SECTION TITLE PAGE 1 GENERAL DESCRIPTION 1.1 General 1.2 Opening Controls 1.3 Application 1.4 Cleaning Principle 1.5 Operating Cycle 1.6 Identification 2 COMPONENT DESCRIPTION 2.1 ELECTRICAL 2.1.1 Electrical Components 2.1.2 Function 2.2 MOUNTING 2.2.1 Beam
2.2.2 Front Support Plate 2.2.3 Wallbox
2.2.4 Pressure Regulating Valve (When Applicable) 2.2.5 Rear Support
2.2.6 Auxiliary Support 2.3 MECHANICAL
2.3.1 Carriage
2.3.2 Electric Drive Motor 2.3.3 Expanda Cable 2.4 BLOWING MEDIUM 2.4.1 Poppet Valve
2.4.2 Poppet Valve Operation 2.4.3 Air Relief Valve
2.4.4 Feed Tube 2.4.5 Lance Tube 2.4.6 Nozzle
2.5 OPERATING SWITCHES
2.5.1 Limit Switches / Pressure Switch 2.6 MANUAL OPERATION
2.6.1 Emergency Retract Air Tool 3 INSTALLATION INSTRUCTION 3.1 Location
3.2 Mounting
3.3 Lifting the Sootblower
3.4 Blowing Medium Supply Pipework 3.5 Scavenging Air 3.6 Lubrication 3.7 Electrical Connections 19 19 19 19 19 20 20 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 34 34 34 34 34 34 35 35
IK545 CONTENTS (Continued)
SECTION TITLE PAGE 4 COMMISSIONING
4.1 Stage 1 - Inspection
4.2 Stage 2 - Functional Checks 4.3 Stage 3 - Pre-Operational Checks 5 OPERATION INSTRUCTIONS 5.1 Operation Precautions 5.2 Blowing Schedule 6 MAINTENANCE INSTRUCTIONS 6.1 Operational Checks 6.2 Periodic Inspection 6.3 Annual Maintenance 6.4 Major Overhaul 6.5 Manual Operation 7 LUBRICATION 7.1 Initial Operation 7.2 Carriage Assembly 7.2.1 Gearbox 7.3 Lance Hub 7.4 General Lubrication 7.4.1 Grease Fittings
7.4.2 Bolt Heads and Threads
7.5 List of Recommended Lubricants 8 MAINTENANCE SCHEDULE 8.1 Operational Checks 8.2 Periodic Inspection 8.3 Routine Maintenance 8.4 Major Overhaul 9 OPTIONAL TOOLS 10 PARTS IDENTIFICATION
11 RECOMMENDED SPARES LIST 12 JOB SHEETS 13 FAULT FINDING 36 36 36 36 38 38 38 39 39 39 39 40 40 41 41 41 41 41 41 41 41 41 43 43 43 43 44 45 55 97 101 160
SECTION TITLE PAGE 14 STORAGE, HANDLING, & INSPECTION DURING STORAGE
14.1 STORAGE
14.1.1 Initial Receipt At Site 14.1.2 Stacking Sootblowers
14.1.3 Feed Tube and Poppet Valve Packing 14.2 HANDLING
14.2.1 Handling Packed Equipment 14.2.2 Handling Unpacked Equipment
14.3 INSPECTION DURING STRAGE 14.3.1 Frequency 14.3.2 Protective Lubrication 163 163 163 163 163 163 163 164 164 164 164
IK545 ILLUSTRATIONS
FIGURE TITLE PAGE 1 IK - 545B Sootblower - Overall View
2 Nozzle Cleaning Pattern
3 Electrical Components - Schematic Diagram 4 Front Support Roller Arrangement
5 Wallbox
5A Sealing Air Connection (Positive Pressure) 6 Rear Support Arrangement
7 Auxiliary Support 8 Carriage Operation 9 Expanda Cable Operation 10 Poppet Valve
11 Popper Valve Linkage 12 Air Relief Valve
12A Feed Tube Packing Arrangement 13 Operating Switches
14 Emergency Retract Air Tool 15 Checking the Blowing Pressure
16 Location of Square Tang for Manual Operation 17 Typical Slinging Arrangement
18 19 21 23 24 24 25 26 26 27 28 29 30 30 32 33 37 40 164
SECTION TITLE PAGE 1 GENERAL DESCRIPTION 1.1 General 1.2 Operating Controls 1.3 Application 1.4 Cleaning Principle 1.5 Operating Cycle 1.6 Identification 2 COMPONENT DESCRIPTION 2.1 ELECTRICAL 2.1.1 Electrical Components 2.1.2 Function 2.2 MOUNTING 2.2.1 Beam 2.2.2 Front Support 2.2.3 Wallbox 2.2.4 Rear Support 2.3 MECHANICAL
2.3.1 Carriage and Drive Mechanism 2.3.2 Guide Assembly
2.3.3 Leadscrew 2.4 BLOWING MEDIUM 2.4.1 Poppet Valve
2.4.2 Poppet Valve Operation 2.4.3 Air Relief Valve
2.4.4 Feed Tube 2.4.5 Lance Tube
2.4.6 Lance Tube Support
2.4.7 Element / Nozzle / Rake Arrg’t 2.5 OPERATING SWITCHES 2.5.1 Limit Switches 2.6 MANUAL OPERATION 3 INSTALLATION INSTRUCTION 3.1 Location 3.2 Mounting
3.3 Lifting the Sootblower
3.4 Blowing Medium Supply Pipework 3.5 Lubrication 3.6 Electrical 174 174 174 175 175 175 175 176 176 176 176 178 178 178 178 179 180 180 180 181 182 182 183 183 184 184 185 185 186 186 186 187 187 187 187 187 187 187
IK1M CONTENTS (Continued)
SECTION TITLE PAGE 4 COMMISSIONING
4.1 Stage 1 - Inspection
4.2 Stage 2 - Functional Checks 4.3 Stage 3 - Pre-Operational Checks 5 OPERATION INSTRUCTIONS 5.1 Operating Precautions 5.2 Blowing Schedule 6 MAINTENANCE INSTRUCTIONS 6.1 Operational Checks 6.2 Periodic Inspection 6.3 Annual Maintenance 6.4 Major Overhaul 6.5 Manual Operation 7 LUBRICATION 7.1 Carriage 7.2 Drive Chain
7.3 Leadscrew and Square Shaft 7.4 General Lubrication 8 MAINTENANCE SCHEDULE 8.1 Operational Checks 8.2 Periodic Inspection 8.3 Routine Maintenance 8.4 Major Overhaul 9 OPTIONAL TOOLS 10 PARTS IDENTIFICATION
11 RECOMMENDED SPARES LIST 12 JOB SHEETS 13 FAULT FINDING 188 188 188 188 190 190 190 191 191 191 191 192 192 193 193 193 193 193 195 195 195 195 196 197 205 231 234 279
SECTION TITLE PAGE 14 STORAGE, HANDLING, & INSPECTION DURING STORAGE
14.1 STORAGE
14.1.1 Initial Receipt At Site 14.1.2 Stacking Sootblowers
14.1.3 Feed Tube and Poppet Valve Packing 14.2 HANDLING
14.2.1 Handling Packed Equipment 14.2.2 Handling Unpacked Equipment
14.3 INSPECTION DURING STORAGE 14.3.1 Frequency 282 282 282 282 282 282 282 283 283 283
IK1M ILLUSTRATIONS
FIGURE TITLE PAGE 1 IK1M Sootblower - Overall View
2 View on Rear of IK1M looking towards Boiler 3 Cleaning Pattern
4 Electrical Components-Schematic Diagram 5 Front Support Arrangement
5A Scavenging Air Arrangement 5B Adjustable Rear Support 6 Drive Arrangement
7 Guide Assembly
8 Leadscrew Arrangement 9 Sectional View of Popper Valve 10 Poppet Valve Linkage
11 Air Relief Valve
12 Feed Tube and Packing 13 Lance Tube Support 14 Limit Switch Operation
15 Square Tang for Manual Operation 16 Checking the Blowing Pressure 17 Manual Operation
18 Typical Slinging Arrangement
173 174 175 176 178 179 179 180 181 181 182 183 183 184 185 186 186 189 182 283
FORM 14164
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
(PAGE 1 of 2) FORM 13519
EQUIPMENT IDENTIFICATION FORM
Diamond Contract No :- N10865
Customer Order No :- 07461-49100-A610-00
Blowing Pressure :- 12.9 kg/cm2 (2nd SH Inlet))
12.6 kg/cm2 (2nd SH (HT) Outlet)
10.0 kg/cm2 (2nd SH (LT) Outlet)
Equipment Supplied :- 27 - Diamond IK545B (Electric Motor Driven)
Long Retractable Sootblower.
Site :- Rabigh, Saudi Arabia
POSITION
No SERIAL No UNIT No CUSTOMER TAG No
LSB A B66494 1 B1HCB01AN301 LSB B B66495 1 B1HCB01AN302 LSB C B66496 1 B1HCB01AN303 LSB A B66501 2 B2HCB01AN301 LSB B B66502 2 B2HCB01AN302 LSB C B66503 2 B2HCB01AN303 LSB A B66508 3 B3HCB01AN301 LSB B B66509 3 B3HCB01AN302 LSB C B66510 3 B3HCB01AN303 LSB A B66515 4 B4HCB01AN301 LSB B B66516 4 B4HCB01AN302 LSB C B66517 4 B4HCB01AN303 LSB A B66522 5 B5HCB01AN301 LSB B B66523 5 B5HCB01AN302 LSB C B66524 5 B5HCB01AN303 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
Diamond Contract No :- N10865
Customer Order No :- 07461-49100-A610-00
Blowing Pressure :- 12.9 kg/cm2 (2nd SH Inlet))
12.6 kg/cm2 (2nd SH (HT) Outlet)
10.0 kg/cm2 (2nd SH (LT) Outlet)
Equipment Supplied :- 27 - Diamond IK545B (Electric Motor Driven)
Long Retractable Sootblower.
Site :- Rabigh, Saudi Arabia
POSITION
No SERIAL No UNIT No CUSTOMER TAG No
LSB A B66529 6 B6HCB01AN301 LSB B B66530 6 B6HCB01AN302 LSB C B66531 6 B6HCB01AN303 LSB A B66536 7 B7HCB01AN301 LSB B B66537 7 B7HCB01AN302 LSB C B66538 7 B7HCB01AN303 LSB A B66543 8 B8HCB01AN301 LSB B B66544 8 B8HCB01AN302 LSB C B66545 8 B8HCB01AN303 LSB A B66550 9 B9HCB01AN301 LSB B B66551 9 B9HCB01AN302 LSB C B66552 9 B9HCB01AN303 NOTE
When ordering Instruction Manuals for the above equipment please quote the Diamond Contract number and the following I.M. number:-123
OCTOBER 1993 FORM 14148
IMPORTANT
---READ THIS MANUAL
BEFORE
COMMISSIONING OPERATING
INSTALLING 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
OCTOBER 2002 (PAGE 1 OF 3) FORM 14274 SECTION TITLE 1 GENERAL DESCRIPTION 1.1 General 1.2 Operating Controls 1.3 Application 1.4 Cleaning Principle 1.5 Operating Cycle 1.6 Identification 2 COMPONENT DESCRIPTION 2.1 ELECTRICAL 2.1.1 Electrical Components 2.1.2 Function 2.2 MOUNTING 2.2.1 Beam
2.2.2 Front Support Plate
2.2.3 Wallbox
2.2.4 Pressure Regulating Valve (When Applicable)
2.2.5 Rear Support
2.2.6 Auxiliary Support
2.3 MECHANICAL
2.3.1 Carriage
2.3.2 Electric Drive Motor
2.3.3 Expanda Cable
2.4 BLOWING MEDIUM
2.4.1 Poppet Valve
2.4.2 Poppet Valve Operation
2.4.3 Air Relief Valve
2.4.4 Feed Tube
2.4.5 Lance Tube
2.4.6 Nozzle
2.5 OPERATING SWITCHES
2.5.1 Limit Switches / Pressure Switch
2.6 MANUAL OPERATION
2.6.1 Emergency Retract Air Tool
3 INSTALLATION INSTRUCTIONS
3.1 Location
3.2 Mounting
3.3 Lifting the Sootblower
3.4 Blowing Medium Supply Pipework
3.5 Scavenging Air
3.6 Lubrication
OCTOBER 2002 (PAGE 2 OF 3) FORM 14274
CONTENTS (Continued)
SECTION TITLE
4 COMMISSIONING
4.1 Stage 1 - Inspection
4.2 Stage 2 - Functional Checks
4.3 Stage 3 - Pre-Operational Checks
5 OPERATING INSTRUCTIONS 5.1 Operating Precautions 5.2 Blowing Schedule 6 MAINTENANCE INSTRUCTIONS 6.1 Operational Checks 6.2 Periodic Inspection 6.3 Annual Maintenance 6.4 Major Overhaul 6.5 Manual Operation 7 LUBRICATION 7.1 Initial Operation 7.2 Carriage Assembly 7.2.1 Gearbox 7.3 Lance Hub 7.4 General Lubrication 7.4.1 Grease Fittings
7.4.2 Bolt Heads and Threads
7.5 List of Recommended Lubricants
8 MAINTENANCE SCHEDULE 8.1 Operational Checks 8.2 Periodic Inspection 8.3 Routine Maintenance 8.4 Major Overhaul 9 OPTIONAL TOOLS 10 PARTS IDENTIFICATION
11 RECOMMENDED SPARES LIST
12 JOB SHEETS
OCTOBER 2002 (PAGE 3 OF 3) FORM 14274
SECTION TITLE
14 STORAGE, HANDLING, & INSPECTION DURING STORAGE
14.1 STORAGE
14.1.1 Initial Receipt At Site
14.1.2 Stacking Sootblowers
14.1.3 Feed Tube and Poppet Valve Packing
14.2 HANDLING
14.2.1 Handling Packed Equipment
14.2.2 Handling Unpacked Equipment
14.3 INSPECTION DURING STORAGE
14.3.1 Frequency
NOVEMBER 1999 FORM 14275
ILLUSTRATIONS
FIGURE TITLE
1 IK-545B Sootblower - Overall View
2 Nozzle Cleaning Pattern
3 Electrical Components - Schematic Diagram 4 Front Support Roller Arrangement
5 Wallbox
5A Sealing Air Connection (Positive Pressure)
6 Rear Support Arrangement
7 Auxiliary Support
8 Carriage Operation
9 Expanda Cable Operation
10 Poppet Valve
11 Poppet Valve Linkage
12 Air Relief Valve
12A Feed Tube Packing Arrangement
13 Operating Switches
14 Emergency Retract Air Tool
15 Checking the Blowing Pressure
16 Location of Square Tang for Manual Operation
SECTION 1
OCTOBER 2000 FORM 14729
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.
The lance tube advances on a 100 mm (4 in.) helix; therefore, the opposing nozzle openings provide cleaning at 50 mm (2 in.) intervals.
FORM 14729 OCTOBER 2000 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.
SECTION 2
JULY 2005 FORM 14332/2
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.
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I 1 841420-0002 Pushbutton Assy, Start, 'F', Green ( I 1 841420-0001 Pushbuton Assy, Reverse, 'R', Red
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* ISOLATE ELSEWHERE BEFORE ACCESSING ANY TERMINALS * SOOTBLOWER MAY START UNEXPECTEDLY ( $ ' ( ) ) ( ) $ ) $ ) ) $ ( 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. 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.
'
'
SECTION 2
APRIL 2002 FORM 14728/1
2.2 MOUNTING 2.2.1 Beam (Fig.1)
The beam comprises a pressed steel canopy to which are welded a front support plate and a rear bulkhead plate. The front support plate arrangement provides the mounting for two roller bracket assemblies which incorporate lance support rollers. The rear bulkhead plate carries a mounting bracket for the poppet valve. Four longitudinal angles, welded to the canopy sides, support the carriage, via rollers and gear racks.
The beam is supported at the front by a wallbox and wallsleeve. Support pins connect the wallbox to the front support plate. Rear suspension is provided by a rear support assembly mounted to the installation structural steelwork. This method of suspension allows the sootblower to take the expansion and contraction of the boiler in three planes.
2.2.2 Front Support Plate (Fig.4)
The front support plate c/w integral support pads is welded to the beam at the forward end of the sootblower. Two roller bracket assemblies mounted onto the pads support and guide the rotating lance tube as it travels.
FIG.4 FRONT SUPPORT ROLLER ARRANGEMENT
The arrangement of the support rollers is shown above. The roller bracket assemblies are positioned so that the axis of rotation of each roller is at right angles to the helical contact path of the lance tube.
FORM 14498 FEBRUARY 1995 2.2.3 Wallbox (Fig.5)
The basic function of the wallbox is to provide a seal where the lance enters the Boiler through the wallsleeve. Since the gas pressure inside the boiler is above atmospheric pressure, the wallbox is pressurised to prevent the flue gasses escaping into the wallbox. Seal air is introduced into the wallbox via a nipple connection located on the underside of the wallbox.
FIG.5 WALLBOX
The wallbox assembly consists of a fabricated steel housing which incorporates a seal plate and seal arrg't. The seal plate and seal arrg't are seated against the cover plate and housing by means of cap screws located through nuts welded to the cover plate.
2.2.4 Pressure Regulating Valve (Fig.5D)
A pressure regulating valve is provided at the sealing air entry to the wallbox. The valve must be connected to the sealing air line and adjusted to maintain adequate sealing air within the wallbox.
FIG.5D PRESSURE REGULATING VALVE
A connection from the sealing air line also runs to the air relief valve to provide a scavenging function. The pressure regulating valve can be installed in two alternative positions as shown above.
SECTION 2
SEPTEMBER 1999 FORM 12951/1
2.2.4 Pressure Regulating Valve (Fig.5D) (Cont'd)
On recovery boilers, an additional steam purge arrangement is supplied. In this case, a connection from the sootblower poppet valve is piped to the wallsleeve. Two inlet pipes are inserted through the wallsleeve facing towards the boiler. When the sootblower operates, steam is blown from these inlets to clean the lance tube.
2.2.5 Rear Support (Fig.6)
The sootblower is supported at the rear by a tube and support plate assembly welded, on-site, to the structural steelwork. A support pin, secured at each end, runs through the tube of the assembly and through two side plates welded to the sides of the beam.
FIG.6 ADJUSTABLE REAR SUPPORT
Each side plate incorporates an elongated hole to assist positioning and to allow for boiler expansion in the horizontal plane.The supporting steelwork is not supplied by Diamond Power, but design information is given on the Installation drawing.
SEPTEMBER 2000 FORM 15280 The IK545B sootblower is fitted with an auxiliary support near the mid-point of the beam. This arrangement supports the lance tube during the first half of forward travel, and when the sootblower is in the rest position. It also supports the feed tube during the last half of forward travel. The auxiliary support is mounted on a channel bolted to both sides of the beam. The assembly incorporates a roller bracket arrg’t similar to that of the front support and a feed tube support arrangement which is linked to the roller bracket by a trigger and lever arrangement.
An actuator arrg’t, mounted on the carriage, trips the trigger arrg’t when the carriage reaches mid-point and the roller bracket arrg’t is lowered by the linkage. The feed tube support arrg’t swings up to support the feed tube during the remainder of the forward travel. On the return travel, the linkage operates in reverse, leaving the roller bracket arrg’t supporting the lance tube.
2.3 MECHANICAL 2.3.1 Carriage (Fig.8)
The carriage drives the lance tube into and out of the boiler and also rotates the lance tube as it travels. The assembly consists of a drive motor, a gearbox, and a lance hub which contains the packing to confine the blowing medium in the lance tube and feed tube.
The primary spur gears are externally mounted for changing the travel speeds of the carriage, when required. The output shaft from the second of the primary spur gears engages a worm gear in the main gearbox for the major gear reduction. The worm gear output shaft, in turn, operates spur gears for translation and bevel gears for rotation of the lance tube.
FIG.7 AUXILIARY SUPPORT
SECTION 2
FORM 14882 MAY 1997
2.3.1 Carriage (Fig.8) (Cont’d)
The translational spur gears operate the main drive shaft which incorporates two drive pinions. The pinions engage with gear racks located on each side of the sootblower beam and enable the carriage to travel along the rack to project the lance tube into the boiler. The main drive shaft also contains two support rollers which run on angles welded to the sides of the beam.
Indexing of the lance tube is effected during reversal at full travel by a 90° keyway in the lance hub bevel gear. The carriage hub contains a mounting flange for the lance tube and a packing gland to seal around the feed tube
2.3.2 Electric Drive Motor (Fig.1)
The standard electric drive motor is a fixed-speed 1.1kW (1.5hp) unit, mounted on a flange on the carriage. Power is supplied to the motor through an expanding cable arrangement (para.2.3.3), which is attached to the underside of the beam. Alternative motors are available on application.
The carriage is also available with differing primary gearing to give carriage travel speeds of: 15mm/sec.(35in/min), 30mm/sec.(70in/min), 40mm/sec.(100 in./min) and 60mm/sec.(140in/min).
2.3.3 Expanda Cable (Fig.9)
The expanda cable arrangement transmits power from the terminal box located at the rear of the sootblower beam to the drive motor mounted on the moving carriage (Fig.9). The arrangement consists of a loop control arrangement supported by a support rod and tow bar arrangement located under the sootblower beam.
FIG.9 EXPANDA CABLE OPERATION
As the sootblower carriage travels forward, the coils of the expanda cable start to come off, one at a time, from the loop control arrangement fixed to the tow bar arrangement.
MAY 1997 FORM 14883 2.3.3 Expanda Cable (Fig.9) (Cont’d)
This action continues until the sootblower reaches its full extent of full forward travel. Each expanda cable arrangement covers a range of sootblower travels, therefore all the coils may not come off the loop control arrangement.
As the carriage retracts, the coils begin to contract and are pushed back by the loop control arrangement until the sootblower is nearing the rear rest position, once resistance builds up, a very rapid flow of coils over the loop control arrangement takes place until the sootblower comes to rest.
2.4 BLOWING MEDIUM 2.4.1 Poppet Valve (Fig.10)
The poppet valve controls the flow of blowing medium to the nozzle and is operated by a cam and trigger arrangement, as described in paragraph 2.4.2.
Sootblowers may be fitted with either 4.0, 6.0 or 12.0 MPa (40 bar, 60 bar, or 120 bar series) poppet valves, depending upon the pressure of the blowing medium. The valve is supplied in carbon steel for standard applications, or in chrome molybdenum for high-temperature applications.
FIG.10 POPPET VALVE
Each poppet valve is fitted with an air relief valve which allows scavenging air to be drawn into the poppet valve between blowing cycles, thus preventing corrosive gases from the furnace being drawn into the poppet valve, feed tube, and lance tube.
SECTION 2
FORM 14884-1 AUGUST 2003
2.4.1 Poppet Valve (Fig.10) (Cont’d)
The poppet valve seat is of flexible construction to allow for distortion due to uneven temperature distribution. The valve disc is loosely attached to the valve stem by a screwed locknut and retaining washer; the loose fit allows the disc to seal positively against the hard-faced valve seat.
The valve stem is positioned by the valve stem guide which is screwed into the valve body. A pressure control disc is screwed onto the lower part of the guide which extends into the valve body and is locked in position by a lockpin which is an integral part of the air relief valve coupling. 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 recess on the upper part of the stem.
An integral inlet flange, cast on the poppet valve body, mates with the associated companion flange and gasket supplied. The valve outlet has a square flange which is bolted to a mounting bracket on the sootblower. This connection secures the end of the blowing medium feed tube. A gasket, in the valve outlet, seals the connection.
2.4.2 Poppet Valve Operation (Fig.11)
The poppet valve is operated mechanically via a cam and trigger arrangement. An adjustable trip stud mounted on the carriage actuates the cam. As the carriage moves forward, the stud pivots the cam, thus pulling the valve trigger forward.
FIG.11 POPPET VALVE LINKAGE
The valve trigger pivots on a lug which forms part of the valve body and depresses the valve stem, thus opening the valve and admitting blowing medium to the feed tube.
APRIL 2002 FORM 14885/1 2.4.3 Air Relief Valve (Fig.12)
The air relief valve performs a scavenglng functlon which prevents corroslve boiler gases from entering the sootblower when it is not operating. On positive pressure installations, a connection from the sealing air line to the wallbox is piped to the air relief valve to overcome the furnace pressure. On negative pressure installations, the atmospheric pressure provides sufficient flow of air through the air relief valve into the sootblower.
In either case, the action of the air relief valve prevents the blowing medium from escaping from the sootblower into the sealing air line, or to atmosphere, when the sootblower is operating.
2.4.4 Feed Tube (Fig.12A)
The feed tube supplies the blowing medium from the poppet valve to the lance tube. The rear end of the feed tube is located in the poppet valve outlet and is keyed to the feed tube plate which is bolted to the valve mounting bracket. The feed tube gasket is compressed in the poppet valve outlet by the feed tube to seal the blowing medium.
FIG.12A FEED TUBE PACKING ARRANGEMENT
At the front end, the feed tube is telescoped into the lance tube and is sealed by the packing in the lance hub. After renewing or adjusting the feed tube packing, care should be taken not to overtighten the gland nuts. The maximum torque applied should not exceed 10 Nm (7 lbs.ft). The feed tube is made of highly-polished stainless steel to provide a leak-free sealing surface for the packing.
FIG.12 AIR RELIEF VALVE
SECTION 2
FORM 14885/1 APRIL 2002
2.4.5 Lance Tube (Fig.1)
The lance tube is flange-mounted to the lance hub on the carriage and is projected through the sootblower wallbox and the wall sleeve into the boiler when the sootblower operates. The lance tube and nozzle are designed to withstand the high temperatures encountered in the boiler; the standard lance material is of low allow steel and the nozzle of stainless steel. For higher temperature applications alternative lance tube materials may be used.
2.4.6 Nozzle (Fig.1)
The nozzle is welded to the end of the lance tube and incorporates either two or four venturi-type openings, arranged in a leading or lagging configuration, depending upon the cleaning application. On large-diameter lance tubes, the nozzle openings are directly opposite each other. The size of each nozzle throat is determined by the type of blowing medium and the pressure required to clean a particular heating surface. The nozzles are balanced at the factory to ensure equal reaction from the opposing jets, thus preventing lance whip. The standard nozzle material is stainless steel, but alternative materials are available for specific applications.
JULY 2005 FORM 14886/1 2.5 OPERATING SWITCHES
2.5.1 Limit Switches (Fig.13)
Limit switches, mounted on the sootblower beam, control forward and reverse travel.
FIG.13 OPERATING SWITCHES
The limit switches are actuated by a limit switch trip arrangement mounted on the sootblower carriage.
SECTION 2
JANUARY 1997 FORM 14802
2.6 MANUAL OPERATION
2.6.1 Emergency Retract Air Tool (Fig.14)
During maintenance, or in an emergency, the sootblower carriage can be operated by turning the square tang on the rear of the carriage with the emergency retract air tool. The tool consists of a vane-type air motor with motor mounting and shaft coupling, a 30 m (100 ft.) length of PVC hose, and a manual shut-off valve. The air motor operates on a clean, dry supply of air at 0.5 to 0.7 MPa (5.5 to 6.9 Bar) pressure, and can be operated in reverse, if required.
FIG.14 EMERGENCY RETRACT AIR TOOL
The tool is secured by engaging the motor mounting with the flange on the carriage. Turning the square tang clockwise results in the carriage travelling forwards and the lance tube going into the boiler. Conversely, turning the square tang anti-clockwise results in the carriage returning towards the normal fully-retracted position.
NOTE : Blowing medium pressure should be ‘ON’ when the sootblower is operated manually to cool the lance tube until it is retracted.
APRIL 1995 FORM 12957
SECTION 3
INSTALLATION INSTRUCTIONS
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
SECTION 5
OPERATING INSTRUCTIONS
General
The sootblower can be operated from a remote panel or from push-buttons mounted on an individual starter box. Once started, it 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
Retractable sootblowers are generally used on boilers of relatively high steaming capacity, but they can also be used on smaller boilers.
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 blowing pressure will more than likely be required.
Before commencing blowing, reference should be made to the operating precautions given in the previous paragraph. 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 super-heater region will pile up in the economiser area. These recommendations are general ones -operating experience with the individual boiler is the most accurate guide.
SECTION 6
APRIL 1995 FORM 14537
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 l2. 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.
6.2 Periodic Inspection
The sootblower should be inspected periodically to ensure that: (a) All mechanisms are functioning correctly.
(b) All moving parts on the carriage are adequately lubricated with recommended lubricants.
(c) Blowing medium is not leaking. (d) Nozzle is in good condition.
(e) Feed tube surface is in good condition. (f) Lance tube surface is in good condition.
The frequency of inspection will depend on operating conditions, but should be at least once a month.
6.3 Annual Maintenance
The IK-545B 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 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.
When renewing a negative pressure wallbox, care should be taken to ensure that the wallbox is correctly orientated, with the word 'TOP' uppermost.
FORM 14537 APRIL 1995 6.3 Annual Maintenance(Continued)
Critical parts include the following:
(a) Poppet Valve, including Air Relief Valve. (b) Feed Tube.
(c) Lance Tube, including Nozzle. (d) Support Rollers.
(e) Limit and Pressure Switches. (f) Expanda Cable.
6.4 Major Overhaul
The IK-545B sootblower should be dismantled every three years for inspection and renewal of all wearing parts, as indicated in the Recommended Spares List (Section 11). Seals, packing, and lubricants should be renewed at this overhaul. Wall sleeves and supporting steelwork should also be checked, and rectified 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.
6.5 Manual Operation (Fig.16)
During maintenance, or in an emergency, the sootblower carriage can be operated manually be attaching a ratchet wrench to the square tang on the carriage. Turning the square tang in a clockwise direction results in the carriage travelling forward with the lance tube going into the boiler. Turning the square tang counter-clockwise results in the carriage returning towards the normal fully-retracted position. Alternatively, the emergency air retract tool (Section 9) can be used to move the carriage manually.
FIG.16 LOCATION OF SQUARE TANG FOR MANUAL OPERATION
NOTE: The blowing medium supply should be 'ON' when the sootblower is operated manually to cool the lance tube until it is retracted.
SECTION 7
JUNE 2002 FORM 14526
SECTION 7
LUBRICATION
General
Prior to shipping, IK500 Series gearboxes are run with a protective oil and then drained. For prolonged storage, the gearbox should be filled with a similar protective oil, such as Esso Rustban 335. This must be drained and thoroughly cleaned out before use. It is the responsibility of the maintenance Inspector to ensure that this is done before operating the equipment.
To maintain the efficiency of the Sootblower, it is essential that periodic checks are carried out at the lubrication points listed in this Section.
7.1 Initial Operation
When IK500 Series Sootblowers are operated initially, it is essential that the lubrication procedures given in the following paragraphs are strictly adhered to.
7.2 Carriage Assembly
7.2.1 Gearbox
In compliance with transportation requirements, IK500 Series Sootblowers are shipped with dry gearboxes. Before operating the equipment, the following must be observed,
The carriage gearbox must be filled to the level indicated on the sight gauge on the carriage with the lubricant specified in the Lubrication Chart. The vent filler plug is located on top of the carriage and is accessible by removing the cover plate on the top of the beam. The capacity of the gearbox is 7.33 litres.
The gearbox should be drained and refilled as specified in the lubrication chart. All external moving components of the carriage which contain sealed bearings do not require lubrication.
7.3 Lance Hub
The lance hub is lubricated during the initial fill of the gearbox via the vent filler plug
7.4 General Lubrication
7.4.1 Grease Fittings
The general grease fittings should be lubricated as specified in the Lubrication Chart.
7.4.2 Bolt Heads and Threads
If any bolts are temporarily removed from the sootblower, the heads and threads should be coated with an anti-seize compound, such as Molykote G or Thread-Gard, before replacement.
7.5 List of Recommended Lubricants
Reference should be made to the Lubrication Chart for the correct lubricants to be used on all IK500 Series Sootblowers.
APRIL 2003 FORM 14418/4
IK545 SERIES LUBRICATION CHART
COMPONENT LOCATION LUBRICATION
POINT LUBRICATEDPART TO BE FREQUENCY LUBRICATIONMEANS OF LUBRICANT
Gearbox
Mineral Oil
(Above 0°C) 6-Monthly
Mobil 600W Cyl Oil Or Shell Valvata J 460
Gearbox
Synthetic Oil
(Above 0ºC) Carriage
Vent Filler Plug on top of
Carriage Gearing 18-Monthly
Fill to middle of site glass with
7.33 Litres of oil Mobil SHC 634 Gearbox
Synthetic Oil
(Below 0ºC) 18-Monthly Mobil SHC 626
Front Support
Rollers At eachRoller
Two Grease
Nipples BearingShafts 3-Monthly
Grease Gun through Lub Fittings
Shell Alvania EP-1 or EP-2
SECTION 8
SEPTEMBER 2003 FORM 14247
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 in Section 12.
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 the motor rating plate. Excessive current consumption, or fluctuating readings, indicate 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 5.
3. Blowing medium is not leaking; refer to Job Sheet 6.
4. All moving parts on the carriage are adequately lubricated; refer to Section 7.
8.3 Routine Maintenance
Routine maintenance should be carried out annually, with the sootblower in situ and with all services connected, but isolated where specified on the relevant Job Sheet.
The 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.
FORM 14247 SEPTEMBER 2003
8.3 Routine Maintenance (Continued)
Gaskets and packing seals should be renewed at this stage; the parts involved are listed in Section 10. Reference should be made to Section 7 for details of lubrication required.
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. Nozzle / 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. Poppet Valve - Dismantle.
Valve Stem and Disc Assembly - Check for wear and renew if necessary. Valve Seat - Check for wear, and lap if necessary.
Reassemble using new packing and gaskets
6. Air Relief Valve - Pressure Test. Ensure that the disc, spring and seat are in good condition
7. Limit / Proximity Switches - Check for correct operation (Job Sheet 33) 8. Motor - Check for overheating and freedom of movement.
9. Expanda / Looped Cable - Renew if necessary (Job Sheet 31)
Upon completion of Routine Maintenance, the sootblower should be recommissioned as described in Section 4.
8. 4 Major Overhaul
The 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 applicable parts are listed in Section 10.
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.
SECTION 9
MARCH 2004 FORM 12964/2
SECTION 9
OPTIONAL TOOLS
Certain Jobs described in the Maintenance Section can best be accomplished using the optional special-purpose tools developed by Diamond Power.These tools are listed below and are available from the Company.To order, quote the relevant 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
Emergency Retract Air Tool
Carriage Hub Oil Seal Locating Tool (For Lance Flange End) Carriage Hub Oil Seal Locating Tool (For 2.375” Feed Tube) Carriage Hub Oil Seal Locating Tool (For 2.750” Feed Tube)
LAPPING EQUIPMENT FOR POPPET VALVE
Item No. Part No. Description No. Off
1 395111-1123 Wobble Stick 1
2 313641-1125 Lapping Disc, Serrated Face (Series 40) 1 314718-1121 Lapping Disc, Serrated Face (Series 60) 1 392442-1120 Lapping Disc, Serrated Face (Series 120) 1 3 313641-2123 Lapping Disc, Plain Face (Series 40) 1 314718-2129 Lapping Disc, Plain Face (Series 60) 1 392442-2128 Lapping Disc, Plain Face (Series 120) 1
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 No. Off
1 863015-2800 Nut 1 2 311938-1113 Stem 1 3 311936-1115 Spacer (Series 40) 1 311936-2113 Spacer (Series 60) 1 393444-1128 Spacer (Series 120) 1 4 311937-1114 Disc (Series 40) 1 311937-2112 Disc (Series 60) 1
Not Applicable Disc (Series 120) -
POPPET VALVE MAINTENANCE TOOL (SPANNER)
Item No. Part No. Description No. Off
1 312227-1129 Valve Packing Nut Spanner 1
SECTION 9
POPPET VALVE MAINTENANCE TOOL (DEPRESSING TOOL)
Item No. Part No. Description No. Off
1 307025-1024 Valve Spring Depressing Tool 1
FEED TUBE PACKING TOOL ASSEMBLY
(Part No. 308191-1012 - Graphite Foil Packing) (Part No. 308191-2010 - Teflon Packing
Item No. Part No. Description No. Off
1 307762-0114 Spring Clip (2-3/8"in o/d Feed Tube) 1
2 306761-0117 Body (Graphite Foil Packing) 1
3 327425-1127 Body (Teflon Packing) 1
SECTION 9
MARCH 1995 FORM 12682
EMERGENCY RETRACT AIR TOOL
(Part No. 395333-1026)
Item No. Part No. Description No. Off
1 395368-1032 Motor and Motor Mounting Assy 1
OCTOBER 2003 FORM 15418
CARRIAGE HUB OIL SEAL LOCATING TOOL (FOR LANCE FLANGE END)
Item No. Part No. Description No. Off
NOVEMBER 2003 FORM 15419 SECTION 9
CARRIAGE HUB OIL SEAL LOCATING TOOL (FOR 2.375” FEED TUBE)
Item No. Part No. Description No. Off
NOVEMBER 2003 FORM 15420
CARRIAGE HUB OIL SEAL LOCATING TOOL (FOR 2.750” FEED TUBE)
Item No. Part No. Description No. Off
SECTION 10
JULY 2005 FORM 14890/4
SECTION 10
PARTS IDENTIFICATION
The correct part number for spares ordering can be identified by referring to the Parts Lists included in this manual. Please quote the contract number and the sootblower serial number when ordering spares.
The main assemblies and sub-assemblies of the Parts Lists are arranged in the following order within Section 10:
Main Assembly (IK-545B)
Progressive helix Mechanism Assembly (When Applicable) Expanda Cable Control Assembly
Carriage Assembly
Roller Assembly (Carriage)
Bracket Assembly, with Webb (Carriage)
Bracket Assembly (Carriage)
Trip Bar Assembly (Carriage)
Limit Switch Trip Assembly
Roller Bracket Assembly (Front Support)
Roller Assembly (Front Support)
Lance Joint and Packing Assembly Blowing Medium Turn-on Assembly Poppet Valve Assembly
Air Relief Valve Assembly
Electric Control Assembly (When Applicable) Electric Control / Wiring Assembly
Terminal Box Assembly (When Applicable) Auxiliary Support Assembly
Roller Bracket Assembly (Auxiliary Support)
Roller Assembly (Auxiliary Support)
Wallbox Assembly
Wallbox Piping Assembly (When Applicable
Scavenge Air Line and Piping Assy (When Applicable) Pressure Switch and Piping Assembly (When Applicable) Rear Support Assembly
(PAGE 1 of 4) FORM 14017
SECTION 10
PARTS IDENTIFICATION (CUSTOMISED)
CONTRACT No.N10865
Assy Desc / Part No Item No Part No Form No
IK545B (EMD) MAIN ASSY 1 N1086514-C004 14991/2
N10865-2-1 (RH) 1A 875005-5639 " 1B 879006-5600 " 1C 879016-5600 " 2 398281-A100 " 3 398067-R260CAA " 3A N10865-811 " 3B 398694-000B " 4 FF2JA0-0963 "
Lance with 1.25” dia (31.8mm) Jets 5 L4AQ1D-0983 "
Lance with 1.125” dia (28.6mm) Jets 5 L4AN1D-0983 "
6 398071-AB00 " 7 398337-R6B0 " 7A 397802-F1A2 " 7B 396775-000G " 8 350256-010A " 9 397556-DDN1 " 10 397473-J120 (6-off) " 11 397474-010A (12-off) " 12 397447-3A10 " 12A 398041-1D00 " 13 398038-1003 " 14 Not Applicable " 14A N10865-2-615 " 15 398176-RAB0 " 16 398179-000B " 17 397940-000B "
EXPANDA CABLE CONTROL ASSY 1 396922-000B 15393
398281-A100 2 396950-000B "
3 TB1E-1030 "
4 398206-62L11 "
6 Not Applicable "
CARRIAGE ASSEMBLY 1 397408-010A 15198
(2-ROLLER ARRANGEMENT) G1 393222-1124 " 398067-R260CAA (RH) 2 397382-010A " G2 323428-1123 " 3 350174-010A " 4 306037-2111 " 5 306038-1112 " G5 323435-1124 "
SECTION 10
(PAGE 2 of 4) FORM 14017
SECTION 10
PARTS IDENTIFICATION (CUSTOMISED)
CONTRACT No.N10865
Assy Desc / Part No Item No Part No Form No
CARRIAGE ASSEMBLY (Cont’d) 6 901110-0136 15198
(2-ROLLER ARRANGEMENT) G6 324125-1127 "
398067-R260CAA (RH) 7 Not Applicable "
G7 323434-1125 " 8 908502-0043 " G8 323423-1136 " 9 Not Applicable " 10 323439-1120 " 11 305654-0127 " 12 304160-0119 " 13 Not Applicable " 14 875005-4836 (1-off) " 15 - 21 Not Applicable " 22 324124-1029 " 23 324128-1124 " 28 397385-010A " 29 397576-000A " 30 397578-000A " 47 Not Applicable " 49 907920-0010 " 59 875005-4437 " 63 Not Applicable " 67 875005-4430 " 91 350180-010A " 92 Not Applicable " 94 Not Applicable " 96 879006-4400 " 97 Not Applicable "
BRACKET ASSEMBLY (CARRIAGE) 1 397577-010A 14937
397578-000A
TRIP BAR ASSEMBLY 2 397491-010A 14250
397080-000C 3 879068-8901 "
5 876004-8907 "
LIMIT SWITCH TRIP ASSEMBLY 2 398693-010B 15435
398694-000B *3 Not Applicable "
(With Mechanical Limit Switch) **3 875005-4438 "
*4 Not Applicable "
**4 Not Applicable "
ROLLER BRACKET ASSEMBLY 1 323403-6022 15093
397940-000B
(PAGE 3 of 4) FORM 14017
SECTION 10
PARTS IDENTIFICATION (CUSTOMISED)
CONTRACT No.N10865
Assy Desc / Part No Item No Part No Form No
ROLLER ASSEMBLY 1 323404-2129 12761
323403-6022 5 323405-2128 "
6 901110-0024 "
LANCE JOINT & PACKING ASSY 1 346160-1134 15197
398071-AB00 1A 396741-010A " 2 316893-1123 " 3 316896-1021 " 4 397473-G085 " 5 879006-4800 " 6 873008-4800 " 7 305656-0117 " 8 876004-0006 " 9 Not Applicable "
BLOWING MEDIUM TURN-ON ASSY 10 398305-0750 15341
398337-R6B0 11 397481-010A "
12 398303-000A "
14 397480-010A "
23 304634-0117 "
POPPET VALVE ASSEMBLY 1 *398580-FAA0 14895
397802-F1A2 2 344381-1033 "
(*Welded with Item 1) 3 309786-1128 "
(*Fitted with item 1) 4 394197-1123 "
11 393802-1122 " 22 397474-010A " 23 397473-J090 " 24 Not Applicable " 25 398325-010A " 26 Not Applicable " TERMINAL BOX ASSEMBLY 1 875003-3525 (4-off) 15486
398348-S0001 2 Not Applicable "
3 Not Applicable " 6 Not Applicable "
AUXILIARY SUPPORT ASSEMBLY 1 394664-010A 15251
398176-RAB0 19 871014-4837 "
20 334404-2126 "
24 398178-000B "
SECTION 10
(PAGE 4 of 4) FORM 14017
SECTION 10
PARTS IDENTIFICATION (CUSTOMISED)
CONTRACT No.N10865
Assy Desc / Part No Item No Part No Form No
ROLLER BRACKET ASSEMBLY 6 - 9 Not Applicable 15252 398033-000A
WALLBOX ASSEMBLY 1 396944-000C 14497
397447-3A10 2 396940-010A "
3 397448-000A "
5 396938-010A (1-off) "
SCAVENGE AIR LINE & PIPING ASSY 1 397737-1003 15175
398038-1003 14 Not Applicable "
WALLBOX PIPING ASSEMBLY 1 394171-1032 15174
398041-1D00 2 394330-4034 "
3 Not Applicable "
REAR SUPPORT ASSEMBLY 1 Not Applicable 15287
MARCH 2005 FORM 14991/2
IK545B MAIN ASSEMBLY. DRG. NO.
PART. NO.
Item No. Part No. Description No.Off
1 Beam Arrg't 1
1A Bolt, Front Bulkhead Arrg’t 4
1B Washer, Front Bulkhead Arrg’t 4
1C Lockwasher, Front Bulkhead Arrg’t 4
2 Expanda Cable Assembly 1
3 Carriage Assembly 1
3A Electric Motor 1
3B Trip Pin, Carriage, Limit Switch (Not Illustrated)
4 Feed Tube 1
5 Lance Tube 1
6 Lance Joint and Packing Assembly 1
7 Blowing Medium Turn-on Assembly 1
7A Poppet Valve Assembly 1
7B Air Relief Valve Assembly 1
* 8 Gasket, Companion Flange 1
* 9 Companion Flange 1
* 10 Stud As Req’d
* 11 Nut As Req’d
12 Wallbox Assembly 1
12A Wallbox Piping Assembly 1
13 Scavenging Air Line and Piping Assembly 1
14 Electric Control Assembly 1
14A Electric Control / Wiring Assy (Not Illustrated) 1
15 Auxiliary Support Assembly 1
16 Rear Support Assembly 1
17 Roller Bracket Assembly (Front Support) 1
18 391750-1128 Warning Tag 1
* 30 909305-0021 Ratchet Wrench (Not Illustrated)** 1 * Items supplied loose ** Per Boiler Set
SECTION 10
MAY 2003 FORM 15393
EXPANDA CABLE CONTROL ASSEMBLY (RH) & (LH) DRG. NO. 398281-0040 PART. NO.
Assembly Notes:
1. Engage fork of tow bar between flanges of loop control assembly before fitting the two retaining screws
2. Attach the expanda cable at the towbar fork and at the rear of the beam using cable clips. 3. Cut off excess cable length, prepare ends and connect directly to the terminal box and the
motor.
4. Paint to be removed from under grounding strap (Item 10) to provide electrical continuity. 5. Support rod tensioning nuts to be torqued to 10-11 Nm (90 - 100 lb. in). Use vice grips or
similar tool to prevent rotation of the rod).
FORM 15393 MAY 2003 EXPANDA CABLE CONTROL ASSEMBLY (RH) & (LH) DRG. NO. 398281-0040
PART. NO.
Item No. Part No. Description No. Off
1 Tow Bar Assembly 1
2 Loop Control Arrg't 1
3 Suspension Rod 1
4 Expanda Cable 1
5 395400-1123 Spacer 1
6 Gland, Cable 1
7 875005-4425 Screw, Hex Hd M10 x 25 lg As Req’d
8 879068-8900 Schnorr Safety Washer 6
9 879010-4400 Lockwasher, Shakeproof M10 1
10 395747-1026 Grounding Strap Arrg’t 1
11 873038-4400 Nut, Hex Brass M10 5
12 879007-4400 Washer M10 1
13 849515-8909 Clip 4
14 875005-3516 Screw, Hex Hd M6 x 16 lg 3
15 873015-3500 Nut, Hex M6 4
16 879016-3500 Lockwasher, Split Type M6 4
17 875005-3533 Screw, Hex Hd M6 x 35 lg 1
SECTION 10 MAY 200 5 (PAGE 1 OF 6) FORM 15198 CARRIAGE ASSEMBLY DRG. NO. 398067 -0040 (2
-ROLLER ARRANGEMENT SHOWN)
(RH)PART. NO.
SECTION 10 200 5 (PAGE 2 OF 6) FORM 15198 DRG. NO. 398067 -0040 (RH)PART. NO. (LH)PART. NO.