soot blower.pdf

1

IK545 CONTENTS

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

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2

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

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3

IK545 CONTENTS (Continued)

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

163163 163 163 163 163 163 164 164 164 164

4

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

1819 21 23 24 24 25 26 26 27 28 29 30 30 32 33 37 40

164

5

IK1M CONTENTS

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

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187 187 187 187 187 187 187

6

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


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

188188 188 188

190 190 190

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7

IK1M CONTENTS (Continued)

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

282282 282 282 282 282 282 283 283 283

8

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

173174 175 176 178 179 179 180 181 181 182 183 183 184 185 186 186 189 182 283

9

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

Tel: Dumbarton (01389) 744000 Fax: Dumbarton (01389) 762669

10

(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





NOTE When ordering Instruction Manuals for the above equipment please quote

the Diamond Contract number and the following I.M. number:-123

11



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.


POSITION

No SERIAL

No UNIT No

CUSTOMER TAG No





NOTE

When ordering Instruction Manuals for the above equipment please quote the Diamond Contract number and the following I.M. number:-123

12

OCTOBER 1993 FORM 14148

------ IMPORTANT ------

READ THIS MANUALBEFORE

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 onequipment

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 donot 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.

13

OCTOBER 2002 (PAGE 1 OF 3) FORM 14274

CONTENTS

SECTION TITLE

1 GENERAL DESCRIPTION1.1 General1.2 Operating Controls1.3 Application1.4 Cleaning Principle1.5 Operating Cycle1.6 Identification

2 COMPONENT DESCRIPTION2.1 ELECTRICAL2.1.1 Electrical Components2.1.2 Function2.2 MOUNTING2.2.1 Beam2.2.2 Front Support Plate2.2.3 Wallbox2.2.4 Pressure Regulating Valve (When Applicable)2.2.5 Rear Support2.2.6 Auxiliary Support2.3 MECHANICAL2.3.1 Carriage2.3.2 Electric Drive Motor2.3.3 Expanda Cable2.4 BLOWING MEDIUM2.4.1 Poppet Valve2.4.2 Poppet Valve Operation2.4.3 Air Relief Valve2.4.4 Feed Tube2.4.5 Lance Tube2.4.6 Nozzle2.5 OPERATING SWITCHES2.5.1 Limit Switches / Pressure Switch2.6 MANUAL OPERATION2.6.1 Emergency Retract Air Tool

3 INSTALLATION INSTRUCTIONS3.1 Location3.2 Mounting3.3 Lifting the Sootblower3.4 Blowing Medium Supply Pipework3.5 Scavenging Air3.6 Lubrication3.7 Electrical Connections

14


CONTENTS (Continued)

SECTION TITLE

4 COMMISSIONING4.1 Stage 1 - Inspection4.2 Stage 2 - Functional Checks4.3 Stage 3 - Pre-Operational Checks

5 OPERATING INSTRUCTIONS5.1 Operating Precautions5.2 Blowing Schedule

6 MAINTENANCE INSTRUCTIONS6.1 Operational Checks6.2 Periodic Inspection6.3 Annual Maintenance6.4 Major Overhaul6.5 Manual Operation

7 LUBRICATION7.1 Initial Operation7.2 Carriage Assembly7.2.1 Gearbox7.3 Lance Hub7.4 General Lubrication7.4.1 Grease Fittings7.4.2 Bolt Heads and Threads7.5 List of Recommended Lubricants

8 MAINTENANCE SCHEDULE8.1 Operational Checks8.2 Periodic Inspection8.3 Routine Maintenance8.4 Major Overhaul

9 OPTIONAL TOOLS

10 PARTS IDENTIFICATION

11 RECOMMENDED SPARES LIST

12 JOB SHEETS

13 FAULT FINDING

15



SECTION TITLE

14 STORAGE, HANDLING, & INSPECTION DURING STORAGE14.1 STORAGE14.1.1 Initial Receipt At Site14.1.2 Stacking Sootblowers14.1.3 Feed Tube and Poppet Valve Packing14.2 HANDLING14.2.1 Handling Packed Equipment14.2.2 Handling Unpacked Equipment14.3 INSPECTION DURING STORAGE14.3.1 Frequency14.3.2 Protective Lubrication

16

NOVEMBER 1999 FORM 14275

ILLUSTRATIONS

FIGURE TITLE

1 IK-545B Sootblower - Overall View2 Nozzle Cleaning Pattern3 Electrical Components - Schematic Diagram4 Front Support Roller Arrangement5 Wallbox

5A Sealing Air Connection (Positive Pressure)6 Rear Support Arrangement7 Auxiliary Support8 Carriage Operation9 Expanda Cable Operation10 Poppet Valve11 Poppet Valve Linkage12 Air Relief Valve

12A Feed Tube Packing Arrangement13 Operating Switches14 Emergency Retract Air Tool15 Checking the Blowing Pressure16 Location of Square Tang for Manual Operation17 Typical Slinging Arrangement

17

SEC

TIO

N 1

FORM

15018/1

JULY

1999

18

SECTION 1


SECTION 1GENERAL DESCRIPTION

Introduction

This instruction manual covers the IK-545B long retractable sootblower supplied byDiamond 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 anddual rack-and-pinion drive. Power is transmitted, through an expanding cablearrangement, from a fixed power connection on the beam to an electric motor onthe carriage. The motor moves the carriage to project a cleaning nozzle into theboiler. Blowing medium flow is controlled by an integral poppet valve, which ismechanically operated by the carriage.

1.2 Operating Controls

The IK-545B sootblower is normally operated from a remote control panel or froman individual starter box. Alternative controls are available to suit specificapplications. Upon completion of the cleaning cycle, the controls automaticallyreset ready for the next cycle. No further action is required by the operator unlessa fault develops. A manual override allows the sootblower to be retracted at anypoint 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 withash-producing fuels, and is used principally to remove slag and ash deposits fromslag screens, superheaters, reheaters, and economisers. It is also used to cleandeposits 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 boilerby the impact energy of high-pressure air, or steam, which is delivered from twoopposing nozzle openings located at the end of a translating and rotating lancetube.

The lance tube advances on a 100 mm (4 in.) helix; therefore, the opposing nozzleopenings provide cleaning at 50 mm (2 in.) intervals.

FIG.2 CLEANING PRINCIPLE

19

SECTION 1

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 blowingpattern 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 isapplied to the electric motor, the carriage moves forward by rack-and-pinion driveto project the lance tube into the boiler. When the nozzle is inside the boiler, thecarriage operates a cam which, in turn, opens the blowing medium valve to startthe cleaning operation. The carriage then continues to project the rotating lancetube into the boiler until it reaches its extreme forward travel. At this point, thecarriage reverses its direction and, at the same time, indexes the lance tube toreturn on a different nozzle path.

The carriage continues to retract until the nozzle is near the boiler wall, at whichpoint the blowing medium is shut off. The operating cycle is completed when thecarriage returns to its retracted position.

1.6 Identification

Each sootblower in an installation is identified by a serial number and a positionnumber, both of which are marked on the sootblower nameplate.

A list of the serial numbers of the sootblowers in the installation is given on theEquipment Identification Form; the position of each sootblower is indicated againstthe relevant serial number. Any features which vary from sootblower to sootblowerare also indicated against the serial number.

A more detailed specification of the equipment covered is given on the EquipmentIdentification Form at the front of this manual.

20

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.

21

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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.

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22

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 supportplate and a rear bulkhead plate. The front support plate arrangement provides themounting for two roller bracket assemblies which incorporate lance support rollers.The rear bulkhead plate carries a mounting bracket for the poppet valve. Fourlongitudinal angles, welded to the canopy sides, support the carriage, via rollersand gear racks.

The beam is supported at the front by a wallbox and wallsleeve. Support pinsconnect the wallbox to the front support plate. Rear suspension is provided by arear support assembly mounted to the installation structural steelwork. Thismethod of suspension allows the sootblower to take the expansion and contractionof 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 theforward end of the sootblower. Two roller bracket assemblies mounted onto thepads 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 bracketassemblies are positioned so that the axis of rotation of each roller is at rightangles to the helical contact path of the lance tube.

23

SECTION 2

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 theBoiler through the wallsleeve. Since the gas pressure inside the boiler is aboveatmospheric pressure, the wallbox is pressurised to prevent the flue gassesescaping into the wallbox. Seal air is introduced into the wallbox via a nippleconnection located on the underside of the wallbox.

FIG.5 WALLBOX

The wallbox assembly consists of a fabricated steel housing which incorporates aseal plate and seal arrg't. The seal plate and seal arrg't are seated against thecover plate and housing by means of cap screws located through nuts welded tothe cover plate.

2.2.4 Pressure Regulating Valve (Fig.5D)

A pressure regulating valve is provided at the sealing air entry to the wallbox. Thevalve must be connected to the sealing air line and adjusted to maintain adequatesealing 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 ascavenging function. The pressure regulating valve can be installed in twoalternative positions as shown above.

24

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.

25

SECTION 2

SEPTEMBER 2000 FORM 15280

2.2.6 Auxiliary Support (Fig.7)

The IK545B sootblower is fitted with an auxiliary support near the mid-point of thebeam. This arrangement supports the lance tube during the first half of forwardtravel, and when the sootblower is in the rest position. It also supports the feedtube during the last half of forward travel. The auxiliary support is mounted on achannel bolted to both sides of the beam. The assembly incorporates a rollerbracket arrg’t similar to that of the front support and a feed tube supportarrangement which is linked to the roller bracket by a trigger and leverarrangement.

An actuator arrg’t, mounted on the carriage, trips the trigger arrg’t when thecarriage 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 theremainder of the forward travel. On the return travel, the linkage operates inreverse, 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 thelance tube as it travels. The assembly consists of a drive motor, a gearbox, and alance hub which contains the packing to confine the blowing medium in the lancetube and feed tube.

The primary spur gears are externally mounted for changing the travel speeds ofthe carriage, when required. The output shaft from the second of the primary spurgears engages a worm gear in the main gearbox for the major gear reduction. Theworm gear output shaft, in turn, operates spur gears for translation and bevel gearsfor rotation of the lance tube.

FIG.7 AUXILIARY SUPPORT

FIG.8 CARRIAGE OPERATION

26

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 twodrive pinions. The pinions engage with gear racks located on each side of thesootblower beam and enable the carriage to travel along the rack to project thelance tube into the boiler. The main drive shaft also contains two support rollerswhich 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° keywayin the lance hub bevel gear. The carriage hub contains a mounting flange for thelance 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 ona flange on the carriage. Power is supplied to the motor through an expandingcable 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 travelspeeds 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 atthe rear of the sootblower beam to the drive motor mounted on the movingcarriage (Fig.9). The arrangement consists of a loop control arrangement supportedby 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 tocome off, one at a time, from the loop control arrangement fixed to the tow bararrangement.

27

SECTION 2

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 forwardtravel. 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 theloop control arrangement until the sootblower is nearing the rear rest position, onceresistance builds up, a very rapid flow of coils over the loop control arrangementtakes 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 isoperated 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, or120 bar series) poppet valves, depending upon the pressure of the blowingmedium. The valve is supplied in carbon steel for standard applications, or inchrome molybdenum for high-temperature applications.

FIG.10 POPPET VALVE

Each poppet valve is fitted with an air relief valve which allows scavenging air tobe drawn into the poppet valve between blowing cycles, thus preventing corrosivegases from the furnace being drawn into the poppet valve, feed tube, and lancetube.

28

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 touneven temperature distribution. The valve disc is loosely attached to the valvestem by a screwed locknut and retaining washer; the loose fit allows the disc toseal positively against the hard-faced valve seat.

The valve stem is positioned by the valve stem guide which is screwed into thevalve body. A pressure control disc is screwed onto the lower part of the guidewhich extends into the valve body and is locked in position by a lockpin which isan integral part of the air relief valve coupling. The upper part of the stem guidecontains the valve stem packing which seals around the stem to prevent leakage ofthe blowing medium. A packing nut, screwed onto the stem guide, compresses thepacking through a packing washer. The packing nut also supports the valve springwhich acts on the stem through a valve yoke. The valve yoke secures the springretainer 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 associatedcompanion flange and gasket supplied. The valve outlet has a square flange whichis bolted to a mounting bracket on the sootblower. This connection secures the endof the blowing medium feed tube. A gasket, in the valve outlet, seals theconnection.

2.4.2 Poppet Valve Operation (Fig.11)

The poppet valve is operated mechanically via a cam and trigger arrangement. Anadjustable trip stud mounted on the carriage actuates the cam. As the carriagemoves 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 depressesthe valve stem, thus opening the valve and admitting blowing medium to the feedtube.

29

SECTION 2

APRIL 2002 FORM 14885/1

2.4.3 Air Relief Valve (Fig.12)

The air relief valve performs a scavenglng functlon which prevents corroslve boilergases from entering the sootblower when it is not operating. On positive pressureinstallations, a connection from the sealing air line to the wallbox is piped to the airrelief valve to overcome the furnace pressure. On negative pressure installations,the atmospheric pressure provides sufficient flow of air through the air relief valveinto the sootblower.

In either case, the action of the air relief valve prevents the blowing medium fromescaping from the sootblower into the sealing air line, or to atmosphere, when thesootblower is operating.

2.4.4 Feed Tube (Fig.12A)

The feed tube supplies the blowing medium from the poppet valve to the lancetube. The rear end of the feed tube is located in the poppet valve outlet and iskeyed to the feed tube plate which is bolted to the valve mounting bracket. Thefeed tube gasket is compressed in the poppet valve outlet by the feed tube to sealthe blowing medium.

FIG.12A FEED TUBE PACKING ARRANGEMENT

At the front end, the feed tube is telescoped into the lance tube and is sealed bythe 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 torqueapplied 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.12AIR RELIEF VALVE

30

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 projectedthrough the sootblower wallbox and the wall sleeve into the boiler when thesootblower operates. The lance tube and nozzle are designed to withstand the hightemperatures encountered in the boiler; the standard lance material is of low allowsteel and the nozzle of stainless steel. For higher temperature applicationsalternative 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 orfour venturi-type openings, arranged in a leading or lagging configuration,depending upon the cleaning application. On large-diameter lance tubes, the nozzleopenings are directly opposite each other. The size of each nozzle throat isdetermined by the type of blowing medium and the pressure required to clean aparticular heating surface. The nozzles are balanced at the factory to ensure equalreaction from the opposing jets, thus preventing lance whip. The standard nozzlematerial is stainless steel, but alternative materials are available for specificapplications.

31

SECTION 2

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.

32

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 operatedby turning the square tang on the rear of the carriage with the emergency retractair tool. The tool consists of a vane-type air motor with motor mounting and shaftcoupling, a 30 m (100 ft.) length of PVC hose, and a manual shut-off valve. The airmotor 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 thecarriage. Turning the square tang clockwise results in the carriage travellingforwards and the lance tube going into the boiler. Conversely, turning the squaretang anti-clockwise results in the carriage returning towards the normal fully-retracted position.

NOTE : Blowing medium pressure should be ‘ON’ when the sootblower is operatedmanually to cool the lance tube until it is retracted.

33

SECTION 3

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.

34

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.

35

SECTION 4

MAY 1998 FORM 14536

SECTION 4COMMISSIONING

General

Commissioning should be carried out in three stages: (1) Inspection; (2) FunctionalChecks; and (3) Pre-Operational Checks, as briefly described in the followingparagraphs. Reference should be made to the Job Sheets in Section 12 for moredetailed instructions, and to the commissioning check list (Job Sheet No.3) for asummary and further references .

4.1 Stage 1 - Inspection

Immediately prior to operating the sootblower for the first time, an inspectionshould 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 beenlubricated as specified in the installation instructions, and that it has not sustainedany damage since installation.

Once the above inspection has been made and any further work requiredcompleted, 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. withoutblowing medium) to ensure that the sootblower mechanism is operating correctly .

The sootblower should initially be operated manually to check for freedom ofmovement 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 ofmotor rotation and correct operation of the limit switches. Power consumptionshould also be compared (where possible) with the normal starting and full loadcurrent, as stated on the motor rating plate.

The sootblower is now ready to be checked with the boiler on-load, as described inthe 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, whereapplicable. This can only be carried out with the boiler on-load and all servicesavailable (i.e. power, blowing medium, and sealing air).

The check for leakage is particularly important where superheated steam is used asthe blowing medium, and should be made before, and during, initial operation ofthe sootblower. Any leakage must be eliminated before moving to the next stageof commissioning.

36

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 Format the front of this manual. The actual blowing pressure must be checked undernormal operating conditions, i.e. with blowing medium available at normal pressureand 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 theair 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 gapis set at approximately 2.5mm (0.1in.) on assembly. Adjustment is made bywithdrawing the lock pin and rotating the pressure control disc. The pressurecontrol 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 pressurecontrol disc; each groove represents approximately 0.2mm (0.008in.) verticalmovement of the pressure control disc.

The sootblower should be operated through several complete cycles, with theblowing medium on, to check that it is functioning correctly before finally putting itinto service.

37

SECTION 5


SECTION 5OPERATING INSTRUCTIONS

General

The sootblower can be operated from a remote panel or from push-buttonsmounted on an individual starter box. Once started, it automatically completes itsoperating 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 steamingcapacity, but they can also be used on smaller boilers.

When the sootblowers are installed on a small boiler, the steaming capacity shouldbe maintained at over 50% and the draft fans should be operating at a high rate offlow during the sootblowing period. This ensures that the amount of cleaningmedium blown in is small compared to the amount of gases passing through theboiler, and also that the deposits removed by the sootblowers are carried throughthe boiler. If the firing rate is low, the sootblowing may agitate combustibles in thefurnace and cause puffing.

On larger boilers,these precautions are not normally necessary, as the amount ofcleaning medium blown in is usually small compared to the amount of gasespassing through.


When a steam generator is first placed into service, the tube surfaces have animmunity to ash and slag adherence. Consequently, it will appear, at first, that therecommended blowing pressures are higher than required. During this period,lasting for a few weeks, it may not be necessary to operate the sootblower veryoften. Later, after the tube surfaces have acquired a coating of residual slag, thedeposits of slag and ash will be more difficult to clean and the recommendedblowing pressure will more than likely be required.

Before commencing blowing, reference should be made to the operatingprecautions given in the previous paragraph. Normal recommended practice is toclean the boiler in the direction of the gas flow. The units nearest to the furnaceoperate first, followed by the superheater and economiser units. If heavyaccumulations are to be removed, a few of the units in the rear passes of the boilershould be operated interchangeably with those in the first pass. This eliminates aheavy accumulation in the boiler output area. If a 'straight-through' schedule isemployed, it is possible that accumulation removed from the super-heater regionwill pile up in the economiser area. These recommendations are general ones -operating experience with the individual boiler is the most accurate guide.

38

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 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.

39

SECTION 6


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.

40

SECTION 7

JUNE 2002 FORM 14526

SECTION 7LUBRICATION

General

Prior to shipping, IK500 Series gearboxes are run with a protective oil and thendrained. For prolonged storage, the gearbox should be filled with a similarprotective oil, such as Esso Rustban 335. This must be drained and thoroughlycleaned out before use. It is the responsibility of the maintenance Inspector toensure that this is done before operating the equipment.

To maintain the efficiency of the Sootblower, it is essential that periodic checks arecarried out at the lubrication points listed in this Section.

7.1 Initial Operation

When IK500 Series Sootblowers are operated initially, it is essential that thelubrication 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 areshipped with dry gearboxes. Before operating the equipment, the following must beobserved,

The carriage gearbox must be filled to the level indicated on the sight gauge on thecarriage with the lubricant specified in the Lubrication Chart. The vent filler plug islocated on top of the carriage and is accessible by removing the cover plate on thetop 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. Allexternal moving components of the carriage which contain sealed bearings do notrequire lubrication.

7.3 Lance Hub

The lance hub is lubricated during the initial fill of the gearbox via the vent fillerplug

7.4 General Lubrication

7.4.1 Grease Fittings

The general grease fittings should be lubricated as specified in the LubricationChart.

7.4.2 Bolt Heads and Threads

If any bolts are temporarily removed from the sootblower, the heads and threadsshould 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 beused on all IK500 Series Sootblowers.

41

SECTION 7

APRIL 2003 FORM 14418/4

IK545 SERIES LUBRICATION CHART

COMPONENT LOCATION LUBRICATIONPOINT

PART TO BELUBRICATED

FREQUENCY MEANS OFLUBRICATION

LUBRICANT

GearboxMineral Oil

(Above 0°C)6-Monthly

Mobil 600W Cyl OilOr

Shell Valvata J 460

GearboxSynthetic Oil(Above 0ºC)

CarriageVent Filler Plug

on top ofCarriage

Gearing 18-MonthlyFill to middle ofsite glass with

7.33 Litres of oilMobil SHC 634

GearboxSynthetic Oil(Below 0ºC)

18-Monthly Mobil SHC 626

Front SupportRollers

At eachRoller

Two GreaseNipples

BearingShafts 3-Monthly

Grease Gunthrough

Lub Fittings

ShellAlvania EP-1 or EP-2

42

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 in Section 12.


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.


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.

43

SECTION 8

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.

44

SECTION 9

MARCH 2004 FORM 12964/2

SECTION 9OPTIONAL TOOLS

Certain Jobs described in the Maintenance Section can best be accomplishedusing the optional special-purpose tools developed by Diamond Power.Thesetools are listed below and are available from the Company.To order, quote therelevant 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)

45

SECTION 9

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


46

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) -

AUGUST 1996 FORM 11828

47

SECTION 9

POPPET VALVE MAINTENANCE TOOL (SPANNER)

Item No. Part No. Description No. Off

1 312227-1129 Valve Packing Nut Spanner 1


48

SECTION 9

POPPET VALVE MAINTENANCE TOOL (DEPRESSING TOOL)


1 307025-1024 Valve Spring Depressing Tool 1


49

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 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

MARCH 1995 FORM 12720

50

SECTION 9


EMERGENCY RETRACT AIR TOOL

(Part No. 395333-1026)


1 395368-1032 Motor and Motor Mounting Assy 12 393088-1036 Hose Assembly 1

51


SECTION 9

CARRIAGE HUB OIL SEAL LOCATING TOOL(FOR LANCE FLANGE END)


1 TD2492-2 Carriage Hub Oil Seal Locating Tool 1

52


SECTION 9

CARRIAGE HUB OIL SEAL LOCATING TOOL(FOR 2.375” FEED TUBE)



53


SECTION 9

CARRIAGE HUB OIL SEAL LOCATING TOOL(FOR 2.750” FEED TUBE)



54

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 Guard Assembly (When Applicable)

55

SECTION 10


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 "

56

SECTION 10



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

57

SECTION 10



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 "

58

SECTION 10



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 398179-000B

59

SECTION 10

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

60

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).

6. Coat thread of gland (Item 6) with hylomar prior to fitment to the motor.

61

SECTION 10

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 18 865022-2732 Screw, Hex Hd 3/8” - 16 x 1” lg As Req’d

62

SEC

TIO

N 1

0

MA

Y 20

05

(PAG

E 1 OF 6

) FO

RM

15198

CA

RRIA

GE A

SSEM

BLY

D

RG

. NO

. 398067-0040

(2

-RO

LLER A

RRA

NG

EMEN

T S

HO

WN

) (R

H)PA

RT. N

O.

(LH)PA

RT. N

O.

63

SEC

TIO

N 1

0

MA

Y 20

05

(PAG

E 2 OF 6

) FO

RM

15198

CA

RRIA

GE A

SSEM

BLY

D

RG

. NO

. 398067-0040

(4

-RO

LLER A

RRA

NG

EMEN

T S

HO

WN

) (R

H)PA

RT. N

O.

(LH)PA

RT. N

O.

64

SECTION 10

MAY 2005 (PAGE 3 OF 6) FORM 15198

CARRIAGE ASSEMBLY DRG. NO. 398067-0040 (NON-ROTATING ARRANGEMENT SHOWN) (RH)PART. NO. (LH)PART. NO.

NOTE – HUB OIL SEALS (DETAIL 8) MUST BE FITTED WITH THE FOLLOWING TOOLS:

TD2492-2 FOR LANCE FLANGE END

TD2493-2 FOR GLAND END, 2.375” FEED TUBE

TD2494-2 FOR GLAND END, 2.750” FEED TUBE

DO NOT USE 351606-010A FOR THESE SEALS

65

SECTION 10

MAY 2005 (PAGE 4 OF 6) FORM 15198

CARRIAGE ASSEMBLY DRG. NO. 398067-0040 (RH)PART. NO. (LH)PART. NO. Item No. Part No. Description No. Off 1 Lance Hub 1 G1 Spur Gear,Motor 1 2 Housing, Carriage 1 G2 Spur Gear,Worm 1 3 Retainer,Bearing 1 G3 332429-1131 Worm Shaft(40:1) 1 4 Key, 1/4” Sq X 1” long 1 G4 349428-010A Gear,Worm(40:1) 1 5 Key, 3/8”Sq x 17/16” long 1 G5 Spur Gear 1 6 Ball Bearing/Spacer 2 G6 Spur Gear 1 7 Spacer 1 G7 Bevel Gear,Pinion 1 8 Oil Seal, Lance Hub 2 G8 Bevel Gear,Lance Hub 1 9 Oil Seal, Drive Shaft 1 G9 324188-1121 Pinion(12 Teeth) 2 10 Drive Shaft 1 11 Hub, Flange 1 12 Key, Hub Flange 1 13 Bracket, Non-Rotating 1 14 Screw, Hex Hd M12 As Req’d 15 Screw, Hex Hd M12 1 16 Spacer, Bracket, Non-Rotating 1 17 Lockwasher M12 1 18 Plain Washer M12 1 19 Bracket, Top Cover 1 20 Roller Assembly 4 21 Washer, Lock Stub Shaft 4 22 Roller Assembly 2 23 Spacer Roller 2 24 350178-010A Shim, Worm Shaft(.005 Blue) As Req'd 350178-010B Shim, Worm Shaft(.0075 Transparent) As Req'd 350178-010C Shim, Worm Shaft(.020 Yellow) As Req'd 25 350176-010A Shim,Bearing Carrier(.005 Blue) As Req'd 350176-010B Shim, Bearing Carrier(.0075 Transparent) As Req'd 350176-010C Shim, Bearing Carrier(.020 Yellow) As Req'd 26 350611-010A Shim,Bearing Retainer(.005 Blue) As Req'd 350611-010B Shim,Bearing Retainer(.0075 Transparent) As Req'd 350611-010C Shim,Bearing Retainer(.020 Yellow) As Req'd 27 398072-010A Shim, Roller Bracket As Req’d 28 Cover, Top 1

66

SECTION 10

MAY 2005 (PAGE 5 OF 6) FORM 15198

CARRIAGE ASSEMBLY DRG. NO. 398067-0040 (RH)PART. NO. (LH)PART. NO. Item No. Part No. Description No. Off 29 Bracket Assembly 1 30 Bracket Assembly 1 31 335592-1127 Caution Plate 1 32 397080-000C Trip Bar Assembly 1 33 306038-4116 Key 3/8”Sq x 17/8” long 1 34 306037-7110 Key 1/4”Sq x 15/8” long 3 35 306037-3119 Key 1/4”Sq x 13/8” long 1 36 395461-1129 Key 8mm x 7mm x 16mm long 1 37 323441-1126 Key 3/16”Sq x 1” long 1 38 901110-0062 Ball Bearing, Worm Shaft 2 39 901110-0130 Ball Bearing, Pinion Shaft. 1 40 901110-0049 Ball Bearing, Pinion Shaft 1 41 901110-0070 Ball Bearing, Pinion Shaft 1 42 901110-0060 Ball Bearing, Bevel Pinion Shaft 1 43 901110-0052 Ball Bearing, Bevel Pinion Shaft 1 44 907920-0136 Retaining Ring, Housing 1 45 907920-0069 Retaining Ring, Pinion Shaft 1 46 907920-0066 Retaining Ring, Housing 1 47 Retaining Ring, Pinion Shaft End 2 48 907920-0080 Retaining Ring, Pinion Shaft 2 49 Retaining Ring, Pinion Shaft End 2 50 907920-0078 Retaining Ring, Worm Shaft 1 51 908502-0044 Oil Seal, Worm Shaft 1 52 901416-0007 Oil Seal, 35x72x10 Viton 1 53 901416-0008 Oil Seal, 40x80x10 Viton 1 54 395539-1119 Oil Level Window 1 55 875005-4412 Screw, Hex Hd M10x12mm long 1 56 875005-4416 Screw, Hex Hd M10x16mm long 4 57 875005-4420 Screw, Hex Hd M10x20mm long 11 58 875005-4425 Screw, Hex Hd M10x25mm long 6 59 Screw, Hex Hd M10x45mm long 2 60 875005-4814 Screw, Hex Hd M12x14mm long 3 61 875005-4830 Screw, Hex Hd M12x30mm long 2 62 875005-4836 Screw, Hex Hd M12x40mm long 7 63 Screw, Hex Hd M12x50mm long 4 64 875005-4845 Screw, Hex Hd M12x85mm long 4 65 866004-9000 Screw, Hex Hd M8x16mm long(Tuflok) 1 66 875007-4420 Screw, Socket Hd M10x20mm long 4 67 Screw, Hex Hd M10x30mm long 2 68 871014-4436 Bolt, Hex Hd M10x40mm long 3 69 873015-4400 Nut, M10 3 70 879016-4400 Lockwasher, Split Type M10 As Req’d 71 879016-4800 Lockwasher, Split Type M12 As Req’d

67

SECTION 10

MAY 2005 (PAGE 6 OF 6) FORM 15198

CARRIAGE ASSEMBLY DRG. NO. 398067-0040 (RH)PART. NO. (LH)PART. NO. Item No. Part No. Description No. Off 72 879071-4800 Washer Plain Copper M12 3 73 869006-8901 Washer, Steel 5/16

”x11/4”x14swg 1 74 906902-0027 Air Vent, 3/8”xNPT 1 75 936309-8600 Plug, Square Hd. 3/4” NPT 1 76 907656-0002 Plug, Expansion 3/4” 2 77 907941-0152 “O” Ring 1 78 907310-0009 Magnet 2 79 901099-0005 Locknut Bearing 1 80 901089-0005 Lockwasher, Bearing 1 81 397233-010A Housing, Change Gear 1 82 350108-010A Gasket, Change Gear 1 83 393728-1123 Gasket, Motor 1 84 332198-1122 Spacer, Worm Shaft 1 85 393221-1125 Distance Piece 1 86 350477-010A Mounting Flange 1 87 863651-2520 Pin, Steel 1/4”Dia x 5/8” long 4 88 397393-010A Carrier, Bearing 1 89 398399-010A Retainer, Bearing, Worm, Motor End 1 90 350613-010A Retainer, Bearing, Carrier End 1 91 Shaft, Pinion 1 92 Shaft, Pinion 1 93 350189-010A Gasket, Bracket Top 1 94 Gasket, Bracket Top 1 95 350175-010A Gasket, Bearing Retainer 2 96 Plain Washer M10 2 97 Breather Plug ¾”NPT 1

68

SECTION 10


ROLLER ASSEMBLY (CARRIAGE) DRG. NO. 324124-1029PART. NO. 324124-1029


1 324129-1123 Roller 12 901110-0045 Ball Bearing 13 907920-0062 Retaining Ring 2

69

SECTION 10


BRACKET ASSEMBLY(CARRIAGE) DRG. NO. 397576-0029(With Web) PART. NO. 397576-000A


1 397570-010A Bracket, Reaction Roller 12 863651-1934 Roll Pin 13 316944-1122 Guide Roller 1

70

SECTION 10


BRACKET ASSEMBLY(CARRIAGE) DRG. NO. 397578-0028PART. NO.


1 Bracket 12 863651-1934 Roll Pin 13 316944-1122 Guide Roller 1

71

SECTION 10


TRIP BAR ASSEMBLY DRG. NO. 397080-0025PART. NO.

Item No Part No Description No Off

1 397079-010A Trip Bar 12 Trip Stud 13 Washer M12 14 305390-0118 Locking Washer 15 Hex Hd Screw 1

72

SECTION 10


LIMIT SWITCH TRIP ASSEMBLY DRG. NO. 398694-0025 PART. NO. Item No Part No Description No Off 1 398699-010A Angle, Limit Switch Trip 1 2 Spacer, Limit Switch Trip Angle 2 * 3 Screw, Hex Hd M10 x 1.5 – 25 lg 2 **3 Screw, Hex Hd M10 x 1.5 – 50 lg 2 4 879016-4400 Lockwasher, Split Type M10 2 WITH MECHANICAL LIMIT SWITCH

* for 4 Roller Carriage ** for 2 Roller Carriage

73

SECTION 10

FORM 15435 MARCH 2005

LIMIT SWITCH TRIP ASSEMBLY DRG. NO. 398694-0025 PART. NO. Item No Part No Description No Off 1 398699-010A Angle, Limit Switch Trip 1 2 Spacer, Limit Switch Trip Angle 2 3 398768-010A Trip Plate, Proximity Switch 1 * 4 Screw, Hex Hd M10 x 1.5 – 25 lg 2 **4 Screw, Hex Hd M10 x 1.5 – 50 lg 2 5 875007-3208 Screw, Soc Hd M5 x 0.8 x 8 lg 2 6 879016-3200 Lockwasher, Split Type M5 2 7 879016-4400 Lockwasher, Split Type M10 2 WITH PROXIMITY LIMIT SWITCH

* for 4 Roller Carriage

** for 2 Roller Carriage

74

SECTION 10


ROLLER BRACKET ASSEMBLY DRG. NO. 397940-0029(Front Support) PART. NO.

Item No. Part No. Description. No. Off.

1 Roller Assembly 12 397938-000A Bracket, Roller 13 397939-010A Shaft, Roller 14 906902-8911 Lubrication Fitting 15 324210-2121 Spacer, Roller 26 863631-2238 Groove Pin 17 875005-5639 Hex Hd Screw M20 28 879006-5600 Washer M20 29 879016-5600 Lockwasher M20 210 876006-4410 Grub Screw 1

75

SECTION 10


ROLLER ASSEMBLY DRG. NO. 323403-1023(Front Support) PART NO.


1 Roller 15 Spacer 16 Ball Bearing 27 907920-0082 Retaining Ring 29 316910-2112 Seal 2

76

SEC

TIO

N 1

0

NO

VEM

BER

2005

FORM

15197

LAN

CE JO

INT A

ND

PAC

KIN

G A

SSEM

BLY

D

RG

. N0. 3

98071-0044

PART. N

0.

77

SECTION 10


LANCE JOINT AND PACKING ASSEMBLY DRG. N0. 398071-0044 PART. N0. Item No. Part No. Description No. Off 1 Packing (Solid Ring)(Set) 1 1A Packing (Split Ring)(Set) 1 2 Bushing 1 3 Gland Arrg’t 1 4 Studbolt 2 5 Washer, Plain 2 6 Nut 4 7 Gasket 1 8 Hex Hd Bolt/Screw 6 9 Spring Assembly, Live Loaded Gland 2 10 Spring Assembly, Live Loaded Gland, Recovery 2

78

SEC

TIO

N 1

0

OC

TO

BER

2006

FORM

15341

BLO

WIN

G M

EDIU

M T

URN

- ON

ASSEM

BLY

(RH

) & (LH

) D

RG

. NO

.398337-0044

PART. N

O.

79

SECTION 10


BLOWING MEDIUM TURN - ON ASSEMBLY (RH) & (LH) DRG. NO.398337-0044 PART. NO.

Item No Part No Description No Off 1 876004-8903 Hex Hd Bolt M16x2.0x65lg 1 2 398301-010A Spacer, Poppet Valve Trigger 2 3 907948-8900 Rod End 1 4 875005-4837 Hex Hd Screw M12x45lg 2 5 873024-5200 Hex Nut M16x2.0 1 6 871014-4840 Hex Hd Bolt M12x1.75x60lg 4 7 879006-4802 "C" Washer M12 8 8 873631-3536 Groove Pin Ø6x40 2 9 873015-5200 Hex Nut M16x2.0 1 10 Adjusting Rod 1 11 Clamping Plate, Feed Tube 1 12 Cam Arrg’t 1 13 398306-000A Pivot Block Arrg’t 1 14 Mounting Bracket 1 15 879016-4800 Lockwasher M12 6 16 869068-0012 Washer 2 17 907920-0007 External Retaining Ring 1 18 879016-4400 Lockwasher M10 2 19 875005-4436 Hex Hd Screw M10x1.5x40lg 2 20 398302-010A Spacer, Poppet Valve Cam 1 21 907948-8901 Rod End 1 22 907920-0005 External Retaining Ring 1 23 Gasket, Feed Tube 1 24 873015-4800 Hex Nut M12x1.75 4 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 06 through the bulkhead (via existing 06 holes in mounting plate) and fit 06 groove pins.

6. Assemble all threads (including feed tube details) with Molykote Gn+.

7. Assemble Rod Ends with Molykote GN+ on the bores.

8. When valve is fully open ensure there is a minimum gap of 0.25mm between valve spring coils.

80

SEC

TIO

N 1

0

OC

TO

BER

2006

FO

RM

14895

POPPET

VA

LVE A

SSEM

BLY

. D

RG

. NO

. 397802-0042

PART. N

O.

81

SECTION 10


POPPET VALVE ASSEMBLY. DRG. NO. 397802-0042 PART. NO. Item No. Part No. Description. No. Off 1 Valve Body 1 2 Valve Stem and Disc Arrg't 1 3 Flexible Valve Seat 1 4 Pressure Control Disc 1 5 398300-000A Trigger Arrg’t 1 6 301235-0116 Valve Yoke Pin 1 7 863603-1716 Cotter Pin 1 8 301158-0119 Trigger Pin 1 9 863603-1934 Cotter Pin 1 11 Lock Pin Plug 1 12 930711-9034 Copper Washer 1 13 301142-0118 Valve Yoke 1 14 301808-0113 Valve Spring Retainer 1 15 302051-0115 Valve Spring 1 16 302032-0119 Packing Nut 1 17 302027-0116 Packing Washer 1 18 398443-010A Valve Stem Packing 1 19 342928-1136 Valve Stem Guide 1 20 301167-2114 Valve Stem Washer 1 21 396774-0121 Adjustable Pressure Tag 1 22 Nut 4 23 Stud / Hex Soc Hd Screw 4 24 Adaptor 1 25 Locking Washer, Poppet Valve Nut 2 26 Plug, G3/4 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.

82

SECTION 10


AIR RELIEF VALVE ASSEMBLY DRG. NO. 396775-1037 PART. NO. 396775-000G Item No Part No. Description No.Off 1 341501-1026 Air Relief Valve Arrg't 1 5 937817-8600 Tee 1 6 935923-8600 Nipple 1 7 936220-8600 Plug 1 8 935924-8902 Nipple 1 10 349569-010E Adapter 1 11 930711-9034 Washer 1

83

SEC

TIO

N 1

0

SEPT

EMBER

2006

(CO

NTRA

CT N

10865)

ELECTRIC

CO

NTRO

L / WIR

ING

ASSEM

BLY

(R

EV B

) DRG

. NO

. N10865-2-615

PA

RT. N

O. N

10865-2-615

84

SECTION 10

(CONTRACT N10865) SEPTEMBER 2006

ELECTRIC CONTROL / WIRING ASSEMBLY (REV B) DRG. NO. N10865-2-615 PART. NO. N10865-2-615

Item No. Part No. Description Qty. 1 * Electric Motor - 2 * Entry, M25 - 3 841402-0071 Cable Gland M25 2 4 * Entry, 25.4mm (for M25) - 5 841402-0079 Locknut, M25 1 6 * Cable, Motor, 4-Core - 7 841405-0116 Limit Switch, Roller Crank (LSR & LSF) 2 8 * Entry, M20 - 9 848300-9784 Terminal Cross Connector, 3 Way 1 10 875007-3236 Screw, Soc Hd M5 x 0.8 – 40 lg 4 11 879006-4002 Washer, Plain M8 4 12 398744-A000 Rail & Fixings Assy 2 13 * Entry, 20.4mm (for M20/Pg13.5) - 14 841402-0067 Cable Gland, M20 2 15 841402-0078 Locknut, M20 2 16 841404-0014 Cable, Limit Switch, 3-core 1 17 841404-0015 Cable, Limit Switch, 5-core 1 18# 398348-S0001 Terminal Box Assy RH c/w fixings 1 19 907506-8901 Warning Label, “Steam Sootblower” 1 20 * Entry 44mm dia clearance hole - 21 * Cable Gland By Others 22 * Locknut By Others 23 * Entry 29mm dia clearance hole - 24 * Cable Gland By Others 25 * Locknut By Others 26# 841420-0002 Pushbutton Assy, Start, ‘F’, Green 1 27# 841420-0001 Pushbutton Assy, Reverse, ‘R’ Red 1 28 879011-3200 Washer, Serrated, M5 4 29 847313-9208 VCI Foam Square 2 30# 398743-AA10 Terminal Block Assy 1 31# 841420-0010 Pushbutton Insert, RED 1 32# 841420-0011 Pushbutton Insert GREEN 1

N10865-2-615 Electrical Parts Assembly, RH Sootblower N10865TB TB Assy, populated, RH Sootblower

* Shown for ref only

# assy of parts only

85

SECTION 10


TERMINAL BOX ASSEMBLY (RITTAL) DRG. NO. 398348-0140 PART. NO. Item No. Part No. Description No. Off 1 Screw, Slt Hd Csk M6 x 1.0 - 25lg As Req’d 2 Screw, Slt Hd Csk M6 x 1.0 - 30lg 1 3 Screw, Slt Hd Csk M6 x 1.0 - 45lg 4 4 873015-3500 Hex Nut M6 8 5 879016-3500 Lockwasher, Split Type M6 4 6 Nylon Spacer 4 7 875006-3500 Washer, Form A, M6 4 8 841406-0009 Terminal Box 1

86

SEC

TIO

N 1

0

NO

VEM

BER

2004

FORM

15251

AU

XILIA

RY

SU

PPORT A

SSEM

BLY

D

RG

. NO

. 398176-0048

PART. N

O.

87

SECTION 10


AUXILIARY SUPPORT ASSEMBLY DRG. NO. 398176-0048 PART. NO. Item No. Part No. Description No. Off 1 Channel (RH) 1 Channel (LH) 1 2 395991-000A Bearing Housing, Auxiliary Support 4 3 879006-4400 Washer Form ‘A’ M10 24 4 875007-4436 Screw, Hex Soc Hd M10x1.5 - 6gx40lg 8 5 879016-4400 Lockwasher, Split Type M10 2 6 873015-4400 Nut, Hex M10x1.5 - 6H 12 7 395403-1138 Support Block, non-Fork Side 1 8 395402-1139 Support Block, Fork Side 1 9 879006-4800 Washer Form ‘A’ M12 4 10 875007-4430 Screw, Hex Soc Hd M10x1.5 - 6gx30lg 4 11 398589-000B Auxiliary Shaft Arrg’t 1 12 398590-000A Lever/Shaft Arrg’t 1 13 334393-1022 Lever Arrg’t 1 14 863607-1932 Split Pin, Ø3x25 2 15 869068-0013 Washer, 27odx16idx13g 4 16 395387-1146 Bracket Arrg’t, Centre Support 1 17 398033-000A Roller Bracket Assembly 2 18 879016-4800 Lockwasher, Split Type M12 8 19 Bolt, Hex Hd M12x1.75 4 20 Shim, Centre Support Roller 4 21 869068-0026 Washer, 1.625” odx0.5” id x 0.83”lg 2 22 876006-4410 Set Screw, Hex Soc Hd M10x1.5 - 6g x10lg 2 23 398177-000A Tube Arrg’t, Centre Support 1 24 Support, Feed Tube 1 25 873008-5600 Lock Nut, M20x2.5 - 6H Hex 1 26 875005-4830 Screw, Hex Hd M12x1.75 - 6gx30lg 6 27 873015-4800 Hex Nut M12x1.75 - 6H 6 28 331696-2020 Actuator Arrg’t 1 29 875005-4438 Screw, Hex Hd M10 x1.5 - 6g x 50lg 2 30 398578-010A Spacer, Auxiliary Support Actuator 2 31 901118-8907 Bush 4

88

SECTION 10


ROLLER BRACKET ASSEMBLY DRG. NO. 398033-0025(AUXILIARY SUPPORT) PART. NO.


1 398032-010A Roller Bracket 12 317061-1127 Shaft, Roller 13 317059-1022 Roller Assembly 14 317062-1126 Spacer 25 863651-2534 Roll Pin 16 Lockwasher, Split Type M12 27 Washer, 1.625”odx0.5”idx0.083” 28 Bolt, Hex Hd M12x1.75 - 45lg 29 Bolt, Hex Hd M12x1.75 - 40lg 2

89


SECTION 10

ROLLER ASSEMBLY DRG. NO. 317059-1022(AUXILIARY SUPPORT) PART. NO. 317059-1022


1 317060-1128 Roller 12 901110-0058 Ball Bearing 13 907920-0022 Retaining Ring 2

90

SEC

TIO

N 1

0

MA

RC

H 2

000

FORM

14497

WA

LLBO

X A

SSEM

BLY

DRG

. NO

. 397447-0

043

PART. N

O.

91

SECTION 10

FORM 14497 MARCH 2000

WALLBOX ASSEMBLY DRG. NO. 397447-0043PART. NO.


1 Housing Arrg't 12 Seal Plate 13 Seal Arrg't 14 869006-3600 Washer As Req'd5 Spacer As Req'd6 396939-010B Cover Plate 17 907920-9001 Spirolox Retaining Ring 18 396937-010A Support Pin 29 873607-4841 Split Pin 410 875005-4444 Hex Hd Screw 411 941401-0012 Plug 112 398068-010A Label, Wallbox Adjustment 1

NOTESPARE PARTS WILL ONLY BE SUPPLIED IN THE FOLLOWINGSOLID AND SPLIT KITS : COMPRISING ITEMS 2,3,6,7 & 10.

PART NUMBER DESCRIPTION397447-0A00 (SOLID) SEAL KIT - (3.5" Lance) (For IK500 Series S/B’s)

397447-0B00 (SOLID) SEAL KIT - (4" Lance) (For IK500 Series S/B’s)

397447-0C00 MOUNTING KIT -- Comprising Items :- 4,5,8 & 9

397447-0D00 (SOLID) SEAL KIT - (2..875" Lance) (For IK4M S/B’s)

397447-0E00 (SOLID) SEAL KIT - (2.375" Lance) (For IK4M S/B’s)

397447-0F00 (SOLID) SEAL KIT - (3" Lance) (For IK1M S/B’s)

397447-0G00 (SPLIT) SEAL KIT - (3.5" Lance) (For IK500 Series S/B’s c/w NPC Nozzles)

397447-0H00 (SPLIT) SEAL KIT - (4" Lance) (For IK500 Series S/B’s c/w NPC Nozzles)

397447-0J00 (SPLIT) SEAL KIT - (2.875" Lance) (For IK4M S/B’s)

397447-0K00 (SPLIT) SEAL KIT - (2.375" Lance) (For IK4M S/B’s)

397447-0L00 (SPLIT) SEAL KIT - (3" Lance) (For IK1M S/B’s)

397447-0M00 (SOLID) SEAL KIT - (3.5" Lance) (For TP500 Thermoprobes)

397447-0N00 (SOLID) SEAL KIT - (2.375" Lance) (For TP500 Thermoprobes)

92

SECTION 10


SCAVENGE AIR LINE AND PIPING ASSEMBLY DRG. NO. 398038-0020PART NO.

93

SECTION 10


SCAVENGE AIR LINE AND PIPING ASSEMBLY DRG. NO. 398038-0020PART NO.


1 Galvanised Tube 12 941422-0001 Socket (¾” BSPT) As Req’d3 941400-0018 Elbow 14 RT020025TI-0085 S.S. Tube 15 941402-0025 Male Stud Coupling 16 941408-0008 Elbow, ¾” BSPT Female 17 841414-0063 Adaptor, ¾” BSPP X ¾” BSPT 18 931403-0011 Elbow, Hosetail, ¾” BSPP X ¾” Hose 19 902210-8911 Hose Clip, Screw and Band 210 931403-0006 Hose As Req’d11 931403-0010 Hosetail, ¾” BSPT X ¾” Tube 112 934008-8600 Street Elbow 114 Pipe, Rear End, Scavenge Air 1

94

SECTION 10


WALLBOX PIPING ASSEMBLY DRG. NO. 398041-0025PART. NO.


1 Tee Valve Spindle Arrg't (2” BSPT) 12 Nipple Arrg't 13 Plug (2” BSPT) 14 941414-0003 Tee (2” BSPT) 1

95

SECTION 10

FEBRUARY 2001 FORM 15287

REAR SUPPORT ASSEMBLY DRG. NO. 398179-0029PART. NO.


1 Plate, Blower Support As Req’d3 397157-010A Pin, Blower Support 14 873607-4841 Split Pin M13x65lg 25 398180-000A Channel Arrg’t 16 869006-3600 Plain Washer 27 879006-6000 Washer M24 68 873015-6000 Hex Nut M24x3.0 89 RZ240130KC-0250 Screwed Rod M24 2

96

SECTION 11


SECTION 11RECOMMENDED SPARES LIST

It is recommended that stocks of the items listed in this Section be maintained asfollows:

1. Running Maintenance

Quantities shown in column 1 should be regarded as a minimum initial stock leveluntil actual usage is established through operating experience.

2. Incurred Maintenance

Diamond sootblowers are designed to operate for long periods with the minimum ofmaintenance and spares usage; component parts do not normally require replacementunless 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 abreakdown 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 forwear or damage as indicated in Section 8, and parts replaced as necessary. Itemswhich 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 thequantities stocked may have to be adjusted to take account of severe usage ordelays in obtaining replacements .

The assembly headings indicate where the items listed are used. Since headingsand items appear in the same order as shown in the Parts Identification Section ofthe Instruction Manual, part numbers of related items can be readily identified.

The quantities recommended have been calculated per ten sootblowers. Thesequantities may require to be adjusted to correspond with the actual number ofsootblowers in use.

97

SECTION 11

(Page 1 of 3) FORM 13123

RECOMMENDED SPARES LIST ( Per 10 Sootblowers )

EQUIPMENT TYPE :- IK545B SOOTBLOWER 1. Running Maintenance (Electric Motor Driven) 2. Incurred Maintenance CONTRACT No :- N10865 3. Major Overhaul

DESCRIPTION PART NO. QUANTITY

1 2 3 MAIN ASSEMBLY (RH) N10865-2-1

Electric Motor N10865-811 - 1 - Feed Tube FF2JA0-0963 - 1 - Lance Tube c/w 1.25” dia (31.8mm) Jets L4AQ1D-0983 - 1 - Lance Tube c/w 1.125” dia (28.6mm) Jets L4AN1D-0983 - 1 - Gasket (Companion Flange) 350256-010A - 2 10

EXPANDA CABLE CONTROL ASSEMBLY 398281-A100 Expanda Cable 398206-62L11 - 1 10

CARRIAGE ASSEMBLY 398067-R260CAA

Spur Gear (Motor) 393222-1124 - 1 - Spur Gear (Worm) 323428-1123 - 1 - Key 306037-2111 - 1 10 Gear (Worm) (40:1) 349428-010A - 1 - Key 306038-1112 - 1 10 Spur Gear 323435-1124 - 1 - Ball Bearing 901110-0136 - 2 20 Spur Gear 324125-1127 - 1 - Gear (Bevel Pinion) 323434-1125 - 1 - Oil Seal 908502-0043 - 2 20 Bevel Gear (Lance Hub) (56 Teeth) 323423-1136 - 1 - Oil Seal 908502-0051 - 1 - Pinion 324188-1121 - 2 - Key 304160-0119 - 1 10 Roller Assembly 324124-1029 - 2 20 Key 306038-4116 - 1 10 Key 306037-7110 - 3 30 Key 306037-3119 - 1 10 Key 395461-1129 - 1 10 Key 323441-1126 - 1 10 Ball Bearing 901110-0062 - 2 20 Ball Bearing 901110-0130 - 1 10 Ball Bearing 901110-0049 - 1 10 Ball Bearing 901110-0070 - 1 10 Ball Bearing 901110-0060 - 1 10 Ball Bearing 901110-0052 - 1 10

98

SECTION 11





1 2 3 CARRIAGE ASSEMBLY (RH) (Cont’d) 398067-R260CAA

Oil Seal 908502-0044 - 1 10 Oil Seal 908502-0039 - 1 10 Oil Seal 908502-0038 - 1 10 Gasket (Change Gear) 350108-010A - 1 10 Gasket (Motor) 393728-1123 - 1 10 Gasket, Bracket Top 350189-010A - 1 10 Gasket (Bearing Retainer) 350175-010A - 2 20

BRACKET ASSEMBLY (With Web) 397576-0029

Guide Roller 316944-1122 - 2 20

BRACKET ASSEMBLY 397578-000A Guide Roller 316944-1122 - 2 20

TRIP BAR ASSEMBLY 397080-000C

Trip Stud 397491-010R - 1 10

ROLLER ASSY (Front Support) 323403-6022 Roller 323404-2129 - 1 - Ball Bearing 901110-0024 - 2 20

LANCE JOINT & PACKING ASSEMBLY 398071-AB00 Packing (Solid Ring) 346160-1134 - - 10 Packing (Split Ring) 396741-010A 10 10 - Bushing 316893-1123 - 1 10 Gland Arrg't 316896-1021 - 1 - Gasket 305656-0117 - 1 10

BLOWING MEDIUM TURN-ON ASSY 398337-R6B0

External Retaining Ring 907920-0007 - 1 10 External Retaining Ring 907920-0005 - 1 10 Gasket, Feed Tube 304634-0117 - 2 10

99

SECTION 11





1 2 3 POPPET VALVE ASSEMBLY 397802-F1A2

Valve Stem and Disc Arrg't 344381-1033 - 2 10 Flexible Valve Seat 309786-1128 - 2 - Pressure Control Disc 394197-1123 - 2 - Valve Yoke Pin 301235-0116 - 2 10 Cotter Pin 863603-1716 - 2 10 Trigger Pin 301158-0119 - 1 10 Lubrication Fitting 906902-8910 - 4 - Lock Pin Plug 393802-1122 - 2 - Lock Pin Washer 930711-9034 - 2 10 Valve Yoke 301142-0118 - 2 10 Valve Spring Retainer 301808-0113 - 2 10 Valve Spring 302051-0115 - 2 10 Packing Nut 302032-0119 - 2 - Packing Washer 302027-0116 - 2 - Packing (Valve Stem) 351523-010A 10 10 10 Valve Stem Guide 342928-1136 - 2 - Valve Guide Washer 301167-0118 - 2 10 Nut 397474-010A - 4 - Stud 397473-J090 - 4 - Locking Washer 398325-010A - 2 20

AIR RELIEF VALVE ASSEMBLY 396775-000G

Air Relief Valve 341501-1026 - 2 - Copper Washer 930711-9034 - 1 10

ELECTRIC CONTROL / WIRING ASSY N10865-2-615

Limit Switch (Rear & Front) 841405-0116 - 2 - ROLLER BRACKET ASSY (Aux Support) 398033-000A Roller Assembly 317059-1022 - 2 20 Spacer 317062-1126 - 4 - Roll Pin 863651-2534 - 1 10

WALLBOX ASSEMBLY 397447-3A10 Mounting Kit 397447-0C00 - 1 - Split Seal Kit 397447-0G00 - 1 -

100

SECTION 12


SECTION 12JOB SHEETS

JOB SHEET TITLENO

1 IK545B Installation Procedure2 Site Erection of Rear Support3 Commissioning Check List4 Blowing Medium Turn-On Linkage - Adjusting Procedure5 Poppet Valve - Checking / Setting the Blowing Pressure6 Pressure Sealing Points - Checking Procedure7 Functional Checks (Prior to Electrical Operation)8 Pre - Operational Checks (With Power ON)9 Manual Operation10 Feed Tube Packing (Split Ring) Adjusting the Packing Gland11 Feed Tube Packing - Renewal12 Poppet Valve - Removal from Sootblower13 Poppet Valve - Dismantling14 Poppet Valve - Valve Stem Packing: Adjusting Procedure15 Poppet Valve - Valve Stem Packing: Renewal16 Poppet Valve - Tools and Equipment for Lapping the Valve Seat17 Poppet Valve - Valve Seat Lapping Procedure18 Poppet Valve - Seat Renewal19 Poppet Valve - Reassembly Procedure20 Poppetr Valve - Replacing on the Sootblower21 Lance Tube Gasket - Adjusting Procedure22 Lance Tube Gasket - Renewal23 Lance Tube and Feed Tube - Removal24 Carriage - Removal25 Carriage Dismantling (1) - Motor and Primary Gear Change Assy26 Carriage Dismantling (2) - Roller and Rack Pinions27 Carriage Dismantling (3) - Pinion Shaft, Pinion, Spur Gear & Roller Assy28 Carriage Dismantling (4) - Lance Hub and Bevel Gear Assembly29 Carriage Dismantling (5) - Shaft and Bearing Assembly30 Carriage Dismantling (6) - Shaft and Bearing & Drive Shaft Assembly31 Expanda Cable - Removal and Renewal32 Wallbox Dismantling33 Limit Switches - Renewal and Adjustment34 Not Applicable35 Support Rollers - Adjustment

101

JULY 2003 (PAGE 1 of 2) FORM 15201

TECHNICAL DATA SHEET

(SERIES ONE CARRIAGE GENERAL NOTES)DRAWING No. 398067-0040

NOTETo be read in conjunction with Job Sheets 24 - 30

1. NUMERIC CRISS-CROSS TIGHTENING PATTERN OF M10 SCREWS SHOWN ONAPPROPRIATE PART TO BE USED.

(A) USE ’MOLY-G’ LUBRICANT UNDER SCREW HEAD AND ON THREADS.(B) TORQUE TO 30 ± 5 lb-ft IN ONE PASS.

2. NUMERIC CRISS-CROSS TIGHTENING PATTERN OF M12 SCREWS SHOWN ONAPPROPRIATE PART TO BE USED.

(A) USE ‘MOLY-G’ LUBRICANT UNDER SCREW HEAD AND ON THREADS.(B) TORQUE TO 30 ± 5 lb-ft IN ONE PASS.(C) TORQUE TO 70 ± 5 lb-ft IN SECOND AND FINAL PASS.

3. SHIM BETWEEN HOUSING (2) AND MOUNTING FLANGE (86) TO GIVE 0.076 TO 0.20WORM SHAFT ENDPLAY. PER DPS STANDARD QC79.

4. FOR CORRECT PINION ALIGNMENT ENSURE THAT THE STAMPED PINION FACINGARE FACING THE SAME DIRECTION (I.E. BOTH LEFT OR BOTH RIGHT.

5. ALL SURFACES TO BE CLEANED AND DE-GREASED PRIOR TO THE APPLICATION OFSEALANT OR ADHESIVES.

6. WORM GEAR (G4) TO BE INSTALLED WITH LARGER DIAMETER HUB NEXT TO SPURGEAR (G5).

7. REFER TO SHOP BOM FOR SPECIFIED TRVEL BEFORE TURN-ON.

8. FOR SHOP TEST ON FULLY FLOODED CARRIAGES ONLY, FILL GEAR CASE WITHRECOMMENDED LUBRICANT TO SIGHT GAUGE LEVEL, AND COMPLETELY DRAINAFTER TEST. FILLER PLUG AND BREATHER TO HAVE ‘LOCTITE 572’ APPLIED TOTHREADS PRIOR TO FITMENT. FILLER PLUG MUST BE RE-SEALED WITH ‘LOCTITE572’ AFTER OIL CHANGE.NOTE, AT THE BREATHER HOLE, A SLAVE ‘BLANK’ PLUG WILL NEED TO BE FITTEDWHEN THE CARRIAGE IS INVERTED DURING ASSEMBLY.

9. WORM GEAR SHIMMING PROCEDURE IS TO BE USED TO OBTAIN PROPERCONTACT PATTERN. SEE DPS STANDARD QC79.

10. ALL GASKETS TO HAVE ‘DOW CORNING SILASTIC 744’ APPLIED THINLY ANDEVENLY ON BOTH SIDES OF THE GASKET (OR BOTH FLANGES).

11. ASSEMBLE BEARING CARRIER (88), BEARING RETAINER (90) AND BALL BEARING(43) WITHOUT SHIMS. MEASURE THE GAP BETWEEN CARRIER AND RETAINER, ADDSHIMS (26) MEASURING 0.0 TO 0.064 GREATER THAN GAP. SEE DPS STANDARDQC 79.

102

JULY 2003 (PAGE 2 of 2) FORM 15201

TECHNICAL DATA SHEET

(SERIES ONE CARRIAGE GENERAL NOTES)DRAWING No. 398067-0040

NOTETo be read in conjunction with Job Sheets 24 - 30

12. FOR THE 4 ROLLER CARRIAGE ONLY - APPLY ‘MOLYKOTE-Gn PLUS’ TO THETHREADS AND SHOULDER OF THE ROLLER SHAFT AND TORQUE TO 90 lb-ftMINIMUM.

13. FOR THE 4 ROLLER CARRIAGE ONLY, BEND LOCK WASHER (21) ONE PLACEAGAINST FLAT ON ROLLER SHAFT (PART OF 20) AND ONE PLACE AGAINST CASTFLAT ON BOTTOM OF TOP COVER BRACKET ARM (19).

14. EXPANSION PLUG (76) TO HAVE ‘DOW CORNING SILASTIC 744’ APPLIED PRIOR TOPRESSING INTO HOLE SO OUTSIDE EDGE IS 0.03 TO 0.06 BELOW CASTINGSURFACE.

15. INSTALL CHANGE GEAR HOUSING (81) PRIOR TO TOP COVER SO THAT TWO TOPSCREWS (NUMBERED 6 AND 7 IN BOLT TIGHTENING PATTERN) CAN BE USED TOPULL TOP COVER INTO CONTACT WITH CHANGE GEAR HOUSING GASKET (82) TOPREVENT LEAKAGE.

16. ALL OIL SEAL LIPS TO BE LUBRICATED ON ASSEMBLY WITH MOBIL SHC 634 ONLY.OIL SEALS SHOULD BE FITTED WITH APPROPRIATE TOOLING.

17. ALL SHIMS TO HAVE ‘LOCKTITE GASKET ELIMINATOR 518’ APPLIED SPARINGLYTO BOTH SIDES.

18. ALL BORES FOR OIL SEAL LOCATIONS TO HAVE ‘DOW CORNING SILASTIC 744’APPLIED THINLY AND EVENLY PRIOR TO PRESSING SEALS INTO THE BORE.

19. OIL SIGHT GLASS TO BE FITTED WITH ‘LOCKTITE 225’.

20. STAMP THE CONTRACT NUMBER AND THE SPEED IN THE AREA AS SHOWN.

21. MOUNTING FLANGE (86) TO BE INSTALLED WITH PINS UP AS SHOWN.

22. FOR 2 ROLLER CARRIAGE ONLY, BRACKET (29) TO BE SHIMMED TO SUITAPPLICATION.

23. SET HUB PROJECTION TO DIMENSION SHOWN. FINAL ADJUSTMENT OF LANCEHUB PROJECTION TO BE CARRIED OUT WHEN FITTING LANCE TO BLOWER.

24. LUBRICATION – TABLE 6 ON DPS MANUFACTURING CARRIAGE DRAWINGINCLUDES APPROPRIATE MOBILITH SHC 007 GREASE (HARDWARE NUMBER 0903-834) AND OIL QUANTITIES FOR THE VARIOUS BUILD POSSIBILITIES. AS THE OIL ISDRAINED FROM THE CARRIAGE BEFORE DESPATCH, OIL QUANTITIES ARE FORREFERENCE ONLY. NOTE – kg IS THE UNIT OF MEASURE FOR GREASE.

25. FIT BREATHER PLUG WITH HOLE FACING DOWNWARD (USE LOCTITE 572 ONTHREAD). NOTE – A SLAVE ‘BLANK’ PLUG WILL NEED TO BE FITTED WHEN THECARRIAGE IS INVERTED DURING ASSEMBLY.

103

FORM 15325

JOB SHEETS

The information within the job sheets areof a general nature and are not intended tocover every individual sootblower system.

WARNING

Before all adjustments, repairs and testsare undertaken the control room should benotified. The appropriate local permitsshould be taken out and all safetyprecautions taken.

NOTE

Refer to the yellow coloured warning sheetat the front of the Instruction manual forgeneral information regarding importantInstallation, Commissioning, Operating andMaintenance instructions.

104

SECTION 12


DIAMOND POWER JOB SHEET No.1

SOOTBLOWER TYPE : IK500 Series (Electric Motor Driven) SHEET

JOB SHEET TITLE : INSTALLATION PROCEDURE 1 of 3

STEP ACTION REF./INFO.

1. Remove all straps and packing from the sootblower.

2. Inspect for damage from shipment or storage.

3. Check that the equipment to be installed is complete asspecified

Packing List

4. Determine the location and mounting position of the sootbloweron the boiler.

InstallationDrawing

5. Ensure that a wallsleeve has been welded to the boiler wall. Inst'n Drg.

6. Remove the wallbox from the sootblower.

7. Position and weld the wallbox to the wallsleeve.

NOTEOn positive pressure installations ensure that the wallbox hasbeen correctly orientated with the inlet hole on the bottom.

NOTEOn negative pressure installations also ensure that the wallboxhas been correctly orientated.

8. Fit guards (When Applicable) Job Sheet 35

9. Lift the sootblower into position using the lifting lugs providedon top of the beam. Fit the sootblower to the wallbox, locatingthe pivot pins correctly.

Installation Drg

NoteFor condensate drainage refer to the installation drg.

10. Position and weld the rear support to the supporting steelworkand to the sootblower.

Installation DrgJob Sheet 2

11. Connect the purge air pipework to the wallbox.(For positive pressure applications only)

12. Connect a syphon tube to the pressure switch & air relief valve When Applicable

13. Bolt the companion flange to the poppet valve inlet flange.

105

SECTION 12

FORM 12683 NOVEMBER 2000





14. Position and weld the customers blowing medium supplypipework to the companion flange.

Installation Drg

NoteAny customer designed arrangement must be carefully installedto prevent any undue stress on the sootblower.

15. Unbolt the companion flange from the poppet valve flange.

16. Install a sheet metal deflector between the companion flangeand the sootblower inlet flange.

17. Blow out the blowing medium supply pipework to remove allscale, weld bead etc.

18. Remove the deflector and insert the companion flange gasket.

19. Bolt the companion flange to the sootblower inlet flange, andcompress the gasket evenly between them.Tighten the studs inthe sequence shown below.

NOTEThe use of a torque wrench is not mandatory but approximatetorque 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)

STUD TIGHTENING SEQUENCE

NOTESeries 40 Bar poppet valve installations have six flange studs.Series 60 and 120 valve installations have eight flange studs.

.20. Observe the alignment of the beam arrangement: check for any

bends, twists or other distortions.

106

SECTION 12






21. Lubricate the sootblower. Section 7

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

23. Leave the sootblower ready for commissioning, with the localisolation switches off and the blowing medium supply isolated.

107

SECTION 12



SOOTBLOWER TYPE : IKSD-E / IK500 SERIES SHEET

JOB SHEET TITLE : SITE ERECTION OF REAR SUPPORT 1 of 1


1.

2.

3.

Assemble the rear support (Items supplied loose) to thelugs welded to the sootblower beam.

Position the sootblower to the boiler-mounted wallbox.

Assemble the rear support screwed rod arrangements tothe supporting steelwork.

Job Sheet 1

Inst Drawing

108

SECTION 12



SOOTBLOWER TYPE : IK500 SERIES SHEETJOB SHEET TITLE : COMMISSIONING CHECK LIST 1 of 1


NOTE

Steps 1 to 5 should be taken before the boiler comes on-load and without the blowing medium on.

1. Check that the sootblower is complete as specified in theequipment identification form at the front of the manual. Itis particularly important to ensure that the correct soot-blower has been installed ; this can be checked byreference to the equipment identification form and the serialnumber typed on the sootblower nameplate.

2. Check that the mounting and connecting bolts are secureand that all connections have been properly made asspecified in the installation section of the manual.

Job Sheet 1

3. Check that all moving parts are free to move & have beenlubricated as specified in Section 7, and that there are noobstructions on the rack or track.

4. Operate the sootblower manually and check that all of themechanisms function correctly.

Job Sheet 7

5. Operate the sootblower from the local push-button (Whenfitted) to check the direction of travel and the operation ofthe limit switches; repeat from the remote control panel.

Job Sheet 8

6. Operate the sootblower with the blowing medium 'ON'.Check for leaks and rectify as necessary.

Job Sheet 6

7. Operate the sootblower with the blowing medium 'ON'.Check the blowing pressure and reset as necessary.

Job Sheet 5

109

SECTION 12

AUGUST 2003 FORM 12686/1

DIAMOND POWER JOB SHEET No.4A

SOOTBLOWER TYPE : IK500 SERIES SHEETJOB SHEET TITLE : BLOWING MEDIUM TURN-ON LINKAGE

ADJUSTMENT PROCEDURE 1 of 1


CAUTIONDo not operate the blowing medium turn-on linkage by

hand with the poppet valve under pressure.

1. Check the amount of adjustment required by reference tothe illustration shown below.

2. Loosen the locking nut and rotate the adjusting rod. Re-tighten the locking nut when adjustment is correct.

110

SECTION 12



SOOTBLOWER TYPE : IK500 SERIES SHEETJOB SHEET TITLE : POPPET VALVE:-

Checking/Setting the Blowing Pressure 1 of 2


NOTEThe Blowing pressure can only be set under normal workingconditions, 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. Disconnect the syphon tube from the air relief valve. When Applicable

7. Remove the 3/8"in BSPT blanking plug from the air reliefvalve.

8. Connect a suitable pressure gauge to the air relief valveoutlet.

Section 4

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

111

SECTION 12

FORM 12687 JANUARY 2004


SOOTBLOWER TYPE : IK500 SERIES SHEETJOB SHEET TITLE : POPPET VALVE:-

Checking/Setting the Blowing Pressure 2 of 2


10. Turn on the blowing medium supply.

11. Reconnect the power supply.

12. Open the poppet valve by running the sootblower carriageforward from the “LOCAL/MANUAL” control position, andnote the pressure gauge reading.

As Applicable

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

14. Remove the lock pin plug.

15. Using a screwdriver inserted through the tapped lock pinside hole, rotate the pressure control disc clockwise tolower or anti-clockwise to raise, thus decreasing orincreasing the blowing pressure between the valve seat andthe valve disc.

16 Replace the lock pin plug after adjustment has beencompleted, ensuring that it seats in one of the deep flutesin the disc.

17. Repeat steps 12-16 until the recommended blowingpressure is obtained.


19. Remove the pressure gauge.

20. Reconnect the syphon tube to the air relief valve. When Applicable

21. Replace the blanking plug.



24. Test run the sootblower.

112

SECTION 12



SOOTBLOWER TYPE : IK500 SERIES SHEETJOB SHEET TITLE : PRESSURE SEALING POINTS :-

Checking Procedure 1 of 1


NOTEA check should be made for leakage at the pressure sealingpoints listed below. This should be carried out by operatingthe sootblower with the blowing medium on.

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

Job Sheet 12

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

Job Sheet 12

3. Lance Tube :If leakage is detected, tighten the retaining bolts whichsecures the lance tube flange to the lance hub. If leakagepersists after further tightening, renew the gasket.

Job Sheet21 and 22

4. Feed Tube Packing :Check for leakage. If leakage is detected, tighten thepacking gland to eliminate the leakage. Do not tighten thepacking gland more than is necessary as this will shortenthe packing life and increase the load on the motor. If theleakage persists, renew the packing.

Job Sheet 11

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

Job Sheet 15

113

SECTION 12



SOOTBLOWER TYPE : IK500 SERIES SHEETJOB SHEET TITLE : FUNCTIONAL CHECKS :-

Prior to Electrical Operation 1 of 1


1. Ensure that both the power and blowing medium supplyhave been isolated from the sootblower to be checked.

2. Ensure that the limit switch lever arms are in the correctposition to receive the trip pin as the carriage movesforward.

Job Sheet 33

3. Ensure that the blowing medium valve turn-on cam is in thecorrect position to receive the trip stud as the carriagemoves forward.

Job Sheet 4

4. Move the carriage forward manually and check the pointsas follows :

Job Sheet 9

(a) Trip stud on the carriage engages the blowing mediumvalve turn-on cam correctly, adjust if necessary.

Job Sheet 4

(b) The position of the nozzle jets as the blowing mediumvalve opens. The jets should be at least 50mm clear ofthe boiler wall. Refer to the contract drawings for thedesign dimensions. Adjust the position of the trip pin ifnecessary.

(c) Indexing (If Applicable) - The lance should not rotateduring the first 50mm of forward travel.

Equipment I.D.Form

(d) Oscillating movement (If Applicable) and blowing arc. Job Sheet 34

(e) Operation of the forward Limit switch by the trip pin onthe carriage.

5. Reverse the carriage travel and check the following :(a) Indexing (If Applicable) - The lance should not rotate

during the first 50mm of forward travel.

(b) The forward limit switch is reset by the carriage trip pin.

(c) Trip stud engages the cam on the blowing medium turnon linkage smoothly & closes the blowing medium valve.

(d) Carriage trip pin operates the rear limit switch.

114

SECTION 12



SOOTBLOWER TYPE : IK500 SERIES SHEET

JOB SHEET TITLE : PRE-OPERATIONAL CHECKS (WITH POWER ON)

1 of 1


1.

2.

3.

4.

5.

6.

7.

Ensure that the sootblower to be checked is isolated from the blowing medium and that it has been checked as specified in Job Sheet 7. Move the carriage forward manually until the trip pin on the carriage clears the rear limit switch. Switch ON the power supply - refer to the control panel instruction manual if in doubt. Press the local 'START' push-button and observe the direction of travel - if the carriage travels towards the rear limit switch switch OFF, isolate the sootblower from the power supply, remove the terminal box cover, and switch two of the three-phase supply wires to correct the travel direction. Replace the terminal box cover and press the 'START' push-button again - direction of travel should now be towards the forward limit switch. Trip the forward limit switch and check that the carriage retracts. If the forward limit switch is a stay-put type (i.e. not spring-return), manually return the carriage to the correct position to accept the trip pin. Ensure that the carriage stops when the trip pin operates the rear limit switch – if it does not stop, switch OFF and investigate the fault. Press the local 'START' push-button again and allow the soot-blower to run through a complete cycle - observe the amperage as it operates and compare it with the motor rating plate figure to determine if overloading is occuring. Rectify if necessary.

Job Sheet 9

Job Sheet 33

115

SECTION 12


DIAMOND POWER JOB SHEET No.9B


JOB SHEET TITLE : MANUAL OPERATION 1 of 1


1.

2.

3.

NOTEIf a fault develops with a set of sootblowers during auto-matic sequential operation, those in use should retractautomatically. If they fail to do so for any reason, such aspower failure, motor stalled, etc., immediate action must betaken to withdraw the sootblowers involved.

IK500 sootblowers can be operated manually by attaching theratchet wrench supplied to the square tang on the carriage.Alternatively, the optional emergency retract air tool can beused to move the carriage manually. The air tool consists of avane-type air motor, shaft coupling, hose, quick-releasecoupling, and manual shut-off valve. The motor operates on aclean dry supply of blowing medium at 0.55 MPa - 0.69 MPapressure (5.5 - 6.9 Bar).

Isolate the sootblower from the power supply.

Attach the ratchet wrench, or emergency retract air tool, tothe square tang on the end of the carriage. The location ofthe square tang is shown in the illustration below.

Rotate the square tang in an anti-clockwise direction to returnthe carriage towards the normally fully-retracted position.

NOTE(a) It is essential to keep the blowing medium supply ‘ON’ to

cool the lance tube until it is retracted.(b) The sootblower must always be returned to the fully

retracted position after manual operation to reset the limitswitches.

Section 9

Section 9

116

SECTION 12




JOB SHEET TITLE : FEED TUBE PACKING - SPLIT RING:ADJUSTING THE PACKING GLAND.

1 of 2


1.

2.

3.

4.


Shut off the blowing medium supply.

Tighten the two packing gland nuts, just enough to preventleakage. The position of the packing gland nuts is shown inthe illustration below.

NOTE: The feed tube packing, which provides a sealbetween the stationary feed tube and thetranslational lance hub, is compressed in thestuffing box by the adjustable packing glandsurrounding the feed tube.

The gland can be tightened until the gland shoulder buttsagainst the end of the lance hub.

On applications where superheated steam is used as theblowing medium, tighten the packing gland when the feedtube is at its hottest condition, as described in Step 3. Thisprocedure will increase the life of the packing and preventover-tightening due to thermal expansion.

If persistant leakage occurs, and further tightening doesnot stop it, add additional packing up to a maximum ofthree rings.

117

SECTION 12




JOB SHEET TITLE : FEED TUBE PACKING - SPLIT RING:ADJUSTING THE PACKING GLAND.

2 of 2


5.0

5.1

5.2

5.3

5.4

6.

7.

8.

9.

Adding Additional Packing

Remove the two nuts which secure the packing gland tothe lance hub. Slide the packing gland towards the rearbulkhead.

Fit new additional split-ring packing into the stuffing boxusing a packing tool.

Replace the packing gland.

Replace the packing gland nuts, and hand-tighten themonly.

Turn on the blowing medium supply.

Reconnect the power supply.

Test-run the sootblower.

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

Section 9

118

SECTION 12




JOB SHEET TITLE : FEED TUBE PACKING - RENEWAL(SOLID RING)

1 of 3


1.

2.

3.

4.

5.

6.

7.

8.

9.


Shut off the blowing medium supply isolating valve.

Remove the four nuts which secure the poppet valve to thesootblower via the mounting bracket and feed tubeclamping plate.

Remove the two bolts and lockwashers which secure thefeed tube clamping plate to the mounting bracket.

Slide the feed tube clamping plate forward along the feedtube to expose the feed tube flange.

Slide the feed tube forward (towards the nozzle).

Remove the gasket, key, and feed tube flange andclamping plate.

Remove the two nuts, locknuts, and washers which securethe packing gland to the hub assembly; slide the packinggland towards the valve mounting bracket and put thepacking gland aside for re-use.

Remove the old packing

119

SECTION 12

FORM 12693/2 AUGUST 2003




2 of 3


10.

11.

12.

13..

14.

15.

16.

17.

Clean out the stuffing box and ensure that all associatedcomponents are also clean and free from damage.

Inspect the packing bushing and renew it if required

Carefully unwrap the replacement packing set and arrangeit on a suitable surface parallel to the feed tube, ensuringthat the angle of the intermediate packing. rings ispositioned as shown below.

Slide the front graphite fibre header ring onto the feedtube, pushing it firmly home against the stuffing boxbushing.

Fit each intermediate ring separately, ensuring at all timesthat the correct direction of the packing slope ismaintained relative to the front of the sootblower. Pusheach ring fully home before fitting the next one.

Fit the rear fibre header ring, ensuring that the flat face isoutermost.

Replace the packing gland

Replace the packing gland nuts loosely, so that the packinggland is just in contact with the packing.

120

SECTION 12





3 of 3


18.

19.

20.

21.

22.

23.

24.

25.

Reassemble the key, feed tube flange nut, and feed tubeclamping plate, and install a new gasket. Slide the feed tubeback towards the mounting bracket.

Hand-tighten the packing gland nuts.

Reassemble the feed tube clamping plate to the mountingbracket. Torque the two M10 bolts c/w lockwashers asindicated. The function of the two bolts is to keep the feedtube in position while the poppet valve is being fitted to thesootblower.

Secure the poppet valve to the sootblower via the mountingbracket and feed tube clamping plate, using the four M20nuts.

NOTE:- Adjust the feed tube flange nut to establish a nominal3mm gap between the faces of the poppet valve andmounting bracket. This adjustment should be carried outbefore torque is applied to the four poppet valve retainingnuts and is necessary to guarantee a satisfactory sealingpoint between the poppet valve and feed tube.




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

CAUTIONAfter several operations of the sootblower, newly installedpacking should be re-adjusted. Re-tighten the gland nuts untilthe gland is firmly seated against the packing. The maximumpermissible torque is 10Nm (7lbs ft.).If, during normal operation, steam leaks are observed furtherpacking adjustment will be necessary.

Warning:- Do not over-tighten.

121

SECTION 12




JOB SHEET TITLE : FEED TUBE PACKING - RENEWAL(SPLIT RING)

1 of 2


1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.



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

Remove the two packing gland nuts and two locknutsholding the packing gland in position.

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

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

Carefully clean the carriage hub stuffing box, packinggland, and all components. A solvent may be required toremove any traces of gum.

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

Repair or renew any damaged parts.

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

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

122

SECTION 12

FORM 12694 JUNE 2000



JOB SHEET TITLE : FEED TUBE PACKING - RENEWAL(SPLIT RING)

2 of 2


12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

Gently insert the packing ring into the stuffing box.

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

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

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

Remove the packing tool and slide the packing gland intoposition.

Tighten the gland nuts evenly until the packing is slightlycompressed; maximum torque is 10Nm (7 lbs.ft.).



Test run the sootblower.


CAUTIONAfter several operations of the sootblower, newly installedpacking should be re-adjusted. Re-tighten the gland nuts untilthe gland is firmly seated against the packing. The maximumpermissible torque is 10Nm (7lbs ft.).If, during normal operation, steam leaks are observed furtherpacking adjustment will be necessary.

Warning:- Do not over-tighten.

123

SECTION 12




JOB SHEET TITLE : POPPET VALVE :-REMOVAL FROM SOOTBLOWER

1 of 1


1.

2.

3.

4.

5.

6.

7.

Isolate the sootblower from the power supply to preventautomatic operation of the unit.


Disconnect the air relief valve from the scavenging air lineand siphon tube (when fitted).

Remove the nut, bolt and spacer, from the cam assemblyat the poppet valve trigger.

Disconnect the poppet valve at the companion flange.

Disconnect the poppet valve at the mounting bracket.

Remove the poppet valve from the sootblower.

124

SECTION 12



SOOTBLOWER TYPE : IK-500 SERIES SHEETJOB SHEET TITLE : POPPET VALVE: DISMANTLING 1 of 1


NOTEThis Job Sheet covers partial dismantling of the poppetvalve in preparation for valve seat lapping or renewal.

1. Remove the poppet valve from the sootblower. Job Sheet 12

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

3. Remove the trigger cotter pin and withdraw the trigger pinfrom the valve.

4. Remove the trigger and replace the trigger pin only.

5. Depress the valve spring just enough to allow removal ofthe yoke; use the optional valve spring depressing tool.

Section 9

6. Remove the yoke and release the spring tension.

7. Lift off the valve spring retainer and the valve spring.

8. Remove the valve stem and disc assembly.

9. Remove the packing nut and packing washer.

10. Remove the valve stem packing.

125

SECTION 12


DIAMOND POWER JOB SHEET

No.14

SOOTBLOWER TYPE : IK500 SERIES SHEET JOB SHEET TITLE : POPPET VALVE :

(Valve Stem Packing Adjustment Procedure) 1 of 2

STEP 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 15

126

SECTION 12



No.14



STEP ACTION REF./INFO. NOTES:

1. Valve Stem Guide, Lock Pin and Plug threads to be coated with ‘Molykote Gn Plus’.(907145-0002)


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.

127

SECTION 12




(Valve Stem Packing Renewal) 1 of 2


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

Job Sheet 13

4. Remove the trigger cotter pin and withdraw the trigger pin

from the valve.

5. Remove the trigger and replace the trigger pin only.

6. Depress the valve spring just enough to allow removal of the yoke : use the valve spring depressing tool.

Section 9

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.


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

9. Insert the new packing, staggering the splits in the rings by

90°. Use only the packing specified in the Parts list. Section 10

10. Seat each ring separately.

128

SECTION 12






11. 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 lbs. ft) maximum. Refer also to note 6.

NOTES:


2. Torque Valve Stem Guide to 80Nm (60lb.ft) 6. This clearance dimension should be set between the



129

SECTION 12

JULY 1996 FORM 12699


SOOTBLOWER TYPE : IK500 Series SHEETJOB SHEET TITLE : POPPET VALVE : Tools and Equipment

Required for Lapping the Valve Seat. 1 of 1


NOTEThe tools and equipment required for lapping are as follows:-

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

2. Lapping Compounds:- Section 9Diamond Compound, Hyprez 45.Diamond Compound, Hyprez 14.Diamond Compound, Hyprez 3.

3. Lapping Equipment:- Section 9Wobble stick, manually-operated valve grinder, or smallcapacity air motor with flexible shaft.

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.

130

SECTION 12



SOOTBLOWER TYPE : IK500 SERIES SHEETJOB SHEET TITLE : POPPET VALVE :

VALVE SEAT LAPPING PROCEDURE 1 of 2


1. Dismantle the poppet valve. Job Sheet 13

2. Charge an unused serrated lapping disc with Hyprez 45compound.

Section 9

3. Rough-lap for two five-minute cycles, checking the valve seatsurface 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 14compound.

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


8. Charge the plain lapping disc with Hyprez 3 compound Section 9

9. Burnish-lap for five minutes.


11. Cover the surface of a blue block with a very thin uniformcoating of Prussian blue.

12. Place the blue block carefully on the lapped seat.

13. Applying finger pressure only, move the blue block back andforth slightly.

14. Carefully remove the blue block.

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

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

131

SECTION 12

FORM 12700 JULY 1996





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

18. Reassemble the valve in the reverse order to that given fordismantling.

Job Sheet 19

132

SECTION 12




JOB SHEET TITLE : POPPET VALVE : SEAT RENEWAL 1 of 2



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 Assy 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

approximately85°, to deposit more metal on the seat than on the body. Two 2.4mm (3/32in) diameter rods should be used per seat.

* Equivalent to AWS 5.18 Class ER-70s-G or BS2901 Part1(1970) A18. *MIG wire * Equivalent to AWS E7028 or BS639 (1976) E5144H. * Welding Rod

133

SECTION 12






5. 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.

6. Overlap 13-19mm (1/2in-3/4in) 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. Lap the valve seat to ensure a flat surface. Job Sheet 17

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

Job Sheet 19

134

SECTION 12




REASSEMBLY PROCEDURE 1 of 1


NOTEThis procedure covers reassembly after partial dismantling forseat-lapping or renewal. The valve should be reassembled inclean conditions to reduce the possibility of grit being trappedbetween the sealing faces.

The reassembly procedure is as follows :

1. Place the poppet valve on its side.

2. Instal the stem and disc assembly, taking care to ensure thatthe sealing faces are clean and undamaged.

NOTEMaintain firm contact between the sealing faces during thesubsequent steps.

3. Insert the new valve stem packing, staggering the splits in therings 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 inletand outlet should be sealed to protect the internals.

8. Replace the trigger and trigger pin.

9. Replace the yoke pin and yoke cotter pin in the valve yoke.

10. Replace the poppet valve on the sootblower. Job Sheet 20

135

SECTION 12

NOVEMBER 2001 FORM 12703/1



REPLACING ON THE SOOTBLOWER 1 of 2


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

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

3. Fit a new feed tube gasket to the poppet valve outlet.

4. Position the poppet valve on the sootblower with the four studsprojecting through the mounting bracket and rear bulkhead. (rearbulkhead not shown in illustration below).

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

6. Ensure that the retaining ring is fully seated in the groove of thefeed tube with the sharpest edge of the retaining ring installedtowards the rear bulkhead.

7. Push the feed tube with the associated clamping plate throughthe rear bulkhead until it makes contact with the feed tubegasket.

8. Slide the feed tube clamping plate along the feed tube ensuringthat the counter bore in the clamping plate engages squarely overthe retaining ring.

136

SECTION 12

FORM 12703/1 NOVEMBER 2001



REPLACING ON THE SOOTBLOWER 2 of 2


9 Loosely fit the locking washers and securing nuts which retainsthe poppet valve to the rear bulkhead via the clamping plate.

10. Locate and tighten the two screws of the clamping plate in turnby torquing them in small increments to 41NM (30 lb.ft.)maximum. This procedure will ensure that the clamping plate ispulled squarely on to the retaining ring, compressing the feedtube gasket between the poppet valve and the end of the feedtube.

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

12. Fit a new companion flange gasket.

13. Reassemble the companion flange to the poppet valve.

14. Reassemble the cam and arm assembly to the poppet valve

15. Reassemble the air relief to the poppet valve.

16. Reconnect the scavenging air line and syphon tube When fitted



19. Test run the sootblower, checking for leaks.

20. Reset the blowing pressure

137

SECTION 12




JOB SHEET TITLE : LANCE TUBE GASKET:-ADJUSTING PROCEDURE

1 of 1


1.

2.

NOTEThe lance tube flange gasket is compressed between thelance hub and the lance tube flange by tightening theretaining bolts as follows:

Tighten the six bolts in the sequence shown in theillustration below and observe the gap recommendation.The bolts should be torqued to 136Nm (100 lbs.ft).

NOTEThe torque figure given applies to bolts coated with anti-seize compound. Higher torque may be necessary when re-tightening in service.

If persistant leakage occurs and further tightening does notstop it, renew the gasket.

Section 7

Job Sheets22 & 23

138

SECTION 12




JOB SHEET TITLE : LANCE TUBE GASKET -RENEWAL

1 of 2


1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

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



Remove the four nuts which secure the poppet valve tomounting bracket, and remove the two cap screws andlockwashers which secure the feed tube clamping plate to themounting bracket.

Slide the feed tube clamping plate forward on the feed tube,and remove the key from the feed tube keyway.

Remove the two nuts and locknuts holding the packing glandin position.


Remove the feed tube packing.

Push the feed tube foward and remove the flange.

Continue pushing the feed tube forward until the end is wellinto the carriage lance hub stuffing box.

Remove the auxiliary support assembly.

Support the lance tube and feed tube securely, using slingsand a hoist.

Remove the six bolts from the lance tube hub flange.

Move the lance tube and feed tube forward far enough toclear the carriage lance hub.

Lower the flange end of the lance tube, along with the feedtube, enough to gain easy access for renewing the lance tubegasket.

Job Sheet 23

Job Sheet 11

(IK545B only)

139

SECTION 12




JOB SHEET TITLE : LANCE TUBE GASKET -RENEWAL

2 of 2


16.

17.

18.

19.

20.

Remove the existing gasket.

Examine the locating face of the lance hub and the lanceflange.

Clean the locating face and remove any loose particles ofdirt, or existing gasket, as applicable.

Insert a new gasket in position.

Reassemble in the reverse order to that given fordismantling.

NOTE

(a). Coat the threads of the six lance hub flange bolts withanti-seize compound before reassembly, and torque to136 Nm (100 lbs.ft.)

(b). Screw the feed tube into the feed tube flange farenough to provide approximately 3 mm (1/8 in.) gapbetween the face of the poppet valve and the mountingplate.

(c). The torque figures given apply to bolts coated withanti-seize compound. Higher torque may be necessarywhen re-tightening in service.

Job Sheet 21&

Section 7

140

SECTION 12



SOOTBLOWER TYPE : IK-500 SERIES SHEETJOB SHEET TITLE : LANCE TUBE AND FEED TUBE :

(REMOVAL) 1 of 2


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



4. Remove the four nuts which secure the poppet valve to themounting bracket, and remove the two cap screws andlockwashers which secure the feed tube clamping plate tothe mounting bracket.

5. Slide the feed tube clamping plate forward on the feed tubeand remove the key from the feed tube keyway.

6. Remove the two nuts and locknuts holding the packinggland in position.

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

8. Remove the feed tube packing. Job Sheets 11A /11B

9. Push the feed tube forward and remove either the flange orthe retaining ring, as applicable.

10. Continue pushing the feed tube forward until the end is wellinto the carriage lance hub stuffing box.

11. Remove the auxiliary support assembly. (IK-545B Only)

12. Support the lance tube and feed tube securely, using slingsand a hoist.

13. Remove the six bolts and lockwashers from the lance tubehub flange.

14. Move the lance tube and feed tube forward far enough toclear the carriage lance hub.

15. Lower the lance tube and feed tube clear of the sootblower.

141

SECTION 12



SOOTBLOWER TYPE : IK-500 SERIES SHEETJOB SHEET TITLE : LANCE TUBE AND FEED TUBE :

(REMOVAL) 2 of 2


16. Install new lance and feed tubes, if required. Job Sheet 22

17. Reassemble in reverse order to that given for dismantling.




142

SECTION 12



SOOTBLOWER TYPE : IK-500 SERIES SHEETJOB SHEET TITLE : CARRIAGE - REMOVAL 1 of 1


1. Ensure that the carriage is in the fully retracted position. Job Sheet 9



4. Support the lance tube by blocking up from the lowerflange of the beam.

5. Disconnect the lance and feed tubes. Job Sheet 23

6. Disconnect or Unplug the expanda cable from the motorterminal box.

7. Remove the limit switch trip pin located on the carriage.

8. Remove the cover plate, screws and lockwashers from theaccess hole on top of the beam.

9. Remove the loop control tow bar from the carriage.

10. Remove the two short carriage support angles at the rear ofthe beam.

11. Lower the carriage clear of the sootblower.

12. Reassemble in the reverse order to that given for removal.

CAUTION:- It is extremely important that the carriage drivepinions are in alignment with the two gear racksto prevent abnormal stress loads at the lancehub joint and to keep rack wear to a minimum.Carriage alignment may be checked by removingthe inspection plates on both sides of the beamand measuring from the rear of the beam to thetooling centre holes in both ends of the pinionshaft. If the variance is greater than 6mm (¼in), the pinions are not engaged correctly withthe corresponding adjacent rack teeth.

143

SECTION 12


DIAMOND POWER JOB SHEET No.25C

SOOTBLOWER TYPE : IK500 SERIES / IKSD-E SHEETJOB SHEET TITLE : CARRIAGE DISMANTLING (1)

(Motor & Primary Gear Change Assy) 1 of 1


(FOR SERIES ONE CARRIAGE DRG NO. 398067-0040)

1. Remove the drain plugs from the bottom of the carriagehousing and completely drain the oil from the carriagesump.

2. Remove the three nuts ,screws and lockwashers whichsecure the motor to the change gear housing.

3. Remove the motor and gasket from the change gearhousing

4. Remove the seven cap screws and lockwashers and removethe change gear housing .

5. Remove the cap screw, washer , motor, spur gear, key anddistance piece from the motor shaft.

6. Remove the retaining ring and key and slide the spur gearfrom the shaft and bearing assembly.

7. Check the gears for wear or damage.

8. Renew any components, if necessary.

9. Coat the gear teeth with the recommended lubricating oil. Section 7


NOTE(a) Cap screws should be lubricated to assist removal.

(b) Raise the motor and change gear assy to the uppermostposition, within the clearance of the cap screw holes, toensure maximum running clearance between the motor spurgear and the worm shaft spur gear before tightening the sixcap screws.

11. Replace the drain plugs and refill the carriage sump with oilto the correct level shown on the oil level window.

144

SECTION 12




(Rollers and Rack Pinions) 1 of 1



1. Remove the retaining rings from both ends of the pinionshaft.

2. Remove the rollers, spacers, pinions and keys from thepinion shaft.

3. Check the condition of the bearings for flat spots, etc, byrotating the inner race relative to the outer race.

4. Check the pinion teeth for wear.

5. Renew any components, if necessary.

6. Coat the gear teeth with a recommended lubricating oil. Section 7

7. Reassemble in the reverse order to that given fordismantling.

NOTEOne face of each rack pinion is marked with an 'X' tomaintain the origional tooth wear patterns. Make sure thatthe pinions are re-installed on the same end of the shaftandthat the marks on the pinions are facing in the samedirection as they were before removal.

145

SECTION 12



SOOTBLOWER TYPE : IK500 Series / IKSD-E SHEET JOB SHEET TITLE : CARRIAGE DISMANTLING (3)

(Pinion Shaft, Pinion, Spur Gear & Roller Assy's) 1 of 2

STEP ACTION REF./INFO. (FOR SERIES ONE CARRIAGE DRG NO. 398067-0040)

1. Remove the motor and gear change housing. Job Sheet 25

2. Remove the carriage rollers and pinions. Job Sheet 26

3. Remove the cap screws and lockwashers and lift off the cover plate and gasket.

4. Remove the seal and retaining ring which secures the

bearing to the outer carriage support hub.

5. Spread the retaining ring and slide it back along the shaft

away from the spur gear to the end of the keyway. Do not stretch the retaining ring out of shape.

6. With a rawhide mallet, drive the pinion shaft towards the

lance hub side of the carriage. As the shaft is removed, the outboard bearing, seal, inboard bearing and key will accompany it, leaving the spur gear in the carriage housing.

7. As the end of the pinion shaft passes through the the gear,

remove the retaining ring before it drops to the bottom of the carriage housing.

8. Check the gears, bearings and seals for wear or damage.


10. Reassemble in the reverse order to that given for dismantling. NOTE When the shaft passes through the gear, position the key-

ways of the shaft and gear upward, install the retaining ring and move it towards the near end of the keyway. When the shaft is in position, lubricate the seal lip & the mating shaft with a recommended light oil.

Section 7

11. Insert key in the keyway and slide it into the gear. Move

the retaining ring into the groove next to the gear hub; ensure that the ring is seated correctly.

146

SECTION 12

FORM 14682/2 SEPTEMBER 1999


No.27C

SOOTBLOWER TYPE : IK500 Series / IKSD-E SHEET JOB SHEET TITLE : CARRIAGE DISMANTLING (3)

(Pinion Shaft, Pinion, Spur Gear & Roller Assy's) 2 of 2


12. Replace the support bearing retaining ring, pinion, spacer, roller, housing cover, and gasket. Ensure that the retaining ring is seated in the groove correctly.

13. Reassemble the carriage rollers and pinions. Job Sheet 26

147

SECTION 12




(Lance Hub & Bevel Gear Assembly) 1 of 2



1. Remove the carriage from the sootblower.

2. Drain oil from carriage via the two drain plug holes.

3. Remove the key and hub flange from the lance hub andbevel gear assembly.

4. Remove the four cap screws and lockwashers which securethe front bearing retainer and packing assy to the carriagehousing.

5. Remove the bearing retainer, packing assy and gasketsfrom the carriage housing.

6. Withdraw the lance hub, bevel gear assembly and bearingfrom the carriage housing.

7. Remove the bearing and lance hub spacer from thethreaded end of the lance hub and bevel gear assy.

8. Remove the bevel gear and retaining ring from the threadedend of the lance hub and bevel gear assy.

9. Remove the four cap screws and washers which secure therear bearing retainer and packing assembly to the carriagehousing.

10. Remove the bearing retainer and packing assembly, gasketand the second lance hub bearing.

11. Remove the key and bevel-pinion gear from the lance driveshaft assembly.

12. Check the bevel-pinion gear for wear and damage andcheck the condition of both lance hub bearings.

148

SECTION 12




(Lance Hub & Bevel Gear Assembly) 2 of 2


13. Re-new any components, if necessary.

14. Lubricate the bearings through the grease nipples. Section 7


NOTECap screws should be lubricated to assist removal. Section 7

149

SECTION 12




(Shaft and Bearing Assembly) 1 of 1



1. Remove the motor and change gear assembly. Job Sheet 25

2. Remove the four cap screws and lockwashers which securethe bearing retainer to the carriage housing.

3. Withdraw the bearing retainer, worm shaft spacer and theshaft and bearing assembly from the carriage housing.

4. Remove the four cap screws and lockwashers andwithdraw the emergency retract flange oil seal and shimsfrom the carriage housing.

5. Check the condition of the bearings and worm teeth andinspect the shaft oil seal.

6. Re-new any components, if necessary.

7. Re-assemble in the reverse order to that given fordismantling.

NOTE(a) Replace all shims to allow 0.025mm to 0.127mm

(0.001 to 0.005 in) axial movement of the worm shaft.

(b) Use a light oil on the seal lip and mating shaft. Careshould be taken not to damage the seal lip.

Section 7

(c) Thrust bearings must be installed on the worm shaftwith the thrust side towards the end of the shaft, asshown in the illustration below. The thrust side can bedetermined by observing the thickness of the outerbearing race from the side; the thicker of the two sidesis the thrust side.

8. Replace the motor and change gear assembly. Job Sheet 25

150

SECTION 12




(Shaft & Bearing & Lance Drive Shaft Assy) 1 of 1



1. Remove the drain plugs which are located in the bottom ofthe carriage housing and drain off the oil.

2. Remove the key and the bevel-pinion gear from thecarriage housing.

Job Sheet 25

3. Remove the shaft and bearing assembly from the carriagehousing.

Job Sheet 27

4. Remove the six cap screws and lockwashers which securesthe lance drive shaft assembly and withdraw the completeassembly.

5. Inspect the bearings, seals and gear teeth for wear, payingspecial attention to the bronze worm gear.

6. Re-new any component, if necessary.


8. Re-assemble in the reverse order to that given fordismantling.

NOTE(a) Re-assemble retainer, carrier and ball bearing without

shims. Then measure the gap between the retainer andcarrier and add shims measuring (0.076mm to0.127mm).

(b) The worm wheel should be blued and run in with theworm shaft. To establish the correct alignmentbetween wheel and shaft, add shims to ensure that thecontact area of the worm is as near as possible to thecentre line of the worm wheel.

(c) All cap screws should be lubricated to assist removal. Section 7

9. Replace the drain plugs & refill with oil to the correct level.

151

SECTION 12


DIAMOND POWER JOB SHEET No.31E


JOB SHEET TITLE : EXPANDA CABLE -REMOVAL AND RENEWAL

1 of 2


1.

2.

3.

4.

5.

6.

7.

8.

8A

Select the correct size and handing of expanda cable tosuit the particular sootblower

NOTE(a) A right-hand sootblower is one with the motor on the

right-hand side when looking from the rear of thesootblower towards the boiler wall; similarly, a left-hand sootblower has the motor on the left-hand sidewhen viewed from the same position.

(b) A right-hand sootblower uses an expanda cable coiledin the direction of a left-hand thread; a left-handsootblower has the expanda cable coiled in thedirection of a right hand thread.

Disconnect the sootblower from the power supply.

Disconnect both ends of the existing expanda cable.

Remove the tow bar arrg’t retaining screws, washers etcon the Carriage.

Remove all the clips holding the expanda cable to thebeam.

Remove the support rod nuts at the front end of thesootblower.

Loosen the locknut at the rear end of the support rod.

Remove the support rod from the rear of the bulkheadplate.

Remove the expanda cable from the support rod.

Alternatively omit steps 5 and 6 and remove the expandacable towards the front of the sootblower after havingpushed the support rod through the front bulkhead plate.

Section 10

152

SECTION 12


DIAMOND POWER JOB SHEET No.31E


JOB SHEET TITLE : EXPANDA CABLE -REMOVAL AND RENEWAL

2 of 2


9.

10.

11.

12.

13.

14.

Reassemble in the reverse order to that given fordismantling.

NOTEThe new expanda cable as supplied, has a line markedalong all the coils which is intended to assist in ensuringthat the correct coil diameter is achieved when fitting anew cable. The position of this line around thecircumference of the coil is not important, although it mustappear on the same side of the coils in all instances as astraight line or a wavy line, On no account should this linespiral around the cable anywhere along the total length ofthe cable.

Ensure that the support rod does not protrude through therear bulkhead plate.

Tension the support rod by fitting the tensioning nut to therear of the support rod and torque to 10 to 11 Nm (88.5 to97.4 lb/in) approx, use a vice grip or similar, on the rod toprevent it from turning during this operation. Fit thelocknut and torque to the above figure.

Re-assemble the tow bar arrg’t to the carriage. Replace allthe clips holding the expanda cable to the beam.



NOTECheck the action of the expanda cable during the forwardtravel, to see if this is satisfactory over the full length oftravel. Check during reverse travel that there is nobunching or snagging all the way back to the rest position.If there is a problem, check the rubber-lined clips at bothends of the cable to see if they are holding the expandacable in a twisted position. Adjust, if necessary, and re-test to check that the cable is now operating satisfactorilythroughout the total travel

153

SECTION 12

FEBRUARY 2001 FORM 14500/1

DIAMOND POWER JOB SHEET No.32P

SOOTBLOWER TYPE : IkSD-E & IK500 SERIES SHEETJOB SHEET TITLE : WALLBOX - DISMANTLING:

(POSITIVE PRESSURE) 1 of 3


1. Isolate the sootblower from the power supply to preventautomatic operation of the unit.



4. Attach a sling around the lifting lugs at the front and rear ofthe sootblower.

5. Remove the split pins and washer(s) from the wallboxsupport pins.

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

7. Remove the spacer(s) from the support pins.

8. Remove the spirolox retaining ring.

9. Remove the cover plate and seal arrg't.

154

SECTION 12

FORM 14500/1 FEBRUARY 2001


SOOTBLOWER TYPE : IKSD-E & IK500 SERIES SHEETJOB SHEET TITLE : WALLBOX - DISMANTLING:



10. Lift the seal plate out of the wallbox.

11. Re-assemble the wallbox using existing/new parts parts asnecessary.

NOTE 1At assembly apply hylomar sealant to the periphery of thecover plate, the bore of the housing, adjacent to the coverplate and the retaining ring groove. Remove excess sealantafter assy.

This is a corrosion prevention measure.

NOTE 2During assembly adjust screws evenly until there is no playin the seal arrgt then turn the screws back by one half turneach.

12. Wallbox Renewal

12.1 Disconnect the sealing air supply from the wallbox.

12.2 Remove the weld between the wallbox and the wallsleeve

12.3 Remove the wallbox housing.

12.4 Position and weld a replacement wallbox to the wallsleeve.

12.5 Check the clearance at the seal arrg't refer to 'NOTE 2'.

155

SECTION 12



SOOTBLOWER TYPE : IKSD-E & IK500 SERIES SHEETJOB SHEET TITLE : WALLBOX - DISMANTLING:



13. Re-install the sootblower in the reverse order to that givenfor removal.




156

SECTION 12

DECEMBER 2003 FORM 15394/2


SOOTBLOWER TYPE : IK500 SERIES SHEETJOB SHEET TITLE : LIMIT SWITCHES (Telemechanique):

RENEWAL AND ADJUSTMENT. 1 of 2




3. Unscrew the cable gland and connecting cable from the faultylimit switch, noting the correct wire termination points.

4. Remove the two mounting screws, lockwashers and nutswhich secure the faulty limit switch to the beam; remove thecomplete limit switch from the beam.

5. Select a new limit switch and install it in the reverse order tothat given for removal; ensure that the wires are fitted to thesame termination points.

6. Adjustment Procedure

6.1. Check that the contact roller engages correctly with the tripbar on the carriage. The angular position of the roller crank canbe altered by loosening the adjustment screw, turning thecrank until the roller makes contact, and then tightening thescrew.

6.2. Operate the sootblower manually to check that the limitswitches operate correctly when tripped by the carriage tripbar.

Job Sheet 9

157

SECTION 12

FORM 15394/2 DECEMBER 2003


SOOTBLOWER TYPE : IK500 SERIES SHEETJOB SHEET TITLE : LIMIT SWITCHES (Telemechanique):

RENEWAL AND ADJUSTMENT. 2 of 2





158

SECTION 12



SOOTBLOWER TYPE : IK545B SHEET

JOB SHEET TITLE : SUPPORT ROLLERS:-ADJUSTMENT

1 of 1


1.

2.

3.

4.

5.

6.

7.

8.

(FOR SERIES ONE CARRIAGE)



Adjust the angle of rolling contact of the rollers to thelance tube by altering the position of each roller bracketassembly on the roller support bracket. An elongated holein each support bracket allows adjustment to be made byloosening the two securing screws.

Check that the axis of rotation of each roller is at rightangles to the helical path at the contact point

NOTEThe helical path can be found by holding a piece of chalkon the lance tube as it is rotated manually.

After adjustment is complete, tighten the securing screws.




NOTEThe above procedures apply to both front and auxiliarysupport roller assemblies.

159

SECTION 13

MARCH 1995 (PAGE 1 of 3) FORM 12969

SECTION 13 FAULT FINDING

SYMPTOM POSSIBLE CAUSE REMEDY

Sootblower fails to (1) No power voltage: start. a. No power to starter. Check power supply. b. Overload heater has Renew heater. burned out. c. Open circuit between Check continuity. starter and motor. (2) Motor winding open or Test and rectify circuit. shorted. (3) One power line open: a. Overload relay has Re-establish continuity. operated without the motor starting due to single phase condition (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' pushbutton fails to make contact. d. Overload contacts are open. e. Coil is burned out. f. Loose wire in forward coil circuit.

160

SECTION 13

FORM 12969 (PAGE 2 of 3) MARCH 1995



Sootblower jams or Drive motor overloaded. fails to travel. (1) Front rollers are not Re-align rollers. set correctly. (2) Lance is fouling in Check the orientation of wallbox the wallbox. on the boiler wall. (3) Lance is fouling on Adjust the mounting angle of the the boiler internals. sootblower.

(4) Dirt or swarf in the Clean the wallbox using compres- wallbox. -sed air. (5) Feed tube packing is Adjust the packing gland. too tight. (6) Pinion is jamming on Inspect the rack for alignment and the rack. clean the pinion teeth. (7) Valve stem binding in Dismantle the poppet valve and valve guide. inspect the valve stem. Re-new the stem if it is damaged. (8) Pipework incorrectly Inspect pipework and re-run if it is supported - strain necessary. transmitted to the sootblower. Sootblower fails to (1) Limit switch has not Tighten the trip lever. stop. operated - trip lever may be loose. (2) Limit switch has Free or re-new the limit switch. jammed. Blowing medium (1) Poppet valve stem is Dismantle the poppet valve and fails to turn off. sticking in the guide. inspect the valve stem. Re-new the stem if it is faulty.

161

SECTION 13

MARCH 1995 (PAGE 3 of 3) FORM 12969



Blowing medium (2) Valve yoke is broken Dismantle the poppet valve. fails to turn off. or detached from the Re-new the valve yoke.

(Continued) valve stem. (3) Valve spring broken. Dismantle the poppet valve and re-new the spring.

(4) Valve disc loose on Dismantle the poppet valve and the valve stem. inspect the disc. Re-new the disc if necessary. (5) Operating pin broken. Re-new the pin. (6) Cam and pin out of Re-align and re-new, if necessary. alignment. Lance tube fails to (1) Bevel gear teeth are Dismantle the gearbox and re-new rotate although the stripped. the bevel gear. motor runs. Boiler tube abrasion (1) Blowing pressure is Re-set to establish recommended or baffle erosion is to high. blowing pressure. present upon internal inspection. (2) Excess moisture is Increase temperature of blowing present in blowing medium. medium. (3) Operating cycle out Check operation of poppet valve of phase. and linkage.

162

SECTION 14


General

Damage resulting from improper handling on site, site storage, or storagemaintenance is not the responsibility of the equipment supplier. Because of themany variables involved in site storage, however, there is always the possibilityof some damage occurring, particularly to electrical equipment on sootblowers.This risk can be minimised by observing the instructions given in the followingparagraphs 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-545B sootblowers should beremoved from their crates or boxes, all polythene wrappings removed, and theequipment then stored in a dry building where temperature and humidity arecontrolled to prevent condensation. Sootblowers should be stored the correctway up and not on their sides.

14.1.2 Stacking Sootblowers

Each sootblower should be placed on timber battens of sufficient thickness tokeep all parts of the equipment well clear of the ground. The battens should beplaced under the main beams at approximately one third of the length in fromeach end. Equipment may be stacked up to three units high, in double rows, byplacing timber battens across each pair directly above the ground supportbattens. 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 removedand, if undamaged by removal, stored for reinstatement prior to commissioning.The method of doing this and the part numbers for replacements are included inthe 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 theboxes. using two slings. Boxes and crates supplied are specially reinforced for thepurpose. A fork lift truck should not be used for handling IK-545B sootblowers .

SECTION 14STORAGE, HANDLING, AND INSPECTION

DURING STORAGE

163

SECTION 14

FORM 14493 JUNE 2000

14.2.2 Handling Unpacked Equipment (Fig 17)

Sootblowers should only be moved by slinging from the four lifting lugs providedon the top of the beam. Use of a two-point sling or fork lift truck is likely tocause damage and prevent proper operation when installed.

FIG.17 TYPICAL SLINGING ARRG'T

14.3 INSPECTION DURING STORAGE

14.3.1 Frequency

IK-545B sootblowers should be inspected at monthly intervals. with particularcare being given to ensuring that the closures (tape, caps. etc.) on all openingsremain intact.

14.3.2 Protective Lubrication

Prior to shipping, all gearboxes in mechanical equipment are run with a protectiveoil and then drained. For prolonged storage. the gearboxes should be filled with aprotective oil. such as Esso Rustban 335. This must be drained prior to use. It isthe responsibility of the Maintenance Inspector to ensure that this is done beforeoperating the equipment.

164

FORM 14165

INSTRUCTION MANUAL

DIAMOND IK-1MTE

SOOTBLOWER ELECTRIC MOTOR DRIVEN

(Customised to suit) Contract No.N10865

IM133

Diamond Power Specialty Limited Glasgow Road Dumbarton Scotland G82 1ES

Tel: Dumbarton (01389) 744000 Fax: Dumbarton (01389) 762669

165



Diamond Contract No :- N10865 Customer Order No :- 07461-49100-A610-00 Blowing Pressure :- 11.6 kg/cm2

Equipment Supplied :- 36 - Diamond IK1M-TE (Electric Motor Driven) Multi-Nozzle Rotating Element Sootblower


POSITION

No SERIAL

No BOILER

No CUSTOMER TAG

No PSB A B66497 1 B1HCB01AN301 PSB B B66498 1 B1HCB01AN302 PSB C B66499 1 B1HCB01AN303 PSB D B66500 1 B1HCB01AN304

PSB A B66504 2 B2HCB01AN301 PSB B B66505 2 B2HCB01AN302 PSB C B66506 2 B2HCB01AN303 PSB D B66507 2 B2HCB01AN304




166



Diamond Contract No :- N10865 Customer Order No :- 07461-49100-A610-00 Blowing Pressure :- 11.6 kg/cm2

Equipment Supplied :- 36 - Diamond IK1M-TE (Electric Motor Driven) Multi-Nozzle Rotating Element Sootblower


POSITION

No SERIAL

No BOILER

No CUSTOMER TAG

No PSB A B66532 6 B6HCB01AN301 PSB B B66533 6 B6HCB01AN302 PSB C B66534 6 B6HCB01AN303 PSB D B66535 6 B6HCB01AN304




NOTE

When ordering Instruction Manuals for the above equipment please quote the Diamond Contract number and the following I.M. number:-133

167


------ IMPORTANT ------

READ THIS MANUALBEFORE

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 onequipment

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 donot 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.

168


CONTENTS

SECTION TITLE

1 GENERAL DESCRIPTION1.1 General1.2 Operating Controls1.3 Application1.4 Cleaning Principle1.5 Operating Cycle1.6 Identification

2 COMPONENT DESCRIPTION2.1 ELECTRICAL2.1.1 Electrical Components2.1.2 Function2.2 MOUNTING2.2.1 Beam2.2.2 Front Support2.2.3 Wallbox2.2.4 Rear Support2.3 MECHANICAL2.3.1 Carriage and Drive Mechanism2.3.2 Guide Assembly2.3.3 Leadscrew2.4 BLOWING MEDIUM2.4.1 Poppet Valve2.4.2 Poppet Valve Operation2.4.3 Air Relief Valve2.4.4 Feed Tube2.4.5 Lance Tube2.4.6 Lance Tube Support2.4.7 Element / Nozzle / Rake Arrg't2.5 OPERATING SWITCHES2.5.1 Limit Switches2.6 MANUAL OPERATION

3 INSTALLATION INSTRUCTIONS3.1 Location3.2 Mounting3.3 Lifting the Sootblower3.4 Blowing Medium Supply Pipework3.5 Lubrication3.6 Electrical

169



SECTION TITLE

4 COMMISSIONING4.1 Stage 1 - Inspection4.2 Stage 2 - Functional Checks4.3 Stage 3 - Pre-Operational Checks

5 OPERATING INSTRUCTIONS5.1 Operating Precautions5.2 Blowing Schedule

6 MAINTENANCE INSTRUCTIONS6.1 Operational Checks6.2 Periodic Inspection6.3 Annual Maintenance6.4 Major Overhaul6.5 Manual Operation

7 LUBRICATION7.1 Carriage7.2 Drive Chain7.3 Leadscrew and Square Shaft7.4 General Lubrication

8 MAINTENANCE SCHEDULE8.1 Operational Checks8.2 Periodic Inspection8.3 Routine Maintenance8.4 Major Overhaul

9 OPTIONAL TOOLS

10 PARTS IDENTIFICATION

11 RECOMMENDED SPARES LIST

12 JOB SHEETS

13 FAULT FINDING

170



SECTION TITLE

14 STORAGE, HANDLING, & INSPECTION DURING STORAGE14.1 STORAGE14.1.1 Initial Receipt At Site14.1.2 Stacking Sootblowers14.1.3 Feed Tube and Poppet Valve Packing14.2 HANDLING14.2.1 Handling Packed Equipment14.2.2 Handling Unpacked Equipment14.3 INSPECTION DURING STORAGE14.3.1 Frequency

171

MAY 2004 FORM 13649/2

ILLUSTRATIONS

FIGURE TITLE 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 Poppet 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

172

SEC

TIO

N 1

JUN

E 2005

FO

RM

14866

173

SECTION 1


SECTION 1GENERAL DESCRIPTION

Introduction

This instruction manual covers the operation and maintenance of the IK-lMsootblower(s) supplied by Diamond Power Specialty Limited; the main features areillustrated in Fig. 1 opposite.

Where the manual is supplied for a specific contract, details of the equipmentcovered are shown on the Equipment Identification Form at the front of themanual. In addition, the Parts Identification (Section 10) is customised to reflectthe parts actually fitted.

1.1 General (Fig’s.1 & 2)

The IK-lM is a one-metre travel sootblower incorporating a travelling motor drivewhich, through reduction gearing and a leadscrew, drives a carriage along asupporting guide tube. A lance tube, attached to the carriage, propels an elementacross the boiler. Blowing medium, controlled by an integral poppet valve, is fed tothe element via a feed tube to provide cleaning jets. The complete mechanism issupported and protected by a rigid beam. The arrangement of the maincomponents of the sootblower is shown in the illustration below.

FIG.2 VIEW ON REAR OF IKlM LOOKING TOWARDS BOILER

1.2 Operating Controls

The basic IK-lM sootblower is normally operated from a remote panel in the controlroom. Control options available include local push-buttons on the terminal box, andoperation from an individual starter box adjacent to the sootblower. It can also bearranged to operate automatically in a pre-determined sequence.

174

SECTION 1


1.2 Operating Controls Cont’d)

Where the controls are supplied by Diamond Power, the electrical instructionmanual gives more specific details. Once started, the lK-lM goes through itscleaning cycle automatically. Limit switches control the extent of travel and areautomatically reset at the end of the cleaning cycle.

The IK-lM can also be operated manually in the event of power failure and formaintenance purposes.

1.3 Application

The IK-lM is designed to clean the back-end section of coal and oil-fired boilers andother industrial units.

1.4 Cleaning Principle (Fig.3)

The IK-1M functions by blasting the surfaces to be cleaned with jets of high-pressure air or steam. Nozzles are positioned in a travelling element whichtraverses the area to be cleaned and then returns to the reset position ready for thenext cleaning cycle. The element is permanently situated inside the boiler and isdesigned, on a per-contract basis, to give maximum cleaning effect.

FIG. 3 CLEANING PATTERN

1.5 Operating Cycle

The operating cycle begins with the IK-lM in the fully-retracted (reset) position.When power is applied to the drive motor, the carriage moves forward. A trip pinon the carriage operates the poppet valve linkage to open the poppet valve, thusadmitting blowing medium to the cleaning element. The carriage continues itsforward movement until it operates the front limit switch via a trip bracket on aguide assembly fitted to the carriage. This action reverses the drive motordirection, thus reversing the carriage movement.

As the carriage reaches its retracted position, the trip pin again operates the valvelinkage this time to close the valve. The trip bracket operates the rear limit switchto stop the sootblower at the reset position. The complete cycle takes place inapproximately 3.25 minutes .

1.6 Identification

Each sootblower in an installation is identified by a serial number and a positionnumber, both of which are marked on the sootblower nameplate.

A list of the serial numbers of the sootblowers in the installation is given on theEquipment Identification Form; the position of each sootblower is indicated againstthe relevent serial number. Any features, which vary from sootblower tosootblower, are also indicated against the serial number.

175

SECTION 2


SECTION 2 COMPONENT DESCRIPTION

General

The IK1M-TE 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.4)

Electrical components on the sootblower comprise a drive motor, forward and reset limit switches and terminal box containing start and reverse push-buttons. 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 trip bracket on the guide assembly fitted to the carriage, makes contact with the forward limit switch. This action reverses the drive motor

FIG.4

REFER TO ELECTRICAL COMPONENTS – SCHEMATIC DIAGRAM

As the carriage approaches its fully retracted position, the trip bracket 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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CAUTION* 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.

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177

SECTION 2


2.2 MOUNTING

2.2.1 Beam (Fig.1)

The beam is a fabricated assembly comprising a pressed-steel canopy with frontand rear bulkhead plates. It provides support and protection for the sootblowermechanism. Lugs, welded to the canopy, provide lifting points and can also beused to support the rear end of the sootblower in service. The front end issupported via the front bulkhead. A stop bar (Fig.5) is welded to the underside ofthe beam interior near the front bulkhead to bring the carriage to a halt shouldmalfunctioning 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, onsite, to a wallsleeve (provided by the customer) in the boiler wall. The arrangementis shown below.

FIG.5 FRONT SUPPORT ARRANGEMENT

The mounting flange is supplied as part of the sootblower assembly and is boltedto 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 withinthe wallbox to prevent leakage of boiler gases.

178

SECTION 2

FORM 14335/1 AUGUST 2005

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.

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 adrop-cord as the power supply. The motor is flange-mounted to the carriagehousing and drives the carriage via a worm reduction gear and drive nutarrangement housed within the carriage.

FIG. 6 DRIVE ARRANGEMENT

The drive nut traverses a stationary leadscrew as it rotates and thus propels thecarriage. Direction and extent of travel are controlled by limit switches, asdescribed in paragraph 2.5. The lance hub forms part of the carriage assembly. Thelance 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 drivearrangement is used to rotate the lance hub.

Where the element is of the non-rotating type, the hub drive arrangement isomitted.

2.3.2 Guide Assembly (Fig.7)

A guide assembly, comprising a mounting plate and two guide blocks, is bolted tothe carriage housing. A guide tube which runs the length of the beam, is located atone end in the front bulkhead. The opposite end of the guide tube is retained bytwo cotter pins on either side of the rear bulkhead.

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.

181

SECTION 2


2.4 BLOWING MEDIUM2.4.1 Poppet Valve (Fig.9)

The poppet valve controls the flow of blowing medium to the element and isoperated automatically by a cam and trigger, as described in paragraph 2.4.2. It isconnected to the blowing medium supply by a companion flange designed to suitthe blowing medium pipework. The valve is flange-mounted to the sootblower rearbulkhead by four studs and nuts which also connect it to the feed tube (paragraph2.4.4), as shown in Figure 12.

The IKlM may be fitted with a 40, 60, or 120 bar poppet valve, depending uponthe pressure of the blowing medium. The valve body is supplied in carbon steel forstandard applications, and in a chrome molybdenum alloy for higher ternperatureapplications.

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 stemand disc assembly in the valve comprises a stem and a flexible valve disc. On 40and 60 bar applications, the valve disc is loosely attached to the stem by ascrewed retainer and lockwasher. On 120 bar poppet valves, the disc is retainedon the valve stem by a welded plug. A slight play, in both cases, ensures positivesealing of the disc on the seat. The sealing face of the valve has a hard depositedsurface to minimise wear.

The valve stem is positioned by a guide which is screwed into the valve body. Anadjustable pressure control disc is screwed onto the lower part of the guide and isheld in position by a lock pin. The upper part of the stem guide contains the valvestem packing which seals around the stem to prevent leakage of the blowingmedium. A packing nut, screwed onto the stem guide, compresses the packingthrough a packing washer. The packing nut also supports the valve spring whichacts on the stem through a valve yoke. The valve yoke secures the spring retainerand 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 toprevent leakage of blowing medium.

182

SECTION 2


2.4.2 Poppet Valve Operation (Fig.10)

The poppet valve is operated automatically via a cam and offset triggerarrangement. As the carriage moves forward, a trip pin mounted on the side of thecarriage, actuates the cam, thus pulling the valve trigger forward. The triggerpivots 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 andadmitting 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-openingposition. Provision is made, also, for adjusting the engagement of the pin with thecam 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 poppetvalve body. The air relief valve allows air to be drawn into the poppet valvebetween blowing cycles, thus preventing corrosive gases from being drawn intothe 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, theair relief valve closes to prevent escape of blowing medium.

183

SECTION 2


2.4.4 Feed Tube (Fig.12)

Blowing medium is admitted to the feed tube when the poppet valve opens at thestart of the cleaning cycle and passes through it into the lance tube. The feed tubeis telescoped inside the lance tube in the fully-retracted position; the blowingmedium is sealed by packing in a gland in the carriage hub. The outside diameter ofthe feed tube is highly-polished to minimise packing wear as the lance hub slidesover it during the cleaning cycle.

FIG.12 FEED TUBE AND PACKING

The feed tube is made of stainless steel, hence no maintenance is required. Theend of the feed tube is sealed against the gasket in the poppet valve outlet by aclamping 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 endof the lance tube is bolted to the hub on the carriage, as shown in Figure 12, andmoves with it. The other end of the lance tube is generally supplied prepared forwelding to the element on-site; a screwed adapter may be fitted where required.Once connected to the lance tube, the element moves with it.

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.

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.

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.

BALL / POPPET VALVE

186

SECTION 3

MAY 1998 FORM 13249

SECTION 3INSTALLATION INSTRUCTIONS

General

Installation drawings are supplied with each set of sootblowers; these drawingsgenerally show the location of the sootblowers, overall dimensions, method ofmounting, extent of Diamond Power supply, and connections to be made.Reference should be made to the Job Sheets (Section 12) for step-by-stepinstallation instructions.

3.1 Location

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

3.2 Mounting

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

3.3 Lifting the Sootblower

When lifting the sootblower into position, the lifting lugs on the beam should beused (Section 14).

NOTE: Do not use a sling around the beam or the protruding lance tube, as thismay cause damage and subsequent malfunctioning.

3.4 Blowing Medium Supply Pipework

The IK-lM is normally supplied complete with a companion flange prepared forwelding on-site to the blowing medium supply pipework. The pipework is notnormally supplied by Diamond Power but must conform to any specification laiddown in the contract paperwork. The basic requirements are that it must bedesigned and installed to avoid straining the sootblower and have a drainage slopeof at least 1 in 25 downwards from the companion flange.

The supply pipework must be blown out to remove all scale, weld bead, etc., uponcompletion of installation work. A sheet metal deflector must be inserted betweenthe sootblower poppet valve inlet and the companion flange before this operationto 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. Referenceshould be made to the electrical control details in Section 2 for the connectionsrequired.

187

SECTION 4

MAY 1998 FORM 13840

SECTION 4COMMISSIONING

General

Commissioning should be carried out in three stages: (1) Inspection; (2) FunctionalChecks; and (3) Pre-Operational Checks as briefly described in the followingparagraphs. Reference should be made to the Job Sheets at the back of thismanual for more detailed instructions, and to the commissioning check list for asummary and further references.

4.1 Stage 1 - Inspection

Immediately prior to operating the sootblower for the first time, an inspectionshould 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 beenlubricated as specified in the installation instructions, and that it has not sustainedany damage since installation.

Once the above inspection has been made and any further work requiredcompleted, 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. withoutblowing medium) to ensure that the sootblower mechanism is operating correctly.The sootblower should initially be operated manually to check for freedom ofmovement and correct functioning of the mechanism, as described in Job Sheet 7.Where the sootblower is an electrically-driven model, it should be operated fromthe local control to check for correct direction of motor rotation and correctoperation of limit switches. Power consumption should also be compared (wherepossible) with the normal starting and full load current, as stated on the motorrating plate.

The sootblower is now ready to be checked with the furnace on-load, as describedin 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, whereapplicable. This can only be carried out with the furnace on-load and all servicesavailable (i.e. power, blowing medium, and sealing air).

The check for leakage is particularly important where superheated steam is used asthe blowing medium. and should be made before, and during, initial operation ofthe sootblower. Any leakage must be eliminated before moving to the next stageof commissioning.

The recommended blowing pressure is given on the Equipment Identification Format the front of this manual.

188

SECTION 4

FORM 13840 MAY 1998

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 inplace, and the air relief valve in good working order. Blowing pressure can bechecked by connecting a suitable pressure gauge to the air relief valve, as shownbelow.

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 gapis set at approximately 2.5 mm (0.1in) on assembly. Adjustment is made bydisconnecting the air relief valve and removing the lock pin coupling, and thenrotating the pressure control disc. The pressure control disc must be locked inposition after adjustment by replacing the lock pin coupling. The lock pin shouldengage one of the deep grooves in the pressure control disc; each grooverepresents approximately 0.2 mm (0.08 in) vertical movement of the pressurecontrol disc.

The sootblower should be operated through several complete cycles, with steamon, to check that it is functioning correctly before finally putting it into service.

189

SECTION 5


SECTION 5OPERATING INSTRUCTIONS

General

The IK1M Sootblower can be operated from a remote panel or from push-buttonsmounted on the sootblower terminal box or an individual starter box. Once started,the sootblower automatically completes its operating cycle and returns to the restposition 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 shouldbe maintained at over 50% and the draft fans should be operating at a high rate offlow during the sootblowing period. This ensures that the amount of cleaningmedium blown in is small compared to the amount of gases passing through theboiler, and also that the deposits removed by the sootblowers are carried throughthe boiler. If the firing rate is low, the sootblowing may agitate combustibles in thefurnace and cause puffing.

On larger boilers, these precautions are not normally necessary, as the amount ofcleaning medium blown in is usually small compared to the amount of gasespassing through.


When a steam generator is first placed into service, the tube surfaces have animmunity to ash and slag adherence. Consequently, it will appear, at first, that therecommended blowing pressures are higher than required. During this period,lasting for a few weeks, it may not be necessary to operate the sootblower veryoften. Later, after the tube surfaces have acquired a coating of residual slag, thedeposits of slag and ash will be more difficult to clean and the recommendedpressures will be more than likely required.

Before commencing blowing, reference should be made to the operatingprecautions given in paragraph 5.1. Normal recommended practice is to clean theboiler in the direction of the gas flow. The units nearest to the furnace operatefirst, followed by the superheater and economiser units. If heavy accumulations areto be removed, a few of the units in the rear passes of the boiler should beoperated interchangeably with those in the first pass. This eliminates a heavyaccumulation 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 inthe economiser area. These recommendations are general ones, operatingexperience with the individual boiler is the most accurate guide.

190

SECTION 6


SECTION 6MAINTENANCE INSTRUCTIONS

General

Maintenance instructions in this Section are grouped under the following headingsfor convenience: Operational Checks; Periodic Inspection; Annual Maintenance; andMajor 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, arelisted in Section 7.


Checks should be made when the sootblower is operating to detect malfunctioningor blowing medium leakage. With the exception of blowing medium leakage, thesechecks are normally made by the operator.


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 atleast once per month.

6.3 Annual Maintenance

The IK1M Sootblower should be inspected annually for deterioration of all criticalparts; these should be renewed, where necessary. Packing and lubricants should berenewed and mechanisms checked and adjusted, where necessary.

NOTE: Components on the carriage assembly which are sealed for life, should onlybe re-lubricated if dismantling has taken place. This does not apply to bearings andsimilar 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

191

SECTION 6


6.4 Major Overhaul

The IK1M Sootblower should be dismantled every three years for inspection andrenewal of all wearing parts. Seals, packing and lubricants should be renewed atthis overhaul. Wall sleeves and supporting steelwork should also be checked, andrenewed if unserviceable.

NOTE Components on the carriage assembly which are sealed for life should onlybe re-lubricated if dismantling has taken place. This does not apply to bearings andsimilar parts, which should be discarded and renewed.

6.5 Manual Operation (Fig.17)

During maintenance, or in an emergency, the Sootblower carriage can be operatedmanually by using the retraction handle. After first removing the protective cap onthe end of the gear reducer, the drive pin can next be removed and the square tangcan now be turned with the handle. With the drive motor thus disconnected,turning the square tang clockwise results in the carriage travelling forward and thelance tube going into the boiler. Conversely, turning the square tang counter-clockwise 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 operatedmanually to cool the lance tube until it is retracted.

(b) The sootblower must always be returned to the retracted position after manualoperation to re-set the limit switches.

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

193

SECTION 7


IK1M LUBRICATION CHART

COMPONENT LOCATION LUBRICATION POINT

PART TO BE LUBRICATED

FREQUENCY MEANS OF LUBRICATION

LUBRICANT ROCOL

LUBRICANT SHELL

Carriage (1) Under

Sootblower Beam

Worm Gear and Shaft

Cavity Gearing Sealed for

Life

Fill with 385 - 400g

(13.6 – 14.0.fl. oz) Sapphire Extreme

Tivela GL 00

Drive Chain (2) At Rear of Carriage

Chain Links Chain Spray or Brush Light Machine Oil

Light Machine Oil

Leadscrew (3) Rotates

through Carriage

Ends only of Leadscrew

Ends only of Leadscrew

Annually Brush Light Machine Oil

Light Machine Oil

194

SECTION 8


SECTION 8MAINTENANCE SCHEDULE

General

Sootblower controls are normally arranged to protect the plant and the sootblowerfrom damage in the event of a fault developing, by rendering the sootblowerinoperative until the fault is rectified.

The Maintenance Schedule, in the following paragraphs, is designed to minimiseloss of use of the sootblower by forming the basis of a system of preventivemaintenance which identifies parts of the sootblower requiring attention beforethey 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.


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. Excessivecurrent 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 maybe due to either a mechanical fault in the sootblower itself, or an external fault,such as inadequate blowing medium supply.


Frequency of this inspection will depend on operating conditions, but should not beless 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 situand 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 andchecked for any malfunctioning, as described in paragraphs 8.1 and 8.2.Dismantling and Reassembly instructions are given on the relevant Job Sheets inSection 12.

Gaskets and packing seals should be renewed at this stage. Reference should bemade to Section 7 for details of lubrication required.

195

SECTION 8


8.3 Routine Maintenance (Cont’d)

Critical parts, which should be examined in more detail at this overhaul, are asfollows: -

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 goodcondition

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, the sootblower should bedecommissioned as described in Section 4.

8.4 Major Overhaul

The IK1M Sootblower should be inspected every three years and dismantled forrenewal of all wearing parts, if necessary. As a preliminary to this operation, thesootblower should be run and checked for any malfunctioning, as described inparagraphs 8.1 and 8.2. Dismantling and Reassembly instructions are given on therelevant Job Sheets in Section 12.

Gaskets, packing, seals, and lubricants, when required should be renewed at thisstage.

The procedure for examining critical parts is similar to that given for RoutineMaintenance.

Upon completion of a Major Overhaul, the sootblower should be recommissioned asdescribed in Section 4.

196

SECTION 9


SECTION 9OPTIONAL TOOLS

Certain jobs described in the Maintenance Section can best be accomplished usingtools developed for the job. These tools are listed below and are available fromDiamond 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

197

SECTION 9

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


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 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) -


199

SECTION 9

POPPET VALVE MAINTENANCE TOOL (SPANNER)


1 312227-1129 Valve Packing Nut Spanner 1


200

SECTION 9

POPPET VALVE MAINTENANCE TOOL (DEPRESSING TOOL)


1 307025-1024 Valve Spring Depressing Tool 1


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 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


202

SECTION 9


WRENCH FOR MANUAL OPERATION


1 909305-0017 Ratchet Wrench 12 901412-0006 Socket Extension (Not Illustrated) 1

203

SECTION 9


TEST PRESSURE GAUGE ASSEMBLY


1 398023-000A Pressure Gauge 1

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)

205

SECTION 10

( PAGE 1 of 3 ) FORM 14017


CONTRACT No.N10865

Assy Desc / Part No Item No Part No Form No

IK1M-TE MAIN ASSEMBLY 1 398299-000A 15442 398742-0043 2 398271-ASRBYT "

2A N10865-861 " 3 FF1DA0-0133 " 4 M3000E-0132 "

JET TUBE ELEMENT MAT’L: Low Alloy 4A JE528 " 5 398339-A000 " 6 397218-010A " 7 397247-A100 " 8 397769-0001 " 8A N10865-2-613 " 9 398565-1C00 " 10 395635-1039 " 10A 907923-0003 " 10B Not Applicable " 10C Not Applicable " 11 397257-000B " 12 397243-010D " 13 395608-4044 " 28 398535-000A " 29 397802-R2A2 " 30 397556-DDN1 " 31 350256-010A " 32 397473-J120 (6-off) " 33 397474-010A (12-off) " 36 Not Applicable " 37 398496-000A " 38 Not Applicable "

CARRIAGE ASSEMBLY 22 395595-1128 15327 398271-ASRBYT 23 395596-1127 "

24 395602-1145 " 25 395586-1020 " 26 395589-1126 " 27 396337-000A " 28 397197-010A " 29 875603-3215 " 30 875005-4030 " 31 Not Applicable " 32 395585-1146 " 33 398336-010A " 35-39 Not Applicable "

206

SECTION 10

( PAGE 2 of 3 ) FORM 14017


CONTRACT No.N10865


CARRIAGE ASSEMBLY (Cont’d) 40 0903-801 (Tivela) 15327 398271-ASRBYT 41 395598-1034 "

42 879006-3502 "

LANCE JOINT & PACKING ASSY 10 346160-1134 13205 395608-4044

BLOWING MEDIUM TURN-ON ASSY 39 398305-0400 15376

398339-A000

POPPET VALVE ASSEMBLY 1 *398580-RAA0 14895/1 397802-R2A2 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 " 25 398325-010A " 26 Not Applicable "

AIR RELIEF VALVE ASSY 1 Not Applicable 14302 397257-000B 2 941402-0001 "

ELECTRIC CONTROL ASSEMBLY 1 398348-S0002 14864

397769-0001 5 & 6 * " *Refer to Wiring Diagram 7 398494-A1500 "

8 - 11 * " 12 875608-3216-(2-off) " 13 398360-010A (4-off) " 14 879016-3200 (6-off) " 15 875611-3237 (4-off) " 16 398360-010B (6-off) " 19 * " 20 849515-8909 " 22 879006-4002 " 23 - 25 * " 26 849534-8903 " 27 - 38 * "

TERMINAL BOX ASSEMBLY 1 875003-3525 15486 398348-S0002 2 875003-3530 "

3 Not Applicable " 6 Not Applicable "

207

SECTION 10

( PAGE 3 of 3 ) FORM 14017


CONTRACT No.N10865


FRONT BULKHEAD ASSEMBLY 2 395570-1135 (2-off) 15479 398535-000A

FRONT ROLLER ASSEMBLY 1 395636-1137 13210

395635-1039

GUIDE ASSEMBLY 1 397235-000A 14304 397247-A100 2 397242-010A "

WALLBOX & SCAVENGE LINE ASSY 1 397704-010A 15417

398565-1C00 2 396940-010C " 3 397448-000D " 17 RT012709CA (1900mm) "

208

SEC

TIO

N 1

0

AU

GU

ST 2

005

FORM

15442

IK1M

MA

IN A

SSEM

BLY

D

RG

. NO

. 398742-0043

PART. N

O.

209

SECTION 10

FORM 15442 AUGUST 2005

IK1M MAIN ASSEMBLY DRG. NO. 398742-0043 PART. NO.

Item No. Part No. Description No. Off 1 Beam Arrg't 1 2 Carriage Assembly 1 2A Motor 1 3 Feed Tube 1 4 Lance Tube 1 4A Steam / Air Lance / Rake Extension (Not Illustrated)1 5 Blowing Medium Turn- On Assembly 1 6 Leadscrew 1 7 Guide Assembly 1 8 Electric Control Assembly 1 8A Electric Control / Wiring Assembly (Not Illustrated) 1 9 Mounting Flange / Wallbox Assembly) 1 10 Roller, Front Support As Req’d 10A Circlip (Not Illustrated) As Req’d 10B Shaft, Front Support (Not Illustrated) 1 10C Set Screw (Not Illustrated) 1 11 A.R.V/ Pressure Switch / Gauge Mounting Assy 1 12 Locating Collar, Lead Screw 1 13 Lance Joint and Packing Assembly 1 14 873607-4841 Cotter Pin 2 15 397243-010A Locating Collar, Lead Screw 1 16 397245-010A Locking Pin, Lead Screw 1 17 873651-4042 Roll Pin 1 18 398704-010A Emblem 2 19 391750-1128 Warning Tag 1 20 398695-010A Nameplate 1 21 864501-8903 Gripnail 4 22 875005-4016 Screw, Hex Hd M8 x1.5 – 16 lg 4 23 879016-4000 Lockwasher, Split Type M8 4 24 398553-010A Top Cover Plate 1 25 398252-000A Leadscrew Clamp Assy 1 26 871014-4841 Bolt, Hex Hd M12 x 1.75 – 65 lg 1 27 873013-4800 Nut, Nylock M12 x 1.75 1 28 Bulkhead Assy, Bolt-On 1 29 Poppet Valve Assembly 1 * 30 Companion Flange (Not Illustrated) 1 * 31 Gasket (Not Illustrated) 1 * 32 Stud (Not Illustrated) As Req’d * 33 Nut (Not Illustrated) As Req’d * 34 909305-0017 Ratchet Wrench (Not Illustrated)** 1 * 35 901412-0006 Socket Extension (Not Illustrated)** 1 36 Guard Assembly (Not Illustrated) 1 37 Rear Support Assembly (Not Illustrated) 1 38 Scavenging Air Assy (Not Illustrated) 1

* Items Supplied Loose Item 37 fitted to rear lifting lugs at site ** Per Boiler Set

210

SEC

TIO

N 1

0

APR

IL 2002

FO

RM

15327

CA

RRIA

GE A

SSEM

BLY

D

RG

. NO

. 398271-0042

PART. N

O.

211

SECTION 10


CARRIAGE ASSEMBLY DRG. NO. 398271-0042 PART. NO. Item No. Part. No. Description No. Off 1 395658-1148 Housing 1 2 395590-1123 Bearing Carrier 1 3 395591-3128 Gasket, Bearing Carrier 1 4 395591-4126 Gasket, Bearing Carrier As Req'd 5 343831-1130 Gasket, Motor Flange 1 6 395648-1133 Collar,Motor Shaft 1 7 395647-2124 Key 1 8 907923-0016 Retaining Ring 2 9 901110-0040 Ball Bearing 2 10 901110-0125 Ball Bearing 2 11 901110-0105 Ball Bearing 1 12 907923-0001 Retaining Ring 2 13 907923-0012 Retaining Ring 1 14 907655-0007 Expansion Plug 1 15 875005-4430 Hex Hd Screw 4 16 879016-4400 Lockwasher 4 17 344093-4135 Key 1 18 875005-3520 Hex Hd Screw 8 19 879016-3500 Lockwasher 8 20 395603-1128 Key 1 21 901416-8900 Seal 1 22 Worm Gear 1 23 Worm Shaft 1 24 Drive Nut 1 25 Sprocket Arrg't 1 26 Sprocket 18T 1 27 Chain Arrg't 1 28 Locking Plate 1 29 Screw 2 30 Hex Hd Screw 8 31 Hub, Sprocket 1 32 Lance Hub 1 33 Trip Pin 1 34 941401-0009 Pipe Plug As Req’d 35 Hub Arrg’t 1 36 Rotary Union 1 37 Nipple 1 38 Coupling 1 39 Torque Bracket Arrg’t 1 40 Lubrication As Req’d 41 Chain Guard Arrg’t 1 42 Plain Washer 2

212

SECTION 10


LANCE JOINT AND PACKING ASSEMBLY DRG. NO. 395608-1040 PART. NO. Item No. Part No. Description No. Off 1 395647-1126 Key 8 x 8 x 19 1 2 395609-1122 Flange 1 3 907923-0016 Retaining Ring, External 1 4 395610-1137 Gasket, Lance Tube 1 5 395638-1135 Bushing, Front 1 6 873015-4400 Nut, Hex M10 x 1.5 2 7 873008-4400 Nut, Hex, Locknut M10 2 8 879006-4400 Washer, Form A, M10 2 9 395615-1124 Stud, Gland Packing 2 10 Packing 1 11 395611-1037 Packing Gland Arrg't 1 12 879016-4400 Lockwasher, Split Type M10 6 13 875005-4437 Screw, Hex Hd M10 x 1.5 – 45Lg 6

213

SECTION 10


BLOWING MEDIUM TURN-ON ASSEMBLY DRG. NO. 398339-0042 PART. NO.

214

SECTION 10



Item No. Part No. Description No. Off 1 907948-8901 Rod End 1 2 907948-8900 Rod End 1 3 869068-0012 Washer, 1.5 x 0.75 x 16G 1 4 398333-000A Cam Arrg't 1 5 398646-000A Mounting Arrg’t 1 6 901118-0054 Oilite Bearing 2 7 398301-010B Spacer, Poppet Valve Trigger 1 8 871014-4840 Hex Hd Bolt M12 x 1.75 x 60 lg 4 9 879006-4802 ‘C’ Washer M12 8 10 873651-3233 Roll Pin ø5 x 35 lg 2 11 879006-4800 Washer Form-A M12 2 12 879016-4800 Lockwasher, Split Type M12 12 13 875005-4836 Hex Hd Screw M12 x 1.75 X 40 lg 8 14 397729-000A Trigger Shaft Arrg't 1 15 873024-5200 Aerotight Hex Nut M16 x 2.0 1 16 398649-010A Bearing Retainer, Poppet Valve Mounting 1 17 398334-000A Pivot Block Arrg’t 1 18 869006-8904 Washer 30 OD x 22 ID x 16G 2 19 398301-010A Spacer, Poppet Valve Trigger 1 20 876004-8904 Hex Hd Bolt M16 x 2.0 x 90 lg 1 21 879006-5200 Washer, Form-A M16 1 22 873015-5200 Hex Nut M16 x 2.0 1 23 398302-010A Spacer, Poppet Valve Cam 1 24 907920-9005 External Retaining Ring 1 25 907920-9010 External Retaining Ring 1 26 304634-0117 Gasket, Feed Tube 1 27 907920-0113 External Retaining Ring 1 28 395875-1129 Clamping Plate, Feed Tube 1 29 879016-4400 Lockwasher, Split Type M10 2 30 875005-4433 Hex Hd Screw M10 x 1.5 – 35 lg 2 31 873015-4800 Hex Nut M12 x 1.75 4 32 301235-0116 Pin, Poppet Valve Yoke 1 33 863603-1716 Cotter Pin, Split Ø2 x 15 1 34 875007-3516 Screw, M6 1.0 x 16 Lg 3 35 873651-4042 Roll Pin, Ø8 x 70 Lg 1 36 876006-4410 Grub Screw, M10 x 1.5 x 10 Lg 4 37 398651-010A Plate, Lead Screw Locking Bracket 1 38 398804-010A Block, Lead Screw Locking 1 39 Adjusting Rod 1

215

SECTION 10



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.

216

SEC

TIO

N 1

0

OC

TO

BER

2006

FO

RM

14895/1

POPPET

VA

LVE A

SSEM

BLY

(IR2G

) / (IK1M

) / (DO

PV)

DRG

. NO

. 397802-0042

PART. N

O.

217

SECTION 10

FORM 14895/1 OCTOBER 2006

POPPET VALVE ASSEMBLY (IR2G) / (IK1M) / (DOPV) DRG. NO. 397802-0042 PART. NO. Item No. Part No. Description. No. Off 1 Valve Body 1 2 Valve Stem and Disc Arrg't 1 3 Flexible Valve Seat 1 4 Pressure Control Disc 1 5 Not Applicable Trigger Arrg’t 1 6 Not Applicable Valve Yoke Pin 1 7 Not Applicable Cotter Pin 1 8 Not Applicable Trigger Pin 1 9 Not Applicable Cotter Pin 1 11 Lock Pin Plug 1 12 930711-9034 Copper Washer 1 13 301142-0118 Valve Yoke 1 14 301808-0113 Valve Spring Retainer 1 15 302051-0115 Valve Spring 1 16 302032-0119 Packing Nut 1 17 302027-0116 Packing Washer 1 18 398443-010A Valve Stem Packing 1 19 342928-1136 Valve Stem Guide 1 20 301167-2114 Valve Stem Washer 1 21 396774-0121 Adjustable Pressure Tag 1 22 Nut 4 23 Stud / Hex Soc Hd Screw 4 24 Not Applicable Adaptor 1 25 Locking Washer, Poppet Valve Nut 2 26 Plug, G3/4 1 NOTES:

1. Valve Stem Guide, Lock Pin and Plug threads to be coated with ‘Molykote Gn Plus’ (907145-0002)


3. Valves to be hydro tested to procedure – QA 002



218

SECTION 10

DECEMBER 1996 FORM 14302

AIR RELIEF VALVE ASSEMBLY DRG. NO. 397257-0034PART. NO.


1 Street Elbow 12 Male Stud Coupling 13 341245-1027 Air Relief Valve Arrg't 14 935923-8400 Nipple 15 937817-8400 Tee Piece 16 936220-8400 Plug 17 935924-8461 Nipple 18 349569-010D Adaptor 19 930711-9034 Copper Washer 110 396774-0121 Adjustable Pressure Control Tag 1

219

SEC

TIO

N 1

0

NO

VEM

BER

2004

FO

RM

14864

ELECTRIC

CO

NTRO

L ASSEM

BLY

D

RG

. NO

. 397769-0043

PART. N

O.

220

SECTION 10


ELECTRIC CONTROL ASSEMBLY DRG. NO. 397769-0043 PART. NO. Item No. Part No. Description No. Off 1 Terminal Box/Assembly 1 5 Cable Gland Pg13.5 2 6 Limit Switch 2 7 Mounting Rail 1 8 Cable 3-core (Length as req’d) As Req’d 9 Cable 5-core (Length as req’d) As Req’d 10 Cable Gland Pg16 2 11 Cable Looped 4-core (Length as req’d) 1 12 Screw M5 0.8 x 16 lg 2 13 Nut As Req’d 14 Lockwasher M5 As Req’d 15 Screw M5 x 0.8 – 45 lg 4 16 Nut 6 19 Nut M6 2 20 Cable Clip 1 22 Washer M8 4 23 Proximity Switch (Rear) (IFM) 1 24 Adaptor, Motor M20 x Pg16 1 25 Proximity Switch (Front) (IFM) 1 26 Grommet Strip 4 27 Screw M6 x 1.0 x 35 lg 4 28 Washer M6 As Req’d 29 Screw, Hex Hd M6 x 1.0 x 16 lg 1 30 Screw M5 x 0.8 – 30 lg 2 31 Proximity Switch (Front) (Telemechanique) 1 32 Gland M20 2 33 Gasket 2 34 Proximity Switch (Rear) (Siemens) 1 35 Proximity Switch (Front) (Siemens) 1 36 Proximity Switch (Front & Rear) (Namur) 2 37 Proximity Switch (Front & Rear) (Ersce) 2 38 Proximity Switch (Front & Rear) (Siemens) 2

221

SEC

TIO

N 1

0

SEPT

EMBER

2006

(C

ON

TRA

CT N

10865)

ELECTRIC

CO

NTRO

L / WIR

ING

ASSEM

BLY

PA

RT. N

O. N

10865-2-613

(R

EV B

) DRG

. NO

. 396600-1723

222

SECTION 10

(CONTRACT N10865) SEPTEMBER 2006

ELECTRIC CONTROL / WIRING ASSEMBLY PART. NO. N10865-2-613 (REV B) DRG. NO. 396600-1723

Item No. Part No. Description Qty. 1 * Electric Motor 1 2 * Entry, Motor, M25 - 3 841402-0071 Cable Gland M25 2 4 * Entry 25.4 mm dia clearance hole (for M25) - 5 841402-0079 Locknut M25 1 6 849518-8949 Cable, Motor, 4-core - 7 841405-0116 Limit Switch, LSR & LSF - Ersce 2 8 * Entry M20 - 9 848300-9784 Terminal Cross Connector, 3 way 1 10 875007-3236 Screw, M5 x 0.8 – 40 lg Soc Hd 4 11 879011-3200 Washer, M5 Serrated 4 12 * CP20 Rail - 13 * CP20 Fixings - 14 * Entry 20.4mm dia clearance hole (for M20/Pg13.5) - 15 841402-0067 Cable Gland M20 2 16 841402-0078 Locknut M20 2 17 841404-0014 Cable, Limit Switch, 3-core, Hi-temp silicon 1 18 841404-0015 Cable, Limit Switch, 5-core, Hi-temp silicon 1 19 907506-8901 Warning Label, “Steam Sootblower” 1 20 * Entry 44mm dia clearance hole - 21 * Cable Gland By others 22 * Locknut By others 23 * Entry 29mm dia clearance hole - 24 * Cable Gland By others 25 * Locknut By others 26 847313-9208 VCI Foam Square, Corrosion Protection 2 27# 398348-S0002 Terminal Box Assembly, RH 1 28# 398743-AA10 Terminal Block Assembly 1 29# 841420-0002 Pushbutton Assy, Start, RED 1 30# 841420-0001 Pushbutton Assy, Reverse, GREEN 1 31# 841420-0010 Pushbutton Insert, RED 1 32# 841420-0011 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

223

SECTION 10


TERMINAL BOX ASSEMBLY (RITTAL) DRG. NO. 398348-0140 PART. NO. Item No. Part No. Description No. Off 1 Screw, Slt Hd Csk M6 x 1.0 - 25lg As Req’d 2 Screw, Slt Hd Csk M6 x 1.0 - 30lg 1 3 Screw, Slt Hd Csk M6 x 1.0 - 45lg 4 4 873015-3500 Hex Nut M6 8 5 879016-3500 Lockwasher, Split Type M6 4 6 Nylon Spacer 4 7 875006-3500 Washer, Form A, M6 4 8 841406-0009 Terminal Box 1

224

SECTION 10


FRONT BULKHEAD ASSEMBLY. DRG. NO. 398535-0028 PART. NO. Item No. Part No. Description. No. Off 1 398389-010A Front Bulkhead Plate (Bolt-on) 1 2 395570-1135 Shaft As Req’d

225

SECTION 10


FRONT ROLLER ASSEMBLY DRG. NO. 395635-1039PART. NO.


1 Roller 12 901110-0058 Ball Bearing 13 907923-0005 Retaining Ring 2

226

SECTION 10


GUIDE ASSEMBLY DRG. NO. 397247-0037PART. NO.


1 Guide Block Arrg't 12 Guide Tube 13 875005-4425 Screw 24 879016-4400 Lockwasher 25 873651-8900 Roll Pin 26 873607-4841 Cotter Pin 2

227

SEC

TIO

N 1

0

SEPT

EMBER

2003

FORM

15417

WA

LLBO

X A

ND

SC

AV

ENG

E LINE A

SSEM

BLY

DRG

. NO

. 398565-0

047

PART. N

O.

228

SECTION 10

FORM 15417 SEPTEMBER 2003

WALLBOX AND SCAVENGE LINE ASSEMBLY DRG. NO. 398565-0047PART. NO.

Item No. Part No. Description. No. Off

1 Wallbox Housing 12 Seal Plate 13 Seal Arrg’t 14 397703-010A Wallbox Flange 15 875005-4444 Hex Hd Screw M10 x 1.50 – 80 lg 46 871014-4852 Hex Hd Bolt M12 x 1.75 –120 lg 47 873015-4800 Hex Nut M12 x 1.75 88 879016-4800 Lockwasher, Split Type M12 89 941414-0010 Reducing Tee 110 932500-8902 Hosetail ½”BSPT 111 902210-8903 Hose Clip 212 931403-0012 90° Elbow 113 841414-0067 Adapter 114 941416-0015 Nipple 115 941401-0012 Plug 116 931403-0005 Rubber Hose (Cut to suit) As Req’d17 Copper Tube (Cut to suit) As Req’d18 902225-0005 Clamp, Copper Tube 119 873015-3200 Hex Nut 120 879016-3200 Lockwasher 121 875005-3220 Hex Hd Screw M5 x 0.8 – 20 lg 122 941406-0001 90° Elbow ½” x ½” 123 873651-3220 Roll Pin 0.5 x 20 lg 1

229

SECTION 10


REAR SUPPORT ASSEMBLY DRG. NO. 398496-0025PART. NO. 398496-000A


1 398496-010A Rear Support Bar 12 RZ240130KC-0250 Screwed Rod 23 873015-6000 Hex Nut M24 44 879006-6000 Washer M24 45 863607-2240 Cotter Pin 3/16”x 2” lg 26 869006-3600 Plain Washer 2

230

SECTION 11


SECTION 11RECOMMENDED SPARES LIST

It is recommended that stocks of the items listed in this Section be maintained asfollows:

1. Running Maintenance

Quantities shown in column 1 should be regarded as a minimum initial stock leveluntil actual usage is established through operating experience.

2. Incurred Maintenance

Diamond sootblowers are designed to operate for long periods with the minimum ofmaintenance and spares usage; component parts do not normally require replacementunless 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 abreakdown 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 forwear or damage as indicated in Section 8, and parts replaced as necessary. Itemswhich 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 thequantities stocked may have to be adjusted to take account of severe usage ordelays in obtaining replacements .

The assembly headings indicate where the items listed are used. Since headingsand items appear in the same order as shown in the Parts Identification Section ofthe Instruction Manual, part numbers of related items can be readily identified.

The quantities recommended have been calculated per ten sootblowers. Thesequantities may require to be adjusted to correspond with the actual number ofsootblowers in use.

231

SECTION 11



EQUIPMENT TYPE :- IK1MTE SOOTBLOWER 1. Running Maintenance (Positive Pressure) 2. Incurred Maintenance CONTRACT No :- N10865 3. Major Overhaul

DESCRIPTION PART NO QUANTITY

1 2 3 MAIN ASSEMBLY 398742-0043

Electric Motor N10865-861 - 1 - Feed Tube FF1DA0-0133 - 1 - Lance Tube M3000E-0132 - 1 - Element: Mat’l: Low Alloy JE528 - 1 - Gasket (Companion Flange) 350256-010A - 2 10

CARRIAGE ASSEMBLY 398271-ASRBYT

Gasket, Bearing Carrier 395591-3128 - 1 - Gasket, Bearing Carrier 395591-4126 - 1 - Gasket, Motor Flange 343831-1130 - 1 - Key 395647-2124 - 1 - Ball Bearing 901110-0040 - 2 - Ball Bearing 901110-0125 - 2 - Ball Bearing 901110-0105 - 1 - Key 344093-4135 - 1 - Key 395603-1128 - 1 - Seal 901416-8900 - 1 - Worm Gear 395595-1128 - 1 - Worm Shaft 395596-1127 - 1 -

LANCE JOINT & PACKING ASSY 395608-4044

Bushing 395638-1135 - 1 10 Packing (Solid Ring) 346160-1134 - - 10 Packing (Split Ring) 396741-010A 10 10 10 Gland 395611-1037 - 1 - Key 395647-1126 - 1 10 Gasket 395610-1137 - 1 10

BLOWING MEDIUM TURN-ON ASSY 398339-A000

External Retaining Ring 907920-9005 - 1 - External Retaining Ring 907920-9010 - 1 - Gasket, Feed Tube 304634-0117 - 1 - External Retaining Ring 907920-0113 - 1 -

232

SECTION 11

FORM 13218 (Page 2 of 2)


EQUIPMENT TYPE :- IK1MTE SOOTBLOWER 1. Running Maintenance (Positive Pressure) 2. Incurred Maintenance CONTRACT No :- N10865 3. Major Overhaul

DESCRIPTION PART NO QUANTITY

1 2 3 POPPET VALVE ASSEMBLY 397802-R2A2

Valve Stem and Disc Arrg't 344381-1033 - 2 5 Flexible Valve Seat 309786-1128 - 2 - Pressure Control Disc 394197-1123 - 2 - Lock Pin Plug 393802-1122 - 2 - Lock Pin Washer 930711-9034 - 2 10 Valve Yoke 301142-0118 - 2 10 Valve Spring Retainer 301808-0113 - 2 10 Valve Spring 302051-0115 - 2 10 Packing Nut 302032-0119 - 2 - Packing Washer 302027-0116 - 2 - Valve Stem Packing 398443-010A 10 10 10 Valve Stem Guide 342928-1136 - 2 - Valve Guide Washer 301167-2114 - 2 10 Nut 397474-010A - 4 - Stud 397473-J090 - 4 Locking Washer 398325-010A - 2 20

AIR RELIEF VALVE ASSEMBLY 397257-000B

Air Relief Valve 341245-1027 - 2 - Copper Washer 930711-9034 - 1 10

(REF) ELECTRIC CONTROL ASSEMBLY 397769-0001 (Per Wiring Diagram N10856-2-613)

Limit Switch (Forward) 841405-0116 - 1 - Limit Switch (Reverse) 841405-0116 - 1 -

FRONT ROLLER ASSEMBLY 395635-1039

Roller 395636-1137 - 2 20 Bearing 901110-0058 - 2 20

WALLBOX & SCAVENGE LINE ASSY 398565-1C00

Seal Plate 396940-010C - 1 -

233

SECTION 12


SECTION 12JOB SHEETS

JOB SHEET TITLENO

1 IK1MTE Installation Procedure.2 Commissioning Check List.3 Blowing Medium Turn-On Linkage - Adjusting Procedure.4 Poppet Valve - Checking / Setting the Blowing Pressure.5 Pressure Sealing Points - Checking Procedure.6 Limit Switches - Renewal and Adjustment.7 Checking the Electrical Operation.8 Manual Operation.9 Feed Tube Packing - Split Ring : Adjusting the Packing Gland.10 Feed Tube Packing - Split Ring : Renewal.11 Poppet Valve - Removal from Sootblower.12 Poppet Valve - Dismantling.13 Poppet Valve - Valve Stem Packing : Adjusting Procedure.14 Poppet Valve - Valve Stem Packing : Renewal.15 Poppet Valve - Tools and Equipment for Lapping the Valve Seat.16 Poppet Valve - Valve Seat Lapping Procedure.17 Poppet Valve - Seat Renewal.18 Poppet Valve - Reassembly Procedure.19 Poppet Valve - Replacing on the Sootblower.20 Lance Tube Gasket - Adjusting Procedure.21 Lance Tube Flange Gasket - Renewal.22 Lance and Feed Tube - Removal.23 Carriage - Removal and Replacement.24 Carriage - Dismantling and Reassembly.25 Wallbox - Dismantling.

234

FORM 15325

JOB SHEETS

The information within the job sheets areof a general nature and are not intended tocover every individual sootblower system.

WARNING

Before all adjustments, repairs and testsare undertaken the control room should benotified. The appropriate local permitsshould be taken out and all safetyprecautions taken.

NOTE

Refer to the yellow coloured warning sheetat the front of the Instruction manual forgeneral information regarding importantInstallation, Commissioning, Operating andMaintenance instructions.

235

SECTION 12



SOOTBLOWER TYPE : IK1M SHEETJOB SHEET TITLE : INSTALLATION PROCEDURE 1 of 3


1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Remove all straps and packing from the sootblower.

Inspect the sootblower for possible damage from shipmentor storage.

Check that the sootblower is complete.

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

Position and weld the wallsleeve to the boiler wall..

Bolt the mounting flange to the front bulkhead.

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

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

Position and bolt the rear support to the supportingsteelwork.

Weld the mounting flange to the wall sleeve.

Connect the blowing medium supply pipework to thesootblower.

NOTEThe supply pipework is not provided by Diamond Powerand must be carefully installed to prevent undue stress onthe sootblower. To ensure correct drainage of condensate,refer to the installation drawing.

Bolt the companion flange to the poppet valve inlet flange.

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

Unbolt the companion flange from the poppet valve flange.

Packing List

Inst. Drg

Inst. Drg

236

SECTION 12





15.

16.

17.

18.

19.

20.

Insert a sheet metal deflector between the companionflange and the sootblower.

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

Remove the deflector and insert the companion flangegasket.

Bolt the companion flange to the sootblower valve inletflange, compressing the gasket evenly between theflanges. Tighten the studs in the sequence shown in thefollowing illustration.

NOTEThe use of a torque wrench is not manditory but theapproximate torque value of a properly tightened stud is asfollows:- 80 - 100 Nm for M20 studs (40 and 60 Bar Valves)125 – 140 Nm for M24 studs (120 Bar Valves)

STUD TIGHTENING SEQUENCE

NOTESeries 60 and 120 poppet valve installations have eight

flange studs.

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

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

Inst Drg

237

SECTION 12





21.

22.

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

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

Section 2

238

SECTION 12



SOOTBLOWER TYPE : IK1M SERIES SHEETJOB SHEET TITLE : COMMISSIONING 1 of 2


1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Isolate the sootblower from the blowing medium andpower supply.

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

Check that the sootblower can be operated safely withoutaffecting any other equipment, and obtain any permitrequired.

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

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

Ensure that all moving parts of the sootblower are free tomove, particularly the leadscrew, guide bar, and frontsupport rollers, if fitted.

Move the carriage forward until the integral trip pinengages the blowing medium turn-on linkage and adjust ifnecessary.

Move the carriage forward until it contacts the front limitswitch. Check the travel against that specified on theInstallation Drawing and adjust the limit switch position ifnecessary. Retract the sootblower fully on completion ofthis step.

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

Check the blowing pressure and adjust if necessary.

Job Sheet 8

Job Sheet 6

Job Sheet 3

Job Sheet 6

Job Sheet 5

Job Sheet 4

239

SECTION 12



SOOTBLOWER TYPE : IK1M SERIES SHEETJOB SHEET TITLE : COMMISSIONING 2 of 2


11.

12.

13.

Check the electrical operation.

Run the sootblower through a complete cycle and check:-

(1) That it reverses automatically when the front limitswitch is tripped.

(2) That it stops when the rear limit switch is tripped.

(3) That the poppet valve operates satisfactorily.

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

Job Sheet 7

240

SECTION 12



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

ADJUSTING PROCEDURE 1 of 1


1.

2.

3.

4.

5.

CAUTIONDo not operate the blowing medium turn-on linkage by

hand with the poppet valve under pressure.


Move the carriage forward manually and note the positionof the cam as the trip pin engages. The correct position isshown below.

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

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

Re-connect the blowing medium and power supply.

241

SECTION 12

MAY 1998 FORM 14306


SOOTBLOWER TYPE : IK1M SHEETJOB SHEET TITLE : POPPET VALVE

(CHECKING/SETTING THE BLOWING PRESSURE) 1 of 2


NOTEThe Blowing pressure can only be set under normal workingconditions, 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.



5. Determine the blowing pressure.

6. Remove the 3/8"in BSPT blanking plug from the air reliefvalve.

7. Connect a suitable pressure gauge to the air relief valveoutlet.

Section 4

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


242

SECTION 12

FORM 14306 MAY 1998


SOOTBLOWER TYPE : IK1M SHEETJOB SHEET TITLE : POPPET VALVE

(CHECKING/SETTING THE BLOWING PRESSURE) 2 of 2


10. Open the poppet valve by running the sootblower carriageforward manually, and note the pressure gauge reading.

11. Run the sootblower back manually to the fully-retractedposition, ensuring that the poppet valve closes.

12. Remove the lock pin plug.

13. Using a screwdriver inserted through the tapped lock pinside hole, rotate the pressure control disc clockwise tolower or anti-clockwise to raise, thus decreasing orincreasing the blowing pressure between the valve seat andthe valve disc.

14 Replace the lock pin plug after adjustment has beencompleted, ensuring that it seats in one of the deep flutesin the disc.

15. Repeat steps10-14 until the recommended blowing pressureis obtained.


17. Remove the pressure gauge.

18. Replace the blanking plug.

19. Turn on the blowing medium supply



243

SECTION 12



SOOTBLOWER TYPE : IK1M SHEETJOB SHEET TITLE : PRESSURE SEALING POINTS

(CHECKING PROCEDURE) 1 of 1


NOTEA check should be made for leakage at the pressure sealingpoints listed below. This should be carried out by operatingthe sootblower with the blowing medium on.

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

Job Sheet 12

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

Job Sheet 12

3. Lance Tube :If leakage is detected, tighten the retaining bolts whichsecures the lance tube flange to the lance hub. If leakagepersists after further tightening, renew the gasket.

Job Sheets21 and 22

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

Job Sheet 11

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

Job Sheet 15

244

SECTION 12



SOOTBLOWER TYPE : IK1M SHEET JOB SHEET TITLE : LIMIT SWITCHES:

RENEWAL AND ADJUSTMENT 1 of 2


1.

2.

3.

4.

5.

Isolate the sootblower from the power supply. Shut off the blowing medium supply. Unscrew the cable gland and connecting cable from the faulty limit switch, noting the correct wire termination points. 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

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.

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.

245

SECTION 12



SOOTBLOWER TYPE : IK1M SHEET JOB SHEET TITLE : LIMIT SWITCHES:

RENEWAL AND ADJUSTMENT 2 of 2


6.

6.1

6.2

6.3

7.

8.

Adjustment Procedure 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. 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. 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. Reconnect the power supply and test-run the sootblower Reconnect the blowing medium supply.

Inst. Drg.

Job Sheet 8

246

SECTION 12



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

1 of 1


1.

2.

3.

4.

4.1

4.2

4.3

4.4

4.5

4.6

5.

6.

Switch on the power supply.

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

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

Check the motor rotation, the sootblower should travelforward. If the motor rotation is wrong, correct it asfollows

Switch off the power supply.

Remove the terminal box cover.

Change over the power wires.

Replace the terminal box cover.

Switch on the power supply.

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

Run the sootblower forward through its complete cycle.

At the end of the cycle, check that the sootblower is in theretracted position, with the blowing medium and powersupply disconnected.

Job Sheet 8

247

SECTION 12



SOOTBLOWER TYPE : IK1M SERIES SHEETJOB SHEET TITLE : MANUAL OPERATION 1 of 2


1.

2.

3.

NOTEEach sootblower can be operated manually duringmaintenance or in an emergency.

If a fault develops with a set of sootbiowers duringautomatic sequential operation, those in use should retractautomatically. If they fail to do so for any reason, such aspower failure, motor stalled, etc.; immediate action mustbe taken to manually withdraw the sootblowers involved.

This is carried out by attaching a ratchet wrench to thesquare tang on the rear bulkhead

Manual operation is as follows:


Unscrew the securing nut and withdraw the locking pinfrom the leadscrew collar; this action disconnects thedrive.

Attach a ratchet wrench to the square tang. Turning thesquare tang clockwise results in the carriage returningtowards the normally fully-retracted position.

Conversely, turning the square tang counter-clockwiseresults in the carriage travelling forward and the lance tubegoing into the boiler.

Section 9.

248

SECTION 12



SOOTBLOWER TYPE : IK1M SERIES SHEETJOB SHEET TITLE : MANUAL OPERATION 2 of 2


3.Cont’d

4.

5.

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

(b) If the poppet valve is ‘ON’, blowing mediumpressure will prevent easy removal of the lockingpin on the leadscrew collar. In this case, thewrench should be used to turn the square tang andapply pressure in a clock-wise direction; this willthen allow removal of the pin. Do not apply morethan 75 NM (55 lbs.ft.) of torque to the squaretang.

After retraction has been completed, replace the lockingpin in the collar, securing it with the nut.

Re-connect the power supply.

249

SECTION 12



SOOTBLOWER TYPE : IK1M SERIES SHEETJOB SHEET TITLE : FEED TUBE PACKING:- (SPLIT RING)

ADJUSTING THE PACKING GLAND. 1 of 2


1.

2.

3.

4.



Tighten the two packing gland nuts, just enough to preventleakage. The position of the packing gland nuts is shown inthe illustration below.

NOTEThe feed tube packing, which provides a seal between thestationary feed tube and the translational lance hub, iscompressed in the stuffing box by the adjustable packinggland surrounding the feed tube. The gland can betightened until the gland shoulder butts against the end ofthe lance hub.

On applications where superheated steam is used as theblowing medium, tighten the packing gland when the feedtube is at its hottest condition, as described in Step 3. Thisprocedure will increase the life of the packing and preventover-tightening due to thermal expansion.

If persistant leakage occurs, and further tightening doesnot stop it, add additional packing up to a maximum ofthree rings.

250

SECTION 12




ADJUSTING THE PACKING GLAND. 2 of 2


5.

5.1

5.2

5.3

5.4

6.

7.

8.

9.

Adding Additional Packing

Remove the nuts which secure the packing gland to thelance hub. Slide the packing gland towards the rearbulkhead.

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

Replace the packing gland.

Replace the packing gland nuts, and hand-tighten themonly.





Section 9

251

SECTION 12




RENEWAL 1 of 2


1.

2.

3.

4.

5.

6.

7.

8.

9.



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

Remove the two packing gland nuts and two locknutswhich hold the packing gland in position.


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

Carefully clean the carriage hub stuffing box, packinggland, and all components. A solvent may be required toremove any traces of gum.

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

Repair or renew any damaged parts.

Job Sheet 8

252

SECTION 12




RENEWAL 2 of 2


10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

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

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

Gently insert the packing ring into the stutting box.

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

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

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

Remove the packing tool and slide the packing gland intoposition.

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




Adjust the packing gland, if necessary.

Section 9.

253

SECTION 12



SOOTBLOWER TYPE : IK1M SERIES SHEETJOB SHEET TITLE : POPPET VALVE:-

REMOVAL FROM SOOTBLOWER. 1 of 1


1.

2.

3.

4.

5.

6.

7.

Isolate the sootblower from the power supply to preventautomatic operation of the unit.


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

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

Disconnect the poppet valve at the companion flange.

Disconnect the poppet valve at the valve outlet flange.


254

SECTION 12



SOOTBLOWER TYPE : IK1M SERIES SHEETJOB SHEET TITLE : POPPET VALVE:- DISMANTLING 1 of 1


1.

2.

3.

4.

5.

6.

7.

NOTEThis Job Sheet covers partial dismantling of the poppetvalve in preparation for valve seat lapping or renewal.

Dismantling procedure is as follows.


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

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.

Remove the packing from the valve stem.

Job Sheet 11

Job Sheet 13

Section 9

255

SECTION 12



No.13

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


STEP 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

256

SECTION 12



No.13



STEP ACTION REF./INFO. NOTES:



6. This clearance dimension should be set between the



shown.

257

SECTION 12






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


3. Remove the poppet valve from the sootblower. Job Sheet 11 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.


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.

Job Sheet 18

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.

Job Sheet 13

258

SECTION 12






NOTES: 1. Valve Stem Guide, Lock Pin and Plug threads to be

coated with ‘Molykote Gn Plus’.(907145-0002)




shown.

259

SECTION 12



SOOTBLOWER TYPE : IK1M Series SHEETJOB SHEET TITLE : POPPET VALVE : Tools and Equipment

Needed for Lapping the Valve Seat. 1 of 1


NOTEThe tools and equipment required for lapping are as follows:-

1. One disc is serrated, for rough lapping, and the other disc isplain, for finishing and burnishing. The surfaces of both discsmust must be kept lapped flat; a lapping machine, or surfaceplate , can be used to maintain the disc surfaces.

2. Lapping Compounds:- Section 9Diamond Compound, Hyprez 45.Diamond Compound, Hyprez 14.Diamond Compound, Hyprez 3.

3. Lapping Equipment:- Section 9Wobble stick, manually-operated valve grinder, or smallcapacity air motor with flexible shaft.

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

260

SECTION 12



SOOTBLOWER TYPE : IK1M SERIES SHEETJOB SHEET TITLE : POPPET VALVE :




2. Charge an unused serrated lapping disc with Hyprez 45compound.

Section 9

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


5. Charge an unused plain lapping disc with Hyprez 14compound.

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


8. Charge the plain lapping disc with Hyprez 3 compound Section 9

9. Burnish-lap for five minutes.


11. Cover the surface of a blue block with a very thin uniformcoating of Prussian blue.

12. Place the blue block carefully on the lapped seat.

13. Applying finger pressure only, move the blue block back andforth slightly.

14. Carefully remove the blue block.

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

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

261

SECTION 12






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

18. Reassemble the valve in the reverse order to that given fordismantling.

Job Sheet 18

262

SECTION 12



SOOTBLOWER TYPE : IK1M SERIES SHEET




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. *MIG wire * Equivalent to AWS E7028 or BS639 (1976) E5144H. * Welding Rod

5. 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.

263

SECTION 12



SOOTBLOWER TYPE : IK1M SERIES SHEET



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

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

Job Sheet 18

264

SECTION 12




REASSEMBLY PROCEDURE 1 of 1


NOTEThis procedure covers reassembly after partial dismantling forseat-lapping or renewal. The valve should be reassembled inclean conditions to reduce the possibility of grit being trappedbetween 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 thatthe sealing faces are clean and undamaged.

NOTEMaintain firm contact between the sealing faces during thesubsequent steps.

3. Insert the new valve stem packing, staggering the splits in therings 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 inletand outlet should be sealed to protect the internals.

10. Replace the poppet valve on the sootblower. Job Sheet 19

265

SECTION 12

NOVEMBER 2001 FORM 14859/1



REPLACING ON THE SOOTBLOWER. 1 of 2


1.

2.

3.

4.

5.

6.

7.

8.

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

Ensure that the valve inlet and outlet sealing surfaces areclean and undamaged.

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

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

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

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

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

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

266

SECTION 12

FORM 14859/1 NOVEMBER 2001



REPLACING ON THE SOOTBLOWER. 2 of 2


9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

Loosely fit the locking washers and securing nuts whichretains the poppet valve to the mounting and clamping platesvia the rear bulkhead.

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

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

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

Fit a new companion flange gasket.

Re-connect the companion flange to the poppet valve.

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


Test-run the sootblower, checking for leaks.

Reset the blowing pressure.

(if fitted)

Section 4

267

SECTION 12



SOOTBLOWER TYPE : IK1M SERIES SHEETJOB SHEET TITLE : LANCE TUBE FLANGE GASKET-

ADJUSTING PROCEDURE1 of 1


1.

2.

NOTEThe lance tube flange gasket is compressed between thelance hub and the lance tube flange by tightening theretaining bolts as follows:-

Tighten the six bolts in the sequence shown in theillustration below. The bolts should be torqued to 23 Nm(17 ft. lbs.)

NOTEThe torque figure given applies to bolts coated with anti-seize compound. Higher torque may be necessary when re-tightening in service.

If persistant leakage occurs and further tightening does notstop it, renew the gasket.

Section 7

268

SECTION 2



SOOTBLOWER TYPE : IK1M SERIES SHEET JOB SHEET TITLE : LANCE TUBE FLANGE GASKET :-

RENEWAL 1 of 2


1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Ensure that the carriage is in the fully-retracted position. Isolate the sootblower from the power supply. Shut off the blowing medium supply. Remove the four nuts which secure the poppet valve to the rear bulkhead; remove the poppet valve.

Remove the feed tube retaining ring. Slide the feed tube to the rear of the sootblower, ensuring that the feed tube and lance tube are supported securely. Remove the six bolts and lockwashers which secure the lance tube flange to the lance hub flange. Move the lance tube forward far enough to clear the carriage hub. Remove the existing lance tube flange gasket. Examine the locating face at the lance hub and lance tube flange.

269

SECTION 12



SOOTBLOWER TYPE : IK1M SERIES SHEET JOB SHEET TITLE : LANCE TUBE FLANGE GASKET :-

RENEWAL 2 of 2


11.

12.

13.

Clean and remove any loose particles of dirt or existing gasket, as applicable. Install the new gasket. Reasemble in the reverse order to that given for dismantling.

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 anti-seize compound. Higher torque may be necessary when re-tightening in service.

270

SECTION 12



SOOTBLOWER TYPE : IK1M SERIES SHEET JOB SHEET TITLE : LANCE AND FEED TUBE :-

REMOVAL 1 of 2


1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

NOTE

This Job Sheet should be used in conjunction with Job Sheet No.23 Carriage Removal and Replacement. Isolate the sootblower from the power supply. Shut off the blowing medium supply. Remove one of the front support rollers. Move the carriage forward manually to obtain sufficient access to feed tube clamping bolts and nuts. Remove the four nuts which clamp the feed tube to the poppet valve via the mounting plate and slide the clamping plate forward.

Remove the feed tube retaining ring. Push the feed tube forward and remove the clamping plate. Disconnect the air relief valve from the scavenging air line. Remove the yoke cotter pin and withdraw the valve yoke pin from the yoke. Remove and aside the poppet valve assembly.

Fig 13

Job Sheet 8

Job Sheet 11

271

SECTION 12



SOOTBLOWER TYPE : IK1M SERIES SHEET JOB SHEET TITLE : LANCE AND FEED TUBE :-

REMOVAL 2 of 2


11.

12.

13.

14.

15.

16.

17.

18.

19.

Withdraw the feed tube via the rear bulkhead plate. Support the lance tube. Remove the six bolts and lockwashers from the lance hub flange. Withdraw the lance tube via the rear bulkhead plate. Inspect the lance and feed tube, repair or renew as required. Reassemble in the reverse order to that given for dismantling again in conjunction with Job Sheet 23.

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 anti-seize compound. Higher torque may be necessary when re-tightening in service. Re-connect the blowing medium supply. Re-connect the power supply. Test-run the sootblower.

272

SECTION 12

MAY 1998 FORM 13281/1


SOOTBLOWER TYPE : IK1M SERIES SHEETJOB SHEET TITLE : CARRIAGE :-

REMOVAL AND REPLACEMENT1 of 2


1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

NOTEThis Job Sheet covers the removal of the carriage from thesootblower for inspection and overhaul, or for thereplacement of a spare carriage. Dismantling for overhaul iscovered by Job Sheet 24.


Disconnect the power supply cable from the motor.

After disconnection, arrange slings to support the lanceand carriage.

Tension the slings to take the weight of the carriage.

Remove the two roll pins at the rear bulkhead andwithdraw the guide tube.

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

Remove the roll pin which secures the collar to theleadscrew.

Withdraw the leadscrew by unscrewing it through thecarriage drive nut.

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

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

Remove the feed tube retaining ring and clamping plate.

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

273

SECTION 12

FORM 13281/1 MAY 1998


SOOTBLOWER TYPE : IK1M SERIES SHEETJOB SHEET TITLE : CARRIAGE :-

REMOVAL AND REPLACEMENT2 of 2


13.

14.

15.

16.

17.

18.

19.

Disconnect the six screws which secure the lance to thecarriage.

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

Lower the carriage onto the gantry.

Remove the carriage to the bench for inspection andoverhaul.

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

Re-connect the power supply cable to the motor.


274

SECTION 12



SOOTBLOWER TYPE : IK1M SERIES SHEETJOB SHEET TITLE : CARRIAGE:-

DISMANTLING AND REASSEMBLY1 of 2


1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Remove the four screws and lockwashers which securethe motor to the housing. Save the screws for re-use, butdiscard the lockwashers. Withdraw the motor; save thecollar and the key for re-use.

Remove and discard the expansion plug and the circlip;withdraw the worm shaft.

NOTETo avoid damage to the worm gear, ensure that it is free torotate as the worm is withdrawn.

Remove the chain guard and chain (if fitted).

Remove the eight screws and lockwashers which securethe bearing carrier to the housing and withdraw the bearingcarrier complete with its bearing; save the gaskets for re-use.

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

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

Remove the retaining ring and pull off the flange.

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

Remove the retaining ring which secures the hub andbearing to the lance hub; the bearing can now be removedfrom the lance hub for examination.

Examine the guide nuts and renew if necessary.

275

SECTION 12



SOOTBLOWER TYPE : IK1M SERIES SHEETJOB SHEET TITLE : CARRIAGE:-

DISMANTLING AND REASSEMBLY2 of 2


11.

12.

Reassembly - GeneralBefore reassembly, all parts should be cleaned andexamined for wear or damage. New oil seals, expansionplugs, and lockwashers should be used. The worm gearcavity should be packed with grease as specified in thelubrication chart.

The procedure to be adopted is generally the reverse ofthat used in dismantling but, if a new worm gear or drivenut is fitted, the drive nut end play relative to the housingmust be checked to ensure that it is within the limits,0.127 mm to 0.508mm (0.005 in. to 0.020 in). The endplay can be varied by adjusting the gasket thicknessbetween the bearing carrier and the housing. Gaskets, areavailable 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.

NOTEOn reassembly torque cap screws to 5.6 Nm (5Oin lbs.);torque pattern one time round only and rewire cap screwstogether in pairs.

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

Section 7

276

SECTION 12

MARCH 2006 FORM 14856/2


SOOTBLOWER TYPE : IK1M SHEET JOB SHEET TITLE : WALLBOX - DISMANTLING.



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



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. Section 10

F15417

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.

277

SECTION 12

FORM 14856/2 MARCH 2006


SOOTBLOWER TYPE : IK1M SHEET JOB SHEET TITLE : WALLBOX - DISMANTLING.



9. 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.

278

SECTION 13

AUGUST 1996 (PAGE 1 of 3) FORM 13283



Sootblower fails to start. (1) No power voltage: a. No power to starter Check power supply. b. Overload tripped or Renew heater. heater burned out. c. Open circuit between Check contiuity. starter and motor. (2) Motor winding open or Test and rectify circuit. shorted. (3) One power line open: Re-establish continuity. a.The overload relay has operated without the motor having started because of a single- phase condition. (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.

279

SECTION 13




Sootblower jams or fails Drive motor overloaded: to travel. (1) Element fouling on

boiler internals. Re-align internal bearing in hot and cold positions.

(2) Feed tube packing is too Adjust the packing gland. tight. (3) Valve stem fouling - Dismantle the poppet valve and binding in valve guide. inspect the valve stem. Re-new the stem if it is damaged. (4) Worm gear stripped. Dismantle carriage and renew

gear. (5) Pipework is incorrectly Inspect pipework and re-run if it supported, strain trans- is necessary. mitted to sootblower. (6) Drive nut failure. Dismantle carriage and renew drive nut. Sootblower fails to stop. (1) Limit switch has not op- Tighten the trip lever. erated,trip lever loose. (2) The limit switch has Free or re-new the limit switch. jammed. (3) Forward / Reverse Inspect contactor and adjust if contactor has failed to necessary. operate.

280

SECTION 13




Blowing medium fails to (1) Poppet valve stem is Dismantle the poppet valve and turn off. sticking in guide. inspect the valve stem. Re-new stem if faulty. (2) Valve yoke is broken or Dismantle the poppet valve and detached from valve stem re-new the valve yoke. (3) Valve spring broken. Dismantle poppet valve and renew spring. (4) Valve disc loose on the Dismantle the poppet valve and valve stem. inspect the valve disc. Re-new the disc if necessary. (5) Operating pin broken. Re-new pin. (6) Cam and pin are out of Re-align and re-new if necessary. alignment. Lance tube fails to rotate (1) Sprocket teeth stripped. Renew sprocket. although the motor runs. (2) Hub key sheared. Renew hub key. (3) Chain broken. Rejoin chain or renew. Boiler tube abrasion or (1) Blowing pressure too Re-set to recommended blowing baffle erosion present high. pressure. upon internal inspection. (2) Excess moisture present Increase temperature of blowing in blowing medium. medium. (3) Element out of alignment. Re-align element.

281

SECTION 14


General

Damage resulting from improper handling on site, site storage, or storagemaintenance is not the responsibility of the equipment supplier. Because of themany variables involved in site storage, however, there is always the possibilityof some damage occurring, particularly to electrical equipment on sootblowers.This risk can be minimised by observing the instructions given in the followingparagraphs 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 removedfrom their crates or boxes, all polythene wrappings removed, and the equipmentthen stored in a dry building where temperature and humidity are controlled toprevent condensation. Sootblowers should be stored the correct way up and noton their sides.

14.1.2 Stacking Sootblowers

Each sootblower should be placed on timber battens of sufficient thickness tokeep all parts of the equipment well clear of the ground. The battens should beplaced under the main beams at approximately one third of the length in fromeach end. Equipment may be stacked up to three units high, in double rows, byplacing timber battens across each pair directly above the ground supportbattens. 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 removedand, if undamaged by removal, stored for reinstatement prior to commissioning.The method of doing this and the part numbers for replacements are included inthe 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 theboxes. using two slings. Boxes and crates supplied are specially reinforced for thepurpose. A fork lift truck should not be used for handling IK-1M sootblowers .

SECTION 14STORAGE, HANDLING, AND INSPECTION

DURING STORAGE

282

SECTION 14


14.2.2 Handling Unpacked Equipment (Figure 18)

Sootblowers should only be moved by slinging from the lifting points provided onthe top of the beam. Use of a two-point sling or fork lift truck is likely to causedamage 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 carebeing given to ensuring that the closures (tape, caps. etc.) on all openings remainintact.

283

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