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1

IK545 CONTENTS

SECTION

TITLE

PAGE

1 1.1 1.2 1.3 1.4 1.5 1.6

GENERAL DESCRIPTION General Opening Controls Application Cleaning Principle Operating Cycle Identification

19 19 19 19 19 20 20

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

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

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

3 3.1 3.2 3.3 3.4 3.5 3.6 3.7

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

34 34 34 34 34 34 35 35

2

IK545 CONTENTS (Continued)

SECTION

TITLE

PAGE

4 4.1 4.2 4.3

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

36 36 36 36

5 5.1 5.2

OPERATION INSTRUCTIONS Operation Precautions Blowing Schedule

38 38 38

6 6.1 6.2 6.3 6.4 6.5

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

39 39 39 39 40 40

7 7.1 7.2 7.2.1 7.3 7.4 7.4.1 7.4.2 7.5

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

41 41 41 41 41 41 41 41 41

8 8.1 8.2 8.3 8.4

MAINTENANCE SCHEDULE Operational Checks Periodic Inspection Routine Maintenance Major Overhaul

43 43 43 43 44

9

OPTIONAL TOOLS

45

10

PARTS IDENTIFICATION

55

11

RECOMMENDED SPARES LIST

97

12

JOB SHEETS

101

13

FAULT FINDING

160

3

IK545 CONTENTS (Continued)

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

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

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

4

IK545 ILLUSTRATIONS

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

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

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

5

IK1M CONTENTS

SECTION

TITLE

PAGE

1 1.1 1.2 1.3 1.4 1.5 1.6

GENERAL DESCRIPTION General Operating Controls Application Cleaning Principle Operating Cycle Identification

174 174 174 175 175 175 175

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

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

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

3 3.1 3.2 3.3 3.4 3.5 3.6

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

187 187 187 187 187 187 187

6

IK1M CONTENTS (Continued)

SECTION

TITLE

PAGE

4 4.1 4.2 4.3

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

188 188 188 188

5 5.1 5.2

OPERATION INSTRUCTIONS Operating Precautions Blowing Schedule

190 190 190

6 6.1 6.2 6.3 6.4 6.5

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

191 191 191 191 192 192

7 7.1 7.2 7.3 7.4

LUBRICATION Carriage Drive Chain Leadscrew and Square Shaft General Lubrication

193 193 193 193 193

8 8.1 8.2 8.3 8.4

MAINTENANCE SCHEDULE Operational Checks Periodic Inspection Routine Maintenance Major Overhaul

195 195 195 195 196

9

OPTIONAL TOOLS

197

10

PARTS IDENTIFICATION

205

11

RECOMMENDED SPARES LIST

231

12

JOB SHEETS

234

13

FAULT FINDING

279

7

IK1M CONTENTS (Continued)

SECTION 14 14.1 14.1.1 14.1.2 14.1.3 14.2 14.2.1 14.2.2 14.3 14.3.1

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

PAGE 282 282 282 282 282 282 282 283 283 283

8

IK1M ILLUSTRATIONS

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

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

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

9

INSTRUCTION MANUAL

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

Diamond Power Specialty Limited

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

Fax: Dumbarton (01389) 762669

FORM 14164

10

EQUIPMENT IDENTIFICATION FORM

N10865

Diamond Contract No :-

07461-49100-A610-00

Customer Order No :-

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

Blowing Pressure :-

Equipment Supplied :-

Site :-

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

Rabigh, Saudi Arabia

POSITION No LSB A LSB B LSB C

SERIAL No B66494 B66495 B66496

UNIT No 1 1 1

CUSTOMER TAG No B1HCB01AN301 B1HCB01AN302 B1HCB01AN303

LSB A LSB B LSB C

B66501 B66502 B66503

2 2 2

B2HCB01AN301 B2HCB01AN302 B2HCB01AN303

LSB A LSB B LSB C

B66508 B66509 B66510

3 3 3

B3HCB01AN301 B3HCB01AN302 B3HCB01AN303

LSB A LSB B LSB C

B66515 B66516 B66517

4 4 4

B4HCB01AN301 B4HCB01AN302 B4HCB01AN303

LSB A LSB B LSB C

B66522 B66523 B66524

5 5 5

B5HCB01AN301 B5HCB01AN302 B5HCB01AN303

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

FORM 13519

11

EQUIPMENT IDENTIFICATION FORM

N10865

Diamond Contract No :-

07461-49100-A610-00

Customer Order No :-

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

Blowing Pressure :-

Equipment Supplied :-

Site :-

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

Rabigh, Saudi Arabia

POSITION No LSB A LSB B LSB C

SERIAL No B66529 B66530 B66531

UNIT No 6 6 6

CUSTOMER TAG No B6HCB01AN301 B6HCB01AN302 B6HCB01AN303

LSB A LSB B LSB C

B66536 B66537 B66538

7 7 7

B7HCB01AN301 B7HCB01AN302 B7HCB01AN303

LSB A LSB B LSB C

B66543 B66544 B66545

8 8 8

B8HCB01AN301 B8HCB01AN302 B8HCB01AN303

LSB A LSB B LSB C

B66550 B66551 B66552

9 9 9

B9HCB01AN301 B9HCB01AN302 B9HCB01AN303

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

FORM 13519

12

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

OPERATING MAINTAINING

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

OCTOBER 1993

FORM 14148

13

CONTENTS

SECTION

TITLE

1 1.1 1.2 1.3 1.4 1.5 1.6

GENERAL DESCRIPTION General Operating Controls Application Cleaning Principle Operating Cycle Identification

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

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

3 3.1 3.2 3.3 3.4 3.5 3.6 3.7

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

OCTOBER 2002

(PAGE 1 OF 3)

FORM 14274

14

CONTENTS (Continued)

SECTION

TITLE

4 4.1 4.2 4.3

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

5 5.1 5.2

OPERATING INSTRUCTIONS Operating Precautions Blowing Schedule

6 6.1 6.2 6.3 6.4 6.5

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

7 7.1 7.2 7.2.1 7.3 7.4 7.4.1 7.4.2 7.5

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

8 8.1 8.2 8.3 8.4

MAINTENANCE SCHEDULE Operational Checks Periodic Inspection Routine Maintenance Major Overhaul

9

OPTIONAL TOOLS

10

PARTS IDENTIFICATION

11

RECOMMENDED SPARES LIST

12

JOB SHEETS

13

FAULT FINDING

OCTOBER 2002

(PAGE 2 OF 3)

FORM 14274

15

CONTENTS (Continued)

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

OCTOBER 2002

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

(PAGE 3 OF 3)

FORM 14274

16

ILLUSTRATIONS

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

NOVEMBER 1999

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

FORM 14275

17

SECTION 1

FORM 15018/1

JULY 1999

18

SECTION 1

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

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

1.2

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

1.3

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

1.4

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

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

FORM 14729

19

SECTION 1 1.4

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

1.5

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

1.6

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

FORM 14729

OCTOBER 2000

20

SECTION 2

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

ELECTRICAL

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

FIG.3 ELECTRICAL COMPONENTS - SCHEMATIC DIAGRAM

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

JULY 2005

FORM 14332/2

21

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

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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.

( 28 '

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

31 32

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

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