General
Installation drawings are supplied with each set of sootblowers. These drawings show the location of the sootblowers in the installation, the blowing medium pressure, overall dimensions, method of mounting, extent of Diamond Power equipment supplied, and connections to be made.
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 sootblower is mounted on the boiler at two points, front and rear. At the front mounting point, the wallbox is welded on-site to a boiler wall sleeve, normally provided by the customer, and, at the rear, by a rear support on the sootblower which is site-welded to the installation supporting steelwork. For condensate drainage, reference should be made to the relevent installation drawings for full mounting details.
3.3 Lifting the Sootblower
When lifting the sootblower into position, the lifting lugs provided on top of 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 supply pipework is site-welded to the companion flange which is bolted to the poppet valve flange. The pipework arrangement must not strain the sootblower mounting.
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 Scavenging Air
As described in Section 2, a scavenging air supply is used for removing the corrosive furnace gases from the sootblower when it is inoperative. On positive pressure installations, pressurised purge air should be used to overcome furnace pressure.
SECTION 3
FORM 12957 APRIL 1995
3.6 Lubrication
Reference should be made to the Lubrication Chart in Section 7.
3.7 Electrical Connections
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 correct connections required.
MAY 1998 FORM 14536
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 in Section 12 for more detailed instructions, and to the commissioning check list (Job Sheet No.3) 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 or 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 boiler 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.
It should then be operated from the local control to check for correct direction of motor rotation and correct operation of the 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 boiler on-load, as described in the following paragraphs.
4.3 Stage 3 - Pre-Operational Checks (Fig.15)
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 boiler 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.
SECTION 4
FORM 14536 MAY 1998
4.3 Stage 3 - Pre-Operational Checks (Fig.15)(Continued)
The recommended blowing pressure is given on the Equipment Identification Form at the front of this manual. 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 in Fig.15 below.
FIG.15 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 2.5mm (0.1in.) on assembly. Adjustment is made by withdrawing the lock pin and rotating the pressure control disc. The pressure control disc must be locked in position after adjustment, by replacing the lock pin.
The end of the lock pin must engage one of the deep grooves in the pressure control disc; each groove represents approximately 0.2mm (0.008in.) vertical movement of the pressure control disc.
The sootblower should be operated through several complete cycles, with the blowing medium on, to check that it is functioning correctly before finally putting it into service.
OCTOBER 2000 FORM 12959