew by unscrewing it through the carriage drive nut.

9.

Disconnect the four nuts which secure the feed tube clamping plate to the poppet valve.

10.

Slide the feed tube forward to expose the feed tube retaining ring.

11.

Remove the feed tube retaining ring and clamping plate.

12.

Slide the feed tube through the gland and into the lance tube.

MAY 1998

FORM 13281/1

273

SECTION 12

DIAMOND POWER JOB SHEET

No.23A

SOOTBLOWER TYPE : IK1M SERIES JOB SHEET TITLE : CARRIAGE :REMOVAL AND REPLACEMENT

SHEET

STEP

ACTION

13.

Disconnect the six screws which secure the lance to the carriage.

14.

Slide the lance and feed tube forward to clear the carriage.

15.

Lower the carriage onto the gantry.

16.

Remove the carriage to the bench for inspection and overhaul.

17.

Re-assemble in the reverse order to that given for removal.

18.

Re-connect the power supply cable to the motor.

19.

Re-connect the blowing medium and power supply.

FORM 13281/1

2 of 2 REF./INFO.

MAY 1998

274

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : IK1M SERIES JOB SHEET TITLE : CARRIAGE:-

DISMANTLING AND REASSEMBLY

STEP

ACTION

1.

Remove the four screws and lockwashers which secure the motor to the housing. Save the screws for re-use, but discard the lockwashers. Withdraw the motor; save the collar and the key for re-use.

2.

Remove and discard the expansion plug and the circlip; withdraw the worm shaft. NOTE To avoid damage to the worm gear, ensure that it is free to rotate as the worm is withdrawn.

3.

Remove the chain guard and chain (if fitted).

4.

Remove the eight screws and lockwashers which secure the bearing carrier to the housing and withdraw the bearing carrier complete with its bearing; save the gaskets for reuse.

5.

Withdraw the drive nut complete with its bearing and worm wheel; the worm wheel and drive nut can now be examined and renewed if necessary.

6.

Remove the bearing from the carrier for examination and or replacement, as required. The seal should be discarded.

7.

Remove the retaining ring and pull off the flange.

8.

Remove the retaining ring at the front end of the lance hub, and withdraw the lance hub, complete with the hub and the bearing, from the carriage housing.

9.

Remove the retaining ring which secures the hub and bearing to the lance hub; the bearing can now be removed from the lance hub for examination.

10.

No.24 SHEET 1 of 2 REF./INFO.

Examine the guide nuts and renew if necessary.

AUGUST 1996

FORM 13282

275

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : IK1M SERIES JOB SHEET TITLE : CARRIAGE:-

DISMANTLING AND REASSEMBLY

STEP

ACTION

11.

Reassembly - General Before reassembly, all parts should be cleaned and examined for wear or damage. New oil seals, expansion plugs, and lockwashers should be used. The worm gear cavity should be packed with grease as specified in the lubrication chart.

No.24 SHEET 2 of 2 REF./INFO. Section 7

The procedure to be adopted is generally the reverse of that used in dismantling but, if a new worm gear or drive nut is fitted, the drive nut end play relative to the housing must be checked to ensure that it is within the limits, 0.127 mm to 0.508mm (0.005 in. to 0.020 in). The end play can be varied by adjusting the gasket thickness between the bearing carrier and the housing. Gaskets, are available in two thicknesses, 0.381 mm and 0,787 mm (0.015 in. and 0.031 in). If a new sprocket (when applicable) requires to be fitted, remove the wire from the cap screws before dismantling. NOTE On reassembly torque cap screws to 5.6 Nm (5Oin lbs.); torque pattern one time round only and rewire cap screws together in pairs. 12.

After reassembly, test-run and check for noise and leaks.

FORM 13282

AUGUST 1996

276

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : JOB SHEET TITLE :

IK1M WALLBOX - DISMANTLING. (POSITIVE PRESSURE)

STEP

ACTION

1.

Isolate the sootblower from the power supply to prevent automatic operation of the unit.

2.

Shut off the blowing medium supply.

3.

Ensure that the carriage is in the fully retracted position.

4.

Attach a sling around the lifting points at the front and rear of the sootblower.

5.

Remove the four nuts, washers and bolts which connects the welded wallsleeve and flange to the sootblower.

6.

Reposition the sootblower to separate it from the wallsleeve and flange arrangement.

7.

Remove the seal plate from the wallbox.

8.

Check that there is enough slack on the control and power cables to allow the sootblower to be pulled back until the lance is clear of the wallbox. If not, it may be necessary to disconnect the cables at the sootblower terminal box.

MARCH 2006

No.25C SHEET 1 of 2 REF./INFO.

Section 10 F15417

FORM 14856/2

277

SECTION 12

DIAMOND POWER JOB SHEET SOOTBLOWER TYPE : JOB SHEET TITLE :

IK1M WALLBOX - DISMANTLING. (POSITIVE PRESSURE)

STEP 9.

ACTION

No.25C SHEET 2 of 2 REF./INFO.

Slacken or remove the four seal plate adjusting screws.

10.

Re-assemble the wallbox using existing / new parts as follows.

11.

Re-ssemble the seal plates to the wallbox with the machined face of the front seal plate towards the wallbox flange.

12.

Apply dow corning 744 silicone sealant to the faces of the wallbox housing.

13.

When the M12 mounting bolts are tightened the wallbox seal plates must be adjusted to give the correct clearance by turning the four(4) M10 seal plate adjusting screws clockwise until there is no seal plate movement. Turn each screw counter-clockwise by I flat (1/6th turn). Check that the seal plates are free to move.

14

Wallbox Renewal

14.1

Disconnect the sealing air supply from the wallbox.

14.2

Remove the weld between the wallbox and the wallsleeve

14.3

Remove the wallbox housing.

14.4

Position and weld a replacement wallbox to the wallsleeve.

15

Re-install the sootblower in the reverse order to that given for removal paying particular attention to steps 11-13.

16.

Reconnect the sealing air supply to the wallbox.

17

Turn on the blowing medium supply.

18

Reconnect the power supply.

19

Test run the sootblower.

FORM 14856/2

MARCH 2006

278

SECTION 13

SECTION 13 FAULT FINDING

SYMPTOM Sootblower fails to start.

POSSIBLE CAUSE (1) No power voltage: a. No power to starter b. Overload tripped or heater burned out. c. Open circuit between starter and motor.

REMEDY

Check power supply. Renew heater. Check contiuity.

(2) Motor winding open or shorted.

Test and rectify circuit.

(3) One power line open: a.The overload relay has operated without the motor having started because of a singlephase condition.

Re-establish continuity.

(4) Forward contactor fails Check continuity. to operate: a. No voltage from panel on lines A and B. b. No signal from panel on line D. c. If operated manually, ‘START’ push-button fails to make contact. d. Overload contacts are open. e. The coil has burned out. f. Loose wire in forward coil circuit.

AUGUST 1996

(PAGE 1 of 3)

FORM 13283

279

SECTION 13

SECTION 13 FAULT FINDING

SYMPTOM Sootblower jams or fails to travel.

POSSIBLE CAUSE Drive motor overloaded: (1) Element fouling on boiler internals.

REMEDY

Re-align internal bearing in hot and cold positions.

(2) Feed tube packing is too Adjust the packing gland. tight.

Sootblower fails to stop.

AUGUST 1996

(3) Valve stem fouling binding in valve guide.

Dismantle the poppet valve and inspect the valve stem. Re-new the stem if it is damaged.

(4) Worm gear stripped.

Dismantle gear.

(5) Pipework is incorrectly supported, strain transmitted to sootblower.

Inspect pipework and re-run if it is necessary.

(6) Drive nut failure.

Dismantle carriage and renew drive nut.

(1) Limit switch has not operated,trip lever loose.

Tighten the trip lever.

(2) The limit switch has jammed.

Free or re-new the limit switch.

(3) Forward / Reverse contactor has failed to operate.

Inspect contactor and adjust if necessary.

(PAGE 2 of 3)

carriage

and

renew

FORM 13283

280

SECTION 13

SECTION 13 FAULT FINDING

SYMPTOM Blowing medium fails to turn off.

Lance tube fails to rotate although the motor runs.

Boiler tube abrasion or baffle erosion present upon internal inspection.

AUGUST 1996

POSSIBLE CAUSE

REMEDY

(1) Poppet valve stem is sticking in guide.

Dismantle the poppet valve and inspect the valve stem. Re-new stem if faulty.

(2) Valve yoke is broken or detached from valve stem

Dismantle the poppet valve and re-new the valve yoke.

(3) Valve spring broken.

Dismantle poppet valve and renew spring.

(4) Valve disc loose on the valve stem.

Dismantle the poppet valve and inspect the valve disc. Re-new the disc if necessary.

(5) Operating pin broken.

Re-new pin.

(6) Cam and pin are out of alignment.

Re-align and re-new if necessary.

(1) Sprocket teeth stripped.

Renew sprocket.

(2) Hub key sheared.

Renew hub key.

(3) Chain broken.

Rejoin chain or renew.

(1) Blowing pressure too high.

Re-set to recommended blowing pressure.

(2) Excess moisture present in blowing medium.

Increase temperature of blowing medium.

(3) Element out of alignment.

Re-align element.

(PAGE 3 of 3)

FORM 13283

281

SECTION 14

SECTION 14 STORAGE, HANDLING, AND INSPECTION DURING STORAGE

General Damage resulting from improper handling on site, site storage, or storage maintenance is not the responsibility of the equipment supplier. Because of the many variables involved in site storage, however, there is always the possibility of some damage occurring, particularly to electrical equipment on sootblowers. This risk can be minimised by observing the instructions given in the following paragraphs and the handling details given in paragraphs 14.2.1 and 14.2.2 14.1

STORAGE

14.1.1 Initial Receipt at Site On receipt at site, it is recommended that IK-1M sootblowers should be removed from their crates or boxes, all polythene wrappings removed, and the equipment then stored in a dry building where temperature and humidity are controlled to prevent condensation. Sootblowers should be stored the correct way up and not on their sides. 14.1.2 Stacking Sootblowers Each sootblower should be placed on timber battens of sufficient thickness to keep all parts of the equipment well clear of the ground. The battens should be placed under the main beams at approximately one third of the length in from each end. Equipment may be stacked up to three units high, in double rows, by placing timber battens across each pair directly above the ground support battens. To allow for inspection, electrical boxes should face outwards. 14.1.3 Feed Tube and Poppet Valve Packing The feed tube packing and the poppet valve stem packing should be removed and, if undamaged by removal, stored for reinstatement prior to commissioning. The method of doing this and the part numbers for replacements are included in the relevant sections of this manual. 14.2

HANDLING

14.2.1 Handling Packed Equipment Sootblowers which are packed in boxes or crates must be handled by slinging the boxes. using two slings. Boxes and crates supplied are specially reinforced for the purpose. A fork lift truck should not be used for handling IK-1M sootblowers .

SEPTEMBER 1998

FORM 13285/3

282

SECTION 14

14.2.2 Handling Unpacked Equipment (Figure 18) Sootblowers should only be moved by slinging from the lifting points provided on the top of the beam. Use of a two-point sling or fork lift truck is likely to cause damage and prevent proper operation when installed.

FIG.18 TYPICAL SLINGING ARRANGEMENT 14.3

INSPECTION DURING STORAGE

14.3.1 Frequency IK-1M sootblowers should be inspected at monthly intervals. with particular care being given to ensuring that the closures (tape, caps. etc.) on all openings remain intact.

FORM 13285/3

SEPTEMBER 1998

283