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DIVISION C

BOILER MOUNTINGS
VOLUME C1
SOOT BLOWERS
LIST OF CONTENTS
Location
TAB-1
(1-4)

Description

Ref. No. / Drg. No

SOOT BLOWERS
LRD IIE Views

1-00-076-60601

Furnace Temp. Probe Views ( FTP IE- AC)

1-00-076-60602

Wall Deslagger Views ( WB IE )

2-00-076-60990

Soot Blower Arrangement

3-00-076-60354

TAB-2
(5-18)

Soot Blower Operations - Emergency Check List

Pub. No. 7515

TAB-3
(19-36)

AC Induction Motor(For Soot Blowers)

Pub. No. 7506

TAB-4
(37-63)

Soot Blower - General Instructions

Pub. No. 7501

TAB-5
(64-91)

Wall Deslagger -Model WB IE

Pub. No. 7503

TAB-6
(92-131)

Furnace Temperature Probe Model FTP IE & IIE

Pub. No. 7505

TAB-7
(132-193)

LRD IIE Long Retractable Soot Blower

Pub. No. 7514

TAB-8
(194-268)

Methods And Procedures For Installation Soot Blowers

Pub. No. 7508

TAB-9
(269)

Soot Blower Arrangement

4-00-076-60871

1610 1611 JINDAL ANGUL

VOLUME-C1

PAGE 1 Of 1

TAB - 1

P
10

04

05 06 07 08

01 02

03

09

DURING BOILER HOT CONDITION

1610 - 1611 VOL - C1 TAB - 1 - 1

A
B
01
VIEW-A

F
SECTION-GG

SECTION-FF

SECTION-EE

E
04
G

03

D
02

E
DETAIL-C

VIEW-D

VIEW-BB

WALL & SLEEVE SECTION

1610 - 1611 VOL - C1 TAB - 1 - 2

1610 - 1611 VOL - C1 TAB - 1 - 3

1610 - 1611 VOL - C1 TAB - 1 - 4

TAB - 2

INSTRUCTION MANUAL
SOOT BLOWER OPERATIONS
EMERGENCY CHECK LIST

Bharat Heavy Electricals Limited


Tiruchirapalli

PUB. NO. 7515


1
1610 - 1611 VOL - C1 TAB - 2 - 5

CONTENTS
INTRODUCTION
SOOT BLOWER OPERATION -EMERGENCY CHECK LIST
SOOT BLOWER JAMMING
BLOWER MOTOR OVERLOAD
SOOTBLOWER OVERRUN
STEAM PRESSURE LOW
STEAM TEMPERATURE LOW
STEAM NO FLOW
A. C. CONTROL SUPPLY/ POWER SUPPLY FAILURE
SOOT BLOWER SEQUENCE INTERRUPTION
VALVE MOTOR OVERLOAD
PHILOSOPHY OF JAMMING RELAY PROTECTION AND OVERLOAD RELAY
PROTECTION IN SOOTBLOWER MCC.

2
1610 - 1611 VOL - C1 TAB - 2 - 6

INTRODUCTION
This manual deals with the emergency actions that are to be carried out when an annunciation
occurs during Sootblower operation. Even though many protections are available in the sootblower
control panel, sometimes it is likely mal-operation can happen. At that time the operating and
maintenance engineers may be in search of correct course of action. We hope this manual will help
the operating and maintenance engineers to know what safe action they can take to protect the
sootblowers as well as the boiler tubes.
The contents of the manual has been carefully prepared. However, it must be understood that no
amount of written instructions will replace intelligent thinking and alertness on the part of the operator
during an emergency to reason the causes of mal-f unctions and to take immediate remedial actions
demanded by the situation.
Suggestions for the improvement of the manual would be welcome.

3
1610 - 1611 VOL - C1 TAB - 2 - 7

SOOT BLOWER OPERATION -EMERGENCY CHECK LIST


The control panel is normally supplied with the following audible and visual annunciations.

S 1.
N o.
1.

S ootblow er jam m ing

Type of
annunciation
audible/visual

2.

S ootblow er m otor overload

audible/visual

3.

S ootblow er overrun

audible/visual

4.

S team pressure low

audible/visual

5.

S team tem perature low

audible/visual

6.

S team no flow

audible/visual

7.

A .C . control supply failure

audible/visual

8.

S ootblow er sequence
com pletion.

audible/visual

9.

V alve M otor overload

audible/visual

10.

S equence interruption

audible/visual

D escription of annunciation

The above alarms can be actuated during the operation of (a) long retractable soot blower (b) wall
deslagger (c) rotary blower (d), half retractable soot blower and (e) airheater cleaner (retractable).
The possible causes and solutions for each of annunciations for long retractable Soot blowers &
wall deslaggers are described in this manual. For other blowers, the causes and solutions may be
more or less similar to long retractable soot blowers.

4
1610 - 1611 VOL - C1 TAB - 2 - 8

1.

SOOT BLOWER JAMMING


This alarm will be actuated when soot blower gets jammed mechanically in the forward direction.
The alarm is given through an instantaneous overload relay which is actuated instantaneously and
will reverse the blower to bring to the home position. The instantaneous overload relay will actuate
the timer which will be set at 2 secs., normally current will be 105 percent of the rated current.

1.1
Sl. No.
(i)

(ii)

Long retractable soot blower Probable causes and solutions for jamming
Probable Causes

Solution

Lance tube fouling with the boiler


tubes or wall sleeve

During shut down the boiler tubes should be


rectified so that a gap of 100-150 mm is kept
in between the lance tube OD and the boiler
tube OD. Realign any tube obstructing the
lance movement.
Physical obstruction for the travelling Check the blower for proper clearance for the
carriage in the housing
travelling carriage. This can be checked only
by local operation

(iii)

If direction of rotation for traverse


motor is incorrect

Change the power cable loads with power off


and run blower again.

(iv)
(v)
(vi)

Failure of reverse limit switch


Valve stem jammed/pitted
Overtightened gland packing in
travelling carriage

Replace the defective switch


Remove the stem and replace or rectify
Loosen the gland

1.2
(i)

Wall Deslagger : Probable Causes and Solutions for Jamming:


Swivel tube fouling with shroud
Position the blower in such a way that the
tube
swivel tube does not foul with the shroud
tube and the perpendicularityto the water
wall is to be maintained.
(ii)
Dust accumulation on the guide
Clean the guide rods and the swivel tube
rods and the swivel tube
once in a week. If the accumulation of dust is
severe, and morefrequent provide additional
covers.
(iii)
Direction of traverse motor is inChange the direction of motor by
correct
changing powerleads.
(iv)
Wrong setting of limit switches
Reset the Cam.
LSTS and LSTE
(v)
Too much of Gland tightness
Loosen the gland nuts to have enough
on wall blower body.
freeness.
(vi)
Valve stem/pitted jammed
Remove the item and replace or
rectify.
'Reset'push button on the panel should be pressed to continue the sequentialoperation after
bypassing the faulty blower.

5
1610 - 1611 VOL - C1 TAB - 2 - 9

2.

SOOT BLOWER MOTOR OVERLOAD

This annunciation will come on as soon as the motor gets overloaded the traverse motor will get
stopped. The thermal overload relay is set to act normally when the current exceeds 105 percent of the
rated current. The probable causes and solutions for his are given below :
2.1

Long retractable soot blower - Motor overload- Probable Causes and Solutions :

Sl. No.
(i)
(ii)
(iii)
(iv)
(v)
(vi)

Causes

Solutions

Lance tube fouling with boiler


tubes
Overtightened gland packing

Same solution as indicated under


sootblower jamming.
Do not overtighten the glands. A
slight leakage of steam is allowed.
Wrong overload relay setting
Check the overload relay setting and
set the relay at the correct value.
Dust accumulation over the rails Clear the dust and debris.
Wrong motor installation in
Check the overload relay setting and
powerpacks.
set the relay at the correct value.
Damaged power/control cables
(Short circuit in any two phases in
M.C.C. or Terminal box)

Check the power cables. It is likely


that cables damage will result in
short-circuiting.
(a) Check the power cable from
MCC. to blower terminal box.
(b) Check the power cable from the
motor to terminal box.
(c) Check the terminal box of motor.
Refer the motor instructions manual.

(vii) Motor winding fault


2.2
(i)

Wall deslagger:
Swivel tube fouling with the boiler
tubes
(ii) Wrong overload relay setting
(iii) Short circuit in the powerloads in
M.C.C. or in terminal box
(iv) Motor winding fault
(v) The rack comes out of pinion

Same solution as indicated under


Sootblower jamming.
Do as suggested in 2. 1. (iii)
Do as suggested in 2.1 (vi)

Do as suggested in 2.1 (vii)


Sometimes because of loose screws
of cams the rotary gear box is
likely to come out of pinion. For this
(a) an easy solution would be to put
two rubber washers on guide rods.
(b) Periodically tighten the cam screws.
(vi) Improper meshing of gears
Dismantle the gear box and check
the meshing of gears.
Overload relay should be reset in M.C.C. before operating the same blower. After ensuring
the lance of the particular blower is withdrawn to the home position only, the
sequential operation should be continued. Physical checking is a must.

6
1610 - 1611 VOL - C1 TAB - 2 - 10

3.

SOOTBLOWER OVERRUN
The total time for forward and reverse operation of sootblowers is supervised by elapsed timers.
When the blower stays for a longer time than its normal working time the blower overrun annunciation
will come and will stop automatic sequence operation and at the same time retract the blowers to its
initial position. Normally the timer is set in excess by 1 or 2 minutes of blower operating time.
The probable causes and suggested solutions are given below
3.1 Long Retractable Soot blower-Soot blower overrun-Probable causes and solutions

Sl. No.

Causes

Solutions

(i)

Faulty reverse limit switch

If the blower is not withdrawn auto-matically


Immediate action
Allow the steam flow if the blower is located in hot
zone. Send one man for closing the regulating valve
manually. Switch off the power,
Then withdraw the lance manually.
Caution
Do not allow the lance inside the boiler for a longer
time with blowing medium.
Later
Check the limit switch contacts, spring, etc. If it is
in serviceable condition service and put back the
switch. If it is not possible then replace the switch
with a new one.

(ii)

Wrong timer setting

Normally the timer is set more than 1 minute than


the operating time. Check the timer setting and set
correctly.
Check the forward and reverse contactor, clean the
terminals and' contacts and put back in M.C.C.
Immediate action :
(a) Allow the steam flow not more than 5 minutes.
(b) Wrap a chain or rope around the travelling
carriage through a winch. If this takes too much
of time, stop the steam flow. By doing so it is
likely that the lance may get bent. In case of
blowers located in low temperature zones, the
steam flow can be cut off just after the jamming has
occurred
(c) And now stop the steam flow.
(d) Pull out the lance tube.
Later : Replace the damaged chain link,
using connector link.
Immediate Action :
(a) Cut off power supply.
(b) Allow the steam flow for not more than 5 minutes.
(c) Retract the lance, using the hand crank.
Later
Assemble a new motor and check the direction of
rotation before the blower is put into operation again.

(iii) Failure of contactor and


contactor reverse (CR) coils
(iv) Traverse chain failure due to
the weak link

(v) Traverse Motor shaft breakage

7
1610 - 1611 VOL - C1 TAB - 2 - 11

Sl. No.

Causes

(vi)

Burnt out or damaged traverse


Motors.

(vii)

Thermal overload
Relay for traverse
motor blows as a
result of which
the traverse motor
stops.

3.2

Wall Deslagger:

(i) LSTR ' limit switch fails to


operate or damaged, missing switch
arm.

(ii)

Wrong timer setting

(iii)

Faulty rotary contactor (CRO)

(iv)

Failure of Traverse motor -shaft


or rotary motor shaft

(v)

Burnt Out or damaged motors

Solutions
Immediate Action :
(a) Cut off the power supply.
(b) Allow the steam flow for not more than 5
minutes.
(c) Retract the lance tube using the hand crank,
after cutting off steam supply.
Later
Assemble a new motor or repaired one and check
the direction of rotations before the blower is put
into operation again.
Immediate Action
(a) Cut oft the power supply.
(b) Allow the steam flow for
not more than 5 minutes.
(c) Retract the lance tube using the hand
crank as suggested in 3.1.(i)
Later
Check why the motor has stalled.
Find out the cause

Immediate Action:
(a) Switch off the power supply.
(b) Using the hand crank, withdraw the swivel
tube. (Hand cranking is possible with steam
on).

Normally the time is set for 120 secs. Check thetimer


setting and set correctly.
Check the rotary contactor, clean the terminals and
contacts and put back in M.C.C.
Immediate Action
(a) Switch off the power supply.
(b) Using the hand crank withdraw the swivel
tube. (Withdrawl of swivel tube by hand cranking
is possible with steam on)
Later :
Assemble a new motor and check the direction of
rotation before ,he blower is put into operation again

Immediate Action :
(a) Cut off the power supply.
(b) Retract the swivel tube using the hand crank.
Later :
Assemble new motors and 'check the direction of
rotation before the blower is put into operation again.
Reset push button on the panel should be pressed to continue the sequential operation after
ensuring the particular blower is in home position. Physical checking is a must.

8
1610 - 1611 VOL - C1 TAB - 2 - 12

4.

STEAM PRESSURE LOW


This annunciation will come to the operator as soon as the system pressure is lower than the set
value. As soon as the annunciation is received, retract the blower immediately and stop the
sootblowing operation. The probable causes and suggested solutions are as follows:

S1. No.
(i)

Probable Causes

Suggested Solutions

Multiple leaks in the system


(a) sootblower valve passing.
(b) Sootblower flange leakage.
(c) Drain valve heavy leakage.
Mal-functioning of pressure reducing
valve

(ii)

(iii)

Hand stop valve partially closed

(c) Then proceed with SB operation.


(iv)
Erratic action of pressure switch or
damaged pressure switch.

(v)

Broken supply line

Stop the sootblower operation.


Later
Identify the leakage in the system
and attend the leaks.
Immediate Action:
Stop the sootblower operation.
Later :
Attend to this problem. Ref.detailed
instructions for trouble shooting
of pressure reducing valve.
Immediate :
(a) Stop the sootblower operation
(b) Open the valve fully.

Immediate Action:
Sootblowing can be continued
by watching the pressure indicator
available on the panel.
Later :
Attend to pressure switch or
replace with a new one.
CAUTION :
Close the steam supply before
attending the work.
Immediate :
Stop the sootblower operation.
Later :
Close the steam supply.
Repair the failed steam piping.
Then proceed with Sootblower
operation.

Reset push button on the panel should be pressed to continue the sequential operation. Physical
checking is a must wherever necessary.

9
1610 - 1611 VOL - C1 TAB - 2 - 13

5.

STEAM TEMPERATURE LOW


This annunciation is provided so that the operator will be cautioned when the medium temperature
is low. It is likely that low steam temperature will cause condensation which will lead to boiler tube
wastage. This may be due to inadequate warm up and poor insulation. The solutions will be
sufficiently warm up the line and ensure sound insulation.
Another cause may be choking in the drain line. The solution would be to remove the condensate
properly.
Reset push button should be pressed after rectifying the fault to continue the sequential operation
further.

10
1610 - 1611 VOL - C1 TAB - 2 - 14

6.

STEAM NO FLOW
During the operation of the blower, if steam supply is interrupted for a longer time than the set time
in the timer, then the annunciation will come, stop the sequence and retract the lance to the home
position.
Steam no flow interlock was caused by failure to turn on the blowing medium approximately 45
secs after a signal was sent to sootblowers.
The probable causes and solutions are as follows :

Sl. No. Probable causes


6.1
(i)

Solutions

Long retractable sootblower.


Missing blowing adjustment bar or
broken adjustment bar.

As soon as the alarm is initiated check whether the


blower lance is retracted back to the home position
bypass the blower and proceed with sequential
operation.
Later :
Assemble the blowing adjustment bar.
(ii)
Mal-adjusted or damaged flow switch If adjustment is to be corrected, correct the switch. If
(common for wall deslagger)
you have found that the switch is damaged then
attend to the damage. If it requires longer time
proceed with the sootblower operation bypassing the
inter-lock. But this can be done only if one or two
men are kept near the blower.
(iii) An improper setting in the timer
Adjust the timer to initiate annunciation after 45 sees.
(common for wall deslagger)
(iv) Valve not opening due to
Immediate
If the blower is retracted back then bypass the blower
(applicable for wall deslagger)
and proceed with, sequential operation..
(a) missing and damaged pins of valve
opening mechanism
Later
Check the pins. If any pins have damaged replace
them. Check the lever engagement pull tod cam etc.
(b) Mal-operation of valve
If it is not OK make it sleight.
operating mechanism
(c)

Overtightened gland packing

d) Stem pitting

(e) Missing of valve opening


screw on lever

6.2
(i)

Wall deslagger
Missing ramp cam on the rack

Check the valve opening and closing. Make the


glands loose. Slight leakage is permissible.
Before removing the valve close the
steam supply. If the stem pitting is
severe replace with a new stem.
Check the presence of screw. If
the screw is not in position, new
screw is to be assembled.
Immediate
Make sure the unit is retracted back
immediately. Bypass the blower and
proceed with sequential operation.
Later :

Check physically the blower and


replace new cam.
If the blower has been retracted to the original position, bypass the blower and
press the reset button for proceeding with sootblower sequential operation.

11
1610 - 1611 VOL - C1 TAB - 2 - 15

7.

A. C. CONTROL SUPPLY/ POWER SUPPLY FAILURE


When the A.C. supply fails during the operation of blowers, an alarm is annunciated. If the sootblowing
operation is proceeding at that time, send a gang for withdrawing the blower back out of the boiler.
Proceed as follows :
7.1

Long Retractable Soot blower

(1)

Send one man for closing the manual operated valve.

(2)

Send another man with hand crank. After declutching withdraw immediately.

7.2 Wall deslagger


Send a man with a hand crank to withdraw the lance tube. Reset button must be pressed in the
control panel before proceeding with the operation after the power is restored.

8.

SOOT BLOWER SEQUENCE INTERRUPTION


This annunciation will come to the operator when the blower does not start even after the sequencing
signal is given to the other blower to start. If the blower does not start after 10 secs. even after the
completion of operation of the previous blower then this annunciation will come. The probable
causes and solutions are as follows :

Sl. No.
(i)

(ii)

(iii)

Probable causes

Solutions

Motor burnt out or damaged


traversing motor

Immediate:
Bypass the blower from sequence operation
Press ' reset ' button and proceed with other
blower operation.
Later :
Check the motor. If possible repair the same
or replace with a new motor.
Immediate:
Bypass the blower from sequence operation
and proceed with other blower operation.
Later :
Identify the problem and rectify the system.

Failure of motor starter, broken


wires, motor overload.

Defective cabling.

Immediate:
Bypass the blower from sequence operation.
Press "reset" button and proceed with other
blowers operation.
Later :
Identify the problem and rectify the
system.
Press "reset" button in the panel before operation is continued.

12
1610 - 1611 VOL - C1 TAB - 2 - 16

9.

VALVE MOTOR OVERLOAD


This annunciation will come if the main supply valve actuator is overloaded. The probable causes
and solutions are as follows :

Sl. No.
(i)

Probable causes

Solutions

Too much gland overtightening

Ensure correct gland packing and


tightness.
(ii)
Score marks on stem
Check Recondition/ Replace stem if
necessary.
(iii)
Non-release of motor brake
Remove the brake mechanism and
service.
(iv)
Wrong setting of limit switch on the Set the limit switches correction as
actuator.
instructed in 0 & M manual.
(v)
Wrong overload relay setting.
Check and set overload relay at the
recommended value.
(vi)
Excessive torque setting of torque
Set the torque switches at the
switches.
recommended value as per 0 & M
manual No. 7001.
(vii)
Jamming of moving components in
Bypass the whole steam line and
the guide ways.
then do servicing, For detailed
repairing procedure refer the relevant
0 & M manuals.
After attending to the fault, press 'reset' button in the panel before the operation
is continued.

13
1610 - 1611 VOL - C1 TAB - 2 - 17

10. PHILOSOPHY OF JAMMING RELAY PROTECTION AND OVERLOAD RELAY


PROTECTION IN SOOTBLOWER MCC.
1.

Overload protection is for all motors and for all blowers.

2.

The setting of overload relay shall be 105% for all the motors for all types of blowers. All
motors in all types of blowers have 110% capacity for 30 mts.

3.

The normal loading of motors in all the blowers when the blower is working with steam is
likely to be around 50%.

4.

The overloading of motor in LR blowers is expected due to hitting of tubes etc.

5.

The overload relay which is set at 105% when about 300% current (starting current) is
flowing will act in about 25/30 secs. (When the relay is hot/ cold).

6.

Jamming relay protection is only for long retractable type blowers. The jamming relay
shall be connected in Traverse Motor power line. Jamming relay will act instantaneously.

7.

The current setting of the jamming relay shall be 105% of traverse motor rated current.

8.

A time delay relay (0-10 secs.) is provided in Jamming relay protection circuit and is set
at 2 secs. This is to avoid the nuisance which may arise due to action of Jamming relay
7during the starting of traverse motor. The starting time of traverse motor is 0.3 sec. The
starting current of traverse motor is 3.0 Amps.

9.

Jamming relay with its circuitry will act when overloaded to 105% due to overload/
jamming while on forward operation and reverse the blower. Overload relay will act when
overloaded to 105% while on traverse operation. The blower stops operating. However
the motor is protected.

10.

Locked rotor withstand time for traverse motor is 40 secs. in hot and 75 secs. in cold
conditions.

11.

Selection of jamming relay and C.T.


CAG 19 English Electric Relay with 5 Amps. operating coil and 20-80%setting range.
5/5A ratio C.T. 5P20, 15VA

14
1610 - 1611 VOL - C1 TAB - 2 - 18

TAB - 3

INSTRUCTION MANUAL
AC INDUCTION MOTOR
(FOR SOOT BLOWERS)

Bharat Heavy Electricals Limited


Tiruchirapalli
PUB. NO. 7506

1610 - 1611 VOL - C1 TAB - 3 - 19

CONTENTS
GENERAL INFORMATION
GENERAL
STORAGE
LOCATION OF MOTORS AND CONTROL APPARATUS
GEAR DRIVES
DRYING OUT
REVERSAL OF ROTATION
INSPECTION AND TESTING5
GENERAL
MECHANICAL
ELECTRICAL
MAINTENANCE PROTECTION OF EXPOSED SURFACE6
GENERAL
INSULATION RESISTANCE
REMOVAL AND REPLACEMENT OF BEARINGS
BALL AND ROLLER BEARINGS
LUBRICATION
CONTROLLERS, STARTERS AND RHEOSTATS
SAFETY DEVICES
CHECK CHART
AC MOTOR CHECK CHART
MAINTENANCE SCHEDULE1
LIMITS OF TEMPERATURE RISE
DATA SHEET FOR SOOT BLOWER MOTORS

2
1610 - 1611 VOL - C1 TAB - 3 - 20

GENERAL INFORMATION
1.1

GENERAL

Where the magnitude of the installation justifies the cost, a set of record plans should be provided
by the installation engineer or contractor, clearly indicating the complete layout of the installation.
There is always the possibility that hair, hands or clothing may be caught in moving parts of
electrical machines, which should thus be so located or guarded as to minimize the risk of such
injuries to those who may come in contact. In the case of equipment subject to the provisions of
the Factories Act such mechanical protection is a statutory requirement.
1.2

STORAGE

If the machine has got to be stored for some time before installation, the same has to be done in
a clean, dry place. If the location is susceptible for vibrations transmitted due to working of
heavy machinery, proximity to rail track, etc. it is desirable to have a resilient pad between the
floor and the machine. Also keep the shaft of the motor locked so that, bearings are not damaged
during storage. However, periodically rotate the shaft free and relock it.
1.3

LOCATION OF MOTORS AND CONTROL APPARATUS

Apparatus shall be so located that all current-carrying parts are adequately ventilated in relation
to the losses to be dissipated in the form of heat.
Note:

In no circumstances should the motor be enclosed in a box or other covering hat restricts
or excludes the ventilating air to a significant extent. Such restriction may result in the
burning out of the motor when a sustained load approaching the full value is reached.

The motor and control apparatus shall not be located where it is liable to exposure to water,
corrosive liquid, oil, steam, carbon, copper dust, dirt or other adverse condition or to risk of
mechanical damage, unless it is suitably enclosed to withstand such conditions.
Adequate access shall be provided to all working parts. The possible need for facilities for
removing the equipment at a later date for repairs or maintenance should be considered in relation
to the accessibility of the equipment.
Note:

For handling heavy equipment it is often advisable to arrange for the incorporation of a
lifting beam in the structure of the building, the beam being located immediately over
such parts of the equipment as may require attention and being capable of supporting
the maximum weight involved.

The placing of apparatus in situations where inflammable material may be present should be
decided in relation to the fire risk involved, and where it is impracticable to segregate the apparatus
from such material, the use of totally enclosed or pipe ventilated apparatus should be considered.
Where resistors are used which are liable to operate at high temperatures, they should be adequately
spaced away from combustible materials such as wood-work, in order to combat the risk of fire.
Whenever the temperature of the casing of the apparatus is liable to exceed 194 Deg. F (or 90
Deg.C) the casing should be so located or guarded as to prevent accidental contact by persons or
with combustible materials.
1.4

GEAR DRIVES

With gear drives, alignment is equally important. The centre of the pinion shall be in line with
the centre of the spur wheel and the two wheels perfectly parallel, the latter being checked by
means of feeler gauges between the teeth of the respective wheels. The gear wheels shall be fully
meshed both in depth and along their width of face and the check for meshing shall be made all
the way round the driven wheel in case it is out of truth. Should the driven wheel be out of truth
and the meshing adjusted correctly at the lowest point of the driven wheel, the gears would jam
when the high parts engage and probably bend the motor shaft.
3
1610 - 1611 VOL - C1 TAB - 3 - 21

Bevel or single helical gears will impose an end thrust on the motor shaft, and are not therefore
recommended unless provision is made to take the thrust. Double helical gears may also transmit
an end thrust if the end-play in the bearings of the driven gear is greater than the end-play in the
motor bearings. Where mechanical conditions are severe it is sometimes necessary, particularly
in the case of large motors, to employ an outboard bearing for the motor shaft and in some cases
to mount the driving pinion in two separate bearings and couple it to the motor through a suitable
flexible coupling. A flexible coupling is invariably necessary when a motor is coupled to a selfcontained gear box. It is advisable, when any drives of the above mentioned or similar types are
considered, that this be specified so that provision can be made to suit the conditions.
Where motors are fitted with ball and roller bearings, care shall be taken to ensure that no axial
strain is imposed on the bearings when the half-couplings are bolted together.
1.5

DRYING OUT

All motors shall be dried out before the full voltage is applied to the terminals, if the insulation
resistance is below one megaohm when the machine is cold. A convenient method of doing this
is to block the motor so that it can not rotate and apply a very low voltage of about 10 percent of
the normal to the stator terminals.
In the case of slip-ring motors, the rotor windings should be short-circuited.
Close supervison is necessary during the process of drying out with this method. The heat
generated in the windings is not easily dissipated and one part of the winding may be exceeedingly
hot before another part has had time to expel the moisture. This may be obviated to some extent
by taking every precaution to exclude draughts from the exposed parts of the windings.
The motor can be placed in oven, if available, but the temperature shall not be allowed to exceed
180 Deg. F (or 82.2 Deg.C). Alternatively, hot air may be blown into the motor but the air should
be clean and dry and at a temperature of not more than 180 Deg.F. If no other means are available,
coke braziers or electric radiators may be placed round the machine. Carbon filament lamps
placed inside the machine can be employed quite satisfactorily, but care shall be taken that the
hot bulb is not in contact with any windings. If it is not possible to reach a sufficiently high
temperature the ventilation may be reduced by covering the stator with a tarpaulin.
Whichever of the above methods of drying out is adopted, the heating shall be continuous and
shall be carefully watched to ensure that it does not attain a temperature sufficiently high to
damage the insulation. The maximum safe temperature of the windings measured by thermometer
is 180 Deg. F (or 82.2 Deg.C). At the same time the temperature should not be allowed to fall too
low as otherwise re-absorption of moisture would take place.
The insulation resistance will be found to drop considerably as the motor warms up, will reach
the minimum and then remain constant for sometime depending upon the dampness of the machine
and as the drying proceeds the insulation resistance will gradually rise. The drying out shall be
continued as long as the insulation resistance rises, or until a sufficiently high value has been
reached, i.e. not less than 1 megaohm per 1000 volts at 75 Deg.C.
During the drying out period, readings of temperature and insulation resistance shall be taken
atleast once an hour in order to see how the drying out is progressing. The temperature of the
motor shall be kept as constant as possible, otherwise the insulation resistance readings may be
misleading.
NOTE:
1.6

The motor should be watched constantly whilst drying out.


REVERSAL OF ROTATION

Reversal of rotation, if required shall be effected by interchanging two of the three supply leads
connected to the stator switch, breaker or starter.
4
1610 - 1611 VOL - C1 TAB - 3 - 22

2.

INSPECTION AND TESTING


2.1

GENERAL

All electrical equipment shall be inspected and tested by competent persons at regular intervals,
the frequency of such inspection depending on the type of equipment and on the operating
conditions. A record of each inspection and of the result of tests should be kept.
2.2

MECHANICAL

Machines shall be checked for alignment to ensure that undue stresses are not imposed on their
bearings.
Where oil-lubricated bearings are employed care should be taken to see that oil does not penetrate
on to windings or other insulation. In addition clearances shall be kept to reasonably close limits
as too large a clearance may affect correct alingment and may cause fouling of the stator by the
rotor, whilst too small a clearance may disturb running mechanical balance. Oil should be checked
to see that it is clean and up to the right level.
The air gaps in sleeve bearing machines shll be checked before commissioning. This check
should be repeated at periodic intervals.
Mechanical operation of motors control gear and protective devices shall be checked for freedom
from external material, care being taken when commissioning to see that all packing materials
are removed.
In the case of motors and control gear, attention should be paid to all contacts, the contact pressure
and contact area being checked and verified as being proper to the operating conditions involved.
If ball roller bearing motors have been kept idle for periods longer than six months whether new,
spare or stand-by plant, the bearing covers should be removed for inspection of grease. If it is
found that the grease has a skin over the surface, the bearings should be washed out thoroughly
in kerosene, and three drops of fine oil added to the race. The bearing housings should be
repacked with new grease recommended by the makers, care being taken to ensure that the balls
or rollers will not churn in the grease. One of the chief functions of grease is to prevent the entry
of dust to the races, very little being required for lubrication.
2.3

ELECTRICAL

All fixed connections shall be checked for tightness and where heavy currents are involved a
check shall be made to see that contact adequate in area and pressure to prevent undue heating is
effected between all contact surfaces.
Before the equipment is put into service, it shall be tested for insulation resistance and other tests
as may be necessary should be made. Continuity tests shall be carried out, particular attention
being given to the secondary connections of current transformers. Before switching in for the
first time, protective devices shall be set at their minimum current values and at the minimum
time setting in order to minimise the consequence of any fault condition which may arise.
The rating of fuses shall be checked by inspecting the marking on the cartridge-type fuses or
inspecting the gauge and type of wire in the case of semi-enclosed type-fuses. Where practicable,
the operation of overload, no volt and other types of protective device shall also be checked. The
results of such checking should be related to the ascertained resistance of the earth-fault current
path so as to determine the prospect of the protective device operating in the event of a fault to
earth. Earth leakage protection should be adopted in the following cases:
a.

If the ascertained resistance is such as to restrict the fault current to a value below the
operating value of the overload releases.

b.

If the margin is too small to ensure reliability in all seasons.


5
1610 - 1611 VOL - C1 TAB - 3 - 23

c.

If, where fuses are used, the resistance is such that sufficiently rapid operation cannot
be ensured, and the earthing conditions cannot be improved.

Protective fuses shall be examined regularly, and, as far as possible tested. Where relays are used
in conjunction with current transformers, the test should preferably stimulate working conditions
by utilizing the injection method whereby current is passed through the relays by the application
of a variable injection voltage from a transformer designed for the purpose.

3.

MAINTENANCE PROTECTION OF EXPOSED SURFACE


3.1

GENERAL

Protective paint and varnish shall be maintained in good condition by repainting or revarnishing
when necessary, it being noted that in many instances, such as that of machine windings, spraying
is the only effective means of application of such protection.
MOTOR
Cleaning of Machines
Motor shall be blown out at regular intervals to keep their ventilating passage clear, it being
emphasised that many types of totally enclosed motors required such attention, particularly when
operating in dusty atmosphere.
Moisture, oil, dirt, grease and carbon or metallic dust are the principal causes of breakdown. The
motor should therefore be kept clean and dry; water dropped on the machine will soon cause
trouble, unless the motor has been designed to withstand such conditions. The stator and rotor
windings must be kept free from oil and grease, damp and dirt. Periodic cleaning with dry
compressed air, bellows or a brush, is very necessary.
All motors require to be examined and dismantled from time to time and the frequency of
successive cleanings will depend upon the conditions under which the machine operates. During
periodic cleanings care shall be taken to clear air passages in the stator and rotor of any accumulated
dirt.
Terminals and screw connections shall be kept clean and tight. If they become dirty or corroded,
they shall be disconnected and all contact surfaces made clean and smooth. Bad contact leads to
sparking and ultimate breakdown.
After reassembly, the gaps shall be tested as a precautionary measure by means of a feeler gauge.
If it is found that the air gap measurements of two diametrically opposite points differ by as
much as 25% the machine shall be examined, because the brackets or bearing housings will not
be correctly aligned. Gap measurements shall always follow reassembly, since rubbing between
stator and rotor will cause extensive damage.
3.2

INSULATION RESISTANCE

The insulation resistance of the windings shall be tested periodically during service and where
this is found to drop below 1 megaohm/KV with a minimum of 1 Megohm the motor shall be
dried out and put in service. If weak insulation, resistance becomes a regular feature the windings
shall be given a coat of good insulating varnish after the machine has been dried out. Where the
motor is installed in locations, subject to dampness, chemical fumes, etc., the installation indicator
such as a neon lamp to show the condition of the insulation of the motors is recommended.
3.3

REMOVAL AND REPLACEMENT OF BEARINGS

In small frame motors, the bearings can be removed with a bearing puller. The cartridge type
bearing housing is employed in large frame motors.
After cleaning, the housing should be greased with the specified grade grease and the bearing
replaced by applying even pressure to the outer race. Having ensured that the bearing is square
with the housing, it may be necessary to tap lightly into position.
6
1610 - 1611 VOL - C1 TAB - 3 - 24

Having ascertained that the outer race beds firmly against the housing shoulder, the whole may
be slipped over the shaft which should be cleaned and oiled.
The bearing may now be forced on to the seating by means of a tube placed over the shaft and
applied to its inner race; this method ensures even pressure and the bearing may be driven home
against its locating shoulder. On no account must the inner race mounted by hitting the outer
race and pressure should not be applied to the outer race during the process. The blows should
be equally distributed all round the inner race and care should be taken to avoid hitting or applying
pressure to the lip of the inner race, in the case of a roller bearing. Otherwise the bearing along
with the bearing housing can be heated in medium oil Shell Tellus 33 Deg. at a temperature not
exceeding 100 Deg. C for about one hour to enable easy mounting by push fit.
3.4

BALL AND ROLLER BEARINGS

Climatic conditions affect the lubrication and it is necessary to ensure that the bearings do not
run hot. This shall be tested from time to time by placing the hand on the bearing cap. A
moderate warmth to the hand is a ready indication that the bearing is running at its best. Higher
or lower temperatures are not dangerous in themselves but increasing temperature or noise are
sure signs that the bearing needs immediate attention. It may be that the addition of a small
amount of grease will arrest and cure the trouble.
When opening up bearings for inspection and cleaning, all dirt and foreign matter shall be removed
from the neighbourhood of the bearing caps. The caps shall then be removed and the bearings,
caps and housings washed with kerosene, all old grease also being removed in the process and
the parts thoroughly cleaned. If the bearing is in good condition, fresh grease shall be pressed
well between the cage, races, balls and rollers. We recommend Shell Alvania No.3 grease or its
equivalent. After packing the bearing, any superfluous grease shall be wiped off. If the bearing
appears dirty or if the grease has become hard and disintegrated the bearing shall be removed
from the shaft, withdrawn from the housings and closely inspected for signs of wear.
3.5

LUBRICATION

It is often assumed that with the substitution of rolling motion for sliding motion in antifriction
bearings, the sources of friction are eliminated and lubrication is of secondary importance. But
this is not correct since sliding friction still occurs at the cage which separates the rolling elements
or between the element themselves if they are not separated.
The smooth and silent running of antifriction bearings depends to a large extent on the high
degree of finish imparted to the tracks and rolling elements, and quite apart from its function of
minimising wear on rubbing surfaces, the lubricant is required to protect these highly finished
working parts. The rolling element bearings require a small amount of lubricant depending upon
the size and type of bearing and generally the lubricating intervals are long. However, lubricant
must always be present in the bearings otherwise their lift may be affected or retarded by injuries
which could have easily been avoided.
The main functions of lubricant in a bearing are:
i.

To provide a separating film between rolling and sliding contacting surfaces, thus pre
venting wear.

ii.

To act as a coolant to maintain proper bearing temperature.

iii.

To prevent the bearing from being contaminated by dirt and other foreign matter.

iv.

To prevent corrosion of bearing surfaces.

When the moving parts of a bearing come in contact with grease, a small quantity of oil adheres
to the bearing surfaces. Oil is therfore removed from the grease near the rotating parts. The oil
that is picked up by the bearing is gradually broken down by oxidation, or lost by centrifugal
7
1610 - 1611 VOL - C1 TAB - 3 - 25

TWO PART BEARING HOUSING

BALL BEARING WITHDRAWAL BALL BEARING REPLACEMENT


force, and volatalisation. Bleeding of the Grease therefore takes place to continue the supply of
a small quantity of oil, which is usually sufficient for satisfactory operation.
Lithium based Multipurpose Grease conforming to Grade 3 of IS 1002-1956 amended upto date,
is recommended for all Rotating machines fitted with antifriction bearings.
The popular greases are:
Shell Alvania (or Multipurpose) Grease 3
Mobilux Grease No.3
Castrol Shperol. AP3
The safe operating temperature range for the above greases is:
-130F to 2480F (approx. Value)
The quantity of Grease which should be applied to the inside of the bearing when relubricating
is,
D x B
W

= x 28.35 Grams
6000

Where

D = O.D. of the Bearing in mm


B = Width of the Bearing in mm
W = Weight of grease in gm

Running conditions, especially speed relative to the bearing size determine the permissible
relubrication frequencies, provided an approved ball bearing grease is used.
Over-lubrication is equally hazardous as under-lubrication. If excess grease is maintained in the
race-track under-pressure, excessive friction develops often resulting in the break-down of the
grease, which in turn affect the life of the bearing considerably.
3.6

CONTROLLERS, STARTERS AND RHEOSTATS

The contact and insulating parts must be kept thoroughly free from dirt and moisture and there
shall be firm metallic connection between fixed and removable contacts when they come together.
The covers shall be removed periodically for inspection.
Fuse contacts and terminals must be examined periodically for cleanliness and tightness. When
a fuse wire or strip has to be renewed, care must be taken that the new is of the correct metal and
size.
8
1610 - 1611 VOL - C1 TAB - 3 - 26

3.7

SAFETY DEVICES

Remote tripping devices and limit switches which are provided for safety reasons but which may
not be called upon to function under normal operating conditions, shall be checked for operation
at regular intervals.
Interlocks designed to prevent unsafe operations shall be checked periodically by a deliberate
attempt being made by a competent person to perform the operations which the interlocks are
designed to prevent.
Where an emergency supply is provided, the source of supply and all ancillary apparatus shall be
checked periodically.
3.8

CHECK CHART

A check chart should be kept for assistance in the maintenance of the motor. A recommended
chart is given in Section 4. All reports and test results shall be recorded in a suitable log book.

4.
SI.No.

AC MOTOR CHECK CHART


Trouble

Cause

Remedy

01

Hot Bearings General.

Bent or sprung shaft.


Excessive belt pull.
Pulley too far away.
Pulley diameter too small.
Misalignment.

Straighten or replace shaft.


Decrease belt tension.
Move pulley closer to bearing.
Use larger pulley.
Correct by realignment of drive.

02

Hot Bearings
ball or roller.

Insufficient grease.

Maintain proper quantity of


grease in bearing.

Deterioration of grease or
lubricant contaminated.

Remove old grease, wash


bearings thoroughly in kerosene
and replace with new grease.

Excess lubricant

Reduce quantity of grease.


Bearing should not be more than
1/2 filled.

Heat from hot motor or


external source.

Protect bearing reducing motor


temperature.

Overloaded bearing.
Broken ball or Rough
races.

Check alignment, side thrust and


end thrust.
Replace bearing; first clean
housing thoroughly.

Stream of overflow plug


not tight.

Remove re-cement threads


replace and tighten.

03.

Oil leakage from


overflow plugs
Cracked or broken
overflow plug.

Replace the plug.

Plug cover not tight.

Requires cork gasket or if screw


type may be tightened.
9
1610 - 1611 VOL - C1 TAB - 3 - 27

SI.No.
04.

Trouble
Motor dirty

Cause

Remedy

Ventilation blocked end


winding filled with fine
dust or lint.

Rotor winding clogged.

Bearing and brackets


coated inside.
05

06.

07.

Motor Wet

Motor stalls

Motor connected
but does not start

Clean motor will run 10 to 30C


cooler. Dust may be cement,
sawdust, rock dust , grain dust,
coal dust and the like.Dismantle entire
motor and clean all windings and
parts.
Clean and grind slip rings. Clean and
treat windings with good insulating
varnish.
Dust and wash with cleaning solvent.

Subject to dripping

Wipe motor and dry by


circulating heated air
through motor.. Install drip
or canopy type covers over motor
protection.

Drenched condition.

Motor should be covered to retain


heat and the rotor position
shifted frequently.

Submerged in flood
water.

Dismantle and clean parts.


Bake windings in oven at
180F (82C) for 24 hours
or until resistance to ground
is sufficient.

Wrong application.

Change type or size.


Consult manufacturer.

Overloaded motor.

Reduce load.

Low motor voltage.

See that nameplate voltage is


maintained.

Open circuit.

Fuses blown, check overload


relay, starter and pushout.

Incorrect control
resistance of wound
rotor.

Check control sequence.


Replace broken resistors.
Repair open circuits.

Mechanical locking in
bearings or at air gap.

Dismantle and repair.


Clean air gap if choked.

No supply Voltage.
One phase open voltage
too low.

Check Voltage on each phase.

10
1610 - 1611 VOL - C1 TAB - 3 - 28

SI.No.

08.

09

Trouble

Motor runs and


then dies down.
(see also SI.No.7).

Motor does not


come upto speed.

Cause

Remedy

Motor may be over


loaded.

Reduce load or try to start


uncoupled from load.

Control gear defective.

Examine each step of the control


gear for bad contact or open
circuit. Make sure that brushes are
making good contact with thering.

Starting torque of load


too high.

If of squirrel cage type and


with auto-transformer
starting change to a higher tap.

Rotor Defective.

If of slip-ring type, lower


the starting resistance.
Look for broken rings.

Poor stator coil


connection.

Remove end belts, locate


with test lamp.

Mechanical locking in
bearings or at air gap.

Dismantle and repair.


Clean air gap if choked.

Power failure.

Check for loose connections


to line, to fuses and to control.

Overload.

Examine overload trips. See


that they are set correctly
to approximately 150 percent
full load current. See
that the dashpots are filled
with correct quantity and
grade of oil.

Not applied properly.

Consult supplier for proper


type.

Voltage too low at


motor terminals
because of line drop.

Use higher voltage on


transformer terminals or
reduce load.

If wound rotor
improper control
operation of
secondary resistance.

Correct secondary control.

Starting load too high.

Check load or motor which is


supposed to carry at start.

Check that all brushes


are riding on rings.

Check secondary connections


Leave no loads poorly
connected.

11
1610 - 1611 VOL - C1 TAB - 3 - 29

SI.No.

10.

Trouble

Cause

Remedy

Broken rotor bars.

Look for cracks near the rings. A


new rotor may be required as
repairs are usually temporary.

Open primary circuit.

Locate fault with testing device


and repair.

Motor takes too


long to accelerate

Excess loading.

Reduce load. If motor is


driving a heavy load or is
starting up a long line of
shafting start more slowly
allowing ample time for
acceleration till it overcomes
the difficulty.

Poor circuit.

Check for high resistance.


Defective squirrel
cage rotor.

Replace with new rotor.

Applied voltage too


low.

Get power company to


increase voltage tap.

11

Wrong rotation.
phases.

Wrong sequence of

Reverse connections of
motor or at switchboard.

12.

Motor overheats
while running
underload.

Check for overload.

Reduce load.

Wrong blowers or
airshields, may be
clogged with dirt and
prevent proper
ventilation of motor.

Good ventilation is manifest


when a continuous stream
of air leaves the motor. If
not,check with manufactuer

Motor may have


one phase open

Check to make sure that all


leads are well connected

Grounded coil.

Locate and repair.

Unbalanced terminal
voltage.

Check for faulty leads,


connections and transformers.

Shorted stator coil.

Repair and then check


watt-meter reading.

Faulty connections.

Indicate by high resistance.

12
1610 - 1611 VOL - C1 TAB - 3 - 30

SI.No.

13.

14.

15.

16.

Trouble

Motor vibrates:
after corrections
have been made.

Unbalance line
current on
polyphase motors
during normal
operation.

Scraping noise

Magnetic noise.

Cause

Remedy

High voltage or
low voltage

Check terminals of motor


with voltmeter.

Rotor rubs stator


bore

If not poor machining,


replace worn bearings.

Motor misaligned.

Realign.

Weak foundations.

Strengthen base.

Coupling out of
balance.

Balance coupling.

Driven equipment
unbalanced.

Rebalance driven equipment.

Defective ball or
roller bearings.

Replace bearings.

Bearings not in line.

Line up properly.

Balancing weights
shifted.

Rebalance rotor.

Wound rotor coils


replaced.

Rebalance rotor.

Polyphase motor
running single phase.

Check for open circuit.

Excessive end play.

Adjust bearing or add washer.

Unequal terminal volts.

Check leads and connections.

Single phase operation.


Poor rotor contacts in
control wound rotor
resistance.

Check for open contacts.


Check control devices.

Brushes not in proper


position in wound
rotor.

See that brushes are


properly seated and shunts
in good conditions.

Fan rubbing air shield.

Remove interference.

Fan striking insulation.

Clean the fan.

Loose on bedplate.

Tighten holding bolts.

Air gap not uniform.

Check and correct bracket


fits bearing.

13
1610 - 1611 VOL - C1 TAB - 3 - 31

SI.No.

Trouble

Cause

Remedy

Loose bearings.

Correct or renew.

Rotor unbalance.

Rebalance.

NOTE : Certain amount of magnetic noise is inherent in some low speed designs and shouls not
cause alarm.
17.

5.

Motor sparking
at sliprings.

Motor may be
overloaded.

Reduce the load.

Brushes may not be of


correct quality and
may be sticking in the
holders.

Use brushes of the grade


recommended.

Brush pressure may be


too light or too much.

Adjust the brush pressure


correctly.

Sliprings may be tough,


dirty or oily.

Clean the sliprings and


maintain them smooth
glossy and free from oil
and dirt.

Sliprings may be ridged


or out of truth.

Turn and grind the slipring


in a lathe to a smooth finish

MAINTENANCE SCHEDULE
The following Maintenance Schedule is suggested as a guide.
5.1

DAILY MAINTENANCE

a.

Examine earth connections and motor leads.

b.

Check motor windings for overheating. (Note that the permissible maximum temperature
is above that which can be comfortably felt by hand.)

c.

Examine control equipment.

d.

In the case of oil ring lubricated machines:


i.

Examine bearings to see that oil rings are working.

ii.

Note temperature of bearings;

iii.

Add oil if necessary;

iv.

Check and plays


14
1610 - 1611 VOL - C1 TAB - 3 - 32

5.2

WEEKLY MAINTENANCE

a.

Check belt tension. In cases where this is excessive it should immediately be reduced
and in the case of sleeve bearing machines the air gap between rotor and stator should
be checked.

b.

Blow out windings of protected type motors, situated in dusty locations.

c.

Examine starting equipment for burnt contacts where motor is started and stopped
frequently.

d.

Examine oil in the case of oil ring lubricated bearings for contamination by dust, dirt,
etc. (This can be roughly ascertained on inspection by the colour of the oil).

5.3

MONTHLY MAINTENANCE

a.

Overhaul Controllers.

b.

Inspect and clean oil circuit breakers.

c.

Renew oil in high speed bearings in damp and dusty locations.

d.

Wipe brush holders and check bedding of brushes of slipring motors.

e.

Check the condition of the grease.

5.4

HALF-YEARLY MAINTENANCE

a.

Clean windings of motors subjected to corrosive or other element. Also bake and varnish
if necessary.

b.

In the case of slip-ring motors check slip-rings for grooving on unusual wear.

c.

Renew grease in ball and roller bearings.

d.

Drain all oil bearings, wash with kerosene, flush with lubricating oil and
clean oil.

5.5

ANNUAL MAINTENANCE

a.

Check all high speed bearings and renew if necessary.

b.

Blow out all windings of motors thoroughly with clean dry air. Make sure that the
pressure is not so high as to damage the insulation.

c.

Clean and varnish dirty and oily windings.

d.

Overhaul motors subject to severe operating conditions.

e.

Renew switch and fuse contacts if badly pitted.

f.

Renew oil in starters subjected to damp or corrosive elements.

g.

Check insulation resistance to earth and between phases of motor windings, control
gear and wiring.

h.

Check resistance of earth connections.

i.

Check air gaps.

refill with

15
1610 - 1611 VOL - C1 TAB - 3 - 33

5.6

RECORDS

Maintain a register (as per the specimen shown or enclosed) giving one or more pages for each
machine and record therein all important inspections and maintenance works carried out from
time to time. These records shall show past performance, normal insulation level, gap
measurements, nature of repairs and time between previous repairs and other important information
which would be of help for good performance and maintenance.

6.

LIMITS OF TEMPERATURE RISE


Permissible maximum temperature rise for class B insulation is
120C
Ambient Temperature

....

....

65C

16
1610 - 1611 VOL - C1 TAB - 3 - 34

DATA SHEET FOR SOOT BLOWER MOTORS

SI.
No.
01.

Description

Long Retract

Long Retract

Wall Blower

Wall Blower

Rotary Blower

Application

Long Retract
Rotary

Long Retract
Traverse

Wall Blower
Rotary

Wall Blower
Traverse

Rotary Blower
Motor

02.

Frame Size

80

80

71

90

71

03.

Flange Type

IS 2223 Type C

IS 2223 Type C

IS 2223 Type C

IS 2223 Type C

IS 2223 Type C

04.

Dimensions(
Drg.No)

4--20-20100303

4--20-201-00303

4--20-201-00303

4--20-201-00303

4--20-201-00303

05.

Power in KW

0.45

0.37

0.05

0.56

0.09

06.

Rated
Voltage

415

415

415

415

415

07.

No. of Phases
& Frequency

3 50 HZ

3 50 HZ

3 50 HZ

3 50 HZ

3 50 HZ

08.

RPM(Approx
imate)

1425

1365

1480

1425

1425

09.

Duty

30 minutes

15 minutes

Continous

30 minutes

Continous

10.

Ambient
Temperature
o
C

65

65

65

65

65

11.

Enclosure &
Protection

Totally
enclosed non
ventilated IP 55
protection

Totally enclosed
non ventilated IP
55 protection

Totally enclosed
non ventilated IP
55 protection

Totally enclosed
non ventilated IP
55 protection

Totally enclosed
non ventilated IP
55 protection

12.

Class of
Institution

13.

Voltage
Variation %

10

10

10

10

10

14.

Frequency
Variation

15.

Combined
Voltage &
Frequency
Variation

10

10

10

10

10

16.

Starting
Torque in
kgm.

1.1

0.46

0.245

1.09

0.29

17.

Rated Torque

0.3775

0.264

0.0329

0.382

0.063

17
1610 - 1611 VOL - C1 TAB - 3 - 35

DATA SHEET FOR SOOT BLOWER MOTORS(CONTD.)

SI.N o

D escription

Long
Retract

Long
Retract

W all
Blow er

W all
B low er

Rotary
Blow er

18.

Breakdow n T orque
in kgm.

1.06

0.485

0.265

1.12

0.29

19.

Full load current in


A mps.(A pproximat
e)

1.26

0.86

0.44

1.36

0.64

20.

N o. of leads

21.

N ame Plate

Stainless
steel

Stainless
steel

Stainless
steel

Stainless

Stainless
steel

22.

Paint

Epoxy
grey

Epoxy grey

Epoxy grey

Epoxy grey

Epoxy grey

23.

Conduct size in the


T erm inal Box

M 20 x
1.5

M 20 x 1.5

M 20 x 1.5

M 20 x 1.5

M 20 x 1.5

24.

Pow er Factor &


Rated
Load(A pproximate)

0.68

0.88

0.34

0.78

0.48

25.

Efficiency in Rated
Load
(A pproximate)

71%

75%

45%

73.5%

44%

26.

M axim um stalling
Time
(A pproximate)

H ot 20
sec cold
35

H ot 40 sec
cold 75

H ot 35 sec
cold 65

H ot 30 sec
cold 55

H ot 35 sec
cold 65

27.

D irection of
R otation

Reversibl
e

Reversible

Reversible

Reversible

Reversible

28.

O ther Construction
al Features

Shaft end
w ith oil
seal

Shaft end
w ith oil
seal

Shaft end
w ith oil
seal

Shaft end
w ith oil
seal

Shaft end
w ith oil seal

29.

W eight of M otor in
kg. (A pproximate)

13.5

13.5

13.5

13.5

13.5

30.

G D 2 of M otor in
kg.(A pproximate)

0.0073

0.0073

0.0027

0.0112

0.0027

18
1610 - 1611 VOL - C1 TAB - 3 - 36

TAB - 4

INSTRUCTION MANUAL
DESCRIPTION, OPERATION AND
MAINTANENCE

SOOT BLOWER
GENERAL INSTRUCTIONS

Bharat Heavy Electricals Limited


Tiruchirapalli
PUB.NO.7501

1610 - 1611 VOL - C1 TAB - 4 - 37

CONTENTS
INTRODUCTION
IMPORTANT INSTRUCTIONS
GENERAL INSTRUCTIONS
PREVENTING PUFFS AND FURNACE EXPLOSIONS DURING SOOT
BLOWING
PROCEDURE FOR SETTING BLOWING PRESSURES FOR SOOT BLOWER
SYSTEMS
SOOT BLOWER CHECK LIST AND RECOMMENDED START-UP
PROCEDURE
SOOT BLOWER MAINTENANCE
RECOMMENDED LUBRICATION CHART FOR SOOT BLOWERS
RECOMMENDED QUANTITY OF LUBRICANTS FOR ONE YEAR
VALVE SEAT GRINDING FOR SOOT BLOWER VALVE HEADS
RECOMMENDED PROCEDURE FOR PACKING INSTALLATION
INSTRUCTIONS FOR STORAGE

2
1610 - 1611 VOL - C1 TAB - 4 - 38

INTRODUCTION
This general instruction, sets some guidelines in preventing puffs and furnace explosions
during soot blowing and outlines the procedure for setting blowing pressures. A check list for
operation and a recommended procedure for start-up are given for general care and correct
start-up. The section on maintenance gives a detailed glimpse into the maintenance problem.
The lubrication schedule helps the maintenance man to choose the correct lubricant and carry
out the lubrication plans.
No Soot Blower system will operate satisfactorily if it is not properly installed, operated and
maintained. It must be recognised that no amount of written instructions can replace intelligent
thinking and reasoning on the part of the operators, especially when coping with unforeseen
operating conditions. It is the operators responsibility to become thoroughly familiar not
only with the equipment but also with all pertinent control equipment.
The instruction contained in this manual is only an outline of the correct procedures for
operation and maintenance. The contents in this manual have been compiled and checked by
experts in this field. Every possible care has been taken to ensure the contents are accurate.
Suggestions for the improvement of the manual are welcome.
If you ever have any query about operation, maintenance or related problems, you are welcome
to write to BHEL without obligation.

IMPORTANT INSTRUCTIONS
DOS
1.

CARELESSNESS IN REPAIRING SOOT BLOWING EQUIPMENT CAN CAUSE


SERIOUS INJURIES. ACCIDENTS CAN BE PREVENTED BY TAKING SIMPLE
PRECAUTIONS.

2.

INCREASE FURNACE DRAFT BY APPROPRIATE ADJUSTMENTS OF THE


INDUCED DRAFT FAN TO TAKE CARE OF THE INCREASED FLUE GAS
VOLUME DUE TO THE SOOT BLOWING OPERATION. THIS WOULD HELP
TO PURGE COMBUSTIBLE GAS POCKETS.

3.

AVOID SOOT BLOWING OPERATION WHEN THE REFRACTORY IS HOT


i.e.IMMEDIATELY AFTER STOPPING OR WHEN THE BOILER IS NOT IN
SERVICE FOR SOME TIME.

4.

ALL STEAM LEAKS SHOULD BE ATTENDED TO IMMEDIATELY.

5.

AVOID EXCESS BLOWING PRESSURE.

6.

MAIN MEDIUM VALVE SHOULD BE CLOSED IMMEDIATELY AFTER THE


COMPLETION OF THE SOOT BLOWING OPERATION.

7.

FOR LUBRICATION, FOLLOW THE LUBRICATION INSTRUCTIONS


CAREFULLY.

8.

RETRACT THE LANCE IMMEDIATELY IN THE EVENT OF FAILURE OF


POWER TO AVOID DAMAGE TO THE LANCE.

9.

EVEN IF THE BOILER IN OPERATION DOES NOT REQUIRE SOOT


BLOWING, KEEP THEM OPERATING AT LEAST ONCE IN A WEEK. THIS
WILL HELP IF COAL CHARACTERISTIC CHANGE AT A LATER DATE AND
TO KEEP THE SOOT BLOWERS IN ORDER.

10.

ALL THE PEEP HOLES SHOULD BE CLOSED AND LOCKED BEFORE WALL
DESLAGERS ARE PUT INTO OPERATION.
3
1610 - 1611 VOL - C1 TAB - 4 - 39

11.

DURING OUTAGES, CHECK THE CLEARANCE BETWEEN THE EDGE OF


THE LANCE TUBE AND THE SUPER HEATER, RE-HEATER TUBES. THERE
SHOULD BE A MIN. GAP OF 100MM.

12.

THE SOOT BLOWER LINE MUST BE STEAM BLOWN BEFORE THE


BLOWERS ARE PUT INTO OPERATION AT THE TIME OF COMMISSIONING.

DONTS

1.

1.

DO NOT ATTEMPT REPAIRS BEYOND YOUR ABILITIES.

2.

DO NOT OPERATE THE BLOWERS WITH WET STEAM.

3.

DO NOT EXTEND THE LANCE OF LONG RETRACT WITHOUT BLOWING


MEDIUM WHEN BOILER IS ON.

4.

DO NOT OVERTIGHTEN THE PACKING.

5.

DO NOT HAND CRANK THE BLOWERS WHILE THE POWER OR BLOWING


MEDIUM IS ON.

GENERAL INSTRUCTIONS
1.1

Ordering Repair Parts

When ordering repair parts, always give the Name, Part No., Drg. No., as found on the parts
lists and Model number as found on the brass name plate.
In the case of bearings and elements, swivel tubes or lances refer to Element Location Drawings
and give the Drawing No. for the specific piece needed. Elements may vary for different
locations.
If you have more than one boiler, give the type, size, rating and location of the boiler or
boilers for which parts are needed, and the order number under which you purchased the
Blowers for which parts are needed.
1.2

A Word of Caution

Carelessness in repairing a blowing equipment can cause serious injuries. Accidents can be
prevented by taking simple precautions.
Always get permission and clearance from the proper authority before starting to repair any
equipment.
Use proper lifting equipment for heavy equipment. Do not attempt repairs beyond your ability.
Before repairing any equipment operated by steam or air, make sure all supply valves have
been closed, tagged or locked and also the electrical connections are cut off. If steam or air
supply lines must be energised for purpose of test, use extreme caution.

2.

PREVENTING PUFFS AND FURNACE EXPLOSIONS DURING SOOT


BLOWING
Explosions, puffs, or blow backs that occur during or as a result of soot blowing operations
should be reported to and discussed with the boiler manufacturer. It is impossible to establish
a definite procedure to prevent these difficulties because of the variation of fuels and the
design and operations of Steam Generating equipment. The start-up or operating engineers
working in conjunction with design engineers or boiler manufacturing firms are best qualified
to recommend procedures of operation on their particular equipment.
The following recommendations are presented for consideration when it is necessary to establish
operational procedure to prevent these difficulties.
4
1610 - 1611 VOL - C1 TAB - 4 - 40

(i)

Cleaning Cycle

As a guide line we suggest a soot blowing cycle of once in a day to start with may be established.
After watching the performance of the particular coal, oil or any other fuel, with reference to
the deposit formation, the blowing cycle can be altered. It is essential to have a satisfactory
cycle so that the heat recovery surfaces are kept free of deposits at the same time the tube
surfaces are not damaged because of frequent blowing. The life of the soot blower parts will
also proportionally decrease with increased frequency. The Boiler operating personnel can
establish the optimum blowing cycle depending on the actual furnace conditions. It is
impossible to predict the deposit formation since too many factors influence the same.
(ii)

When possible, the boiler to be cleaned should be operating at or near the maximum
design load.

When soot blowers are operated at low boiler loads, clouds of soot may be blown into the gas
stream to form explosive mixtures which may be ignited by the heat from furnace walls or by
smoldering soot fires. Soot blower operation at low boiler load, with a resulting colder furnace
may also result in some of the unburned combustibles escaping from the furnace and collecting
in pockets in back passes.
Agitation and ignition of these gas pockets will cause puffs or explosions. All tube surfaces
and gas passes, therefore, should be blown with the gas flow at or near maximum to purge the
boiler of these possible explosion causes.
(iii)

On oil or pulverised fuel fired boilers, soot blowers should be used with the burners
operating at the highest possible burning rate, maintaining even stable combustion.
Soot blowing schedules should be established to take place during the heaviest load
periods, or the burner firing rates should be increased during soot blowing. Burners
should be checked during soot blowing for stability.

A high burning rate assures a lower oxygen content in flue gases which eliminate the difficulty
as explained in (ii) above.
High and stable burning rates also prevent flames from being blown out by small puffs or
agitation of the gas flow common while soot blowing.
(iv)

Before operating soot blowers the furnace drafts should be increased by opening the
boiler outlet damper or by making the appropriate adjustments of the induced draft
fan to take care of the increased flue gas volume due to the soot blowing operation.
Increased furnace draft helps to purge combustible gas pockets explained in (ii) above.

Increased furnace draft improves cleaning by moving soot particles through gas passes rather
than re-depositing them on adjacent surfaces.
(v)

Conditions may require the operation of soot blowing equipment with the burners
out of service as when cleaning prior to outages to facilitate inspections.This procedure
is dangerous. If unavoidable, soot blowing operation should not proceed while the
refractory is still hot and there is any possibility of soot fires still smoldering in the
setting. Be sure the boiler is cold and inspect the setting for smoldering soot before
blowing.

(vi)

The normal sequence of soot blowing is to follow the gas flow through the boiler.
The first soot blower to be operated should be the nearest to the burners then each
unit in turn along the gas passes to complete the cleaning cycle. This method
thoroughly cleans the entire unit by moving along the passes rather than blowing
them loose and redepositing them on adjacent surfaces. It may be desirable to reverse
this procedure when soot deposits are unusually heavy to avoid plugging and puffs
or explosions in the back passes.
5
1610 - 1611 VOL - C1 TAB - 4 - 41

Blowers should then be operated in reverse order from rear to front to rear. This procedure
may be desirable during period of low load operation, as when units are banked, or on Marine
installations when ships are put out to sea after time spent in port.
(vii)

3.

For operating wall deslaggers,operate the row of wall deslaggers at the highest
elevation first and then follow downwards, so that, heavy slags dislodged and
deposited at lower elevation will be cleared by further soot blowing operation and
fall to the ash hopper due to its weight.

PROCEDURE FOR SETTING BLOWING PRESSURES FOR SOOT


BLOWER SYSTEMS
3.1

Introduction

All large, high pressure boilers and many medium and small boilers today employ a pressure
reducing valve in the steam supply to the soot blower system. This requirement, coupled with
the fact that all individual soot blower operating head pressures can be easily adjusted externally
while the units operating, permits adjustment of the blowing pressures without internal orifices
and at the same time permits operation of the system on a relatively low supply pressure.
The reduced supply pressure reduces packing and valve maintenance and makes the system
more flexible for pressure adjustment at later dates without the necessity of installing orifices.
A step by step procedure is outlined to attain this set up.
Use the pressure gauge and the connected fittings issued by us for measuring the blowing
pressure. Connect the pressure gauge fittings as shown in the figure.
3.2

Recommended Blowing Pressures

The suggested blowing pressures are listed out in the blowing pressure table, released in
00,076 erection drawing group separately for each contract.
When these pressures are not shown on the blowing pressure Table BHEL should be contacted
for this information. Request for this information should be complete with blower no. location
and the existing blowing pressure.
3.3

Customer Information

It is a most important step that the customer, the operators and the maintenance personnel
understand that these Recommended Blowing Pressures are based on past experience with
similar fuels, boiler design and firing conditions. The pressures are recommended for trial as
a starting point. Blowing pressures are those that are required to clean can only be determined
after a period of operation and trial settings with adjustment later, if necessary.
3.4

Set High Pressure First

The unit marked for highest blowing pressure on the Blowing pressure table is set up first.
This will usually be a retractable unit in the platen section or in front of the slag screen,
(i)

The valve head is designed for high pressure. The valve opening of each blower is
adjusted using the setscrew to the required blowing pressure such that the valve dis
is opened fully or partially without completely compressing the spring (i.e. spring
should not be solid).

(ii)

The steam supply is then turned on and the pressure recommended is set on this high
pressure unit from the blowing pressure table by adjusting the supply pressure at the
Pressure Reducing Valve. As an example the blowing pressure on this first unit may
be 18 Kg./cm2 and the supply pressure may be as low as 21 or 25 kg/cm2 depending
on line drop.
6
1610 - 1611 VOL - C1 TAB - 4 - 42

3.5

Set Pressures on Other Models

The next step is to set pressures on one each of the other models in the system one wall
deslagger, one rotary and one air preheater cleaner if they are employed in the particular
system.
In selecting the one unit of each of these models to be checked, consideration should be given
to the highest blowing pressure used on that particular model as well as the unit farthest from
the source of steam supply. Line drop will be the only reason for not being able to obtain the
recommended pressures.
Where pressure cannot be set as high as desired because of line drop on these secondary
model settings, it obviously will be necessary to increase the supply pressure through the
Pressure Reducing Valve and reduce the pressure on the individual high pressure unit first set
up.
3.6

Setting Pressure on all Other Units

From the above procedure we have established the minimum header supply pressure to give
the maximum blowing pressure on all of the various soot blower models or types of equipment
used in the system. It is now only necessary to set the other pressure by restricting valve
opening on other units using lesser pressures.
These pressure settings must be made with pressure gauges and the units in actual operation.
Measuring the valve opening or using feeler gauges is not reliable since accumulation of
tolerances in the valve linkage causes a variation in pressure settings.
Normally, no alteration is necessary to the safety valve setting. The seal on safety valves must
not be broken or changes made to these safety settings without specific reasons. Safety valves
are for the protection of the equipment and system in case of Pressure Reducing Valve failure
and their setting does not coincide with this method of pressure setting in any way.
PRESSURE SETTING ARRANGEMENT

ITEM NO. OFF


NO.
01
1
02
2
03
1
04
1

BPS W. DRG. NO

DESCRIPTION

3.20.998.00796
4.20.998.0 1763
4.20.998.01759
V75 141 0250

CONDENSING LOOP
PACKING (COPPER)
CONNECTOR
PR. GAUGE 150 RANGE 0.70 ata

Safety Valve set pressure


Because of the pressure fluctuations occuring in the system when each soot blower valve
head is opened and closed the slow reaction of the Pressure Reducing Valve actuator the
safety vave is likely to pop or chatter depending on the set pressure. The set pressure can be
7
1610 - 1611 VOL - C1 TAB - 4 - 43

increased if the set pressure is not already in the maximum setting. Normally a set pressure
upto 42 Kg./cm2 (g) can be set with a 600 psi rated safety valve.
Do not alter the set pressure if the system is stable.
With the above procedure of setting pressure we have the maximum valve opening possible
on any and all individual soot blower operating heads which reduces valve maintenance. We
have the minimum steam pressure on packing, also reducing maintenance.
We have a more flexible system in that, if loads are increased or inferior fuels are used for
shorter periods where higher blowing pressures are required, one single adjustment can be
made at the pressure reducing valve rather than changing and gauging all individual units.
When the emergency is past, the original pressures can be restored again with one adjustment
at the pressure reducing valve.
If there are questions or if difficulties should arise in following this procedure, please contact
us for further advice and counsel.
Do not set pressure reducing valve supplied systems at 600 psi and reduce blowing pressures
with orifices and individual head linkage adjustment.
3.7

Blowing Pressures

When new jobs are commissioned or started up, we can , based on past experience with the
type of fuels, firing, boilers and equipment involved, recommend blowing pressures for trial
or starting. An operating period then dictates if pressures and operating frequency should be
changed.

Pressure Adjustment In Long Retract


Observation while the boiler is in operation and inspections at outages are always necessary
to see that cleaning is adequate and that tube damage does not result. In order to evaluate
either cleaning problems or tube erosion and determine corrective steps to be taken, down
steam blowing pressures should be gauged and tabulated along with the operating frequency
of the units.
Pressure, nozzle size, nozzle angle, drainage of condensate and frequency of operation items
that should be reviewed and checked relative to cleaning and erosion conditions. We wish the
customer to feel free to call on our service department for advice and counsel which will be
based on our past experience in this type of work.
3.8

Inspections

Inspections of all tube surfaces at any scheduled outage, are essential to determine tube damage
and cleaning. Wall blower inspection is difficult and costly because of the need of scaffolds
or bosunchair, nonetheless inspection is necessary because of the fact that they are hard to see
and check while in operation.
8
1610 - 1611 VOL - C1 TAB - 4 - 44

We recommend that inspection be made at every scheduled outage of sufficient length to


permit installing a bosunchair or scaffold. We also recommend that inspection be made of all
the tube surfaces at each blower location as soon as the boiler is cool enough to enter and
before any hand cleaning is accomplished. This early inspection gives true picture of the
deposits before they are disturbed and also permits repair during the scheduled outage.

4. SOOT BLOWER CHECK LIST AND RECOMMENDED START-UP


PROCEDURE
4.1

Blowing Medium Supply System

(i)

Steam System

(ii)

(a)

Check expansion loops for thermal expansion provision.

(b)

Check for slope or pitch for drainage as called for on drawings.

(c)

Condensate discharge from trap should be led to atmospheric pressure.

(d)

Condensate drain should slope down and away from trap for gravity drain.

Both Air and Steam Systems


(a)

Check provisions for boiler expansion


Expansion loops provided on steam system
Flexible couplings or expansion loops on air system.

(b)

Pipe Hangers
Sufficient in number
Properly located to eliminate any pipe strain on soot blower inlet
flange when system is in hot operating position.

(c)

Blow down either system completely


On Candelabrum or gradually rising header and branch line systems,
it is recommended that all branch lines be blown before inlet
flanges of soot blower operating heads are made up.
On properly designed drain systems having a drain connected to each
operating head, blowing down of construction debris and cleaning
lines can be limited to blow down of drain lines and condensate
reservoir immediately preceding the drain valve.

(d)

Drains
All drain lines must be blown down before final welding in of the
drain valve proper.
The thermometer or thermocouple should be checked for goodworking
conditions.

4.2

Suggested Operation Procedure

(i)

The frequency of soot blower operation depends on the operting conditions, status
of the boiler and boiler cleanliness. Some things which may indicate the need for
cleaning are; increase in boiler exit gas termperature, decrease in boiler gas flow
(assuming constant boiler load) and visual inspection.

(ii)

It is important when starting up a boiler that the soot blowers be used frequently and
soon after lighting off. Inefficient combustion in a boiler being started up may result
9
1610 - 1611 VOL - C1 TAB - 4 - 45

in abnormal deposits on the tubes. Unless they are removed frequently, furnace
explosions or puffs may result later. It is usually also desirable to use the soot
blowers just before taking a boiler out of service.
(iii)

When using the soot blowers for the first time, it is advisable to increase the furnace
draft as much as possible during the blowing cycle. After several blowing cycles, it
will be possible to tell how much the furnace draft shoud be increased for blowing.
The furnace draft can be increased by opening the boiler outlet damper wider, in
creasing the induced draft fan speed, or opening the induced draft fan damper wider.
No increase in forced draft is recommended.

(iv)

When the soot blowers are not being used, the main steam supply valve should
always be closed tightly and the drain valves opened wide. The motor equipment
for electrically driven blowers is housed in suitable enclosures. For all blowers it is
necessary to make the power and control connections from the motor control centres
and panel to each blower. There is usually a local starting button for each blower as
well as a remote button on the control panel. These buttons are indicated on the
wiring diagrams.
Suggested Procedures

(v)
(a)

Assure that power is available at the proper voltage and frequency as specified on
the application drawings.

(b)

Increase the furnace draft as described above.

(c)

For steam blowing systems, open all drain valves wide. If traps are used, be sure
isolation valves are open and the by-ass valve is closed.

(d)

Open the main steam or air supply valve slowly until it is wide open. With steam
blowing cycle, do not operate any blowers until all the piping has been warmed and
drained. Then, if traps are not used, close the drain valve. The hole in the valve seat
will serve to keep the lines drained. Never blow with wet steam.

(e)

Operate the blowers in the numerical sequence shown on the general arrangement
drawing. There is a panel start push button for each blower. The buttons may be
included in the automatic sequential operation; they may be individual (buttons for
manual operation) therefore, one button must be used to start each blower. Each
button should be held in about 5 seconds and then released. The blower will start
operating, complete the cycle and this will be indicated in the panel; start the next
blower after this blower operation is over.

Pressure Adjustment wall Deslagger


10
1610 - 1611 VOL - C1 TAB - 4 - 46

(f)

Operate each blower in sequence, each may be operated as many times as necessary
to clean. (Note: Allow a cooling period of 1 hr. before subsequent operaion of the
same blower) NEVER ALLOW A BLOWER TO BLOW UNLESS THE NOZZLE
IS ROTATING.

(g)

When the entire blowing cycle is complete, close the main stop valve tightly. Open
the drain valves wide if they are closed.

(h)

Adjust the furnace draft to Normal.

(i)

Open the power and control circuit.

(j)

Be sure all blowers have completely retracted and all heads are fully closed.

5. SOOT BLOWER MAINTENANCE


5.1.

Soot blowing, once considered a necessary evil, has become a positive necessity on
modern coal and oil-fired boilers. Fuel costs are rising, and heat value per pound of
fuel seems to be decreasing. Ash, sulphur and low-fusion-temperature slags cause
more trouble with lower Bth. U fuels and demand dependable soot blower operation.

Many cost-conscious engineers are now setting up suitable maintenance programme on soot
blowers, and since peculiarities of each boiler plant usually require a programme tailor-made
for each plant, it is advisable to enlist the aid of the manufacturers field-service engineers in
setting up a specific programme. However, the following paragraphs will help to bring light
the more important things to be considered.
The factors that may cause, or contribute to tube cutting are:
(i)

Excessive pressure causing excessive nozzle or jet velocity.

(ii)

Abrasive dust from baffles and sheaves adjacent to blowers entrained in the blowing
jet.

(iii)

Condensate in steam, or water in air, whichever is used as the blowing medium.

(iv)

In air heaters or economizers where dew points may be low or boiler gases highly
corrosive tube metal may be rusted or eaten away, especially where any condensate
or drops of water from blower elements may be deposited on tube surfaces. These
rust scales are removed when blowers are operated, thus exposing new metal and the
cycle continues until tube failure occurs.

To check tube erosion


(a)

Observe, report and record any tube erosion, cutting or polishing that is evident in
the slightest degree. The permanent record will help determine on future inspections
whether the condition has been corrected.

(b)

Blowing pressures may be reduced on some equipment by adjusting the valve screw,
on other equipment by adjustable orifices in still other equipment by a permanent
orifice in the line. Manufacturers service instructions will indicate the proper
procedure. No higher pressure should be used than that needed to clean the boiler.
This decreases tube erosion and prevents excessive use of steam or air, thus aiding
economy.

(c)

Follow the instructions given under individual blowers.

5.2

External Inspection

(i)

Make sure valve mountings or head supports are secure. Loose mounting permits
head and element to move in and out of the wall sleeve, undoing all the careful
internal alignment.
11
1610 - 1611 VOL - C1 TAB - 4 - 47

(ii)

Check the operating head and valve to make sure it is functioning properly,
mechanically and that it can rotate without undue binding.

(iii)

See that mechanical parts are clean and free from rust. Dirt and rust act as an
abrasive, causing moving parts to wear.

(iv)

Remove immediately any and all water pockets in the supply piping system. PROPER
DRAINING OF PIPING IS OF PRIME IMPORTANCE. When the blowing medium
is steam the supply pipe should have an independent direct connection to the boiler
drum, to obtain the direct possible steam at maximum pressure. Stem supply piping
should be insulated for safety, and to reduce condensate in the soot blowing system.

(v)

Make sure piping connections to soot blowers are flexible enough that no leakage
to abnormal stresses will develop. Proper hangers should be provided for the pipe.
Pipe risers should never depend on the soot blower head for any support. This always
causes binding when the unit is operated.

(vi)

If condensate traps are used on steam systems, dis-assemble them and clean the
screens during outages to make sure they operate properly.If a drain valve with
4mm hole in the seat be used instead of a trap, make sure it is in place and in
operating condition.

(vii)

Make sure condensate is drained to atmosphere. If drains are led to blow-down


tanks, check valves should be used. If drain systems are connected in series to two
or more boilers, check valves should be used to prevent steam from backing up on
unused equipment.

5.3

Maintenance

Things listed so far have been inspection points to check during boiler outages. There are
other points that can be checked while the boiler is in service.
(i)

Operation personnel should be instructed to report immediately to the maintenance


personnel any difficulty encountered in operating.

(ii)

Competent maintenance personnel should be required to follow and observe each


and every soot blower through its operating cycle on certain definite dates. These
inspection periods should be bi-weekly or monthly, depending on the size and
importance of the soot blower installation to proper boiler operation.

(iii)

All steam leaks should be corrected immediately.

(iv)

All valves should seat tightly to prevent wire drawing.

(v)

All packing glands should be drawn just tight enough to prevent leakage without
binding or breaking down packing fibre by excessive pressure.

(vi)

All cams and moving parts should be cleaned and properly lubricated.

(vii)

Gear boxes should be filled to proper levels with correct gear oils or grease. Greases
should be checked regularly to see if they have hardened or separated from their
bases because of high ambient temperatures. On outdoor installations, they should
be checked when temperatures drop to see if hardening or channelling occurs.

(viii)

Lubrications in air lines to air motors should be checked at least once a week to
make sure oil reservoirs are full and feed is correct.

(ix)

With electric motors, insulation, brushes and commutators should be clean and free
from oils. General rules for care of electrical equipment and industrial controls
should be followed.
12
1610 - 1611 VOL - C1 TAB - 4 - 48

(x)

Where drive chains are used, the chain should be kept as dry as possible.Only enough
oil to prevent rust should be applied. Excess oil picks up fly ash and grit to form a
cutting abrasive between link connections.

(xi)

With any lubricants, manufacturers specifications for correct types, amounts and
frequency of application should be closely followed.

5.4

Preparing for outages

Where boilers are subject to extended outages, as in heating plants, maintenance can be reduced
by giving proper attention to the equipment before and during the down period.
(i)

Moving cams, etc., should be well coated with rust-preventive lubricants.

(ii)

Mechanical units should be covered with canvas, oil cloth or paper for protection
against moisture or excessive dust.

(iii)

If operating valves or pistons have rings or parts not made of rust-resistant alloys
these parts should be removed. They can be protected by a rust inhibitor by a rust
inhibitor or stored until the equipment is required.

(iv)

Where feed lines or telescope tubes are of carbon steel, the units should be extended
and rust preventive applied to these parts.

(v)

Inspections and repairs should be made immediately when the boiler is shut down to
assure proper operation when the boiler is put back into service.

Care, adjustment and maintenance of automatic control, panels for automatic-sequentital


systems are properly entrusted to the instrument personnel. Such systems usually require
little care after being placed in service, except to keep all parts thoroughly clean.
Generally speaking, they require the same maintenance as any industrial control system except
that the loads on relays, indicator lamps and switches are comparatively light, therefore,
requiring less attention. Little maintenance trouble is met, if this equipment is kept clean and
free from dust and oil.
5.5

Operation

Correct operating procedure will help to minimize maintenance problems. These are important
check points.
(i)

Drain valve should be fully open, and supply valve opened slowly, during warm-up
period. Drain valve should not be closed until the steam leaving the drain is absolutely
dry. Drain valves should remain open when units are not operated. These precautions
prevent condensate from entering elements to warp or distort them.

(ii)

Rotation of elements should be slow, even and continuous from the time steam flow
starts until it is shut off. Should the automatic valve-in-head unit fail to shut off, the
entire system should be shut down immediately, and the offending unit be corrected
or blanked off before proceeding with the other units in the cleaning cycle. To proceed
with the other units after one operating head has failed to shut off would cause tube
damage. In addition, there would be reduced blowing pressures to the other elements
which would prevent proper boiler cleaning.

(iii)

All units should be kept in operating condition as far as possible. Loss of one unit
could cause plugging and thus divert hot gases over an adjacent unit to destroy that
element.

(iv)

Blowers should be operated in proper sequence along the gas flow lanes with dampers
fully open. This moves soot out, rather than blowing it from one place to another.
13
1610 - 1611 VOL - C1 TAB - 4 - 49

Boiler load should be to full, if possible to prevent puffs or possible explosions.


(v)

Blowers should be operated at proper intervals to reduce temperatures and prevent


loss of elements and nozzles. Operating intervals should not be set for certain hours
of the day or shift, unless the boiler steams vary evenly and neither soot nor slag
conditions are of much concern. Blowing intervals should be adjusted to load, firing
and fuel conditions. The guiding rule is that flue gas temperature should not rise
more then 20 Deg. C between soot blower operating periods.

Soot blowers should also be operated after any abnormal fuel burner operation resulting in
heavy smoke while burning oil. This is especially true if there is an economiser or air heater.
Soot blowers are expected to clean efficiently and safely. They are intended to operate on low
power and labour cost, and to give long life with minimum maintenance expense. This is
possible, even if the equipment be subjected to high temperatures and adverse operating
conditions.
Soot blowing engineering takes these points into consideration and uses the highest possible
engineering standard in design and construction. As a result, blower equipment properly
installed and cared for is as trouble-free as possible. To maintain this standard of operation
requires only a regular programme of inspection and preventive maintenance.

14
1610 - 1611 VOL - C1 TAB - 4 - 50

6.RECOMMENDED LUBRICATION CHART FOR SOOT BLOWERS


6.1 LRD-IE Long Retractable Soot Blower and LRD-IA Long Retractable Soot Blower (Air -Operated)
LUBRICATION
POINTS

PART
DESCRIPTION

LUBRICANT

FILLING
OBSERVATION
FREQUENCY
FREQUENCY

M ETHOD

OF

APPLICATION

QTY PER
BLOWER PER

REMARKS

FILING

1.1

Power Pack
(Rotary)

Servosystem
Annual
68

3 Months

Fill the reservoir


removing vent plug

0.8 litre

See Note 2

1.2

Power Pack
(Traverse)

Servosystem
Annual
68

3 Months

Fill the reservoir


removing vent plug

0.8 litre

Sea Note 2

1.3

Chain

1.4

1,5
1.6

Travelling
carriage
(Steam
Blowing)
Travelling
carriage
(Air Blowing)
Air Motor

Servosystem
150
Almasol
1250 or
Annual
Servogem
HTXX

3 Months

Fill in the reservoir

0.6 Kg

Servomesh
28

Annual

3 Months

Fill in the reservoir

0.6 Kg

Servospin 6

2 Months

2 Months

Air line lubrication

I litre

See Note 1

See Note 3

Only for
LRD- IA

15
1610 - 1611 VOL - C1 TAB - 4 - 51

NOTE: 1

All the chain and chain links are prelubricated by special treatment by which lubrication is required normally. But as and when sign
of rust is identified twofold lubrication is recommended. First the chain is cleaned and trichloroethylene is applied over surfaces.
(This is used as a degreasing agent and carrier for penetrating the heavy lubricant. Servosystem 150 is applied as a second cost).

NOTE: 2

Lubricating oil levels should be checked and maintained every month.

NOTE: 3

Almasol 1250 is recommended only when the soot blowing medium temperature exceeds 427C. For recovery boiler irrespective of
temperature Almasol 1250 is recommended.

6.2 RECOMMENDED LUBRICATION CHART FOR LRD-IIE LONG RETRACTABLE SOOT BLOWER

LUBRICATION
POINTS

PART DESCRIPTION

LUBRICANT

FILLING
OBSERVATION
FREQUENCY
FREQUENCY

M ETHOD

OF

APPLICATION

QTY PER
BLOWER PER

REMARKS

FILING

16

2.1

Travelling carriage
(Air Blowing)

Servomesh
28

Annual

3 Months

Fill in the
reservoir

0.8 litre

See Note 2 in
section 6.1

2.2

Travelling carriage
(Steam Blowing)

Almasol
1250 or

Annual

3 Months

Fill in the
reservoir

0.6 Kg.

See Note 3 in
Section 6.1

2.3

Chain

Servosystem
150

See Note 1 in
Section 6.1

2.4

Power Pack Rotary


and Traverse

Servomesh
28

Annual

3 Months

Fill in the
reservoir

0.8 litre

See Note 2 in
Section 6.1

1610 - 1611 VOL - C1 TAB - 4 - 52

6.3 RECOMMENDED LUBRICATION CHART


FOR
RB-IM ROTARY SOOT BLOWERS -MANUAL
RB-IE ROTARY SOOT 6 LOWER S-ELECTRICALLY OPERATED
RB-IA ROTARY SOOT BLOWERS-AIR-OPERATED

LUBRICATION
POINTS

PART D ESCRIPTION

LUBRICANT

FILLING
FREQUENCY

OBSERVATION
FREQUENCY

M ETHOD

OF

APPLICATION

QTY PER
BLOWER PER

REMARKS

FILING

17

3.1

Power Pack

Servosystem 68

Annual

3 Months

Fill in the
reservoir

0.5 litre

See Note 2 in
Section 6.1

32

Bull gear/(cluster
gear of Manuel rotary)

Servogem 3 or
Servogem
HTXXX

2 Months

1 Month

Apply grease

0. 5 kg

3.3

Air motor

Servospin 6

2 Months

2 Months

Air line
lubrication

1 litre

O nly for RBlA

1610 - 1611 VOL - C1 TAB - 4 - 53

6.4 RECOMMENDED LUBRICATION CHART OF WB-IE WALL DESLAGGER

LUBRICATION
POINTS

PART
D ESCRIPTION

LUBRICANT

FILLING
FREQUENCY

OBSERVATION
FREQUENCY

M ETHOD

OF

APPLICATION

QTY PER
BLOWER PER

R EMARKS

FILING

18

4.1

Gear Rack
Housing

Servomesh
S P 460

Annual

3 Months

Fill in the
reservoir

0.5 litre

4.2

Linkage

Servogem 3
or Servogem
HTXXX

2 Months

2 Months

Pressure
filling

0. 1 kg

4.3

Rotary gear box


(steam blowing)

Servomesh
S P 460

Annual

3 Months

Fill in the
reservoir

0,5 litre

4.4

Rotary gear box

Servorex LO

Annual

3 Months

Fill in the
reservoir

0.5 litre

See N ote 2 in
Section 6.1

See N ote 2 in
Section 6.1

For Air
operation only

1610 - 1611 VOL - C1 TAB - 4 - 54

6.5 RECOMMENDED LUBRICATION CHART-FTP-IE FURNACE PROBE AND THE TRAVERSING SOOT
BLOWER

LUBRICATION
POINTS

5.1

19

5.2

PART
DESCRIPTION

Power pack

Chain

FILLING
LUBRICANT

FREQUENCY

QTY PER
OBSERVATION M ETHOD OF
BLOWER PER
FREQUENCY APPLICATION

REMARKS

FILING

Servosystem 68

Servosystem 150

Annual

3 Months

Fill in the
reservoir

0.8 litre

See Note 2 in
Section 6.1

See Note 1 in
Section 6.1

1610 - 1611 VOL - C1 TAB - 4 - 55

6.6 Comparable Equivalents of international Lubricants


Sl.
N o.

Indian Oil
Corporation

1.

Servosystem
68

2.

Servogem
HTXXX or
Servogem 3

Hindus tan
Pe trole um
Enklo 68

ESSO
Terresso 52
or Nuto 53

Pen- o- led
EP2

Te xaco and
Calte x

Gulf

Thermatex
EP- 1

Mobil
temperature
grease 78

Macoma oil 68

Meropa oil
N o. 2

Mobil
Compound BB
(Mobil Gear
62.9)

Exxon spartan
EP 150

Mobil
compound FF
(Mobil gear
634)

Exxon spartan
EP 460

Bharat
Amocam oil
460

Mobilux EPO

Exxon Lidok
EPO

Bharat
Velocite E
Exxon Avox EP
(gargoyle Arctic
Hydrol 15
45
oil light)

Gulf Leymoly

EP Lubricant 65

Macoma oil 78

5.

Servorex LO

Limaplexo

Nebula EPO

Shell Alvania
Grease EPO

Texaco
Gulf crown
Multifak EPO Grease EPO

6.

Servospin 6

Spintek 12

Spinnesso 34 Shell Tellus oil 10 Spintex RS

20

4.

Meropa
EP Lubricant
lubricant No.
115
5

1610 - 1611 VOL - C1 TAB - 4 - 56

Servosystem
150

Yantrol 150

Bharat
Pe trole um

Davina Grease
N o. 2

Pen- o- led
Gervil EP460
EP5

Exxon

Mobil Delvac
special 1O W30

Sarvomesh
S P 460

M obil

Servomesh 28 Gervil EP15

*Lubrication
Engine e rs Inc.

Shell Tellus oil 33 Regal oil PC


Harmony 61
(R&O )

3.

Note 1:
Note 2 :

She ll

Vitrea 69

Texol ' F '

Gulf spin 35

Gulf EB 7

Almasol 1250

Vactia oil extra


heavy

Bharat
Extra Motor oil
Hydrol 68
1O W- 30

Bharat MP
Grease 3

Bharat
Hydrol 150

Address of this firm is M/s.Lubrication Engineers Inc., Post Box No. 7128,Forth Worth, Texas 7611, USA.
The equivalent lubricants listed above will not have the same characteristics,but they can be used considering the application. names of
equivalent lubricant are based on the information available with us.Any revisions in the name of equivalent lubricant may be confirmed
with the respective lubricant manufactures.

7.RECOMMENDED QUANTITY OF LUBRICANTS FOR ONE YEAR


Sl. N o.

Lubricant

TYPE OF BLOWER

UN IT

1-6

7-12

13-18

19-24

25-30

313-40

40 AN D
ABOVE

K g.

12

18

24

31

40

1.

Almosal 1250
Almosal 1250

2.

Servomesh 28

Long Retractable Model LRD- 1 E (Air Slowing)

Lit.

18

27

36

45

54

Servomesh 28

Long Retractable Model LRD- 11 E (Air


Blowing)

Lit.

18

27

36

45

54

Servomesh 28

Long Retractable Model LRD- 11 E (Steam


Blowing)

Lit.

18

27

36

45

54

Servosystern 68

Long Retractable Model LRD- 1 E/I A

Lit.

12

24

36

48

60

80

Rotary Blower RB- 1 E

Lit.

10

12

18

24

Wall Blower WB- l E (Steam Blowing)

Lit.

12

18

24

30

40

Wall Slower WB- l E (Air Blowing)

Lit.

12

15

20

Long Retractable LRD- 1 E

K g.

12

24

36

48

60

80

Long Retractable LRD- 11 E

K g.

18

36

54

72

90

120

21
4.

5.

Servomesh 60

Servogem HTXXX

Long Retractable Model LRD- I E


Long Retractable Model LRD - II E

STEAM BLOWING

1610 - 1611 VOL - C1 TAB - 4 - 57

6.

Servorex LO

Wall Deslagger (Air driven)

Lit.

12

15

20

7.

Servospin 6

All types of air operated Blowers

Lit.

10

15

20

25

30

8.

Trichloroethylene

Long Retractable Model LRD (All Types)

Lit.

12

15

30

9.

Servosysterm
n 150

Long Retractable Model LRD (All Types)

Lit.

12

15

30

60
30
30
60
40
40

8.

VALVE SEAT GRINDING FOR SOOT BLOWER VALVE HEADS


8.1.

Caution

DO NOT re-grind seats unless absolutely necessary. Every attempt should be made to lap
seat and valve into condition without using the re-grinding tool.
Only when the normal valve grinding procedure with valve grinding compounds does not
remove cuts and wire drawing from the seating surfaces should be grinding tool be resorted
to.
DO grind very lightly.
When the grinding tool is employed only sufficient grinding should be done to remove
imperfections. Removing hard stellite face unnecessarily is wasteful and time consuming.
DO maintain a 210 angle on the fixed seat in the main body and 19-1/20 angle on valve disc
of the valve assembly.
It is permissible to be off a few minutes from these angles on both seating surfaces.
We endeavour to maintain full width contact for greater life expectancy. This is desirable
rather than the ring contact which would be present with different angles on the matching
seats. The ring contact seal cuts through and starts to leak in a relatively short time.
8.2

Disassembly of Operating Heads

All valve heads are stripped down whether removed or still in place on the unit. The valve
disc and all packings are removed. The packing gland remains in place.
Where packing glands show wear at the valve stem guide area or are to be replaced for any
reason, the replacement should be made before re-seating is done.
The packing gland is used as a guide for the pilot and the stone sleeve in the re-seating procedure.
The packing gland must therefore remain in place after grinding to insure concentricity of the
operating parts when the unit is re-assembled.
8.3

Test Checking Valve and Seat

Immediately after dis-assembly an examination of the parts should be made to see that they
are not fractured or broken beyond repair that would require replacement. The seating surfaces
are then checked.
Cracked seat surface in the valve body may require re-stelliting. This is not a recommended
field procedure. The valve body with packing gland and valve stem assembly should be returned
to our plant for re-stelliting and grinding in the valve.
The valve stem assembly may be craked or the valve stem worn or scored requiring replacement.
The packing gland may be worn in the valve stem guide area and require replacing.
When the body with the final packing gland in place is available the valve assembly is then
lapped with fine valve grinding compound. The valve grinding compound should be the
water mixed automotive type. The procedure for lapping the valve is comparable to automotive
valve grinding using the screwdriver slot in the top of the valve disc to rotate the valve with
compound on the seat surface.
This light test lapping will indicate the extent of wire drawing, cuts or imperfections in the
seating surfaces. From this test lapping, it can be determined if heavy grinding compounds
and continued hand grinding with fine lapping compounds used in turn will correct the surfaces
or if it will be necessary to resort to the more drastic valve re-grinding.
22
1610 - 1611 VOL - C1 TAB - 4 - 58

8.4

Dressing the Grinding Stone

The stone is installed on the stone sleeve by turning the threaded end of the sleeve into the
threaded bushing in the stone.
The stone on the sleeve is then installed on the lightly oiled upright stem of the grinder.
The sleeve and stone assembly is then rotated with the driver.

Valve Seat Grinding Tool set


1.Drive RPM of Drive Shaft = 12000 4. Stone Sleeve
2.valve Body

5. Stone (Norton ME 105420 or Equivalent)

3.Pilot
The cutting angle of the diamond point dresser should be set on the angle indicator to 210.
The dressing of the stone should be with very slow feeds of the micrometer adjustment in the
diamond feed screw to avoid waste and damage to the stone.
8.5

The Pilot

The pilot is then installed in the soot blower head from the stuffing box side. Pilot plug
should enter and fit snugly in the packing box of the packing gland in order to insure
concentricity of the newly made seat with the guide of the packing gland.
8.6

The Stone Sleeve and Stone Assembly

The sleeve and stone assembly is then inserted in the operating head from the opposite side of
the packing gland. The stem on the pilot entering into the sleeve should be lightly oiled. A
minimum amount of oil should be used to avoid oil loading of the grinding stone.
8.7

The Driver

The driving head is then fitted into the sleeve. The stone should be off the seat and ride on the
pilot stem only as driver is started. The driver with sleeve and stone assembly is advanced
slowly until the seat surface is contacted only very lightly. The driver is then withdrawn very
slowly. Cutting on these seats is extremely rapid because of the angle, therefore, we repeat,
proceed slowly in removing metal. A slight check after the first touch will indicate if additional
grinding is required.
8.8

Valve Stem Assembly

The valve disc of the valve stem assembly may be cut or wire drawn with marks too deep to
remove by compounds and hand work. These assemblies can be dressed to the 20 Deg. with
a grinder in a lathe or a regular automotive valve grinder.
Extreme care should be exercised where the disc seating surface of the valve stem assembly is
ground or refinished that excessive metal is not removed.
23
1610 - 1611 VOL - C1 TAB - 4 - 59

Never more than a total of 0.25mm should be removed from the face of the disc on the valve
stem assembly as it is received from the factory. Removing excessive metal by this grinding
of the disc on the valve stem assembly will reduce the diameter and thin the seating wall of
the valve disc permitting it to be driven through the fixed seat. This is not dangerous to
personnel but does impose a more expensive maintenance problem. We recommend
replacement of the valve stem assembly when the seat surface is damaged.
8.9

Check for Mating Seat Angle

When both seating surfaces have been regrouped the mating angles can be checked by the use
of Prussian Blue. With blue applied to the seating surface a light turn of the valve assembly
will indicate not only imperfections but will determine if the angles of both seat and valve are
identical in the lapped area. The fixed seat in the body should show full width contact on the
valve disc rather than ring contact. If ring contact is apparent the angle on the grinding
stone may require a slight correction in the dressing angle.
8.10

Re-dressing the Grinding Stone

The grinding stone should not be permitted to develop a ring or groove between dressing.
The side angle of the stone should remain straight and flat. Dressing is also essential to
prevent oil carbon loading.
8.11

Lapping after Grinding

When seats have been reground the valve should be hand lapped with very fine lapping
compound. This procedure again is very very light. Only sufficient pressure is applied with
a very few turns so that a fine frosted surface appears on the newly polished ground parts.
Actually this lapping procedure should be more of a check to see that surfaces properly made
on both parts. Figures show a hand tool suggested for this purpose.
8.12

Re-Assembly

The re-assembly of the operating head is of course in the reverse order of dis-assembly. Where
the operating heads are rotary soot blower, heads, care should be exercised when the head is
reinstalled that element flange is registered properly on the operating head. If some marks or
care is exercised in this respect it will save resetting the blowing cams in order to correct the
blowing arc.
Blowing arcs should be double checked on all rotaries after replacement to avoid cutting tube
destroying baffles or inducing improper cleaning that would be encountered if the blowing
arc were established in the improper segment or if the element is improperly moved end
ways.
Note: We recommend that the SB valve assembly to be sent to the factory for re-conditioning
rather than the customer trying to recondition the valve since special care should be taken in
repairing this valve.

9.

RECOMMENDED PROCEDURE FOR PACKING INSTALLATION


The useful life of packing is dependent on the method of installation. Poor installation can
cause the best packing to fail prematurely. The methods in this procedure, if followed, will
lead to better sealing and longer life.
These packing method apply both to installing packing in new equipment and replacing packing
in equipment that is in service.

24
1610 - 1611 VOL - C1 TAB - 4 - 60

9.1

Installation method

Clean out the old packing. Flexible packing hooks are available for removing the packing.
Inspect the feed pipe stem for wear or damage. Remove any raised metal that projects above
the normal surface. Do not try to file out depressions or scratches. Raised metal will tear
packing. Any reworking of scratches will only worsen the condition.
Keep the new packing clean during installation. Grit or other hard foreign matter that is
installed with the packing may score the feed pipe causing an early failure of the packing.
Install all packing rings so that the joints are staggered and kept approximately 90 Deg. apart.
Spot the joints in clockwise direction to facilitate locating them when removing the packing.
9.2

Install the rings one at a time

Each ring must be set firmly into place with either the gland or a tamping tool as shown in
figure. After each ring is installed, the ring must be compressed with approximately the same
force that it will have with the final gland force. Each ring should be equally compressed
when the entire set is installed. If this is not done, only the last ring will do the sealing and
will wear quickly.

Install each ring as per the figure.


Bevelled packing is to be installed with the bevel lip on the shaft pointing toward the pressure.
One end of the tamping tool is angled for bevelled packing. Fit the bevel on the packing to the
bevel on the tool see figure.
Oil or grease may be applied to the outside of braided asbestor packing to help in installing it
in the stuffing box.
Tighten the gland follower, sufficiently tight, after the packing has been installed to insure
final seating of the packing. The nuts should be backed off two or three turns to relieve
excessive pressure. Adjust packing to operating conditions.
Allow packing to leak a small amount, if possible, when starting newly packed equipment.
Tighten the gland slowly as the packing seats.
Do not be afraid to let packing leak a small amount. It is good assurance that packing is not
too tight and the liquid usually has some lubricating qualities.
When renewing packing, use all new clean packing. Worn packings are dry, highly compressed,
have high friction and may develop scoring. Remember packing is relatively cheap. Labour
and materials necessary to replace worn feed pipes are expensive and critical commodities.
The most expensive seal is a seal that fails.
Light gland pressure should be maintained at all times. Too much pressure will cause binding,
scoring of the shaft and force the lubricant out the packing. Too little gland pressure will
allow excessive leakage and washing out of the packing.
When the packing has been compressed to less than of its original height, it should be
replaced. The loss of height in packing may indicate a loss of essential lubricant.

25
1610 - 1611 VOL - C1 TAB - 4 - 61

lAPPING TOOL

9.3

Packing

Keep packing glands just tight enough to prevent leakage : Do not overtighten them. Replace
packing that leaks excessively. Refer to instruction Recommended Procedure for Packing
Installation.

10.

INSTRUCTIONS FOR STORAGE


All the Soot Blowers, though designed for outdoor applications, require special care during
storage before erection and commissioning. These instructions may please be taken seriously
to avoid costly replacements or breakdowns at a later date.
(i)

On receipt of the Soot Blowers, carefully check for any damage of the components.
List out the damaged components with reference to the item no. in the concerned assembly
drawings to BHEL, Tiruchirapalli for further action.

(ii)

See the Soot Blower assemblies are shipped completely covered with waterproof
coverings. Unless the blowers are taken for immediate erection please do not disturb
the coverings. Coverings are to be replaced wherever damaged.

(iii) Some assemblies like Wall Deslaggers and Rotary heads are shipped with temporary
wooden platforms to prevent parts getting damaged during erection. These need not be
removed till the blowers are erected.
26
1610 - 1611 VOL - C1 TAB - 4 - 62

(iv) All the electrical items are to be covered with waterproof and dust proof coverings.
Nozzle and valve openings are shipped covered. This may be checked and covered
wherever necessary.
(v)

Normally storage under covered roof is not necessary for Soot Blowers when the
waterproof covers are not removed. Wall Deslaggers and Rotary Soot Blower heads
can be stored under covered roof if the interval between Soot Blower erection and
receipt is more than two months.

(vi) Always use the lifting lugs or hooks provided to avoid damage to the connected parts.
Similarly avoid hitting the assembly against structures or other boiler components while
the Soot Blowers are being lifted.
(vii) The above instructions are for guidelines only and the concerned persons may use their
own discretions knowing well that these are electro-mechanical components.

27
1610 - 1611 VOL - C1 TAB - 4 - 63

TAB - 5

INSTRUCTIONAL MANUAL
WALL DESLAGGER
MODEL-WB IE

Bharat Heavy Electricals Limited


Tiruchirapalli

PUB.NO.7503

1610 - 1611 VOL - C1 TAB - 5 - 64

CONTENTS
INTRODUCTION
IMPORTANT INSTRUCTIONS FOR ERECTION,START-UP & OPERATION
DESCRIPTION
WALL DESLAGGER BASIC ASSY. (REF. DRG. 0-00-073-60026)
INSTALLATION

CHECK LIST AND ADJUSTMENTS


CHECK LIST
ADJUSTMENTS

START UP CHECKS
OPERATION
OPERATIONAL PROBLEMS AND MAINTENANCE
MAINTENANCE AND LUBRICATION
RECOMMENDED SPARES

2
1610 - 1611 VOL - C1 TAB - 5 - 65

Wall Deslagger
LIST OF DRGS INCLUDED IN THE MANUAL
1.

0-00-073-60026

WALL DESLAGGER BASIC ASSY.

2.

0-00-073-60027

SWITCH BOX ASSY.

3.

1-00-073-60003.

SBV HEAD ASSEMBLY

4.

1-00-073-60109

RACK GEAR HOUSING ASSY.

5.

1-00-076-60110

ROTARY GEAR BOX ASSY.

6.

2-00-073-60088

WALL DESLAGGER MAIN ASSY.

7.

3-00-073-60008

CAM ASSY. (TERMINAL BOX)

8.

3-00-073-60105

CLEVIS BRACKET ASSY.

9.

3-00-073-60006

WALL BLOWER WIRINGDIAGRAM

10.

3-00-073-60106

RACK CAM ASSEMBLY

11.

4-00-073-60165

SPECIAL ALLEN KEY

12.

4-00-073-60166

SPECIAL SQUARE KEY

13.

4-00-073-60167

VALVE SPRING TOOL

3
1610 - 1611 VOL - C1 TAB - 5 - 66

INTRODUCTION
The coal fired boilers demand the maximum in effective Furnace wall slag control. Effective
deslagging entails- high striking power combined with barest minimum dead time between
blowings. WBIE Wall Deslagger is designed to efficiently meet these needs.
No soot blower system will operate satisfactorily if it is not properly installed, operated and
maintained. It must be recognised that no amount of written instructions can replace intelligent
thinking and reasoning on the part of the operators, especially when coping with unforeseen
operating conditions. It is the operators responsibility to become thoroughly familiar not
only with the equipment but also with all pertinent control equipment.
The instruction gives the general description of the wall deslagger and its installation
procedures. Details of the, adjustments of blowing speed, valve stroke and nozzle are outlined.
The operation, maintenance and lubrication details are also given.
The contents in the manual have been compiled and checked by experts in the field. Every
possible care has been taken to ensure the contents are accurate. However, it must be understood
that the manual is not a contract document.
If you ever have any query about operation, maintenance or related problems, you are welcome
to write to us without obligation.
BHARAT HEAVY ELECTRICALS LTD.
BOILER PLANT - TIRUCHIRAPPALLI.

4
1610 - 1611 VOL - C1 TAB - 5 - 67

WALL DESLAGGERS
IMPORTANT INSTRUCTIONS FOR ERECTION,START-UP & OPERATION
DOS
ERECTION
1

Check the opening in the boiler wall. It shall be minimum 75 mm through.

2.

Check the wall sleeve for perpendicularity and concentricity.

3.

Check blower number with reference to location drawing.

4.

Check the ACCESSIBILITY FOR HAND CRANK and the Switch box assembly.

5.

Check whether the WALL DESLAGGER is PERPENDICULAR after mounting.

6.

Check the PROJECTION OF NOZZLE INTO THE WALL.

7.

Support the SOOT BLOWER piping on the Boiler STEEL such as BUCK STAYS,
FURNACE GUIDES etc.

8.

After the nozzle setting, PUNCH MARK on the alignment plate.

BEFORE START-UP
1.

FLUSH the gear boxes thoroughly with SERVOMESH 60 and fill the gear boxes
with the lubricants as recommended.

2.

Make sure the DRAIN HOLES in the MOTOR FRAMES point downwards and are
open.

3.

Check the direction of rotation of both the MOTORS.

4.

Make sure that the stop nuts are in place on the rods.

5.

Check whether covers are put on the blower.

6.

Check the perpendicularity of the blower when the blower is working.

START-UP AND OPERATION


1.

Check Lubricating oil levels frequently.

2.

Ensure all the interlocks are in use.

3.

Ensure availability of hand cranks for immediate use.

4.

Set the Blowing as per recommendation.

5.

Ensure proper valve opening and close during operation.

6.

Ensure the blowers are at home position after cycle completion.

7.

Ensure a gap of 3-6mm between rotary gear box and rack gear guide rod boss at the
extended position.

8.

Attend steam leakage immediately.

9.

In case off emergency alarm due to elapsed timer, Low header pressure, No blowing
medium, A/C supply failure, interlocks, etc., immediately withdraw the swivel tube
using emergency hand cranks, after switching off the Power Supply.

10.

Pay immediate attention of rectifying the mechanical and electrical faults.

11.

Observe all the safety practices.


5
1610 - 1611 VOL - C1 TAB - 5 - 68

DONTS
ERECTION
1.

Do not place heavy Loads on wall deslagger.

2.

Do not use the blowers as welding platform.

3.

Do not remove the wooden supporting planks until soot. blower is firmly fixed to
wall.

4.

Do not leave the swivel tube at extended position.

START-UP AND OPERATION

1.

1.

Do not operate wall deslagger with wet steam.

2.

Do not operate the blower without blowing during boiler operation.

Do not attend any maintanence work on soot blowers when power and /or steam
supply is ON.

4.

Do not operate the blower with excessive steam leakage through packing.

5.

Do not use hand crank lever for retract when power is ON.

6.

Do not stand near peepholes when the blower is operating.

DESCRIPTION
1.1

Wall Deslagger Basic Assy. (Ref. DRg. 0-00-073-60026)

The deslagger consists of a stationary body (item 10) and rack gear housing (item 2) and a
rotary gear box assy. (item 3) to which the swivel tube assy. (item 5) is attached. The swivel
tube assy, is supported by Bushing (item 17) at each end of the body casting. The horizontal
guide rods (item No. 09 of Drg. No. 1- 00-073-60109) are used to assure proper alignment of
the relay gear box assy.
A stationary electric motor (item 59) is situated on the right side of the. blower. This motor,
through a Rack gear housing Assy. operates a pinion which drives a horizontal rack assembly,
(item 11) the outer end of which is fastened to the rotary gear box Assy. (item 3).
When the Rotary gear box approaches the fully extended position a ramp cam (item 2) attached
to the free end of the rack (item No. 01, 3-00-073-60106) contacts a bearing surface, which is
a part of the clevis bracket Assy. (item 6) and pushes the valve stem assy. (item No.02 of drg.
No. 1-00-073-60003), admitting the steam to the swivel tube. When the blower is started the
rack pinion moves the rack (item 11) and rotary gear box towards the boiler. Operation of the
Rack gear housing causes rotation of a shaft extending out -from the rack gear housing into a
switch box Refer Drg. No. 0-00-073-60027. Located in this switch box are two cam actuated
limit switches. One cam holds limit switch LSTE in the open position when the blower is
fully retracted. Extending of the blower moves the cam allowing LSTE to close. The blower
is then under its own control.
Near the fully - extended position, the ramp cam strikes the lever that open the SBV head
valve. The second limit switch cam strikes the LSTS limit switch, which opens the circuit to
the traverse motor (item No. 59) and closes the circuit to the rotary motor (item 60).
The rotary motor is attached to the rotary gear box assy. When LSTS closes, the motor rotates
the swivel tube through a gear train.
When the blowing sweep is finished the cam assy. (item 7) on the swivel tube contacts and
rotates the arm on the limit switch LSTR. The traverse motor begins to retract the blower.
Near the fully retracted position the cam again opens the switch LSTE to haet the blower.
6
1610 - 1611 VOL - C1 TAB - 5 - 69

CAUTION : Care should be exercised when operating the WB-IE with its guard assy. (item
9)and its holding nuts (item 30) removed. If, for any reason, the stop limit switch. (LSTE) is
not actuated during the retract portion of the operating cycle, it is possible for the rotary gear
box to overtravel and drop off the end of the guide rods.
If the rack should come free of the gear rack pinion drive, the cams for the limit switches will
require resetting.
The end of the worm shaft (item 7 Drg.No. 1-00-073-60109) is slotted so that a hand crank
can be inserted to allow manual operation of the blower. Be sure the power circuits are deenergized before using this crank.
1.2

INSTALLATION

i.

Wall Deslagger Sleeves


A wall blower is supported by four studs attached to the flange of a sleeve or wall
box inserted in the boiler wall.

ii.

For steel - cased wall: Install sleeve as shown on application drawing. Be sure
elevation and vertical location are exactly as shown in the relevant contract drawing.

Sleeves are usual ly attached to waterwall tubes to maintain proper distance between the fully
extended nozzles and the tube surfaces. Application drawings show how to allow for movement
of a sleeve relative to the boiler wall.
Cut the proper size hole in the casing panel or plate. With sleeve and panel or plate positioned,
build wall around it as shown in the drawing. If the sleeve flange is shown welded to the panel
or plate, tack welds will be sufficient if they are one inch apart on each of the four sides
iii.

Erecting the Soot Blower

With sleeve properly installed, lift the blower into position.


Make sure there are no obstructions in the path of the rotary gear box.
Slide blower forward, so that the four M20 studs on the sleeve flange fit into the four holes on
the boiler end of the blower body. Screw one jam nut tightly against each side of each hole to
give the blower firm support.
Unless otherwise specified on the job drawings, no other support is needed.
iv.

Adjusting the Blower Position

The blower must be positioned so the relationship between the fully extended nozzle and the
boiler wall (or the waterwall tubes) is correct.
In the absence of a specific dimension on the drawings, set the centre line of the back nozzle
38 mm from the face of the wall tubes.
Adjust the blower in or out of the boiler by turning the stud nuts on the sleeve plate.
To check the location of the nozzle, the swivel tube and nozzle should be extended fully into
the boiler. The blower is completely assembled and if clear, is ready to operate once the power
has been connected properly. For directions on making the electrical connections and setting
switches, see the instructions below. Before extending the swivel tube and nozzle, make sure
there are no obstructions in the path of the rotary gear box.
V.

Erection of Piping

When the piping is erected, great care should be taken to make up the inlet flanged joint
properly. No piping should be supported by the blower.
7
1610 - 1611 VOL - C1 TAB - 5 - 70

Proper piping supports and guides should be used to prevent piping strain. When the companion flange is attached to the pipe correctly and the gasket is intalled, the flange should
match property. Then add the flanges, studs and nuts. When the nuts and studs are removed,
the flanges should not spring apart or to either side, nor should the pipe exert an upward force
on the head.
Whenver wall boxes are attached to waterwall tubes (as is usually the case) the blower will
move with the tubes when the boiler expands and contracts.
All piping and electrical connections should be sufficiently flexible and have expansion loops,
etc., to allow for this movement and prevent severe strains from being exerted on the blower.
Refer to the application drawings for the amount and direction of any movement of the
blower.
CAUTION : Switch Box Assy. Refer Drg. 0-00-073-60027
When adjusting limit switches, power to the unit must be turned off to avoid injury of the
operator. Operation of the unit should be by means of the hand crank (item 11) provided.
The operation of the deslagger is controlled by three limit switches. Two of these (LSTE &
LSTS) are located inside the switch Box enclosure, mounted on the right side of the blower.
The thi rd switch (LSTR) is situated below the swivel tube and is operated by a split cam
(item 9) on the tube.
The setting of switches LSTE and LSTS are shown in the drawing referred above. The cams
operating the switches are set at the factory. Minor adjustment may be necessary. The inner
cam operates the LSTS switch, which starts the rotary motor. Ensure the Rotary gear box
stops 3 to 8 mm before the guide bar bush ( without ramming against the boss). The outer
cam operates stop switch LSTE and must be set to trip LSTE, and hold it open when the gear
box is 8 to 10 mm from the fully retracted or park position. When first operating the blower,
check this carefully. It must be so set to allow for drift after motor is shut off.
The inner switch cam for LSTS, must be set to trip the switch when the travelling gear box is
in between 3-6 mm from the fully extended position. This also should be checked when
running the blower for the first time.
Since packing friction affects the amount of drift, care must be taken to avoid ramming the
rotary gear box against the stops in either directions.
vi.

Electric Connections
WIRING DIAGRAMS: Refer Drg. 3-00-073-60006

The electrical connections can now be made as shown on the application drawings. For
Blowers with integral terminal box, all wiring connections are made to the terminal box. For
blowers without integral terminal boxes all connections are still made to one point - the small
cast box on the top of the blower. The number of connections to be made are shown on the
wiring diagrams.
Before operating any blower, make sure the drain holes in the motor frames point downward
and are open. Add the proper quantity of oil to the two gear boxes (rotary and traversing) and
assure that the vents point up and are open.

8
1610 - 1611 VOL - C1 TAB - 5 - 71

2.

CHECK LIST AND ADJUSTMENTS


2.1

Check List

i.

Lubrication
a.

Rotary gear box

b.

Traverse gear box

ii.

External Electrical connections

iii.

Nozzel position adjustment

iv.

Perpendicularity of swivel tube with respect to furnace wall.

v.

Pressure setting
a.

Initial setting

b.

Final setting

vi.

Limit switch adjustment for rotary gear box travel

vii.

Removal of SBV head NRV plug.

2.2

Adjustments

i.

Adjustment of Blowing Sweep

The sweep of some wall blowers is restricted because of their proximity to corners or
burners. Refer to the application drawings to determine sweep.
It is important that the sweep be set as closely as possible to that shown on the application
drawings, otherwise damage to the boiler may result.
The nozzle opening position is indicated by a mark on the swivel tube or by the key slot in
the swivel tube which can be seen by, removing the guard and the nut and washer at the end
of the swivel tube. To adjust the sweep, remove the sheet metal guard. If it is convenient to
operate the blower with electrical power use the local start push button station. The swivel
tube and rotary gear box extend rapidly; be sure there are no obstructions in the path of the
rotary gear box.
To stop the swivel tube rotation and retract the tube and gear box, rotate the lever on the
reverse limit switch operated by the split cam on the swivel tube. This will retract the blower
rapidly. Make sure there are no obstructions in the path of the rotary gear box
On standard wall blowers there is one stop collar or split cam on the swivel tube, (item 7)
adjacent to the rotary gear box (item 3).
This collar contacts the lever of the reverse limit switch to retract the blower at the end of its
sweep. On wall blowers with restricted sweeps there are two cams. One cam contacts the
limit switch to reverse the swivel tube at the end of the sweep, while the other retracts the
swivel tube and rotary gear box at the end of the blowing sweep. Loosen the set screws in
these cams and assure that they are loose on the swivel tube before adjusting the sweep. To
adjust the sweep, start the blower and allow the swivel tube to rotate until it is in the proper
position for the end of the blowing sweep. Retract the swivel tube, using the reverse limit
switch. Set the reverse limit switch stop collar so that the side of the collar will just contact
the side of the reverse limit switch lever. Tighten the setscrew.
With all adjustments completed, operate the blower and check the sweep for correctness,
preferably from inside the boiler. Replace the guard (item 9).
9
1610 - 1611 VOL - C1 TAB - 5 - 72

ii).

Valve Stroke Adjustment

SBV HEAD ASSY: Refer Drg. 1-00-073-60003


The SBV head allows the blowing pressure of the blower to be adjusted by limiting the stroke
of the head valve. Where it is necessary to reduce pressure greatly, a fixed orifice may be
installed in the head inlet flanges.
The stroke of the head valve is governed by adjustment of the drive screw which contacts the
head valve stem. In the closed position, a minimum clearance of 1 mm must be maintained
between adjusting screw and valve stem, to assure tight valve seating.
In general, slag removal will necessitate blowing pressure of 10-14 kg/sq cm. Soot and fly ash
will need 10-18 kg/sq cm and dust removal pressure may be as low as 7 kg/sq cm. Always
consult the General Arrangement Drawing for recommended blowing pressure.
The stroke of the head valve is governed by adjustment of the drive screw which contacts the
head valve stem. Maximum stroke of the valve is 14.5 mm. If this maximum stroke is desired
adjust the valve drive screw so the screw begins to depress the valve stem when the pad on the
rotary gear box is 38 mm from the rack housing pad. When these two pads touch, the rotary
gear box is fully extended. Extending the screw through the lever increase valve opening and
blowing pressure. In the closed position, a minimum clearance of 0.8 mm must be maintained
between the drive screw and the valve stem, to assure tight valve seating.
When proper pressure has been established, by gauge reading, lock the drive screw in place
with lock nut.
iii.

Nozzle Adjustment

Nozzle alignment should be made from inside the furnace, referencing the centreline of the
nozzle and wall tube surface, with the nozzle opening parallel to the wall tubes. If the units
are set from outside the boiler, they should be checked inside at the first opportunity.
After the unit is installed, it should be checked to make sure that it is perpendicular with the
boiler wall, to insure cleaning through the full blowing arc.
The sweep should then be set, if possible, so that the nozzle is pointing down or in the 6
Oclock position, when the head opens. This helps to prevent tube cutting from condensate
since the nozzle blows parallel with the tube when the head first opens and condensate is
blown off before the jet sweeps across tubes.

3.

START UP CHECKS
For detailed Start up checks

4.

a.

Check the blower numbers and their location.

b.

Check the perpendicularity of the wall sleeve with reference to water wall

c.

Check the mounting of the blower for perpendicularity to the water wall.

d.

Ensure the nozzle projection inside the boiler. (Normally the nozzle centre line
should be 38 mm from water tube).

e.

Check the free manual movement.

f.

Check whether all the blowers are in the initial position.

OPERATION
When just putting the blower into service, start it locally so that the operation of all parts can
be observed. It is advisable to check the blowing pressure, using an auxiliary gauge. Start the
10
1610 - 1611 VOL - C1 TAB - 5 - 73

unit and observe to confirm that the blowing steam comes on at the proper time. If not, hand
operate the blower reversing switch LSTR. If the boiler is in operation do not allow the
blower extended for any length of time as the swivel tube may get damaged. If the valve head
has failed to open, retract the blower before examining the head.
There is a panel start push button for each blower. Each button should be held in about three
seconds, then released. The blower then extends, open the head, completes a blowing cycle,
closes the head and retracts. Operate each Push button once for each blowing cycle.

5.

OPERATIONAL PROBLEMS AND MAINTENANCE


Problem

Causes

Suggested Remedy

1.Steam leakage through

1. Improper tightening
swivel tube gland packing

Tighten the glands (Do not


over tighten)

2. Excessive wear on the


glands

Replace the glands with


packings

3. Scratch marks, dents for


surfaces defect on the
swivel tube

In case excessive surface


defect change the swivel
tube

4. Defective packing or poor


quality of packing

Replace the defective


packing

1. Physical obstruction to
gear box assy.

Observe for any obstruction


and clean

2. Dust deposition on swivel


tube, guide rods

Clear the dust and debris


using compressed air

3. Overtightened gland
packing

Maintain proper tightness of


packing rings

1. Overtightening of swivel
tube packing

A slight amount of steam


passing is advisable for
ensuring proper tightness

2. Defective surface

Replace the swivel tube


condition of swivel tube

3. Valve stem seizure

Service the valve head


adjust valve stem packing
tightness

2. Traverse Motor over


loading

2. (a) Gear box assy. not


moving

2. (b) Motor over loading at 1. Limit switch LSTS


extended position
improper setting

3. Steam leakage through


valve stem

Reset the cam in limit


switch box

2. Improper setting of O/L


relay at MCC

Check the setting and do


the connection

3. Accumulation of slag
inside the sleeve tube.

Clear the slag accumulation

1. Poor defective packing

Use good quality packing

11
1610 - 1611 VOL - C1 TAB - 5 - 74

Problem

Causes

Suggested Remedy

2. Defective surface
condition of valve
stem/gland bushing

Check the condition of valve


stem and gland bushing and
replace the defective one

3. Inadequate tightening of
packing rings

Tighten the packing rings


(Do not over-tighten the
packing)

4. Valve passing: (through 1. Gland packing over


bushing
seat)
tightened
2. Insufficient lapping or
improper lapping or
damaged valve disc

3. Foreign material trapped


in between disc and seat

6.

Slightly loosen the gland


so that the stem is not
tightly held by the packing
Dismantle the valve Disc
and seat using lapping tool
(As suggested in Pub. No.
7501) for severe damages
either in disc or seat replace
the damaged part.
This will be cleared when
the valve is wide opened.

MAINTENANCE AND LUBRICATION


1.

General

Soot blowers, nozzles and swivel tubes are continuously subjected to high temperatures and
dirty atmosphere. Therefore, proper maintenance is necessary to keep this equipment as trouble
- free as possible. To assure efficient operation and long life, attention must be given to the
item below
a.

Cleanliness

To assure long life and good performance of soot blowers, the outer surfaces should be cleaned
of dirt and rust periodically. If allowed to accumulate, dirt and rust will enter the operating
mechanism, prevent proper operation and cause excessive wear on moving parts. If a blower
is not to be used for appreciable time, coat all exposed surfaces with a good grade of grease.
b.

Equipment Inspection

A regular check, at least every six months should be made for wall deslaggers while the boiler
is on service to ensure that the wall blowers remain perpendicular to the boiler wall. Pipe
strain and boiler movement can after the position of these units in such a manner that, the
swivel tube is not perpendicular to the surfaces of the wall being cleaned. This check is necessary
to prevent tube erosion and it can be made visually or by placing a spirit level on the rack of
swivel tube. Correction is accomplished by adjusting the nuts on the studs of the wall box
adaptor where the stud passes through wall deslagger steam chest mounting flange.
Check the distance from the centre line nozzle to the surfaces to be cleaned. This distance
should be given in arrangement drawing issued for the relevant contract. Normally the distance
will be 38 mm.
Mounting : Check the soot blower mounting periodically to make sure the blower is securely
mounted and properly adjusted. The mounting position is adjusted by means of the stud nuts
on the sleeve. Be sure each nut on each side, of the blower body flange is tight. Loose mounting
12
1610 - 1611 VOL - C1 TAB - 5 - 75

or improper adjustment may result in misdirection of the blowing medium and possible poor
cleaning or boiler damage.
Piping : Check the external piping periodically for leaks. Tighten fittings to stop leaks or
replace faulty fittings and connections. Be sure the piping places no strain on any blower.
Swivel Tube Nozzle : At every boiler outage an inspection should be made of each swivel
tube nozzle. If a nozzle is split or cracked, it should be replaced.
Blowing Sweep : Any blower with a sweep of less than 360 deg. should be checked periodically
for adjustment. The sweep should be kept the same as that on the application drawings. It is
also advisable to check adjacent boiler tubes and walls for any possible damage.
ii.

Lubrication

a.

Rack Gear Box : Every six months remove the inspection plug and make an inspection
for sufficient lubrication of the gears. Apply the lubricant directly to the gear box.
Use 0.6 lit. of Servomesh 60 or equivalent poured through the inspection opening.
The oil level plug is small brass pipe plug on the front of the box about 50 mm from
the bottom.

b.

Rotary Gear Box : Every six months make an inspection for sufficient lubrication
of the gears at the combination inspection and filler fitting. The lubricant is Servomesh
60 added through the combination filler and level elbow on the side of the box.
For detailed lubrication instruction refer to Lubrication Chart and Recommended
quantity of Lubricants per annum in the publication No. 7501 : Soot Blower General Instructions.

iii.

Packing

See Recommended Procedure for Packing Installation in the Publication No. 7501 Soot Blower:
General Instructions.
iv.

Swivel Tube Removal

Removal of swivel tube will be necessary because of:


a.

Cracked or damaged nozzle.

b.

Persistent steam leakage even with new packing set due to swivel tube surface defects.

In order to remove the swivel tube, the main guard (item 9 of Drg. 0-00-073-60026) and the
rotary gear box are the only part that have to be removed. These two parts can be dismantled
without distrubing the Wall Deslagger assembly or any other pressure parts.
To dismantle the rotary gear box, the lock huts (item Nos.30,35 of Drg. No. 0-00-073-60026)
fixing the rack and ~the swivel tube to the rotary gear box should be removed and then the
gear box can be dismantled. After removing the rotary gear box the swivel tube assembly can
be pulled out of the Wall Deslagger body. The limit switch cam assembly shall be removed so
that it can be reused in the swivel tube assembly.
The procedure has to be followed in the reverse order for the assembly of new swivel tube.
For the Wall Deslagger with long extended swivel tube, the full assembly itself should be
removed from the mounting sleeve.
V.

Spares

While ordering spares, indicate Item No., Drg. No., BPS No. as found in Bill of materials in
addition to the old contract No. etc. for early delivery.
In the enclosed drawings spares that are recommended for stock bytheuser are marked by S.
Section 7 gives the recommended List of Standard Spares.
13
1610 - 1611 VOL - C1 TAB - 5 - 76

7.

LIST OF RECOMMENDED SPARES FOR WALL DESLAGGER WB - 1 E


NOTE The list of spares under is to aid the selection of the required item.The editing and
deletion of number of pieces solely lie on the user.

Sl.No Description
No

Item

Assembly

No

Drawing No.

Part Material

No. of WB - IE

Code

1-6

7 - 16 17 - 24 25 - 40 over 40

1.

Valve gland Packing


set

12

2-00-073-60088 963533150000

12

16

20

2.

* Packing set
(Steam)

11

2-00-073-60088 9653533180000

12

16

20

3.

Gland

16

0-00-073-60026 160133990000

12

20

4.

Bushing

17

0-00-073-60026 160134080000

12

20

5.

Bearing SKF 6205


2RS

45

1-00-073-60109 55/119/0620500

10

SKF 6204

46

1-00-073-60209 55/111/0620400

10

Mc Gill CYR 13/8

12

3-00-073-60105 97/353/3130000

10

SKF 51101

31

1-00-073-60110 55/211/5110100

10

SKF 51102

32

1-00-073-60110 55/211/5110200

10

6.

Motor (Rotary)

60

0-00-073-60026 962720730000

7.

Motor (Traverse)

59

0-00-073-60026 962720050000

B.

SBV Head Assy.

01

0-00-073-60026 84202010010

9.

Oil Seal

17

0-00-073-60027 96/353/0830000

10.

Oil Seal

37

1-00-073-60109 96/353/0820000

11.

Limit Switch Heavy


duty

18

0-00-073-60027 963582820000

12.

Limit Switch (Micro)

03

0-00-073-60027 96/362/0640000

13.

Limit Switch (Micro)

03

0-00-073-60027 96/362/0630000

14.

Gaskets
18

0-00-073-60026 963533590000

TVA5

Element Gasket

Sl.

Description

Item
No

No

Assembly

Part Material

No. of WB - IE

Motor Gasket

49

Drawing No.
0-00-073-60026

Code
96/353/113

1-6
1

Cover Gasket
Gasket
Gasket
Cover Gasket
Gasket
Gasket
Gasket
15. Swivel tube
Assy.

42
50
43
12
05
09
09
05

1-00-073-60109
0-00-073-60026
1-00-073-60109
0-00-073-60027
1-00-073-60003
1-00-073-60110
2-00-073-60088
0-00-073-60026

96/353/046
96/353/047
963530540000
96/353/112
22/021/303
96/353/044
22/021/269
842020125500

1
1
1
1
1
1
1
-

7 - 16 17 - 24
2
3
2
2
2
2
2
2
2
1

3
3
3
3
3
3
4
1

25 - 40
4

Over 40
5

4
4
4
4
4
4
6
2

5
5
5
5
5
5
8
2

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25
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TAB - 6

FURNACE TEMPERATURE
PROBE
MODEL FTP IE & IIE

Bharat Heavy Electricals Limited


Tiruchirapalli

PUB. NO. 7505


1610 - 1611 VOL - C1 TAB - 6 - 92

CONTENTS
INTRODUCTION
GENERAL
GENERAL DESCRIPTION
GENERAL
DETAILED DESCRIPTION
POWER PACK ASSEMBLY
THE TRAVELLING CARRIAGE
LANCE ASSEMBLY
POSITION INDICATOR
CONTROL CIRCUITRY
INSTRUCTIONS FOR INSTALLATIONS
INSPECTION CHECK LIST
INSTRUMENTATION WIRING
OPERATION
THREE PUSH BUTTON OPERATION (LOCAL AND REMOTE)
EMERGENCY RETRACTION
REMOTE POSITION INDICATOR
MAINTENANCE INSTRUCTIONS
LUBRICATION
REPLACEMENT
THERMOCOUPLE REPLACEMENT
POTENTIOMETER REPLACEMENT
RECOMMENDED LIST OF SPARES FOR TEMPERATURE PROBE
REQUIRED TOOLS FOR TEMPERATURE PROBE
RECOMMENDED LUBRICATION CHART

2
1610 - 1611 VOL - C1 TAB - 6 - 93

LIST OF DRAWINGS
(WITHOUT AIR COOLING)
0-00-073-60028

FURNACE TEMPERATURE PROBE BASIC ASSY.

0-00-073-60004

POWER PACK ASSEMBLY - TRAVERSE

1-00-073-60112

LANCE BEARING ASSEMBLY

2-00-073-60006

WIRING DIAGRAM

2-00-073-60092

TRAVELLING CARRIAGE HOUSING ASSEMBLY

2-00-073-60091

FURNANCE TEMP. PROBE MAIN ASSY.

2-00-073-60093

STOP LIMIT SWITCH ASSEMBLY

2-00-073-60094

REVERSE LIMIT SWITCH ASSEMBLY

3-00-073-60107

LANCE ASSY.

3-00-073-60108

DRIVE JACK SHAFT BEARING ASSEMBLY

3-00-073-60109

IDLER JACK SHAFT BEARING ASSEMBLY

3-00-073-60110

POTENTIOMETER ASSEMBLY

3-00-073 60001

THERMOCOUPLE ASSEMBLY

4-00-073-60005

TRAVERSE CHAIN ASSEMBLY

4-20-001-00523

CHAIN ADJUSTMENT

4-00-073-60110

REQUIRED TOOLS FOR FURNACE TEMPERATURE PROBE

3
1610 - 1611 VOL - C1 TAB - 6 - 94

LIST OF DRAWINGS
(WITH AIR COOLING)
0-00-073-60029

POWER TRACK FURNACE PROBE ASSY. (WITH AIR COOLING)

1-00-073-60128

B.O.M. FOR FURNACE TEMP. PROBE BASIC ASSY.

0-00-073-60004

POWER PACK ASSEMBLY - TRAVERSE

1-00-073-60112

LANCE BEARING ASSEMBLY (FOR 76mm O.D. LANCE ONLY)

2-00-073-60096

SOLENOID VALVE ASSEMBLY

2-00-073-60097

LANCE ASSEMBLY

2-00-073-60098

TRAVELLING CARRIAGE HOUSING ASSEMBLY

2-00-073-60093

STOP LIMIT SWITCH ASSEMBLY

2-00-073-60094

REVERSE LIMIT SWITCH ASSEMBLY

3-00-073-60123

COOLING AIR LIMIT SWITCH ASSEMBLY

3-00-073-60124

CYCLING LIMIT SWITCH ASSEMBLY

3-00-073-60108

DRIVE JACK SHAFT BEARING ASSEMBLY

3-00-073-60109

IDLER JACK SHAFT BEARING ASSEMBLY

3-00-073-60110

POTENTIOMETER ASSEMBLY

3-00-073 60001

THERMOCOUPLE ASSEMBLY

3-00-073-60125

PUSH BUTTON ASSEMBLY

4-00-073-60005

TRAVERSE CHAIN ASSEMBLY

4-20-001-00523

CHAIN ADJUSTMENT

2-00-073-60099

PHYSICAL WIRING DIAGRAM

3-00-073-60127

SCHEMATIC WIRING DIAGRAM

4
1610 - 1611 VOL - C1 TAB - 6 - 95

INTRODUCTION
The Furnace temperature probe installed in various power station installations is manufactured by
BHEL with its Engineering know-how and the sum of the experience gained on many new installations
in India. The BHEL Furnace probe gives the reach needed for a constant check on gas temperatures
in critical boiler start-up phases and provide an extra measure of protection during periods when
boiler equipment is subject to the most hazard. The temperature measurement system will function
satisfactorily with a little attention to installation, operation and maintenance.
It must be recognised that no amount of written instructions can replace intelligent thinking and
reasoning on the part of the operators, especially when coping with unforeseen operating conditions.
It is the operators responsibility to become thoroughly familiar not only with the equipment but also
with all pertinent control equipment.
The instruction contained in this manual is only an outline of the correct procedures for installation,
operation and maintenance. The contents in the manual have been compiled and checked by experts
in the field. Every possible care has been taken to ensure the contents are accurate. However, it
must be understood that the manual is not a contract document.
If you ever have any query about operation, maintenance or related problems you are welcome to
write to us without obligation.

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1610 - 1611 VOL - C1 TAB - 6 - 96

GENERAL
This standard BHEL furnace probe is equipped with chromel alumel thermocouple installed in a
lance tube. Air cooling for the lance tube is also available for special applications.
Model FTP-IE for travels from 1.5 metre to 7.3 metre, has a 76mm O.D. lance. Model FTP-IIE
for travels from 7.4 metre to 12.2 metre has a 108mm O.D. lance.
In both the models, probes are available with or without air cooling.
The probe may be operated in furnace gas temperature upto 537C (100F) and for very short
period of time in gas temperature as high as 565 C (1050F) without air cooling.
The temperature probe can be used to measure furnace gas temperature upto max. 815C (1500F)
with the lance cooled by air.
This standard equipment will be limited to monitoring furnace temperatures upto, but not exceeding
815C (1500F) during boiler start-up. While using for temperature above 565C (1050F), air
cooling of the lance probe must be used.
Cooling air requirement for the temperature probe is determined by the diameter of the lance, length
of travel and the temperature of the area in which the probe is expected to operate. Operators are
requested to observe four important limiting factors in the operation of standard furnace temperature
probes.
i.

Never exceed 537C (1000F) without cooling air for continuous operation.

ii.

Never exceed 565C (1050F) for short intermittent periods without cooling air.

iii.

Never exceed 815C (1500F) with arrangement for cooling air.

iv.

Ensure availability of sufficient cooling air.

Contact Engineering Division of Bharat Heavy Electricals Limited, Trichy for information concerning
specific applications and operations.

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1610 - 1611 VOL - C1 TAB - 6 - 97

2.

GENERAL DESCRIPTION
2.1

GENERAL

The BHEL Furnace temperature probe is an electro-mechanical equipment for positioning a thermocouple element in the furnace gas stream for temperature measurement. The thermocouple is
fixed to the tip of a lance tube which travels into and out of the gas passage. The lance travels
approximately two metres per minute while extending and retracting. The thermocouple can be
retracted manually in case of emergency.
Gas temperatures in the area just before the superheater elements at the exit of the furnace, can be
critical during boiler start- up, before steam circulation for the cooling of the superheater/reheater
tube material is sufficiently established. The furnace temperature probe, by permitting continuous
measurement of the gas temperatures, helps to reduce the danger of heat damage to the tubes. For
this reason, such probes are also known as basic start-up probes.
The furnace temperature probe can also be used to obtain gas temperatures during the low load
operation of the boiler.
2.2

DETAILED DESCRIPTION

Ref. Assembly drawing of temperature probe: (Drg.No.0-00-073- 60028 & 0-00-073-60029)


i. Probe Housing (Item No. O1/03 of Main assembly drawing as above.
The housing of the temperature probe is a pressed steel section and it covers all the moving parts.
The lips are cut off from the outboard end to a distance of approximately 750 mm to facilitate
removal of travelling carriage. Angle tracks are welding on either side of the casing to guide the
travelling carriage. The rods are provided at the bottom to hold the open ends of the housing. At the
front end a wall plate is welded on to the casing, to which the lance bearing assembly is fixed. The
lance bearing assembly carries an hour glass shapped roller for supporting the lance tube and a plain
cylindrical roller on top for guiding the lance. The mechanical stop for the carriage is also welded to
the housing top in the front. The stop at the outboard end is adjustable and is provided in the side of
the housing. The jack shaft bearing assembly which is fixed to the housing provides for the adjustment
of the tension in the traversing chain.4
A cable carrier drag chain (Item No. 42/36 of Drg.No. 0-00-073- 60028 & 0-00-07360029
respectively) is attached with travelling carriage, by the driving end and the fixed end of the drag
chain is connected with a mounting bracket assembly on the middle bottom of the housing. This drag
chain is supported by the track covers hanging from the housing on both right and left side and
guided by two angle plates on the bottom cover. The thermocouple lead wire is taken through the
drag chain support plates and connected to the terminal head near the mounting bracket assembly.
When provision for air cooling of the lance tube is made, an air hose is also taken through the
support plates of drag chain from the mounting bracket assembly to the travelling carriage housing
and it is connected with connectors at the both ends.
A ball valve with pneumatic actuator and a solenoid valve is mounted near the mounting bracket
assembly with a pressure switch. The hose pipe is connected to the outlet side of ball valve and inlet
side is the customer air connection (7 Kg/Cm(g)).
Lifting eyes for sling attachment are welded to the side of the housing at convenient places, to
facilitate lifting. The probe is supported at two places. The boiler end is supported in the wall box
through two shoulder bolts which allow the probe to move when the wall moves. The outboard end
again is hinged support and is fixed to the boiler structures.

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1610 - 1611 VOL - C1 TAB - 6 - 98

ii.

POWER PACK ASSEMBLY (01 of assembly Drawing No. 0-00-073- 60004)

The main prime mover for the probe is a fractional horse power motor. A reduction gear box
attached to the motor has an output speed of 9.2 rpm. The motor with the reducer is fixed on top of
the housing at the front end. The reducer output shaft drives the jack shaft through a set of sprockets
and an endless chain. The jack shaft transmits the rotary motion to a long chain for the entire length
of the probe, the ends of which anchored to the travelling carriage, through another jack shaft and
idler sprocket at the other end of the housing. The idler jack shaft is provided with adjusting screws
for keeping the chain in the right tension.
iii.

The Travelling Carriage. (Drg.No. 2-00-073-60092 and 2-00- 073-60098)

The travelling carriage of the probe is a cast iron housing to which the lance tube is bolted. The
carriage assembly has two wheels which are guided by the inner side of the housing and the top of
guide angles. Two rollers on the sides of the travelling carriage prevent the sideways movements.
The travelling carriage guide rollers at the side also operate the arms of the terminal limit switches of
the heavy duty type which are fixed to the sides of the housing. Removal of the travelling carriage
assembly is achieved by unscrewing the removable portion of the angle guide track at the outboard
end and slipping the assembly down carefully without causing damage to the thermocouple at the
lance head.
In case of air cooled temperature probe, the travelling carriage is made, up cast steel/Ductile iron in
order to maintain pressurised chamber and a hose connector is screwed on the carriage to couple
the hose with it. (Ref.Drg.No. 1, 2-00-073-60098)
iv.

Lance Assembly (Drg.No. 3-00-073-60107 & 2-00-073-60097)

The lance tube Assembly is bolted to the travelling carriage and the lance is a alloy steel tube. The
lance tube is not normally air cooled, when the probe is used for gas temperatures upto 537C
(1000F). If air cooling is provided, the air house is connected to a coupling at the travelling carriage
end of the lance tube.
The thermocouple is normally of the grounded chromel alumel type enclosed in a stainless steel
sheath. It is fixed to the end of the lance tube, by means of a threaded coupling. The thermocouple
extends through the lance tube to the terminal coupling at the carriage end where a female connector
for the lead wires is provided. The corresponding male connector is connected to the thermocouple
lead wire which terminates at the thermocouple terminal head, fixed on the housing, through cable
drag chain. The probe has to be connected to a suitable temperature indicator which will show the
gas temperature.
For preventing any damage to the thermocouple head a cage type protective shield is provided, and
this will allow free access of flue gases to the tip of thermo couple during operation. In case of air
cooled probe, an inner S.S.tube called lance liner tube is supported by equidistant lugs as shown in
the drawing 2-00-073- 60097 at various intervals inside the lance tube and two straight bore nozzles
are provided to expand the entering air pressure to furnace pressure. The air enters through the
annular space between liner tube and lance tube and enter the liner tube through the gap provided at
the front end to reach the nozzles thereby it maintains the cooling effect on the surface of the lance.
V.

Position Indicator (see assembly drawing)

In order to know the position of the lance tube, corresponding the gas temperature, a position
indicator is normally provided with the temperature probe. The position indicator is a voltmeter
calibrated to continuously indicate the position of the thermocouple in. The voltmeter is connected in
parallel with a linear, ten turn helipot potentiometer (variable resistor) which is driven by a no slip
belt drive on the jack shaft. The mechanical arrangement of the potentiometer drive is illustrated in
Drg. 3-00-073-60109 and 3-00-073-60110.
8
1610 - 1611 VOL - C1 TAB - 6 - 99

The details of the electrical wiring for the probe without air cooling are illustrated in the Drg.
2-00-073-60006 and for the probe with air cooling refer drawing 2-00073-60099 and 3-00-07360127. A 0-10 voltmeter calibrated in percentage of travel and at toroidal type 12k ohm. 50 watts
variable resistor are supplied loose, as position indicating instruments along with the probe. The
voltmeter and the variable resistor are to be mounted in the control cubicles and wired to the helipot
poten tiometer by the customer. The variable resistor is to be used for calibrating the travel indicated
by the voltmeter. The calibration of the position indicator is to be done during commissioning of the
temperature probe. 110V single phase 50 cycle is recommended for this circuit.
Vi.

Control Circuitry

The control circuitry on the temperature probe is designed as per the requirement. All electrical
hardwares for control and indication are subject to the customers option. For this reason, control
arrangements are presented in detail by specific contract circuit descriptions and contract drawings.

3.

INSTRUCTIONS FOR INSTALLATIONS


3.1

Inspection check list

i.

Check the thermocouple tip for any damage from handling or shipment, after removing
the shield for the thermocouple.

ii.

Check all control and power wiring for loose terminals, proper connections etc.,

iii.

Check connection of motor for proper direction of rotation.

iv.

Check all thermocouple junctions for tight terminal connections.

V.

Check the limit switch actuating arms to see that they are in correct operating positions.

vi.

Check alignment of frame structure, track and sheave wheel track, particularly for any
bend, twist or other distortions.

vii.

Check roller chain sprockets for correct engagement with the chains.

viii.

Check alignment of the roller bearing for the lance tube and adjust only, if required.

ix.

Check lubrication of roller chains, sprockets bearings, wheels, rollers, etc., and fill in oil
for the reduction gear of the power pack.

x.

Check for pressure tightness of the air hose reel, if the probe is provided with air cooling
arrangement.

3.2

Instrumentation wiring

The thermocouple lead wires are internally connected to the fixed terminal head on the probe during
manufacture. The extension wire should be taken from the terminal head. Ensure the use of the
correct compensating cable corresponding to chromel/Alumel thermocouple, the leads connecting
to the indicating instrument should be connected to the junction head according to the polarity
indicated by the marking of the terminals and the code markings on the leads. Ensure that all
connections are tight and firm. A potentiometer type instrument is recommended as the temperature
indicating device.
NOTE : Check connections of measuring instrument, position transmitter etc., for proper polarity.

4.

OPERATION
Refer to the contract circuit diagram for the correct operating description.
4.1

Three push button operation (local and remote)

This push button station has Extend, Retract and Stop push buttons. By operating the Extend
push button the forward contacts of the drive motor will be energised and the probe will move
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1610 - 1611 VOL - C1 TAB - 6 - 100

forward. Normally, approximately 35 seconds lag is expected between the thermocouple position
and the corresponding thermocouple temperature. If multipoint recorder is used, the lag will increase.
If the temperature registered by the probe is below 538C it is expected to be within approximately
50C to the actual temperature measured at the location.
The position transmitter will indicate to the operator the travel of the probe in percentage of full
travel.
At the end of the travel, the travelling carriage side thrust roller will actuate the reverse limit switch
and then the reverse contactor will be energised to reverse the drive motor and retract the probe.
An indicating red light may be connected in the panel which will momentarily indicate when the
reverse limit switch is actuated.
If required with a change in the circuit the probe may be stopped at the full extended position when
the reverse limit switch is actuated. Indicating light can be suitably connected to indicate full extended
position as red light in the panel. When the reverse push button is operated the probe reverses
from any position and when the stop limit switch is actuated the probe stops at the fully retracted
position and a green light will come on the panel. In the intermediate position both lights will be off.
By utilizing the STOP push button, the probe lance can be stopped at any desired location. This
will enable the operator to check and concentrate on any hot spots in the furnace.
A remote contact on the temperature recorder which will close when the temperature measured is
+300C more than the maximum 538C is necessary to give an alarm; and the same time the probe
can be retracted.
A parallel push button station in the panel will be necessary for remote operation.
4.2

Please refer to application and wiring diagrams (Drg.No. 3-00-073-60127)

This BHEL Furnace Temperature Probe is equipped with a duplex Chromel-Alumel Thermocouple
either duplex or simplex. The equipment is limited to monitoring furnace temperatures upto, but not
exceeding 1000F without cooling air; and up to, but not exceeding 1500F with cooling air. Confirm
that sufficient cooling air is available. Operators must observe the temperature limitations to avoid
damage to, or loss of, the lance. Contacts (RC) on the customers recorder are to close when the
temperature reaches 1500F, energizing the RA relay which will cause the probe to retract to its AT
REST position and bring in the customers alarm.
The temperature probe controls include PARK, EXTEND, RETRACT and STOP push buttons, a
solenoid valve SV, pressure switch PS (opens on flow), timer T, alarm relay RA and relay P. (Please
note the following are not by PS 20 Group; Alarm relay RA, and Relay P).
Solenoid Valve SV and timer T will be energized when the blower moves away from its PARK
position and actuate Limit Switch LS-4. SV, PS and timer T form the cooling air supply interlock. If
cooling air is not sensed within the time relay period (10 seconds), relay RA will be energized to
bring in the alarm. The probe will be caused to retract to its PARK position. Loss of cooling air
during operation will also energize the alarm relay.
The control push button function as follows:
EXTEND -

Depress this push button to cause the probe to extend into the boiler.As the
probe moves away from its AT REST position, it will trip LS-3 and LS-4 limit
switches. When the probe reaches its fully extended position, it will momentarily
trip limit switch LS-1 causing the probe to retract. This circuit will be through
closed RET and LS 3 contacts to the RET motor starter.

RETRACT Depress this pushbutton to cause the probe to retract to its fully retracted position.
The probe will not remain in its fully retracted position, but will be caused to extend as it momentarily
10
1610 - 1611 VOL - C1 TAB - 6 - 101

trips limit switch LS-2, creating a circuit to the EXT motor starter.
STOP

PARK

4.3

Depress this pushbutton to stop the probe, at any position, on the EXTEND or
RETRACT cycle, to take a reading to continue the EXTEND or RETRACT
cycle, depress the desired pushbutton to reinstate the circuit.
-

Depress the pushbutton to cause the probe to return to the fully retracted position
and stop. The probe will also be caused to PARK if the RA alarm is brought in.

Emergency Retraction

Using a hand crank, the lance can be retracted manually in case of emergency. Before using the hand
crank the power supply to the drive motor should be disconnected and the drive should be declutched.
For declutching pull out the coupling item 05 of Drg. 3-00-073- 60108 and turn about 900 clockwise
thereby the spring lock provided will lock the coupling in the declutched position. For clutching just
turn the coupling lock 900 anticlockwise which will keep the coupling engaged with sprocket. A
slight adjustment of the sprocket may be necessary in some cases to align the clutch jaws with the
sprocket.
4.4

Remote Position Indicator

Setting and Installation Instructions for the slidewire Type position Indicator.
CAUTION:
The voltmeter indicator is built to accept a maximum of ten (10) volts only. Therefore, it will be necessary to use a separate test voltmeter with a scale suitable for the maximum
incoming control voltage.
i.

Refer to BHEL Wiring Diagram.

ii.

Mount the adjustable resistor as near as possible to the voltmeter indicator.

iii.

WITH POWER OFF connect all wires as shown on the W/D except the two on the
voltmeter indicator; connect these two to the test meter, (see caution above).

iv.

Move the slider of the adjustable resistor to the extreme opposite end of the resistor from
the power connection.

v.

Position Probe to a fully Retracted position. Turn the zero screw on the indicator face to
zero meter.

vi.

Rotate helipot shaft to the zero degree position and recouple shaft.

vii.

Turn POWER ON. Test meter should now read zero or almost zero.

viii.

Run or crank the unit to the fully extended position.

ix.

Move the adjustable resistor slider towards the power connected end until the test meter
reads ten (10) volts.

x.

TURN POWER OFF - Disconnect the test meter and connect the leaders to the voltmeter
indicator.

xi.

TURN POWER ON - Indicator should now read 100%.

xii.

Final adjustment may be necessary. If indicator reads less than full open move the adjustable
resistor slider ahead slightly being careful not to exceed full 100% on the scale. If meter
reads more than zero, when unit is fully closed repeat setting starting with step 6.

xiii.

After setting indicator, lock adjustable resistor slider in place.


11
1610 - 1611 VOL - C1 TAB - 6 - 102

5.

MAINTENANCE INSTRUCTIONS
5.1

Lubrication

Refer to the lubrication chart.


The drive chains are prelubricated in the manufacturing stage itself and normally we do not recommend any lubrication. Any grease if applied will only attract fly ash accumulation and will result in the
loss of articulation of the chain links. Periodically inspect the chain for any rusting or loss of articulation. If severe damage is noticed degrease the chains and apply a thin coat of oil equivalent to Grade
SAE 30 with a brush so that all the parts will be covered.
5.2

Replacement

A. Thermocouple Replacement
i.

Before replacing the thermocouple, the following checks are recommended to insure that
the replacement is necessary:
a.

Check all the wiring for breaks and insure that all electrical connections are tight.

b.

With the boiler operating run the probe tube forward approximately 300 mm to
place the tip in the higher gas temperature. The temperature read out device should
indicate an increase in temperature if the thermocouple is operating satisfactorily.

c.

An alternate method will be to apply heat to the thermocouple and observe the
thermocouple output using a portable potentiometer.

d.

If no change in temperature is indicated from the above check, disconnect the


read out device and monitor the thermocouple signal with a suitable test device to
insure that the read out device is operating satisfactorily.
Before proceeding further, disconnect the motor and control power supply.

ii.

Remove the housing cover in the out board end and the travelling carriage cover to have
an access to the thermocouple disconnecting plugs. Disconnect the thermocouple extension
wire from the compensating cable.

iii.

Pull back the travelling carriage to the extreme out board end and support the lance tube
at two places so that it will not damage to compensating cables. Disconnect the lance
flange from the travelling carriage.

iv.

Push the lance inside to some distance so that the thermocouple extension wire is out of
the travelling carriage and remove the lance by tilting and pulling back from the boiler.

v.

Loosen the S.S. compression fitting which fixes the thermocouple to the lance and the
thermocouple guide. Pull out the thermocouple from the flange side after attaching a wire
or string to the thermocouple.

vi.
B.

Follow the above procedure in reverse for assembling the new thermocouple. Use high
temperature antiseize thread compound in all the threads for easy removal.
Potentiometer Replacement:

The variable potentiometer used in the position transmitters assembly is limited mechanically to a
maximum of 10 revolutions of the input drive shaft. Eventhough the maximum possible travel of the
probe utilizes only about 8 revolutions, in order to safeguard the potentiometer at either end of the
10 turn range, proper care should be taken during installation. When replacing the potentiometer,
turn the potentiometer shaft clockwise to the full 10 turn and then turn counter clockwise half turn
before mounting the unit. The position is corresponding to the fully retracted position of the probe.

12
1610 - 1611 VOL - C1 TAB - 6 - 103

RECOMMENDED LIST OF SPARES FOR TEMPERATURE PROBE


SI.No.

Description

Drg.No./Code No.

Qty./Probe

01.

Lance Flange Gasket

4-20-791-00389

02.

STOP Switch Assembly

2-00-073-60093

03.

Reverse Switch Assembly

2-00-073-60094

04.

Chain Traverse 11/2"P

97-366-023

1.5m

05.

Connector Link 11/2"

97-366-025

06.

Offset Link 11/2"

97-377-024

07.

Cycling Switch Assembly

3-00-073-60124

08.

Cooling Air Switch Assembly

3-00-073-60123

09.

Potentiometre Assembly

3-00-073-00110

10.

Roller Chain3/4"P

97-366-026

0.5m

11.

Connector Link3/4"P

97-366-028

12.

Offset Link3/4"P

97-366-027

13.

No Slip Pulley 32T

97-366-154

14.

Bearing 6208 2 RS

55-119-06208

15.

Gasket (Power Pack)

96-353-052

16.

Gasket (Travelling carriage)

17.

Thermocouple Asse mbly

Per order

18.

Airvent

4-20-201-01540

19.

Gasket

4-20-952-01535

20.

Bearing 6209 2 RS

55-119-06209

21.

Bearing 6208 2 RS

55-119-06208

22.

SPRING

96-353-058

23.

Motor 0.37 KW

96-272-004

24.

No slip belt

97-366-153

* Only for air cooled Temperature probe

REQUIRED TOOLS FOR TEMPERATURE PROBE


Spanner

Allen Key

Circlip Pliers

13
1610 - 1611 VOL - C1 TAB - 6 - 104

RECOMMENDED LUBRICATION CHART


SI.No

01.

02.

Equipment
Description

Recommended Lubricant
IOC
HP

Power pack

Servosystem 68
system 68

Chain
See Note: 2

NOTE.-1

Servo

Enklo 68

Enklo 150

BP

Bharat Hydrol 68

Bharat Hydro 150

Method
of Filling

Reservoir

By Brush

Frequency
of Change

Annual

...

Frequency
of Observation

Quantity/
probe
(Annual)

3 Months
(See Note:8)

1 Litre

...

1 Litre

Lubricant oil level must be checked and maintained every month.

14

NOTE.-2
All the Chain and Chain links are prelubricated by a special treatment by which no lubrication is required normally but as and when
sign of rust is identified two fold lubrication is recommended First the chain is cleaned and then Trichloroethylene is applied over the surfaces. Servoline
150 Enklo 150 Bharat Hydrol 150 is applied as a second coat by brush.

1610 - 1611 VOL - C1 TAB - 6 - 105

ESTIMATED TOTAL QUANTITY OF EACH LUBRICANT


ANNUAL REQUIREMENT PER PROBE
Servosystem 68 (IOC) or Enklo 68 (HP) or Bharat Hydrol 68 (BP)
Servosystern 150 (IOC) or Enklo 150 (HP) or Bharat Hydrol 150 (BP)

- 0.6kg
- 1.6 litres

15
1610 - 1611 VOL - C1 TAB - 6 - 106

16
1610 - 1611 VOL - C1 TAB - 6 - 107

17
1610 - 1611 VOL - C1 TAB - 6 - 108

18
1610 - 1611 VOL - C1 TAB - 6 - 109

19
1610 - 1611 VOL - C1 TAB - 6 - 110

20
1610 - 1611 VOL - C1 TAB - 6 - 111

21
1610 - 1611 VOL - C1 TAB - 6 - 112

22
1610 - 1611 VOL - C1 TAB - 6 - 113

23
1610 - 1611 VOL - C1 TAB - 6 - 114

24
1610 - 1611 VOL - C1 TAB - 6 - 115

25
1610 - 1611 VOL - C1 TAB - 6 - 116

26
1610 - 1611 VOL - C1 TAB - 6 - 117

27
1610 - 1611 VOL - C1 TAB - 6 - 118

28
1610 - 1611 VOL - C1 TAB - 6 - 119

29
1610 - 1611 VOL - C1 TAB - 6 - 120

30
1610 - 1611 VOL - C1 TAB - 6 - 121

31
1610 - 1611 VOL - C1 TAB - 6 - 122

32
1610 - 1611 VOL - C1 TAB - 6 - 123

33
1610 - 1611 VOL - C1 TAB - 6 - 124

34
1610 - 1611 VOL - C1 TAB - 6 - 125

35
1610 - 1611 VOL - C1 TAB - 6 - 126

36
1610 - 1611 VOL - C1 TAB - 6 - 127

37
1610 - 1611 VOL - C1 TAB - 6 - 128

38
1610 - 1611 VOL - C1 TAB - 6 - 129

39
1610 - 1611 VOL - C1 TAB - 6 - 130

40
1610 - 1611 VOL - C1 TAB - 6 - 131

TAB - 7

INSTRUCTION MANUAL
LRD IIE LONG
RETRACTABLE SOOT BLOWER

PUB.NO.7514

1610 - 1611 VOL - C1 TAB - 7 - 132

CONTENTS
GENERAL INFORMATION
LONG RETRACTABLE SOOT BLOWER MODEL LRD-IIE
GENERAL DESCRIPTION (REFER DRG. NO. 0-00-073-60024)
SBV HEAD (DRG. NO. 1-00-073-60003)
INSTZLLATION INSTRUCTION
INSTALLATION INSTRUCTIONS
GENERAL
PIPING
WIRING
ERECTION CHECKS
START UP CHECKS
SOOT BLOWER OPERATION
CHECK LIST
OPERATION
EMERGENCY OPERATION OF SOOT BLOWER
TROUBLE SHOOTING AND MAINTENANCE
PREVENTIVE MAINTENANCE CHECK LIST
INTERNAL INSPECTIONS
EXTERNAL INSPECTION-LONG RETRACT
LUBRICATION
PROCEDURE FOR LANCE AND FEED TUBE REMOVAL
PACKING INSTALLATION
CHAIN TENSION ADJUSTMENT (DRG. NO. 4-20-001-00523)
RECOMMENDED LUBRICATION CHART FOR LRD IIE LONG
RETRACTABLE SOOT BLOWER
OPERATIONAL PROBLEMS AND MAINTENANCE

2
1610 - 1611 VOL - C1 TAB - 7 - 133

RECOMMENDED SPARES FOR LONG RETRACTABLE SOOT


BLOWER(MODEL LRD IIE)
ASPIRATING AND SEALING AIR FOR LONG RETRACTABLE BLOWERS
WITH SINGLE SCRAPER PLATE
SINGLE SCRAPER PLATE AIR SEAL
ASPIRATOR
AIR SEAL
SCRAPER PLATE
FORCED PRESSURE AIR VALVE

3
1610 - 1611 VOL - C1 TAB - 7 - 134

LIST OF DRAWINGS FOR LONG RETRACTABLE


SOOT BLOWER
MODEL T 30 LRD - IIE
SI
No

Drawing No.

Description
LRSB T 30 M ark
II-E

LRSB T 30 M ark
II-E Special

1.

LRSB M ain Assembly

2-00-073-60080

2-00-073-60084

2.

General Arrangement

0-00-073-60024

0-00-073-60025

3.

Bill of M aterial

1-00-073-60098

1-00-073-60099

4.

M ain Gear Box Assembly (Traverse)

0-00-073-60022

5.

M ain Gear Box Assembly(Rotary)

0-00-073-60023

6.

Carriage Housing Assembly

0-00-073-60021

7.

SBV Head Assembly

8.

D.A. Head Main Assembly

1-00-073-60100

9.

Basic Head Assembly

1-00-073-60101

10.

Adjustable Bearing Assembly

2-00-073-60078

11.

Stop Switch Assembly

2-00-073-60079

12.

Reverse Switch Assembly

2-00-073-60079

13.

W all Blowing limit switch

2-00-073-60082

14.

Control circuit for combination long


Retract and W all blower

2-00-073-60083

15.

W iring diagram

16.

Chain Tightener(Traverse)

3-00-073-60093

17.

Chain Tightener(Rotary)

3-00-073-60094

18.

Traverse Chain Assembly

3-00-073-60095

19.

Rotary Chain Assembly

3-00-073-60096

20.

3-00-073-60097

21.

Jackshaft Bearing Assembly


(Traverse)
Jackshaft Bearing Assembly (Rotary)

22.

Tools Chart for LRSB

3-00-073-60099

23.

Valve Lapping Tool

3-00-073-60094

24.

Valve Spring Tool

4-00-073-60157

25.

Valve Tamping Tool

4-00-073-60155

26.

W rench

4-00-073-60156

27.

Valve Spring Tool Assembly

4-00-073-60158

28.

Chain Adjustment

4-00-073-00523

1-00-073-600003

3-00-073-60004

3-00-073-60100

3-00-073-60098

FOR DETAILED ERECTION AND START-UP INSTRUCTIONS REFER M ETHODS AND


PROCEDURS FOR INSTALLATION OF SOOT BLOW ERS. PUBLICATION No.7508-78

4
1610 - 1611 VOL - C1 TAB - 7 - 135

GENERAL INFORMATION
The Long Retractable Soot Blowers are designed and manufactured with a view to keep the
boiler operating efficiently. Because of their exclusive dual motor drive, they assure optimum
cleaning of all heating surfaces. BHELs Soot Blowers are installed in various power stations
in India and abroad and the sum of the experience gained on many new installations goes
long way in continuous perfection of the equipment. The equipment will function satisfactorily
with a little proper attention to installation, operation and maintenance.
It must be recognized that no amount of written instructions can replace intelligent thinking
and reasoning on the part of the operators, especially when coping with unforeseen operating
conditions. It is the operators responsibility to become thoroughly familiar not only with the
equipment but also with all pertinent control equipment.
The instruction contained in this manual is only an outline of the correct procedures for
installation, operation and maintenance. The contents in the manual have been compiled and
checked by experts in the field. Every possible care has been taken to ensure the contents are
accurate. However, it must be understood that the manual is not a contract document.
If you ever have any query about operation, maintenance or related problems, you are welcome
to write to us without obligation.

5
1610 - 1611 VOL - C1 TAB - 7 - 136

SAFETY NOTICE
PROPER SERVICE & REPAIR IS IMPORTANT TO THE SAFE AND RELIABLE
OPERATION OF SOOT BLOWERS. THE SERVICE PROCEDURES DESCRIBED IN THIS
MANUAL INSURING ACCURATE AND PREDICTABLE PRODUCT PERFORMANCE
ARE EFFECTIVE METHODS OF OPERATIONS. THE SPECIAL TOOLS
RECOMMENDED BY BHEL SHOULD BE USED IN SOME OF, THESE SERVICE
OPERATIONS.
IT IS IMPORTANT TO NOTE THAT THIS MANUAL CONTAINS VARIOUS WARNINGS
AND CAUTIONS WHICH SHOULD BE CAREFULLY READ AND FOLLOWED TO
AVOID THE RISK OF PERSONNEL INJURY OR DAMAGE OF THE EQUIPMENT. ANY
ONE WHO USES, A SERVICE PROCEDURE OR TOOL WHICH IS NOT
RECOMMENDED BY BHEL MUST SATISFY HIMSELF THOROUGHLY THAT
NEITHER HIS SAFETY NOR THE EQUIPMENT SAFETY, WILL BE JEOPARDIZED
BY THE SERVICE METHOD HE SELECTS.
EVERY PRECAUTION SHOULD BE TAKEN TO PREVENT INJURY, TO PERSONNEL
DURING -THE PERFORMANCE OF ANY TEST, INSTALLATION OR REMOVAL. BHEL
COULD NOT POSSIBLY EVALUATE ALL CONDITIONS THAT COULD INJURE
PERSONNEL OR EQUIPMENT, BUT DOES OFFER THESE SAFETY PRECAUTIONS
AS AN ASSISTANCE ONLY.
Important instruction for erection, start-up & operation of long retractable soot blowers
DOS
ERECTION
1.

CHECK THE BLOWER NUMBERS BEFORE ERECTION.

2.

USE ONLY THE LIFTING LUGS FOR HANDLING THE BLOWERS.

3.

CHECK THE SQUARENESS AND CONCENTRICITY OF THE WALL BOX.

4.

OPERATE THE BLOWER MANUALLY FOR CHECKING THE CLEARANCE


INSIDE THE BOILER.

5.

CHECK FOR ACCESSIBILITY FOR THE HAND CRANK FOR MANUAL


OPERATION.

6.

COVER THE JUNCTION BOXES AND CABLE OPENING TO PREVENT


WATER ENTRY.

BEFORE START-UP
1.

FLUSH THE GEAR BOXES WITH SERVO MESH 28 AND FILL THEM WITH
THE LUBRICANTS AS RECOMMENDED.

2.

CHECK THE DIRECTION OF ROTATION OF BOTH THE MOTORS.

3.

CHECK WHETHER ALL COVERS ARE PUT ON THE BLOWER.

4.

CHECK THE OPERATION OF THE STOP AND REVERSE LIMIT SWITCHES.

5.

OBSERVE ALL SAFETY PRACTICES.

6.

CHECK WHETHER THE CORRECT BLOWER IS INSTALLED IN THE


CORRECT LOCATION.

7.

CHECK THE LANCE DROOP AT FULLY EXTENDED CONDITION AND


MAKE SURE THAT THERE IS A SURFACE TO SURFACE CLEARANCE OF
100 mm TO 150 mm BETWEEN TOP BOILER TUBES AND LANCE TUBE. IF
6
1610 - 1611 VOL - C1 TAB - 7 - 137

THE CLEARANCE IS LESS, PROVIDE SHIELDING AS INDICATED IN


DRAWING.
8.

IN THE SIMILAR WAY, CHECK THE SIDE CLEARANCE IN THE


HORIZONTAL PASS.CREDIT SHOULD BE TAKEN FOR PROVISION OF
HORIZONTAL EXPANSION.

START-UP & OPERATION


1.

CHECK LUBRICATING OIL LEVELS FREQUENTLY. FOLLOW THE


LUBRICATION SCHEDULE.

2.

OBSERVE ALL SAFETY PRACTICES IN USE.

3.

ENSURE THAT ALL INTERLOCKS ARE IN OPERATING CONDITION.

4.

CHECK WHETHER HAND CRANKS ARE AVAILABLE AT EACH ELEVATION.

5.

INSPECT PERIODICALLY FOR THE FOLLOWING


(a)

PACKING WEAR (SHOWED BY STEAM LEAKAGE).

(b)

RUSTING OF CHAINS.

(c)

GASKET LEAKAGE.

(d)

CHAIN TENSION.

6.

SET THE BLOWING PRESSURE AS PER RECOMMENDED VALUE. ENSURE


THAT THE VALVE GETS COMPLETELY CLOSED AFTER SETTING.

7.

ENSURE THE BLOWER LANCES ARE IN HOME POSITION BEFORE AND


AFTER THE SOOT BLOWING CYCLE.

8.

WHEN AN ALARM IS SOUNDED DUE TO ELAPSED TIMER, LOW HEADER


PRESSURE, NO BLOWING MEDIUM INTERLOCKS, MAKE SURE THE
LANCE IS WITHDRAWN IMMEDIATELY.

9.

IMMEDIATELY ATTEND TO ANY LEAKAGE CAUSED DUE TO:


(a)

VALVE LEAKAGE.

(b)

FLANGE LEAKAGE.

10.

MAKE SURE THE VALVE OPENING LINKAGES ARE IN GOOD WORKING


CONDITION AND THE OPERATION IS SMOOTH.

11.

QUICKLY RECTIFY THE TROUBLES WHEN MALFUNCTION IS INDICATED


IN THE PANEL.

12.

WHEN THE BLOWERS ARE OPERATED FROM PANEL, KEEP ONE MAN
NEAR TO OBSERVE THE OPERATION.

DONTS
ERECTION
1.

DO NOT MIX UP THE BLOWERS.

2.

DO NOT LIFT/HANDLE THE BLOWER WITH ROPE/CHAIN WRAPPED


AROUND.

3.

DO NOT USE THE HOUSING AS THE WELDING PLATFORM.

4.

DO NOT PLACE HEAVY LOADS ON THE BLOWER.

5.

DO NOT PLACE THE BLOWER ON THE PLATFORM WITHOUT PROPER


SUPPORT.
7
1610 - 1611 VOL - C1 TAB - 7 - 138

6.

DO NOT LEAVE THE LANCE AT EXTENDED POSITION.

START-UP & OPERATION

1.

1.

DO NOT OPERATE THE SLOWER WITH WET STEAM.

2.

DO NOT OPERATE WITHOUT BLOWING MEDIUM DURING BOILER


OPERATION.

3.

DO NOT ATTEMPT MAINTENANCE WORK WHEN POWER AND BLOWING


MEDIUM ARE NOT CUT OFF.

4.

DO NOT CRANK THE LANCE MANUALLY WITH STEAM SUPPLY ON.

5.

DO NOT OPERATE THE SOOT BLOWER WITH EXCESSIVE STEAM


LEAKAGE THROUGH PACKING.

6.

DO NOT OPERATE THE BLOWER IN QUICK SUCCESSION. MINIMUM ONE


HOUR COOLING PERIOD BEFORE SUBSEQUENT OPERATION IS A MUST
TO AVOID ANY DAMAGE TO MOTOR WINDINGS.

7.

DO NOT OVERTIGHTEN THE DRIVE CHAINS (NOISY RUNNING IS O.K.


SILENT RUNNING IS NOT ADVISABLE).

8.

DO NOT LEAVE THE LANCE FOR A LONG TIME WITH BLOWING MEDIUM
INSIDE THE BOILER. (IT WILL DAMAGE THE BOILER TUBES, IF KEPT
INSIDE WITH BLOWING MEDIUM).

LONG RETRACTABLE SOOT BLOWER MODEL LRD-IIE


1.1

General Description (Refer Drg. No. 0-00-073-60024)

The LRD-IIE model Soot Blower is a boiler cleaning device in which a rotating lance extends
into and retracts from the boiler to make sure that the cleaning medium-steam air-directed
through the nozzles, removes the deposits from tube or wall surfaces.
The lance (item 07) is attached to a carriage housing (item 5) which runs on tracks inside the
blower housing. The carriage and lance are moved by means of a traversing chain (item 15)
operated by a 0.56 kW electric power pack (item 2). Rotary motion is applied to the lance
through the travelling carriage by a second chain (item 16) driven by a separate 0.75 kW
electric power pack (item 3). Control movement is by a stop limit switch and a reverse limit
switch (items 11 and 12).
The unit can be supplied with different traversing and rotating speeds. Standard traversing
speeds are available in various increments from 1.25 to 3.65 m. per minute. Standard rotating
speeds are available in various increments from 4.25 rpm to 7.75 rpm. These speed variations
are accomplished by changing the power pack and jack shaft drive sprockets. Other speeds
are possible for special application by the use of special sprockets.
Normally the blowers will be supplied with 1.65 m/min and 5.92 rpm.
Flow of blowing medium through the retractable soot blower is controlled by the valve (item
4 detailed description is given under the head SBV head -) mounted at the rear end of the
blower. The feed pipe item no. 08 is attached to the outlet of this valve head. This feed pipe
passes through packing gland in the traveling carriage and lies inside the lance tube (item 07)
extending to almost the entire length of the blower.
The wheels on the travelling carriage run on tracks welded to the inside of the blower housing
(item 1). Sideways motion is limited by a roller on each side of the carriage which use the
housing sides as guides.
8
1610 - 1611 VOL - C1 TAB - 7 - 139

The ends of traversing chain are connected to each end of the carriage (3-00-073-60095). The
rotary chain is continuous (3-00-073-60096). It passes over sprockets on the carriage and
causes rotation through a gear train.
The lance is flanged to the carriage and supported on the boiler end by bearing and yoke plate.
(item 6)
The electric gear box on the right side is for traversing and the electric gear box on the left
side is for rotation when viewed from the rear end of the blower.
Motion is transmitted from the gear boxes to jack shafts on each side of the blower.
Tension on the internal chains are adjusted by adjusting the screws on chain tighteners which
hold the idler sprockets on the outboard end of the unit.
The housing completely covers the blower except the traversing and rotating gear boxes.
The housing is open at the bottom except for tie bars at intervals. A section of the top of the
housing near the rear end of the blower is cut away to, allow access to the travelling carriage.
The access areas have removable cover. A short section of the track at the rear is removable to
permit removing the travelling carriage for major maintenance.
The soot blower valve head item No. 04 is operated by a trip pin (item No. 18 of
(0-00-073-60021) on the top of the travelling carriage which engage a trip cam item No. 27
and through the trip rod item No. 30 linkage and valve lever item No. 25 causes the head
valve to open or close.
The stroke of the head valve is governed by the length of the trip rod. To change the valve
stroke, loosen the jam nuts where it screws into the rod connection and
turn the rod.
One end of the rod has a right hand thread, the other end in left hand. When the desired length
is attained tighten the join nuts. The spring on the trip rod should be adjusted to eliminate all
looseness in the assembly.
1.2

SBV Head (Drg. No. 1-00-073-60003)

The Soot Blower Valve head allows the blowing pressure of the blower to beadjusted by
limiting the stroke of the valve. Where it is necessary to reduce the pressure greatly, a fixed
orifice may be installed in the head inlet flange.
The stroke of the head valve is governed by adjustment of the drive screw which contacts the
head valve stem. In the closed position, a minimum clearance of 1mm must be maintained
between adjusting screw and valve stem, to assure tight valve seating.
In general, slag removal will necessitate blowing pressure of 10-16 kg./cm. Soot and fly ash
will need 8-15 kg/cm and for dust removal, pressure may be as low as 7 kg/cm. In locations
of high gas temperatures, the flow from the lance is determined by cooling requirements of
the lance and may exceed 75 cubic metres per min. of air or 4,500 kg per hour of steam. This
cooling requirement is determined by the furnace gas temperature in which the blower is
operating and the number of square inches of lance surface exposed to these furnace
temperatures. Obviously a 6 metre lance requires a higher flow of blowing medium to keep
it cool than a 3 metre lance. Likewise a 3 metre lance of 76.1 O.D. requires less cooling than
a 3 metre lance of 108 O.D. Always refer to the general arrangement drawing (refer General
Instructions) for a recommended blowing pressure.
CAUTION
: DO NOT ADJUST THE VALVE ADJUSTMENT SCREW SO THAT
EVEN IN COMPLETELY RETRACTED POSITION THE VALVE IS KEPT IN OPEN
CONDITION.
9
1610 - 1611 VOL - C1 TAB - 7 - 140

2.

INSTZLLATION INSTRUCTION

2.

INSTALLATION INSTRUCTIONS
2.1

GENERAL

A wall sleeve and lance scraper plate are provided with each soot blower. The scraper plate
usually just floats on the lance.
In cases where tube and wall movement are identical the sleeve is Welded to both and the
retractable unit is hinged to the sleeve.
The outboard mounting is from auxiliary., steel. via a -hinge hanger arrangement which allows
the boiler end to move with the walls.
For particular information regarding any installation, refer to job drawings. For either type
installation, support members must be installed to avoid interfering with travelling carriage
operation. All supports should be securely made to prevent vibration, which could subject the
supply piping to fatigue strain.
2.2

PIPING

A companion flange, complete with gaskets and fasteners is supplied with each unit. This
flange is to be attached to the blowing medium supply piping. The piping must be free of
strain and have flexibility to allow the blower to move.
2.3

WIRING

Refer to wiring diagrams 3-00-073-60004 for full information on power and control wiring
integral with the blower.

3. ERECTION CHECKS
Ref. Installation Manual Pub. No. 7508-78 for detailed instructions.

4.

(a)

The blower should be supported in suck a way that it normally sloped towards the
boiler when the boiler is steaming Please ref. manual Pub. No. 7508-78.

(b)

Do not place heavy loading on the blowers. They are not designed for taking, such
heavy loads.

(c)

Ensure a minimum surface to surface clearance of 100 mm between boiler tubes


and lance tube at the extended condition of th a lance tube.

(d)

Ensure a minimum clearance of 100 mm between the top surface of the boiler tube
and the lowest surface of the lance tubes.

(e)

If the clearance is not achieved, the boiler tubes shall be shielded.

(f)

Cover all the sliding and electrical parts to prevent accumulation of filth, debris and
water. Make sure all the openings and cover in the junction boxes are, completely
closed during and after field cable connections.

(g)

The soot blowers are like precision machines and hence to be handled with care.
Use the lifting lugs and skids to prevent damage to the housing electrical cables and
other parts.

(h)

Make sure sufficient number of hand cranks are available at each elevations.

START UP CHECKS
For detailed start up checks. (See Pub. No. 7508.)
(a)

Check the blower numbers and their location.


10
1610 - 1611 VOL - C1 TAB - 7 - 141

5.

(b)

Check the chain tension.

(c)

Check the position of valve opening cam. (See Pub. NOL. 7508 for details.)

(d)

Check all the cable connections.

(e)

Check lubrication in the gear box.

(f)

Check for free manual movement.

(g)

Check the lance/boiler tube clearances.

(h)

Check the clearances for manual hand cranking.

(i)

Check whether all the blowers are in the initial position.

SOOT BLOWER OPERATION


5.1

CHECK LIST

For Long Retractable Soot Blower (LRD-IIE) the following items are to be checked carefully
before initial operation of the blower:
(i)

(ii)

(iii)

(iv)

Lubrication level
(a)

Travelling carriage.

(b)

Rotary Gear box.

(c)

Traverse Gear box.

Chain Tension
(a)

Rotary side.

(b)

Traverse side.

Blowing Pressure
(a)

Initial setting.

(b)

Final setting.

SBV Head Air Valve (Non-return valve)

Plug is to be removed and the air valve to be installed only in case of forced draft furnace.
11
1610 - 1611 VOL - C1 TAB - 7 - 142

(v)

Motor Rotation
(a)

(vi)

(vii)

(viii)

Rotary drive motor should run-top rotary chain to rear and bottom rotary
chain towards the furnace unless specified.

Installation of Air Vents


(a)

Rotary Gear box.

(b)

Traverse Gear box.

(c)

Travelling carriage.

Interference
(a)

External interference.

(b)

Internal tube (clearance and alignment)

Pecking Tightness

To be tightened slightly for minimum leakage during operation.


(ix)

External Power and Control cable connections. CONTROL PANEL FULLY


OPERATIONAL WITH ALL THE INTERLOCKS IN OPERATING CONDITION.

CAUTION:

DO NOT OPERATE THE BLOWER IN QUICK SUCCESSION.


MINIMUM I HOUR COOLING PERIOD BEFORE SUBSEQUENT
OPERATION IS A MUST To AVOID ANY DAMAGE TO MOTOR
WINDINGS.

5.2

OPERATION

i)

General

As the start button is pressed the unit begins to extend and rotate. As the nozzles clear the
boiler Wall the carriage strikes the cam, opening the head and blowing commences. At the
fully extended position the travelling carriage strikes the reverse limit switch, (item No. 12 of
main assembly) which closes. momentarily to reverse the unit. As the carriage retracts, it
again strikes the cam closing the - SBV head. The travelling carriage continues its rearward
travel until the cleaning nozzle is retracted into the protection of the wall box at which time
the stop limit switch (item No. 11 in the main assembly) is struck to stop the unit.
(ii)

Frequency

The frequency of Soot Blower operation depends on the operating conditions of the boiler
and boiler cleanliness. Some events which may indicate the need for cleaning are, increase in
boiler exit gas temperature, increase in gas pressure loss across the boiler (assuming constant
boiler load) and visual inspection.
It is important when starting up a boiler that the soot blowers be used frequently, and soon
after lighting off. Inefficient combustion in a boiler during start up may result in abnormal
deposits on the tubes. Unless these are removed frequently, furnace explosions or puffs may
result later. It is usually also desirable to use the soot blowers just before taking a boiler out of
service.
Care must be taken to avoid extending the lance into the boiler without flow of blowing
medium, or in subjecting the lance to temperatures in excess of 550C.
If the lance becomes stalled when partially extended, allow blowing to continue in order to
cool the lance until manual emergency retract Procedure is taken up. When first placing the
12
1610 - 1611 VOL - C1 TAB - 7 - 143

blower in service make sure it is in good mechanical condition and that flow of blowing
medium is established properly.
When the soot blowers are not being used, the main blowing medium valve should be closed
tightly.
5.3

EMERGENCY OPERATION OF SOOT BLOWER

(i)

To put the soot blower on manual operation.

(ii)

(a)

Switch off power and control supply.

(b)

Close the main stop valve of soot blower system to shut off steam/air supply.

(c)

Insert the handcrank on the worm shaft and rotate until the blower reaches
starting position.

Warning
(a)

No soot blower should be operated for a second time within one hour interval
to avoid damage to motor windings.

(b)

No soot blower should be operated without blowing medium when the boiler
is on.

(c)

Soot blower should never be manually operated with steam. At the time of
any failure of power or control supply during operation of soot blower, the
blower should be immediately brought to its starting position to avoid any
possible damage to heating surfaces or lance tube. At the end of the traversing
gear box, a slotted stub shaft is provided for hand cranking. After removing
the cap, a hand crank can be engaged to move the lance manually. One hand
crank is normally furnished with each blower.
It is also possible to move the gear box with a portable air motor.
(SPEC: Pneumatic drill suitable adopter for stubbed shaft; SPEED 275
to 300 rpm)

6.

(d)

No soot blower lance should be left with blowing medium inside the boiler
for a long time. Failure of bringing the lance to the start position will lead to
damage boiler tubes and the lance.

(e)

In compliance with transportation codes, blowers must be shipped with dry


gear boxes. Before operating the blowers fill the power packs with
recommended lubricants.

TROUBLE SHOOTING AND MAINTENANCE


Unless soot blowers are properly operated and maintained, there can be lengthy and costly
outages, and need for more expensive replacement of boiler equipments.
Preventive Maintenance Check List
The following is a suggested maintenance schedule. Establish a regular maintenance
programme compatible with conditions at installation.
6.1

At one week intervals

Check for steam leakage in the travelling carriage gland packing. Aslightamount of leakage is
required and permitted. If leakage is excessive change the packing. The entire packing set
should be changed at one time. Follow the instructions for changing the packing. Check for
scoring marks on the feed tube.

13
1610 - 1611 VOL - C1 TAB - 7 - 144

6.2

At one month intervals

(a)

Check the travelling carriage and valve for steam leakage. If steam leakage is noticed
tighten the glands and watch the performance during the next Operation.

(b)

Check for the steam leak through valve seat. A HOT lance tube (when the line is
charged with steam) is the indication of steam leak through seat, if it is supported by
the hissing noise of steam leakage.

(c)

Check the presence of Stop pin on the cam bracket.

(d)

Check the angle tracks and chain. If ash building is noticed, clean them.

6.3

At 6 month intervals

(a)

Check chain tension of both rotary drive and traversing drive chain. These chains
should be adjusted to ride on the upper angle iron track and on the lower turned
edge of the main housing. The chain should be supported and carried free from
either the driver or the idler end sprockets, or both, for a minimum distance of 750
mm and a maximum distance of 1 metre. Refer Drg. 4-20-001-00523.

(b)

Check chain tension of both jack shaft drive chain. The jack shaft drive chains
should be tightened so that normal hand pressure will depress either side of the
chain at the mid point approximately 25 mm.

(c)

Chains subjected to caustic or corrosive atmosphere or extremely high temperatures


may require re-lubrication. Lubricate chains as soon as they show signs of rust on
any of the external parts. Replace any chain that is badly rusted or corroded and has
lost articulation. Refer to LUBRICATION SECTION of General Instructions for
recommended lubricants and lubrication procedure. (Pub. No. 7501-79)

(d)

Check both Stop and Reverse limit switches. The actuating arms should be
tight and secure on the switch pivots. The pivots should be free of paints or oil so
that no hinderance or binding of movement occurs. The actuating arm should be
correctly adjusted so as to pass freely through the slots in the housing and be properly
engaged by the travelling carriage slide roller.

6.4

At one year intervals

(a)

Check gaskets at travelling and rotary gear box covers. (Gaskets may have. dried
and shrunk permitting oil seepage). Cap screws on covers should be. tightened.
Replace gaskets if seepage is excessive.

(b)

Check oil level in travelling carriage gear boxes. Add recommended lubricant, if
necessary. Refer to LUBRICATION SECTION of General Instructions. (Pub. No.
7501)

(c)

Check oil in the reduction gear boxes on the traversing and rotary power packs. Add
recommended lubricant, if necessary. Refer to Lubrication Section of General
Instructions.

(d)

Check complete assembly. Tighten loose bolts, nuts and cap screws. Replace missing
cotter pins and springs.

(e)

Change motor bearings, if required.

(f)

Coat the threaded components with Molyka or antiseize compound so that the rusting
will be prevented.

(g)

Check the valve stem assembly for pitting and if pitting is severe replace the stem
with a new one. Apply Molyka on the stem while assembly.
14
1610 - 1611 VOL - C1 TAB - 7 - 145

(h)

Check the mountings and hanger supports of blower. The hinge pin should be
secured by cotter pins. Lock clamp washers are required to secure mounting shoulder
bolts.

(i)

Test, Operate each individual blower

Using the local start button with the blowing medium of the unit under normal operating
conditions, test, operate each individual blower.
Along with the mechanical operation of each blower the blowing pressure also should be
checked by using pressure gauge, in the SBV operating head. The recommended blowing
pressure is shown on the general arrangement drawings Blowing pressure chart.
This manual check is essential to assure that excessive blowing pressures are not incurred
what would cause boiler tube wastage.
6.5

Shut-down checks

In addition to the annual checks as in 6.4 the following checks are to be carried out :
(a)

Check whether the boiler tubes have eroded. If thickness is reduced to a very low
value provide of shielding.

(b)

Check the gap between the lance tube and the boiler tube. The gap should be kept
min. of 100 mm. For the blowers located in the second pass, the gap between the
lance tube, (at the extended condition) and the coil edge is to be checked. The
minimum distance of 100 mm is to be maintained.

(c)

Paint the blowers once in two years.

6.6

Periodical check determined by installation conditions

(a)

Check motor starter cabinets.


Cabinets should be kept securely closed and gaskets should be in place to prevent
contamination.
If cabinets have been opened for servicing, carefully blow surfaces free of dust or
foreign material with tight air pressure from a dry, clean air supply. Position
gasketand secure cover.

(b)

Packing on the feed tube in the travelling carriage and the valve stem in the SBV
operating head should be tightened. When packing glands are fully down and leakage
is still present, the units should be marked for repacking after the blowing medium is
turned off and the header secured and tagged.

(c)

Scraper plates should be inspected for wear as a regular maintenance procedure.


Immediately following start-up, routine examination should begin and should be
scheduled for two month intervals. After completing several bimonthly checks, the
frequency of these inspections may be altered by increasing or decreasing the time
interval between checks (to be determined by the wear pattern)

(d)

Internal Inspections

(i)

Check to see that nozzles are not worn, cracked or split. Examine inner wall sleeve
edges to make sleeves are not breaking down under heat and thus failing to protect
nozzle heads when they are retracted. See that nozzles are properly retracted for
protection.

(ii)

Examine thoroughly all tubes cleaned by these units by rubbing the hands over them
to determine if there are any grooves or flat spots indicating erosion or cutting. Tube
15
1610 - 1611 VOL - C1 TAB - 7 - 146

erosion or cutting with Retractable Units is invariably due to excessive blowing


pressure. This pressure should be controlled to avoid the damage. On Long Retract
able Units be careful not to reduce pressure to a point where the volume of
steam.passing through the lance will be insufficient for cooling the lance when
fully
extended.
(iii)

Space between Water wall tubes where these lances enter is sometimes limited by
boiler construction. Check to see that lances enter the centre of the operating without
striking the boiler tube which could thus be damaged.

(iv)

Lances should be straight and true. Straightening procedures as outlined for Rotary
Equipment can be followed.

(e) External Inspection-Long Retract


(i)

For general instructions refer Section 5.2-EXTERNAL INSPECTION of Publication


No. 7501.

(ii)

Take care when mounting long retractables. Where outboard bearing or boiler end
of the unit is supported and attached to the boiler, the other point should be attached
to structural steel. The boiler will move under heat and load. Thus if more than one
point is attached to steel structures, twisting and bending of the unit will occur with
boiler load changes.

(iii)

All units of this type have some sort of the telescoping tube or feed tube running
through a packing gland. Surfaces passing through these glands should be clean,
smooth and free from burrs, cuts of scoring. If they cannot be cleaned, they should
be replaced to prevent excessive packing replacement or damage to mating parts.

(iv)

It is sometimes necessary to relocate soot blower units or add additional equipment


to relieve troubles or reduce maintenance. This, as well as a question of change in
design should be deferred until all possible sources of trouble have been eliminated.

6.7

Lubrication

The capacity of the travelling carriage is 1 litre of gear oil. We recommend SERVOMESH 28
for air blowing and 0.6 kg of SERVOGEM HTXX for steam blowing. Where SERVOGEM
HTXX or equivalent is used in the travelling carriage, the grease, after it has been run through
a few operations will find its own level. The volume of this grease should be approximately
half-way on the hollow spindle as a maximum, minimum should be upto the oil level plug.
(if temperatures of blowing steam exceeds 427C use Almasol 1250).
The reduction gear boxes on the motor power packs have a capacity of 0.75 litre each. Also
the recommended lubricant is SERVOMESH 28. Replace the pipe plugs in the highest opening
in the box with air vents provided loose. Should the chains be subject to caustic or corrosive
atmosphere or extremely high humidity conditions they may require lubrication. Failure to
properly tighten and constantly maintain packing in the travelling carriage of steam blowing
installations will rapidly deplete lubrication on the drive chains.
Chains should be lubricated as soon as they show signs of rust or any of the external
parts. Should chains be badly rusted and corroded in the pins and rollers and the movement
(or articulation) lost, no amount of penetrating oil or lubrication will free those parts which
have seized up. Two-fold lubrication is recommended, when required:
For the first step of the chain lubrication procedure, a light body penetrating fluid should be
applied not only to wash out rust, fly ash, and debris but also to act as a carrier to help the
heavier, lasting lubricant enter the close clearances between pins and rollers.
16
1610 - 1611 VOL - C1 TAB - 7 - 147

We recommend for the first coat Trichloroethylene. Since this penetrating spray must be thin,
it will volatilize and evaporate rather quickly. The application of a heavier more permanent
lube must follow immediately while the penetrating oil is still present, to carry the heavy lube
to the working parts. We recommend for the second coat, Light oil to the grade of SAE-30.
The second coat, should be applied as a thin coat with brush so as to cover and penetrate the
bearing areas. Too much of the lubricant will trap the flyash and will make the chain stiff and
loose the articulation. The Indian Oil grade of SAE-30 will be SERVOLINE-140.
6.8

Procedure for Lance and Feed Tube Removal

The lance tube and feed tube can be removed from the bottom of the blower. For their removal
proceed as follows :
(i)

Remove M20 nuts attaching the SBV valve head to the blower and remove the
head.

(ii)

Loosen the packings on the travelling carriage.

(iii)

Slide the feed tube out of several centimeters and remove two feed pipe retainer
ring halves.

(iv)

Disconnect the lance flange from the travelling carriage. Slide the feed tube into the
lance several centimeters. The lance should be supported by a sling through the
housing.

(v)

Remove tie bars from the bottom of housing at the head end to allow the lance to be
dropped.

(vi)

Lower the end of the lance and feed pipe and pull the lance out of the roller bearing
at the boiler end of the blower and slide it out of the blower housing.

(vii)

To reassemble the lance and feed pipe, follow the steps in reverse order.

6.9

Packing Installation

(i)

The travelling carriage utilizes a formed packing set. The packing gland nuts should
be drawn up tight enough to effect a seal but not excessive enough to restrict the
travel of the carriage.

(ii)

Recommended procedure for Packing Installation

(a)

The useful life of packing is dependent on the method of installation. Poor installation
can cause the best packing tofail prematurely. The methods in this procedure, if
followed, will lead to better sealing and longer life.
These packing methods apply both to installing packing in new equipment and
replacing packing in equipment that is in service.

(b)

Installation Method (Travelling Carriage Assembly)


Clean out the old packing. Flexible packing hooks are available for removing the
packing.
Inspect the feed pipe for wear or damage. Remove any raised metal that projects
above the normal surface. Do not try to file out depressions or scratches. Raised
metal will tear packing. Any reworking of scratches will only worsen the condition.
Keep the new packing clean during installation. Grit or other hard foreign matter
that is installed with the packing may score the feed pipe causing an early failure
of the packing.
Install all packing rings so that the joints are staggered and kept approximately 90
17
1610 - 1611 VOL - C1 TAB - 7 - 148

apart. Spot the joints in clockwise direction to facilitate locating them when removing and
packing.
Install the rings one at a time. Each ring must be set firmly into place with either the gland
or a tamping tool as shown in Drg. 4-20-996-01241. After each ring is installed, the ring must
be compressed with approximately the same force that it will have with the final gland force.
Each ring should be equally compressed when the entire set is installed. If this is not done,
only the last ring will do the sealing and will wear quickly.
Bevelled packing is to be installed with the bevel lip on the shaft pointing toward the pressure.
One end of the tamping tool is angled for bevelled packing. Fit the bevel on the packing to the
bevel on the tool.
Oil or grease may be applied to the outside of braided asbestos packing to help in installing it
in the stuffing box.
Tighten the gland follower, sufficiently tight, after the packing has been installed to insure
final seating of the packing. The nuts should be backed off two or three turns to relieve excessive
pressure. Adjust packing to operating conditions.
Allow packing to leak a small amount, if possible, when starting newly packed equipment.
Tighten the gland slowly as the packing seats.
Do not be afraid to let packing leak a small amount. It is good assurance that packing is not
too tight and the liquid usually has some lubricating qualities.
(c)

Installation Method (SBV Head Assembly)

The new packings on the soot blower valve head assembly can be easily assembled removing
the valve from the soot blower.
If packings are installed with the valve mounted on the blower, care should be taken to see the
valve stem assembly does not fall in the soot blower pipe line.
Install the rings one at a time. Each ring must be set firmly into place using the gland bushing.
Follow the Installation procedwe as suggested in 6.7 (b).
For assembling the spring retainer of the valve (item 08 of 1-00-073-60003), use the spring
tool as suggested in the drawing 4-00-073-60158.
When renewing packing, use all new clean packing. Worn packings are dry, highly compressed,
have high friction and may develop scoring. Remember packing is relatively cheap. Labour
and materials necessary to replace worn valve stems are expensive and critical commodities.
The most expensive seal is a seal that fails.
Light gland pressure should be maintained at all times. Too much pressure will cause binding,
scoring of the shaft and force the lubricant out the packing. Too little gland pressure will
allow excessive leakage and washing out of the packing.
When the packing has been compressed to less than 3/4 of its original height, it should be
replaced. The loss of height in packing may indicate a loss of essential lubricant.
6.10 Chain Tension Adjustment (Drg. No. 4-20-001-00523)
The chain must ride on the upper angle iron track and on the lower turned edge of the main
housing. Under no circumstances can the chain be so tight that it will be supported only by the
drive and idler sheave sprockets.
When the chain is being adjusted, the chain should be supported and carried free from either
or both end sprockets, that is either the driver or the idler for a minimum distance of 750 mm
and a maximum of 1000 mm from the sprocket to the track.
18
1610 - 1611 VOL - C1 TAB - 7 - 149

The mid-point of the chain from 750to 1000 mm of the driver and 750 to 1000 mm of the
idler must ride on the lower rail.
6.11 Spares
In the enclosed drawings spares that are recommended for stock by the user, are marked by
S. While ordering spares the item number and drawing number as found in the Bill of
material and details furnished in the soot blower name plate must be indicated for quick
supply of these items. Section 10 gives the recommended list of standard spares.

7.

RECOMMENDED LUBRICATION CHART FOR LRD IIE LONG


RETRACTABLE SOOT BLOWER

Lubrication
Points

Part Description

Lubricant

Filling
frequency

Observation Method of
frequency application

Qty. per Blower


per Filling

2.1

Travelling carriage
(Air blowing)

Gervil EP 2 of HPC
or Servomesh 28

Annual

3 Months

Fill in the
reservoir

0.8 litre

2.2

Travelling carriage
(Steam Blowing)

Trisona 2 of H PC
or Almasol 1250 or
Servogem HTXX

Annual

3 Months

Fill in the
reservoir

0.6 Kg.

2.3

Chain

Servoline 140 or
Enklo 65 of HPC

2.4

Power PackRotary and


Traverse

Servomesh 28 or
Enklo 53 of HPC

Annual

3 Months

Fill in the
reservoir

0.8 litre

Remarks
See Note 2

See Note 3

See Note I

See Note 2

19
1610 - 1611 VOL - C1 TAB - 7 - 150

8.

OPERATIONAL PROBLEMS AND MAINTENANCE

Problem
1.Overheating
of the
lance tube

Probable Cause
No steam flow/less steam
flow
(a)
(b)
(c)

(d)
(e)

3 Steam
leakage
through
valve stem

Insufficient blowing
pressure
Valve stem doesnt move
valve stem

Increase the blowing


pressure
Dismantle and clean the

Increase in flue gas


temp. than the designed
value
Absence of valve
opening screw

Check the boiler


parameters
Assemble the valve
openingscrew

Slipping of valve opening lever from Tripping


Lever
Selection of nozzle size

Adjust the pull rod to


have proper engagement

(g)

Keeping the lance without


the blowing medium
lance is bent, straighten

Retract the lance immediately as soon as noticed. If

(a)

Poor quality of packing


recommended
used for use

Use packing

(b)

Further compression
impossible as the packings
become solid

Use new packings

(c)

Inadequate tightening
(Caution : Do not overtighten the packings)

Tighten the packings:

(d)

Excessive wear of glands


new glands

Replace the packing with

(e)

Scratch marks, dents or


other surface defect on
the feed pipe

If excessive scratch marks


are noticed, change the feed
pipe

(a)

Poor quality of packing


used recommended

Use the quality packing

(b)

Further compression
impossible as the packings become solid

Use new packings

(c)

Inadequate tightening
(Caution : Do not overtighten)
20

Tighten the packings

(f)

2 Steam
Leakage
through
travelling
carriage

Suggested Remedy

Refer with BHEL (T) and


change the nozzle head

1610 - 1611 VOL - C1 TAB - 7 - 151

Problem
4. Chain failure

Probable Cause
(a)

Rusting of the chain and


loss of articulation
Assambly of commercial
chains and links
These chains will fail frequently. Install spl. quality
chains only

Install new chain

(c)

Mounting of wrong motor


on the traverse power
pack and wrong setting
of thermal overload relay

Check the installation of


correct motor. Check
and set the O/L relay as per
recommendation

(d)

Improper assembly of
connector links

Assemble connector links


properly

(e)

Wearing of chain links


and rivets
worn out links

Protect chains from ash


build up or change the

(a)

Bent lance due to overheating

Remove and straighten the


lance tube

(b)

Wrong setting of O/L


relay

Set the O/L relay as per


recommendation

(c)

Accumulation of ash build


up over angle tracks

Clean the angle tracks


periodically

(d)

Overtightened gland
packings in the travelling
carriage

Do not tighten the packing


too much Profuse leakage
will not harm any parts

(e)

Slag build up in wall sleeve


or physical obstruction

Clean the sleeve or adjust


the SB alignment

(f)

Shifting of super heater


reheater tubes

(g)

Housing Damage during


Erection

During shut-down or align


boiler tubes so that a min.
100-150 mm. of gap is
ensured
Rectify the housing so that
the travelling carriage moves
freely

(h)

Valve opening cam in


wrong direction or valve
opening cam placed at
wrong position ensured

Reposition the cam so that


smooth engagement with
blowing adjustment bar is

(i)

Earthing of cable at any


point

Find out the cable and


replace the damaged cable
with a new one

(j)

Rusting of terminals
which will be indicated
by chattering of contacts
21

Replace the terminals with


new ones

(b)

5 Motor
overload

Suggested Remedy

Commercial chains are


having low breaking load.

1610 - 1611 VOL - C1 TAB - 7 - 152

Problem

6 Limit Switch
Failure

Probable Cause
(k)

Supply voltage low


correct voltage

Ensure the availability of

(l)

Gear box jammed or no


lubricant

Service the gear box or fill


in the recommend lubricant

(a)

Sticking of contacts due


to damage, or due to poor
quality contact material
or due to underrating of
contacts

Replace the limit switch


with new ones

(b)

Failure of internal parts,


springs, locking notches
etc.

Replace the limit switch


With new ones

(c)

Build up of foreign
particles on limit switch
which may result in
breakage of operating
arm
Wrong assembly of limit
switch

Replace the broken switch


arm with a new one

(d)

7 Valve seat
leakage

Suggested Remedy

Reassemble the limit switch


so that the overtravel is
restricted to within 50
Correct the directions of
the actuation

(e)

Wrong direction of L.S.


actuation

(a)

Gland packings overtightened

Loose the gland packings


so that the valve stem
closes properly

(b)

Insufficient lapping or
damage to the valve disc

(c)

Valve opening setscrew


pressing the valve stem
while the travelling carriage is in the home

Dismantle the valve and


lap the valve stem disc with
the use of seat with the hand
lapping tool(as suggested in
7501)
Adjust the valve opening
setscrew so that a min.
gap of 1 mm is maintained
position

(d)

Valve stem corrosion.


replace the valve stem

If the corrosion is excessive,

(e)

Likely small particles


trapped between seat and
disc.

This can be avoided by


tapping the valve through
a lever

22
1610 - 1611 VOL - C1 TAB - 7 - 153

S. COMBINATION LONG RETRACT AND WALL BLOWER


Please refer to. the T 30 MK II-E Installation Instructions for general installation and maintenance
information. The specific assembly drawings for this combination retract-wall blower follow this
description of the blower operation. The Assembly drawing and description of the DA head
furnished on this blower are also included.
Description of Operation (Refer Drg. 0-00-073-60025 and 2-00-073-70083)
Blower operation is initiated by depressing the Panel start - or the Local start push button. This
creates the circuit to energize the CRO - relay and thus starts the rotary motor, causing the lance
to rotate. This EXT - relay will be energized through closed centrifugal contacts on the rotary
motor or through CRO contact and the limit switch LS1 thus causing the traverse motor starts,
causing the lance to extend from initial position. The circuit will be locked by limit switch LS2 is
tripped.
After a pre-determined travel, limit switch LS3 will be tripped energizing the latching solenoid
valve SV that -controls the DA head, permitting the blowing medium to be admitted to the lance.
The blower will continue to rotate and. extend until the limit switch LS1 is momentarily tripped,
breaking the circuit to EXT and bringing in RET to cause the lance to retract. The circuit will
be locked by 101 R contacts.
The lance will retract until limit switch LS3 is tripped energizing the timer T and R2 through closed
R1 contacts. This causes the blower to stop, rotate and blow in position until timer Ttimes out.
When timer T times out, 101 R2 will be do-energized. The circuit will be created through closed
R1 and R2 contacts to permit the blower to continue toretract. When timer T times out. energizing
releasing solenoid valve SV to close the DA head and blowing will Stop. Limit switch LS2 will be
stroked causing the blower to atop at its .REST position.
diaphragm Operated DA Head
Assembly Drawing 1-00-073-60100. The DA Head is a diaphragm operated valve which controls
the flow of blowing medium to the blower. This head has a poppet type valve, which is stroked by
the interaction of the diaphragm plate, spindle and a lever. The 40 square inch operator requires
air loading pressure in the range of 40 to 80 psi.
When air is supplied to diaphragm it moves up racking lever No. 21 causing adjusting screw No.*
26 to stroke the head poppet valve.
There must be a back lash of at least 1- 16" between adjusting screw No. 26 and poppet valve
stem. Increasing. this backlash reduces blowing pressure.
A number 60 drill blood hole is required in the tubing fitting in stalled in the diaphragm chamber
while the vent port is open to atmosphere.

23
1610 - 1611 VOL - C1 TAB - 7 - 154

10. RECOMMENDED SPARES FOR LONG RETRACTABLE SOOT BLOWER


(MODEL LRD IIE)

S 1.
N o.
1.

Ite m
N o.

De s cription
Valve Gland Packing

..

As s e mbly
Drawing No

Part Drawing
No

04

2- 00- 073- 60080

09

1- 00- 073- 60101

Part
M ate rial
Code

1- 6

7- 12

96/353/365

12

16

12

16

MARK
No. Off T 30 M
ark II-EII - E

13- 19 Over 20

24
1610 - 1611 VOL - C1 TAB - 7 - 155

2.

Packing (Travelling Carriage).

41

0 - 0 0 - 0 7 3 - 6 0 0 21

97/366/141

3.

Chain 2- Pitch
..

04

3- 00- 073- 60095

97/366/125

4.

Connector Link 2- Pitch ..

01

3 - 0 0 - 0 7 3 - 6 0 0 95

97/366/126

5.

Offset Link 2- Pitch

02

3- 00- 073- 60095

97/366/127

6.

Chain 3/4- Pitch


..

04

3- 00- 073- 60096

97/366/026

7.

Connector Link 3/4" Pitch

01

3 - 0 0 - 0 7 3 - 6 0 0 96

97/366/028

8.

Offset Link 3/4" Pitch

02

3- 00- 073- 60096

97/366/027

9.

SBV Head Assembly

04

0- 00- 073- 60024

1- 0 0 - 0 7 3 - 6 0 0 0 3

18

0 - 0 0 - 0 7 3 - 6 0 0 23

96/353/066

12

13

0 - 0 0 - 0 7 3 - 6 0 0 22

Oil Seal

39

0 - 0 0 - 0 7 3 - 6 0 0 21

96/353/310

12

12. Oil Seal

40

0- 00- 073- 60021

96/353/311

12

10. Oil Seal BSI

11.

..

One blower requirement length


varies contract to contract

One blower requirement length


varies contract to contract

S 1.
N o.

De s cription

Ite m
N o.

As s e mbly
Drawing No

Part Drawing
No

Part M ate rial


Code

M ark II-EII - E
No. Off T 30 MARK
13- 19 Over 20

1- 6

7- 12

22/021/303

22/021/610

GASKET
13 .

Spiral Wound Gasket

55

0- 00- 073- 60024

14 .

Gasket

05

1- 00- 073- 60003

11

1- 00- 073- 60101

12

0 - 0 0 - 0 7 3 - 6 0 0 23

16

0 - 0 0 - 0 7 3 - 6 0 0 22

25

0- 00- 073- 60023

52

0- 00- 073- 60022

22/021/619

15.

16.

Gasket

Motor Gasket

25
1610 - 1611 VOL - C1 TAB - 7 - 156

17 .

Cover Gasket

15

0 - 0 0 - 0 7 3 - 6 0 0 22

22/021/609

18 .

Gear Box Cover Gasket

17

0 - 0 0 - 0 7 3 - 6 0 0 22

22/021/615

19.

Gasket

4,2-

0 - 0 0 - 0 7 3 - 6 0 0 21

22/021/611

20.

Gasket

22/021/612

21.

Bearing Housing Gasket

14

0 - 0 0 - 0 7 3 - 6 0 0 22

22/021/613

22.

Motor 1 hp

03

0- 00- 073- 60023

23.

Motor 3/4 hp

03

0- 00- 073- 60022

43

0- 00- 073- 60021

BEARINIGS
24.

Bearing SKF 6210 2RS

06

3- 00- 073- 60097

55/119/06210

25.

Bearing SKF 6206 2RS

06

3- 00- 073- 60098

55/119/06206

S 1.
N o.
26.

De s cription
Guide Roll Bearing

Ite m
N o.

As s e mbly
Drawing No

Part Drawing
No

05

3- 00- 073- 60093

05

3- 00- 073- 60094

No. Off T 30 M ark II-E

Part M ate rial


Code

1- 6

7- 12

13- 19

Over 20

97/366/124

27.

Ball Bearing

07

2- 00- 073- 60078

96/353/305

28.

Ball Bearing SKF 6309

10

0 - 0 0 - 0 7 3 - 6 0 0 22

55/111/06309

03

' 0 - 0 0 - 0 7 3 - 6 0 0 23

26

29.

Ball Bearing SKF 6204

11

0 - 0 0 - 0 7 3 - 6 0 0 22

55/111/06204

30.

Ball Bearing SKF 6202

12

0 - 0 0 - 0 7 3 - 6 0 0 22

55/111/06202

31.

Ball Bearing SKF 6021 ' C4

33

0 - 0 0 - 0 7 3 - 6 0 0 21

55/111/06021

32,

Ball Bearing SKF 6020 ' C4

34

0 - 0 0 - 0 7 3 - 6 0 0 21

55/111/06020

33.

Ball Bearing SKF 6209 2RS.

35

0 - 0 0 - 0 7 3 - 6 0 0 21

55/119/06209

34.

Ball Bearing SKF 6205


213S.

36

0 - 0 0 - 0 7 3 - 6 0 0 21

55/119/06205

35.

Ball Bearing SKF 6305 . .

55/111/06305

37

0- 00- 073- 60021

1610 - 1611 VOL - C1 TAB - 7 - 157

36.- Ball Bearing SKF 6005 2RS

38

0 - 0 0 - 0 7 3 - 6 0 0 21

55/119/06005

21

37.

02

1- 00- 073- 60101

02

1- 00- 073- 60003

Valve Stem Assy.

2
8

38.

Gland

11

0- 00- 073- 60021

4 - 2 0 - 2 0 1, 0 0 2 2 9

39.

Bushing

10

0- 00- 073- 60021

4 - 2 0 - 2 0 1- 0 0 0 7 5

40.

Lance Tube Assy.

07

0- 00- 073- 60024

0- 00- 073- 60025


41.

Feed Tube Assy.

08

0- 00- 073- 60024

42.

Umit Switch

09

2- 00- 073- 60079

97/353/900

4,

43.

Limit Switch

03

2- 00- 073- 60008

97/353/021

0- 00- 073- 60025

RECOMMENDED SPARES FOR (SPECIAL) COMBINATION LONG RETRACTABLE


AND WALL BLOWER

Sl.
no

Description

Item

Assembly

Part

No.

Drawing number

Drawing number

Part

No. off T 30 Mark II E

Material code

1-6

7-12 13-19 over 20

27

01

DA Head valve assembly

01

1-00-073-60100

1-00-073-60101

02

Gasket

10

1-00-073-60101

03

Gasket

19

1-00-073-60100

22/021/617

04

O Ring

22

1-00-073-60100

96/353/307

05

Solenoid valve

42

0-00-073-60025

97/366/129

06

Exhaust valve

43

0-00-073-60025

97/366/130

1610 - 1611 VOL - C1 TAB - 7 - 158

11.

ASPIRATING AND SEALING AIR FOR LONG RETRACTABLE


BLOWERS WITH SINGLE SCRAPER PLATE
(Applicable for Pressurised Furnace)
Single Scraper Plate Air Seal
When soot blowers are used on boilers with positive furnace pressures, it is necessary to use
air seal aspirators with the soot blower sleeves. The air seal sleeve is used to prevent escape
of furnace gases from around the lance. The use of an aspirator, while not mandatory with air
seal sleeves, permits removal of a lance with the boiler in operation, without danger of escape of furnace gases. The air seal and aspirator are attached to the soot blower sleeve.
Aspirator
The aspirator consists of a cylindrical annular air chamber, into which high pressure air is
admitted. The lance passes through the central portion of the aspirator. In the cylinder forming the inner wall of the aspirator chamber, there are a series of nozzles drilled on an angle so
that discharge of air through them forms a cone with the base at the aspirator and the apex
several inches forward of the lance tip. When air is admitted to the aspirator the cone of air
prevents flow of furnace gases back through the aspirator and allows removal of the lance or
scraper plate.
Air Seal
The air seal is located directly behind the aspirator. The lance scraper plate forms the rear
wall of this chamber. Low pressure air is introduced into the chamber at a pressure greater
than furnace, and due to small clearance between outside diameter of lance and inside diameter of the scraper plate, an effective seal is formed against furnace pressure.
Scraper Plate
The scraper plate is held in position by a horizontal spring through which the lance passes.
The scraper plate is hardened, and in addition to sealing, will remove deposits on the lance.
When air is admitted to the air seal, an effective seal is made at the lance outside diameter so
furnace gas cannot escape from the boiler.
The lance is positioned so that both nozzles lie behind the air seal in the fully retracted
position, thus the nozzles.are outside the seal, away from furnace gas, which prevents damage from corrosion caused by boiler gases in the lance.
Air at some pressure (see contract drawings) above furnace pressure must be provided at the
inlet to the air seal chamber to effect a proper seal, seal air should be ON whenever the boiler
is in service, with the lance in place. If the lance is removed, the opening must be covered and
the seal air shut off. Aspirating air must be ON when removing or installing the lance or
scraper plate.
Aspirator air pressure is determined by lance size (see contract drawings). Permanent air
connections for aspirating air are not required. Quick disconnect fittings for air hook up are
desirable to speed hook up for maintenance.
The manifold valve must be in seal - position when the boiler is in operation. Aspirating air
is supplied (only for short periods) when repairs or replacements are being made with the
boiler in operation.
Before attempting scraper plate maintenance, make sure the aspirating air is ON by placing
the manifold in the aspirate position. If the seal is to be opened for an extended time, cover
the open end of the aspirator and reduce the aspirator air flow to that necessary to keep the
sleeve cool.
28
1610 - 1611 VOL - C1 TAB - 7 - 159

Never allow the aspirator or air seal to be open ended when the boiler is in service without
having aspirating air ON.
The air seal should be reassembled by reversing the above procedure. Determine, that the
nozzle head is in the proper position. When the air seal chamber is secured the aspirating air
should be turned OFF and the seal air should be ON.
NOTE:

NOZZLES ARE TO BE ON THE OUTBOARD SIDE OF THE SCRAPER


PLATE WHEN THE BLOWER IS FULLY RETRACTED AND IN THE
AT REST POSITION.

The proper location of these soot blower nozzles should be checked prior to start-up and at
every outage. Should nozzle openings straddle the scraper plate or be on the inboard side, the
seal will be lost and furnace gas will escape which will destroy the lance tip.
Where design dictates that the blower lance be extra, long, so as to extend any blowing nozzle
beyond this air seal (or where half tract blowers are employed) with nozzles on the furnace
side of the scraper plate, while the blower is at rest special provisions are made to seal or
purge furnace gases from the blower.
Forced Pressure Air Valve
For those installations where nozzles are on furnace side of seal air chamber, a forced pressure air valve is located on the soot blower valve. Seal air is supplied to the forced pressure air
valve, by tubing connected to the seal air header. The forced pressure air valve acts as a check
valve to retain high pressure steam in the operating head valve while blowing. After blowing
has been completed, a small spring opens the check to admit seal air to the blower lance and
drive out furnace gases.
Check contract drawings and specifications to determine aspirator and seal air volume required. This will vary, depending on furnace pressure; there of, specifications on contract
drawings should be checked and followed.
Seal air pressure differential can be checked by extending the retracted soot blower nozzles to
the furnace side of the seal air chamber and through the wall sleeve into the furnace cavity
several inches. The blower is extended as far as possible without actuating the blowing valve
linkage. This will place the blowing nozzles in the furnace area, which will allow furnace
pressure into the lanceand back to the soot blower valve.
CAUTION:

SECURE BOTH BLOWING MEDIUM AND ELECTRIC DRIVE


CIRCUITS BEFORE EXTENDING THE LANCE FOR THESE
READINGS TO AVOID INJURY TO PERSONS TAKING THE
READINGS.

The furnace pressure reading can then be obtained on this individual soot blower by installing
a manometer in the 3/8 inch tap on the soot blower valve normally used to measure blowing
pressures.
The seal air pressure should be measured as close as possible to the inlet to theair seal downstream of all air hose fittings and branch line connections. This usually requires a tap in the
last fitting to the air seal manifold valve. The tap can be 1/8 or 1/4 inch pipe thread and a
standard pipe plug used to close the opening when readings have been completed.
With the lance extended and one leg of a U tube manometer connected to the soot blower
valve tap and the other leg of the manometer to the seal air supply (as described above) the
differential pressure between seal air supply and furnace presssure may be read directly on the
U tube.
29
1610 - 1611 VOL - C1 TAB - 7 - 160

At least two readings should be taken under two or more boiler load conditions. Readings are
desirable at nominal or high boiler loads and at relatively low boiler loads. These readings
should be checked against contract data to insure adequate seal air pressure and flow are
available.
Cover
Along with the air seal and aspirator assembly a cover is supplied separately for covering the
furnace opening, in case the seal is to be kept opened for extended period.

30
1610 - 1611 VOL - C1 TAB - 7 - 161

31
1610 - 1611 VOL - C1 TAB - 7 - 162

32
1610 - 1611 VOL - C1 TAB - 7 - 163

33
1610 - 1611 VOL - C1 TAB - 7 - 164

34
1610 - 1611 VOL - C1 TAB - 7 - 165

35
1610 - 1611 VOL - C1 TAB - 7 - 166

36
1610 - 1611 VOL - C1 TAB - 7 - 167

37
1610 - 1611 VOL - C1 TAB - 7 - 168

38
1610 - 1611 VOL - C1 TAB - 7 - 169

39
1610 - 1611 VOL - C1 TAB - 7 - 170

40
1610 - 1611 VOL - C1 TAB - 7 - 171

41
1610 - 1611 VOL - C1 TAB - 7 - 172

42
1610 - 1611 VOL - C1 TAB - 7 - 173

43
1610 - 1611 VOL - C1 TAB - 7 - 174

44
1610 - 1611 VOL - C1 TAB - 7 - 175

45
1610 - 1611 VOL - C1 TAB - 7 - 176

46
1610 - 1611 VOL - C1 TAB - 7 - 177

47
1610 - 1611 VOL - C1 TAB - 7 - 178

48

LRD IIE

1610 - 1611 VOL - C1 TAB - 7 - 179

49
1610 - 1611 VOL - C1 TAB - 7 - 180

50
1610 - 1611 VOL - C1 TAB - 7 - 181

51
1610 - 1611 VOL - C1 TAB - 7 - 182

52
1610 - 1611 VOL - C1 TAB - 7 - 183

53
1610 - 1611 VOL - C1 TAB - 7 - 184

54
1610 - 1611 VOL - C1 TAB - 7 - 185

55
1610 - 1611 VOL - C1 TAB - 7 - 186

56
1610 - 1611 VOL - C1 TAB - 7 - 187

57
1610 - 1611 VOL - C1 TAB - 7 - 188

58
1610 - 1611 VOL - C1 TAB - 7 - 189

59
1610 - 1611 VOL - C1 TAB - 7 - 190

60
1610 - 1611 VOL - C1 TAB - 7 - 191

61
1610 - 1611 VOL - C1 TAB - 7 - 192

62
1610 - 1611 VOL - C1 TAB - 7 - 193

TAB - 8

METHODS AND PROCEDURES


FOR INSTALLATION
SOOT BLOWERS

Bharat Heavy Electricals Limited


Tiruchirapalli

PUB.NO.7508

1610 - 1611 VOL - C1 TAB - 8 - 194

CONTENTS
INTRODUCTION
PRECAUTIONS FOR SOOT BLOWER ERECTION
IMPORTANT INSTRUCTIONS ERECTION AND START-UP-LONG
RETRACTABLE SOOT BLOWERS
IMPORTANT INSTRUCTIONS ERECTION AND START -UP-WALLDESLAGGER
IMPORTANT INSTRUCTIONS - ERECTION AND START-UP-ROTARY SOOT
BLOWER
LIST OF DRAWINGS
PREPARATION
ERECTION INSTRUCTIONS : LONG RECTRACTABLE SOOT BLOWER
ERECTION INSTRUCTIONS : WALL DESLAGGER
ROTARY SOOT BLOWER
FURNANCE TEMPERATURE PROBE
ERECTION INSTRUCTIONS : HALF RETRACTABLE SOOT BLOWER
ERECTION INSTRUCTIONS : TEH BLOWERS FOR AIR HEATERS
START UP CHECKS
ERECTION INSTRUMENTATIONS : SOOT BLOWER PIPING
START-UP CHECKS - PIPING
THERMAL OVERLOAD RELAY SETTING FOR SOOT BLOWER MOTOR
PROTECTION
CHECK SHEETS

2
1610 - 1611 VOL - C1 TAB - 8 - 195

INTRODUCTION
The following pages contain a recommended procedure for the erection and start-up of all types of
Soot Blowers and Furnace Temperature Probe manufactured by Bharat Heavy Electricals Limited,
Tiruchirapalli. Detailed operation and maintenance instructions are dealt in separate manuals.
The contents are compiled from the expertise available with us. Sufficient care has been taken to
include salient points on erection and commissioning based on the observations made at site as well
as on the feed back available from site.
Every possible care has been taken to ensure- the contents are accurate. Generally the procedure
has been profusely illustrated. It must be recognized that no amount of written instructions can
replace intelligent thinking and reasoning on the part of the erectors, especially when coping with
individual site conditions.
Suggestions for the improvement of the manual would be welcome.
BHARAT HEAVY ELECTRICALS LIMITED
BOILER PLANT - TIRUCHIRAPALLI

3
1610 - 1611 VOL - C1 TAB - 8 - 196

PRECAUTIONS FOR SOOT BLOWER ERECTION


STORE THE SOOT BLOWER COMPONENTS PROPERLY UNDER COVERED ROOF.
BLOWERS SHOULD BE LIFTED USING THE LIFTING LUGS/EYE BOLTS.
EXTRA CARE YOU TAKE DURING ERECTIONWILL ENSURE TROUBLE FREE
OPERATION.
REFER TO ENGINEERING DEPARTMENT FOR ANY DOUBTS/DEVIATIONS IN THE
DRAWINGS.
ENSURE ALL ERECTION WELDING IS DONE BY A CERTI FIED/QUALIFIED WELDER
ONLY.
CHECK THE BLOWER NOS. BEFORE INSTALLATION.
TONNAGE AND QUALITY ERECTION SHOULD GO HAND IN HAND.
INSPECT THE SQUARENESS AND CONCENTRICITY OF WALL BOX WITH RESPECT
TO OPENING.
OPERATE THE SOOT BLOWERS MANUALLY TO CHECK THE INTERFERENCE AFTER
INSTALLATION.
NEVER USE THE SOOT BLOWERS AS WELDING PLATFORM.

IMPORTANT INSTRUCTIONS ERECTION AND START-UP-LONG RETRACTABLE


SOOT BLOWERS
DOS
ERECTION
1.

Look for Blower Numbers on the name plates before erection.

2.

Operate the blower manually for checking the clearance inside.

3.

Check the squareness and concentricity of the wall box.

4.

Check for accessibility for the hand crank for manual operation.

5.

Use lifting lugs for lifting.

BEFORE START-UP
1.

Flush the power packs with SERVO SYSTEM 68 and fill them with the lubricants as
recommended.

2.

Check the DIRECTION OF ROTATION of both the MOTORS.

3.

Check whether all covers are put on the blower.

4.

Check the OPERATION of the STOP AND REVERSE LIMIT SWITCHES.

5.

Observe all safety practises.

6.

Check whether the correct blower is installed in the correct location.

7.

For air operated blowers:


(i)

Install lubricator and filter near the blower and adjust the lubricator..

(ii)

Ensure sufficient compressed air pressure at the inlet.

(iii)

Ensure sufficient quantity lubricant in the lubricator periodically.

ADDITIONAL INSTRUCTIONS FOR HALF RETRACTABLE SOOT BLOWERS AND THE


BLOWERS FOR AIR HEATERS.ERECTION
4
1610 - 1611 VOL - C1 TAB - 8 - 197

1.

USE CORRECT ELECTRODE FOR WELDING THE LANCE/BLOWING ARM.

2.

Check for Alignment of support bearings in the case of half retracts and support channels
in the case of LRNR-IE blowers for Air Heaters.

NOTE: FOR IMPORTANT INSTRUCTIONS ON START-UP, SHUT-DOWN AND


MAINTENANCE REF. INSTRUCTIONS MANUAL PUB. No. 7502 LONG
RETRACTABLE SOOT BLOWER.
DONTS
ERECTION
1.

Do not MIX UP the blowers.

2.

Do not use the housing as the welding platform.

3.

Do not place HEAVY LOADS on the blower.

4.

Do not place the blower on the platform without PROPER SUPPORT.

5.

Do not leave the lance at extended position.

BEFORE START-UP
1.

Do not operate the blower WITH WET STEAM..

2.

Do not operate WITHOUT BLOWING MEDIUM during boiler operation.

3.

DO NOT attempt maintenance WORK when POWER AND BLOWING medium are
ON.

4.

DO NOT crank the lance manually with STEAM SUPPLY ON.

5.

Do not operate the soot blower with excessive steam leakage through packing.

6.

Do not operate the blower in quick succession. MINIMUM ONE HOUR COOLING
PERIOD before subsequent operation is a must to avoid any damage to motor windings.

7.

For air operated soot blowers:


DO NOT OPERATE the blower WITHOUT LUBRICATOR AND FILTER.

8.

Do not over tighten the drive chains Noisy running is O.K., silent running is NOT Allowed.

NOTE: LONG RETRACTABLE SOOT BLOWER MODEL LRD-11E SHOULD HAVE


STEAM SUPPLY DURING EMERGENCY RETRACT.

IMPORTANT INSTRUCTIONS ERECTION AND START -UP-WALL-DESLAGGER


DOS
ERECTION
1.

Before erecting the blower, check the opening in the boiler wall. It shall be MINIMUM
80 MM through out.

2.

Before erecting the wall deslagger, check the wall sleeve for perpendicularity and
concentricity. Check the blower number with reference to location drawing.

3.

Check the ACCESSIBILITY FOR HAND CRANK and the switch box assembly.

4.

Check whether the WALL DESLAGGER IS PERPENDICULAR after mounting.

5.

Check the PROJECTION OF NOZZLE INTO THE WALL.

6.

Support the soot blower piping on the BOILER STEEL SUCH AS BUCK STAYS,
FURNACE GUIDES etc.
5
1610 - 1611 VOL - C1 TAB - 8 - 198

7.

Check and mark up those units where nozzle is not pointing downwards.

BEFORE START-UP
1.

FLUSH the gear boxes thoroughly with SERVOM ESH SP460 and fill the gear boxes
with the lubricants as recommended.

2.

Make sure the DRAIN HOLES in the MOTOR FRAMES point DOWNWARDS and
are open.

3.

Check the DIRECTION of rotation of both the MOTORS.

4.

Make sure that the stop nuts are in place on the GUIDE RODS.

5.

Check whether the COVERS are put on the blower.

6.

Check the perpendicularity of the blower when the boiler is working.

NOTE: FOR IMPORTANT INSTRUCIONS ON START- UP, SHUT-DOWN AND


MAINTENANCE.REFER INSTRUCTION MANUAL PUB. No. 7503 WALL
DESLAGGER.
DONTS
ERECTION
1.

DO NOT SUPPORT the blower separately unless otherwise specified.

2.

Do not use the blower as a platform/ladder.

3.

Do not support the soot blower piping from boiler columns and platforms.

4.

Do not place the blowers on the platform without proper support.

BEFORE START-UP
1.

DO NOT operate the blower with WET STEAM.

2.

Do not set the cam for Micro Limit Switches with POWER ON.

3.

Do not operate the blowers under low boiler loads without trial operation.

4.

Do not hand crank with power and/or steam ON.

IMPORTANT INSTRUCTIONS - ERECTION AND START-UP-ROTARY SOOT


BLOWER
DOS
ERECTION
1.

Erect the correct Blower in the correct location. (Look for the BLOWER NUMBER on
the reaction plate).

2.

Check for the ALIGNMENT of the SUPPORT BEARING of the blowing element.

3.

Look for the CORRECT BLOWING ELEMENTS as per the blower number given on
the element.

4.

Adjust the nozzle position as per requirement.

BEFORE START-UP
1.

FLUSH the power pack thoroughly with SERVO SYSTEM 68 and fill the same with
the lubricant recommended.

2.

Check whether the SWITCH BOX COVER is put on the blower.


6
1610 - 1611 VOL - C1 TAB - 8 - 199

3.

Check the DIRECTION OF ROTATION of the motor and blowing element.

4.

Check whether the CORRECT BSLOWER is installed IN THE CORRECT


LOCATION.

5.

For air operated blowers:


(i)

Install the LUBRICATOR AND FILTER near the blower and adjust the
lubricator.

(ii)

Ensure SUFFICIENT COMPRESSED AIR PRESSURE at the inlet.

(iii)

Ensure SUFFICIENT QUANTITY OF LUBRICANT in the lubricator


periodically.

NOTE:

FOR IMPORTANT INSTRUCTIONS ON START-UP, SHUT-DOWN AND


MAINTENANCE.REFER INSTRUCTIONS MANUAL PUB. No. 7504
ROTARY SOOT BLOWER.

DONTS
ERECTION
1.

DO NOT MIX UP the blower.

2.

Do not SUPPORT the blower EXTERNALLY unless otherwise specified.

3.

Do NOT USE the blower as the PLATFORM.

4.

Do not connect the seal air piping rigid. Connect it with a FLEXIBLE hose

5.

DO NOT MIX UP the blowing elements.

BEFORE START-UP
1.

Do not operate the blower with wet steam.

2.

Do not admit steam into the blower when the blowing element is stationary.

3.

Do not attend to any repair work with STEAM/POWER ON.

4.

Do not attempt manual rotation when power is ON.

5.

For air operated blowers:

DO NOT OPERATE THE BLOWER WITHOUT THE LUBRICATOR AND FILTER.


LIST OF DRAWINGS
(1)

4-00-073-60085

Long Retractable Soot Blower.

(2)

4-00-073-60086

Wall Deslagger.

(3)

4-00-073-60087

Rotary Soot Blower.

(4)

1-00-073-60059

Seal Air Connection for LRSB.

(5)

3-00-073-60039

Important of Blower Location.

(6)

3-00-073-60040

Typical Alignment of Blowing Element -(Rotary Blower).

(7)

3-00-073-60041

Erection of Wall Blower.

(8)

3-00-073-60044

Location of Filter & Lubricator.

(9)

3-00-073-60045

Erection of LRSB.

(10)

3-00-073-60046

Erection of LRSB.
7
1610 - 1611 VOL - C1 TAB - 8 - 200

(11)

3-00-073-60047

Supporting the Wall Deslagger on the Platform.

(12)

3-00-073-60049

Welding of Wall Sleeve.

(13)

3-00-073-60050

Supporting Rotary Soot Blower on the Platform.

(14)

4-00-073-60013

Flange Tightening Sequence.

(15)

4-00-073-60014

Lifting the Rotary Soot Blower.

(16)

4-00-073-60015

Piping Insulation (upto Valve Flange).

(17)

4-00-073-60016

LRSB Support.

(18)

4-00-073-60017

Supporting of Soot Blower Piping (WB-IE).

(19)

4-00-073-60057

Nozzle Adjustment.

(20)

4-00-073-60058

Supporting Long Retractable Soot Blower on the Platform.

(21)

4-00-073-60059

Alignment of Rotary Blower Element.

(22)

4-00-073-60060

Manual Operation of Rotary Blower.

(23)

4-00-073-60062

Alignment of Swivel Tube.

(24)

4-00-073-60063

Position of LRSB.

(25)

4-00-073-60064

Arrangement of the Valve during Steam Blowing.

(26)

4-00-073-60070

Setting of Wall Deslagger Control Cams.

(27)

4-00-073-60071

Draining Arrangement.

(28)

4-00-073-60072

Clearance Space around LRSB.

(29)

4-00-073-60073

Clearance Space around WB-IE.

(30)

4-00-073-60074

Clearance Space around RB-IE.

(31)

4-00-073-60075

Clearance Space around FTP-IE.

(32)

4-00-073-60076

Sealing Air Connection for RB-IE.

(33)

4-00-073-60088

LRD - I - Point Loading - Motors Rear Top Mounted.

(34)

4-00-073-60089

Furnace Temperature Probe - Support Point Loading.

(35)

4-00-073-60090

Seal Air Requirement Chart.

(36)

4-00-073-60091

Aspirating Air Requirements.


LEGEND

LRSB

Long Retractable Soot Blower

WB-IE

Wall Deslagger

RB-IE/RB-IA/RBIM -

Rotary Soot Blower

FTP-IE

Furnace Temperature Probe

8
1610 - 1611 VOL - C1 TAB - 8 - 201

LIST OF ERECTION DRAWINGS


BOILER

: ....................................................................................

CUSTOMER NO
:
....................................................................................
A.

LONG RETRACTABLE SOOT BLOWERS:

(i)

LRD-I Soot Blower Views.

(ii)

LRD-I Long Retrac:


Sleeve Views.

B.
(i)
C.

WALL DESLAGGER:
WB-IE Soot Blower Views.
ROTARY BLOWERS:

(i)

Rotary Blower Views.

(ii)

Blowing Element.

(iii)

Blowing Element.

(iv)

Blowing Element.

D.

FURNACE TEMPERATURE PROBE:

(i)

Furnace Temperature Probe Erection Views.

(ii)

Furnace Temperature Probe Sleeve Views.

E.

HALF RETRACTABLE SOOT BLOWER:

(i)

LRD-1 Half Retract Views.

(ii)

LRD-I Half Retract sleeve view

F.

TEH BLOWERS FOR AIR HEATERS:

(i)

LRNR-I Non Rotating Soot Blower Views.

(ii)

LRNR-I Non Rotating Soot Blower Sleeve Views.

G.
(i)

OTHERS:
Soot Blower Arrangement.

(ii)
(iii)
(iv)
(v)
(vi)

9
1610 - 1611 VOL - C1 TAB - 8 - 202

H.

SOOT BLOWER PIPING:

(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
1.

PREPARATION

(i)

Inventory the shipment and immediately report shortages.

(ii)

List out the damaged components with reference to the item number in the concerned
assembly drawings and report to Bharat Heavy Electricals Limited, Tiruchirapalli. Refer
the following manuals for the concerned assembly drawings.

(iii)

(a)

Pub. No. 7502: Long Retractable Soot Blowers - LRD-IE.

(b)

Pub. No. 7503: Wall Deslagger - WB-IE.

(c)

Pub. No. 7504: Rotary Soot Blower - RB-IE.

(d)

Pub. No. 7505: Furnace Temperature Probe - FTP-IE.

(e)

Pub. No. 7507: Long Retractable Soot Blower Air Operated - LRD-IA,

(f )

Pub. No. 7509: Long Retractable Soot Blower Model LRNR-IE.

(g)

Pub. No. 7511: Manual Rotary Soot Blower - Model RB-IM.

(h)

Pub. No. 7512: Rotary Soot Blower - Air operated - RB-IA.

(i)

Pub. No. 7513: Pneumatic Control Panel - CPP.

(j)

Pub. No. 7514: Long Retractable Soot Blower - LRD-11E..

Check Blower number ,as given in the shipping list/location drawings.

NOTE: ALL BLOWERS ARE NOT IDENTICAL


(iv)

Plan for tools, tackles, rigging and handling facilities required for the installation of the
Blowers.

(v)

Ensure that all documents like Erection Manuals, Erection Drawings and other relevant
documents are available before commencement of the erection. If not contact BHEL,
Tiruchy for complete documents.

(vi)

Programme a sequence of erection in relation to the type of the blowers being erected.
Economics and safety are equally important while erecting the blowers.

(i)

Transport

The soot blower assemblies are shipped completely covered with water proof coverings. UNLESS
THE BLOWERS ARE TAKEN FOR IMMEDIATE ERECTION, DO NOT DISTURB THE
10
1610 - 1611 VOL - C1 TAB - 8 - 203

COVERINGS. Replace the damaged covers wherever required.


Some assemblies like wall deslaggers; and rotary blowers are shipped with temporary wooden
platforms to prevent parts getting damaged during erection.
THESE ARE NOT TO BE REMOVED TILL THE BLOWERS ARE ERECTED. This will ensure
that the parts are not damaged during handling.
Cover all the electrical items with water proof and dust proof coverings. Nozzle and valve openings
are shipped covered. If any damages are noticed to the covering take necessary actions to rectify it.
(ii)

Storage

Normally storage under covered roof is not necessary for soot blowers. When the water proof
covers are removed, wall deslaggers; and rotary blowers must be stored under covered roof if the
interval between soot blower erection and receipt is more than one month.
Always use the lifting lugs or hooks provided to avoid damage to the connected parts Similarly
avoid hitting the assembly against the structures or other boiler components while the soot blowers
are being lifted.
Ensure that the air vent plug in the gear boxes are in place. Avoid leaving open holes in the gear
boxes. IF THE STORAGE PERIOD IS LIKELY TO EXCEED 2 MONTHS FILL THE GEAR
BOXES WITH OIL FOR PROTECTION.
Support the blowers properly during storage. Avoid stacking the blower or placing heavy weights
on the blowers.
(iii)

Weight

(a)

LongRetract: The weight varies with the travel. For actual values refer 4-00-073-60088.

(b)

Wall Deslagger: 150 Kg per blower.

(c)

Rotary Soot Blower: 90 Kg per blower.

(d)

Furnace Temperature Probe: The weight varies with travel. For actual weight refer
4-00-073-60089.

ERECTION INSTRUCTIONS : LONG RECTRACTABLE SOOT BLOWER


(i )

Supports

The long retractable soot blowers are to be supported at both boiler and rear ends. Unless otherwise
indicated in the drawing, the boiler end shall not be supported in the platforms. (Refer Drg.
4-00-073-60016).
Long retracts are normally slopped towards the boiler when the unit is working. To achieve this,
while erecting due consideration shall be given to the boiler expansion so that at boiler hot conditions
the blower will be slopping towards the boiler. This is to aid condensate drainage into the boiler after
the blowing operation is over. (Refer Drgs. 3-00-073-60045, 3-00-073-60046 & 4-00-073-60063).
The retractable soot blowers are also to be erected inclined considering the horizontal expansion, so
that when the boiler is working the blower will be perpendicular to the wall in the horizontal plane.
The expansion values at different soot blower points are given in the soot blower piping drawings.
NOTE: THIS SLOPE WILL NOT BE APPLICABLE TO HALF RETRACTS AND TUBULAR
AIR HEATER CLEANERS.
(ii)

Lifting

While lifting the long retractable soot blower take care to see that no damage is caused to the wiring
and other components by hitting with other structures. Use only the lifting lugs. It is suggested to
have wooden blocks on the sides of the housing so that the slings will not damage the electrical
wiring while lifting.
11
1610 - 1611 VOL - C1 TAB - 8 - 204

CAUTION: DO NOT REMOVE THE WOODEN GUARDS (Refer Drg. 4-00-073-60058).


(iii)
(a)
(b)

General
Ensure adequate clearance for the lance removal.
Weld the wall boxes with the seal box in such away that the wall box centre line is
perpendicular to the water wall and concentric to the opening (Refer Drgs. 3-00-073-60045
& 3-00-073-60046).

If the lance does not travel perpendicular to the water wall, at the end of forward travel, the gap
between the lance and the nearby tube will be very small. This may lead to erosion and damage to
boiler tubes.
(c)

The mounting lugs should be kept horizontal (Refer Drg. 3-00-073-60049) while welding
the wall sleeve assembly.

(d)

IMPORTANT: Ensure that the correct blower is erected at the correct location. (Refer
Drg. 3-00-073-60039). The blower number on the name plate should correspond to the
location number in the drawing. All the long retractable blowers are not identical. For example
the size, shape, and position of the nozzle, the material composition of the lance etc., will be
different. Interchanging of the blower will result in damage of the lance tube. Record the
blower Number in 13A Check Sheet Blower Number.

(e)

After erecting the long retracts, move the lance forward and backward to check whether
the gap between the lance edge and the boiler tubes is uniform after considering the
allowance kept for horizontal vertical expansion.

(f )

After the electrical connections have been completed, close the terminal box with the
terminal box cover. The cover should be tightened with all screws and gaskets to make
the terminal box weather proof. The incoming cables should be flexible to take up blower
movements and the connections should be properly sealed.

(g)

Check whether the scraper plate in the blower assembly rides on the lance loosely. There
should not be any binding.

(h)

In the case of pressurised boiler ensure that the nozzle does not lie in the seal chamber
(Refer Drg. 1-00-073-60059).

(i)

Do not remove the flange protection plate and the wooden block attached to the
blower
near the boiler end, till, the blower is installed. These will protect
the blower parts and the
sealing face of the flange.

(j)

While erecting the blower ensure that the minimum access is available for maintenanc.Refer
Drg. 4-00-073-60072. It is not possible to alter the soot blower locations, since these are
linked up with the boiler tubes inside. Modification can be only on the structures and
platforms wherever required.

(k)

Do not place any heavy objects on the blowers. They are not designed for taking such
heavy loads.

(l)

For Air Operated Long Retracts, install the lubricator and filter very close to the blower
(Refer Drg. 3-00-073-60044).

(m)

Do not use the blower as the welding platform

IMPORTANT: THE AIR INLET CONNECTIONS SHALL BE KEPT COVERED TILL THE
AIR PIPING IS CONNECTED.
12
1610 - 1611 VOL - C1 TAB - 8 - 205

ERECTION INSTRUCTIONS : WALL DESLAGGER


(i)

Supports

The wall deslaggers are not to be separately supported unles otherwise specified. The wall deslagger
along with its wall box should be welded with the seal box (Refer Drg. 3-00-073-60041).
(ii)

Lifting

Use the eye bolt provided for lifting the wall deslagger see Fig. Since some of the components like
gear housing etc., are made of aluminium, care should be taken while lifting the blowers so that
these parts will not get damaged.
IMPORTANT: Careless handling will break the casting connecting the switch box. DO NOT
REMOVE THE WOODEN PLATFORMS TILL THE BLOWER IS ERECTED. (Refer Drg.
3-00-073-60047)
(iii)

General

(a)

Ensure adequate clearance for access to the.switch box and hand cranking (Refer Drg.
4-00-073-60073).

(b)

IMPORTANT: WELD THE WALL BOX WITH THE SEAL BOX IN SOCH A WAY
THAT THE WALL BOX CENTRE LINE IS PERPENDICULAR TO THE WATER
WALL. IF THIS IS KEPT UP, THE NOZZLE CENTRE LINE WILL
AUTOMATICALLY BE PARALLEL TO THEWATERWALL. WALL BOX SLEEVE
ALSO SHOULD BE CONCENTRIC TO THE SLEEVE BOX OTHERWISE
INTERFERENCE OF THE SWIVEL TUBE WITH THE WATER WALL WILL
RESULT (Refer Drgs. 3-00-073-60041 & 4-00-073-60062).

(c)

Check all wall daslaggers for the following :

Axis of swivel tube is to be perpendicular to plane of boiler wall tubes. NO DEVIA.


TION CAN BE ALLOWED!

Distance of centre line of clearing nozzle to face the boiler tubes to be cleaned must be 38
mm. (Refer Drg. 4-00-073-60057). This should be set from inside the furnace only. After
this is set by mounting studs and nuts, punch mark the setting on the alignment plate,
taking the wall box flange as the reference. This will be helpful for quick adjustment for
setting, if blowers are dismantled and re-erected for detailed instructions see (iv) Nozzle
adjustment.

(d)

Ensure the incoming cables to the switch box are flexible and supported externally.
Connections shall be sealed water tight.

(e)

The piping for wall blower should always be supported on the buckstays, furnace guides
etc., and never on the supporting structures of platform (Refer Drg. 4-00-073-60017).

(f )

Never allow anybody to stand on the wall deslaggers. This will damage the components
and also whatever adjustment done earlier will be lost. See Fig. 8. NEGLIGENCE OF
THIS WILL RESULT IN TUBE FAILURE.

(g)

Ensure the blower with the correct blower number is erected at the correct location.
Some wall deslaggers may have limited angle blowing arrangement.

(h)

Do not place any heavy load on the blower especially on the switch box. If this is NOT
FOLLOWED THE SWITCH MOUNT CONNECTOR WILL BREAK.

(i)

Before erection, verify whether the nozzle is pointing downwards. If not mark up those
units for adjustments during start up.
13
1610 - 1611 VOL - C1 TAB - 8 - 206

(iv)

Nozzle adjustment

Nozzle alignment should be made from inside the furnace, referencing the centre line of the nozzle
and wall tube surface, with the nozzle opening parallel to the wall tubes. If the units are set from
outside the boiler through expediency, they should be checked from inside at the first opportunity.
A tool (gauge) for checking the 38 mm nozzle position is supplied in PGMA 20-998 and this could
be used for setting the nozzle position properly thig method of checking from inside is preferred.
Since it is not always possible or practical to check and adjust the location of the wall blower nozzle
from inside the boiler, the following procedure can be used for determining the nozzle location from
outside the boiler, with blower removed. Care must be taken to make sure the proper A dimension
is established between the centre line of the nozzle and the face of the tube (usually 38 mm). Refer
to job drawings for the proper dimensions. The swivel tube should be fully extended with the hand
crank and a measurement taken from the centreline of the nozzle to the face to steam chest flange.
This is shown as dimension B on Drg. 4-00-073-60057.
A rod of sufficient length to reach through the boiler wall, with 76 mm hook bend at 900 to its
longitudinal axis is used, as shown in the drawing, to establish the location of the inside adjustment
nuts on the mounting studs in relation to the tube. This is shown as dimension C. (This is to be
carried out before mounting the blower.)
Dimension Cis equal to dimension Bminus dimension A. The length Co should then be marked
on the rod and the adjusting nuts set to this dimension.Otten the unit is installed, it should be checked
to make sure that it is prependicular with the boiler wall, to ensure cleaning through the full blowing
arc.
The sweep should then be set, if possible, so that the nozzle is pointing down, or in the 6 Oclock
position, when the head opens. This helps to prevent tube cutting from condensate since the
nozzle blows parallel with the tube when the head first opens and condensate is blown of before
the jet sweeps across tubes (Refer Drg. 4-00-073-60057).

5.

ROTARY SOOT BLOWER


(i)

Supports

The rotary blowers need not be externally supported unless otherwise specified. The rotary blower
along with its wall sleeves should be either welded of fastened as the case may be.
(ii)

Lifting

Use the eye bolt provided on the blower for lifting. Since some of the components like reaction
plate, switch box are made of aluminium, care should be taken (Refer Drg. 4-00-073-60014) while
lifting to avoid damage to these parts.
(iii)

General

(a)

Ensure adequate clearance for the access to switch box and hand cranking (Refer Drg
4-00-073-60074).

(b)

Weld the wall boxes with the seal box in such a way that the wall box centre line is
perpendicular to the wall and also concentric. If this is kept up the nozzle centre line will
come parallel to tube lanes (Refer Drg. 3-00-073-60040).

(c)

Align the supports for blowing element properly.


If this is not carried out correctly, blowing element may fail or motor may get overloaded
(Refer Drg. 4-00-073-60059)

(d)

Unless otherwise indicated, keep the nozzle position of the blowing element downwards
at rest (Refer Drg. 3-00-073-60040). Punch rmarks on element indicate nozzle position
14
1610 - 1611 VOL - C1 TAB - 8 - 207

(See Fig.).

7.

(e)

Do not allow the men to stand or place heavy weight on rotary blowers, this will damage
the components and dislocate the alignment.

(f)

Ensure the incoming power and control cables are flexible and supported externally The
connections shall be leak tight.

(g)

After the installation check the nozzle position for correctness. The nozzle position should
be always as indicated in drg.

(h)

Ensure proper element is kept at proper location. The position numbers are usually
punched/stencilled at shop (Refer the concerned erection drg.). Element for high
temperature areas will be stainless steel or chrome plated. ALL ELEMENTS ARE NOT
IDENTICAL.

(i)

Install the correct blower in the correct location. There may be variation in the angle of
blowing and the direction of rotation. ALL ROTARY HEADS ARE NOT SAME.

(j)

DO NOT REMOVE THE WOODEN PLATFORMS TILL THE BLOWER IS


ERECTED (Refer Drg. 3-00-073-60050).

(k)

or detailed instructions on setting the blowing sweep refer to Pub, No. 7504-00, Rotary
Soot Blower, Section 4.

FURNANCE TEMPERATURE PROBE


(i)

Supports

The Furnace Temperature Probe is to be supported at both boiler and rear ends. Unless otherwise
indicated in the drg., the boiler end shall not be supported in the platforms. While erecting due
consideration shall be given to the boiler expansion so that at hot boiler conditions the probe will be
horizontal and perpendicular to the plane of water wall.
ii)

Lifting

Refer to Section 3 (ii) Long Retractable Soot Blower.


iii)

General

(a)

Before installation, the thermocouple head should be checked.

(b)

Weld the wall box on the seal box so that the wall box centre line is perpendicular to the
water wall and concentric to the opening.

Eye hangers are provided for lifiting.Use them.DO not wrap around the wall deslagger for
lifting.
15
1610 - 1611 VOL - C1 TAB - 8 - 208

(c)

Ensure adequate clearance for hand cranking and accessibility to other parts (Refer drg.
4-00-0173-00075).

ERECTION INSTRUCTIONS : HALF RETRACTABLE SOOT BLOWER


(i)

Supports

Half retract shall be horizontal when the Boiler is steaming. While erecting consider the boiler expansion for mounting the Half retract. Refer the relevant contract drgs. for expansion values. Blower
should be supported at both boiler and rear ends as indicated for long retractable soot blower.
(ii)

Lifting

Refer to Section 3 (ii) of Long Retract.


(iii)

Alignment of Supports

The lance extension requires support inside the boiler. This support is to be correctly aligned with
the soot blower opening. If it is not done, motor will get overloaded and/or lance will break
(iv)

Alignment of Lance

The lance extension is to be welded with the lance tube in the field. The lance after welding shall be
horizontal. Check the same in different planes using the spirit level.
(v)

Welding of Lance

Material of the lance, may be carbon or alloy steel, hence correct electrodes to be used for this
weld. If in doubt, please get the confirmation. This weld is a pressure containing weld and shall be
tested by Radiography.
(vi)

Lance Supports

After welding the lance check whether the lance rests on the supports. Extend the lance using the
hand crank and check whether there is any bending.

ERECTION INSTRUCTIONS : TEH BLOWERS FOR AIR HEATERS


(i)

Supports

Supports to be provided at (a) Wall box (b) at the rear end. The blower shall be horizontal during
erection.
(ii)

General

(a)

Alignment of the cross arm to the lance tube to be correctly carried out to prevent binding
of the lance.

(b)

The weld between the cross arm and the lance tube is a pressure weld, and this is to be
done by a high pressure welder.

(c)

Use the correct electrode for this joint. If in doubt get the confirmation.

(d)

Before welding the cross arm, move the cross arm to the full length along the guide
channels. It shall move smoothly.

(e)

After welding, extend the lance and check whether the movement is smooth. Take corrective
action if the movement is tight.

(f)

Check the level of the support channel before welding the cross arm.

9. START UP:START UP CHECKS


9.1

Long Retractable Soot Blower

(i)

Correct blower at correct location.


16
1610 - 1611 VOL - C1 TAB - 8 - 209

(ii)

Check the retract slope.

(iii)

Check the chain tightness, if loose tighten the adjusting screws provided on the jack shaft
bearing as per the requirement. See Fig. 12 and refer the Instructions Manual Pub. No.
7502: Long Retractable Soot Blower.

(iv)

Check whether stop pin is present on the cam bracket.

(v)

Check the operation of the limit switches.

vi)

Check whether the clutch is engaged.

(vii)

Check the direction of rotation of the lance tube (Rotation should be counter-clockwise
viewing from the rear and of the blower.)

(viii)

Check whether the proper lubricants are filled up in the gear box and travelling carriage.

(ix)

Check the position of the valve opening cam.

(x)

Extend the lance manually to check the clearance on the sides. Power shall be off during
manual operation. For manual operation, declutch.

(xi)

Close the terminal box with all screws after power and control wiring.

(xii)

Check for the smooth operation of the valve opening linkages. Jerky operations must be
corrected.

CAUTION:

DO NOT OPERATE MANUALLY WHILE BLOWING MEDIUM IS ON.

9.2

Wall Deslaggers

(i)

Extend the swivel tube manually to see whether it interferes with the water wall tube.

(ii)

Check the nozzle at the extended portion. The nozzle shall be pointing down at the start of
the cycle.

(iii)

Check operation of the micro limit switches and set the same by operating the manual
crank - For setting Limit Switches Refer Detailed Drg. 4-00-073-60070.

(iv)

Check whether the cable to rotary gear box is cleared while the gear box is advancing.

(v)

Check the direction of rotation of swivel tube. Usually it will be clockwise viewing from
the rear end of the blower.

(vi)

Check whether the switch box is tightly closed.

(vii)

Check whether the lubricants are filled in the gear boxes.

(viii)

Check whether the limit switch operating cam on the swivel tube is correctly positioned.

(ix)

Check whether the nuts on the guide rods are present. If not, do not operate till they are
placed.

CAUTION:

DO NOT OPERATE MANUALLY WHILE POWER IS ON.

17
1610 - 1611 VOL - C1 TAB - 8 - 210

9.3

Rotary Soot Blower

(i)

Disengage the coupling and check the rotation of the blowing element with a spanner
(Refer Drg. 4-00-073-60060).

(ii)

Check the starting position of the blowing, the direction, angle of blowing, and the nozzle
position.

(iii)

Check the operation of the valve opening and closing mechanism.

(iv)

Check whether the switch box cover is closed tightly.

(v)

Check whether the correct blowing element is erected at the correct location.

(vi)

Check whether the proper lubricants are filled in the gear box.

9.4

Half Retractable Soot Blower

(i)

Check the points (i) to (xi) given under 9.1.

(ii)

Operate the blower, during the hot boiler condition and check whether motors draw more
current than the rated.

CAUTION: DO NOT OPERATE THE BLOWER IN DECLUTCHED CONDITION WITH


STEAM.
9.5

T.E.H. Blowers or Air Heaters

(i)

Check the points (i) to (xi) given under Section 9.1.,

(ii)

Operate the blower during the hot boiler condition and check whether the motor draws
more current than the rated.

CAUTION: DO NOT OPERATE THE BLOWER IN DECLUTCHED CONDITION WITH


STEAM.
9.6

Air Operated Long Retractable and Rotary Soot Blowers

(i)

Check whether the lubricator and filter are in the compressed air line and fill the lubricator
and adjust the same for 5 drops/mt.

(ii)

Check the pressure of the compressed air. It should be min. of 80 PSIG at the Soot
Blower.

(iii)

Check for air leakages in the power and control air lines.

9.7

Furnace Temperature Probe

(i)

Check the chain tightness and presence of rusting.

(ii)

Check the operation of the Limit Switch.

(iii)

Check whether the proper lubricant is filled in the gear box.

(iv)

Check all thermocouple junction for tight terminal connections.

(v)

Check for pressure tightness of the air hose if the probe is provided with air cooling
arrangement and the required air pressure.
18
1610 - 1611 VOL - C1 TAB - 8 - 211

(vi)

Use the Rheostat for adjusting position indicator.

(vii)

Check whether the temperature Indicating/recording circuit is provided with temp high
retract interlock.

9.8

General

(i)

All the gear box should be checked for lubricant at required quantity and topped up if
necessary. All the air vents should be in place

(ii)

Check all the valve operating linkages, the valve opening setscrew should project sufficiently
to open the valve.

(iii)

Check the IR value of the motors. Normally all motors will be alright, since all are weather
proof.

(iv)

If boiler is not working all the blower can be electrically operated with local push button
stations without steam. Check the correct directions of rotation/operation.

(v)

When the soot blower is in operation observe the smoothness of valve opening and
closing, the operation should be smooth without any jerks. Check whether retract lance is
rotating while advancing.

(vi)

Check the electrical overload relays and thermal relays for proper matching with the soot
blower motor particulars.

(vii)

If orifice is indicated in the valve head, check whether this is installed.

(viii)

Check before operating on steam whether the valve opening screws will open the valve.

(ix)

If the furnace is pressurized check whether seal and aspirating air have been connected
properly and required pressure is available.

(x)

Check whether lubricator and filter are provided in air line for AIR OPERATED SOOT
BLOWER, and proper lubricant with sufficient quantity is available.

(xi)

Follow the commissioning procedures for commissioning the soot blowers as indicated in
Pub. No. 7501 Soot Blower: General Instructions.

(xii)

Set the blowing pressures on all blowers as per the chart given in General Instruction
7501 (or concerned contract drg.)
Follow the procedure as indicated in General Instruction 7501 and record in 13-B Check
Sheet: Blowing Pressure.

NOTE: IN CASE THE CONTROL PANEL AS WELL AS MOTOR CONTROL CENTRE


ARE NOT READY, PRE-COMMISSIONING OF SOOT BLOWERS CAN BE
CARRIED OUT USING A TEST CONTROL BOX. FOR THE DETAILED
INFORMATION ON THIS, CONTACT BHEL, TIRUCHY.

ERECTION INSTRUMENTATIONS : SOOT BLOWER PIPING


10.1

SOOT BLOWER PIPING

(i)

Routing

Routing of the pipe line shown in the concerned contract drawing is suggestive. Carry out the final
routing suitably considering the following points.
(a)

Easy accessibility for operation and maintenance of valves and fittings.

(b)

Adequate head room wherever the tubes are crossing walkways and platforms.

(c)

Enough clearance for pipe from structural members.


19
1610 - 1611 VOL - C1 TAB - 8 - 212

(d)

Adequate flexibility to absorb differential expansion.

(e)

Clearance from approach to doors and other apertures.

(ii)

Drain

Erect the piping with adequate slope (5to 15) so that the drain canflow away promptly. Avoid
horizontal pipe arrangement. If unavoidable provide suitable drain piping to the vertical header.
iii)

Support the pipe line with eye hooks (eye hangers) as indicated in the concerned contract
drawing.

iv)

Support the pipe line to wall deslaggers to boiler steel such as buck stays, furnace guides
instead of supporting on structural steel.

(v)

Provide the expansion loops as indicated in the concerned contract drawing.

(vi)

Insulate the soot blower piping upto the valve head mating flange as shown in Drg. No.
4-00-073-60015.

vii)

Tubes, angles, channels are issued in running meters and to be cut for the required lengths
at site.

viii)

Prepare the edge preparations for the tubes as per standard edge preparation.

(ix)

Carry out the welding with the certified welders.

(x)

Do not,support the piping on the soot blower valve.

(xi)

Support,the safety valve exhaust pipe as indicated in the concerned contract drawing.

xii)

Use pipe anchors and pipe guides as suggested in the contract drawing.

xiii)

Follow the sequence of tightening of the soot blower companion flange and the valve
head as indicated in Drg. No. 4-00-073-60013.

10.2

SEAL AIR PIPING - ERECTION

Seal air piping is provided to prevent the flue gases escaping through the wall openings in the case of
pressurised furnace. Normally seal air is taken from forced draft fan outlet.
(i)

Avoid sharp bends in the air line.

(ii)

Avoid rigid connections to the blower and use flexible rubber hoses in between the air line
header and the blower to prevent the boiler expansion stressing the seal air piping.

(iii)

See that all the connections are air tight.

(iv)

Connect the seal air line to the points indicated in the respective soot blowers. These will
normally be indicated in the contract drawings (Refer Drg. 1-00-073-60059
4-00-073-60076).

10.3

ASPIRATING AIR PIPING-ERECTION

Aspirating air is provided in the pressurised wall boxes of long retracts and furnace probes to
facililate their removal while the boiler is working. This line taken from the plant compressed air
system, and will be having a pressure of minimum 5 Kg/cm2 g.
(i)

Avoid sharp bends.

(ii)

All joints shall be pressure tight.

(iii)

Provide an orifice to reduce to the required pressure.

(iv)

Isolating valves are to be provided for each air connection to the blowers.

20
1610 - 1611 VOL - C1 TAB - 8 - 213

11.

START-UP CHECKS - PIPING


(i)

Soot Blower Piping (Steam)

(a)

Check expansion loops for thermal expansion provision.

(b)

Check for slope drainage.

(c)

Condensate drainage shall be from trap to atmospheric pressure.

(d)

Condensate drainage through permanent leak off valve shall be to blowdown tank.

(e)

Check whether the piping is supported with sufficient pipe hangers.

(f )

Check whether the piping at the wall blower locations are supported at the buck stays or
furnace guides etc.

(g)

Carry out the hydraulic test at the pressure of 70 Kg/cm2 g in the piping. While doing so
check whether all the flanges are blanked with blank flange supplied in P.G. 21. The soot
blower valve heads are not to be included. DO NOT PRESSURIZE THE VALVE MORE
THAN THE T.C. VALVE

(h)

Blow off the piping with steam as suggested below:

The practice of steam blowing the main line (main vertical header) through the drain valve will result
in incomplete cleaning of the branch line, which may lead to valve failure and Scoring of the finely
ground feed tube and swivel tube.
TO AVOID THIS, BLOW THE INDIVIDUAL LINES TO SOOT BLOWER SEPARATELY.
During steam blowing protect the valve internals. Use a flat sheet to cover the valve flange and tie it
with the flange, as shown in Drg. 4-00-073-60064. The pressure of steam blowing should be
minimum 15 Kg/cm2g. At this time keep the control valve, full open and drain valve closed. Repeat
the blow 3 or 4 times for each branch.
(i)

Check and record the warming up time required for the piping. Identify the branches
where water hammer is present. Additional drain connections may be required in these
lines, since the slope is not sufficient for draining the condensate (Refer Drg.
4-00-073-60071).

(j)

Check the function of the control valve. Control valve shall be in operation before
commencing the soot blower operation. Check control valve function when the soot
blower is in operation. Safety valves will not open if the control valves are acting fast
enough.

(k)

Check for leakages and binding in the aspirating and seal air lines.

(l)

Check the differential pressure of seal air when the seal air is on. This check will ensure
adequate seal air pressure for each opening (Refer Drg. 1-00-073-60059). Check whether
the measured pressure is correct as given in 4-00-073-60090 (for Retracts and Probe).

(m)

Check the function of the aspirating arrangement for proper working.

(n)

Check pressurized furnace seal air systems.

(o)

Check the aspirating air pressure on all blowers and check for correctness as given in
4-00-073-60091 (for Retracts and Probe).

21
1610 - 1611 VOL - C1 TAB - 8 - 214

(ii)

Pressurized Furnace Seal Air Systems

A.

Retracts

(a)

Check all nozzles to see that all parts of nozzles are within two scraper plates that form the
seal air void in the case of two scraper plate design. This should be checked and inspected
before boiler operation.

(b)

Follow the instructions of extending blowing nozzles into furnace and reading seal air
pressure differential against dynamic seal air supply pressure where it enters the manifold
valve on the air seal aspirator assembly.

(c)

Where nozzles are extended beyond seal air void, as on short stroked or extended lances
on half retracts and air preheater cleaners, see that the forced pressure air valves are
properly installed and properly supplied with seal air.

(d)

Make certain all manifold valves are correctly positioned to deliver seal air when boiler is
under load and being fired.

B.

Wall Deslagger

(a)

Follow instructions on extending blowing nozzles into furnace and reading sealair pressure
differential against dynamic seal air supply pressure where it entres wall box adoptor.

(b)

Check all wall deslaggers to see they are properly equipped with forced pressure air
valves are properly tubed and supplied with seal air so as to purge blower internals.

(c)

Make certain that all 3 way supply valves on the seal air aspirator combined supply line
are correctly positioned to supply seal air when the boiler is fired.

22
1610 - 1611 VOL - C1 TAB - 8 - 215

23
1610 - 1611 VOL - C1 TAB - 8 - 216

13-A CHECK SHEET: BLOWER NUMBER

S 1. N o.

Type of Soot
Blowe r

Blowe r No.

As in Contractdrg.
drg

As e re cte d

S 1.N o.

Type of Soot
Blowe r

Blowe r No.

As in Contract drg.

As e re cte d

24
1610 - 1611 VOL - C1 TAB - 8 - 217

13-A CHECK SHEET: BLOWER NUMBER

S 1. N o.

Type of Soot
Blowe r

Blowe r No.

As in Contractddrg
rg.

As e re cte d

S 1.N o.

Type of Soot
Blowe r

Blowe r No.

As in Contract drg.

As e re cte d

25
1610 - 1611 VOL - C1 TAB - 8 - 218

13-A CHECK SHEET: BLOWER NUMBER

S 1. N o.

Type of Soot
Blowe r

Blowe r No.

As in Contractddrg
rg.

As e re cte d

S 1.N o.

Type of Soot
Blowe r

Blowe r No.

As in Contract drg.

As e re cte d

26
1610 - 1611 VOL - C1 TAB - 8 - 219

13-A CHECK SHEET: BLOWER NUMBER

S 1. N o.

Type of Soot
Blowe r

Blowe r No.

As in Contractddrg
rg. As e re cte d

S 1.N o.

Type of Soot
Blowe r

Blowe r No.

As in Contract drg.

As e re cte d

27
1610 - 1611 VOL - C1 TAB - 8 - 220

13-B CHECK SHEET: BLOWING PRESSURE


TIME FOR WARM UP : IN MINUTES
Blowing pre s s ure
S 1.N o.

Type of Soot
Blowe r -

Blowe rNo.

As in Contract
drg.in kg/cm2(g)

As me as ure d
in kg/cm2(g)

Blowing pre s s ure


S 1.N o.

Type of Soot
Blowe r

Blowe rNo.

As in Contract drg.in
kg/cm2(g)

As me as ure d in
kg/cm2((g)
g)

28
1610 - 1611 VOL - C1 TAB - 8 - 221

13-B CHECK SHEET: BLOWING PRESSURE


TIME FOR WARM UP : IN MINUTES
Blowing pre s s ure
S 1.N o.

Type of Soot
Blowe r -

Blowe rNo.

As in Contract
drg.in kg/cm2(g)

As me as ure d
in kg/cm2(g)

Blowing pre s s ure


S 1.N o.

Type of Soot
Blowe r

Blowe rNo.

As in Contract drg.in
kg/cm2(g)

As me as ure d in
kg/cm 2(g(g)
)

29
1610 - 1611 VOL - C1 TAB - 8 - 222

13-B CHECK SHEET: BLOWING PRESSURE


TIME FOR WARM UP : IN MINUTES
Blowing pre s s ure
S 1.N o.

Type of Soot
Blowe r -

Blowe rNo.

As in Contract
drg.in kg/cm2(g)

As me as ure d
in kg/cm2(g)

Blowing pre s s ure


S 1.N o.

Type of Soot
Blowe r

Blowe rNo.

As in Contract drg.in
kg/cm2(g)

As me as ure d in
2
kg/cm ((g)
g)

30
1610 - 1611 VOL - C1 TAB - 8 - 223

13-B CHECK SHEET: BLOWING PRESSURE


TIME FOR WARM UP : IN MINUTES
Blowing pre s s ure
S 1.N o.

Type of Soot
Blowe r -

Blowe rNo.

As in Contract
drg.in kg/cm2(g)

As me as ure d
in kg/cm2(g)

Blowing pre s s ure


S 1.N o.

Type of Soot
Blowe r

Blowe rNo.

As in Contract drg.in
kg/cm2(g)

As me as ure d in
kg/cm2((g)
g)

31
1610 - 1611 VOL - C1 TAB - 8 - 224

13-C CHECK SHEET: SEAL AIR PRESSURE


FOR PRESSURISED BOILERS

S 1.N o.

Type of s oot
Blowe r

Blowe r No.

Se al Air Pre s s ure

As in. Contract
drg.in mm of
Wate r Column

As me as ure d
in mm of
Wate r Column

Sl. No.

Type of Soot
Blowe r

Blowe r No.

Se al Air Pre s s ure

As in Contract drg. in
mm of Wate r Column

As me as ure d in
mm of Wate r
Column

32
1610 - 1611 VOL - C1 TAB - 8 - 225

13-C CHECK SHEET: SEAL AIR PRESSURE


FOR PRESSURISED BOILERS

S 1.N o.

Type of s oot
Blowe r

Blowe r No.

Se al Air Pre s s ure

As in. Contract
drg.in mm of
Wate r Column

As me as ure d
in mm of
Wate r Column

Sl. No.

Type of Soot
Blowe r

Blowe r No.

Se al Air Pre s s ure

As in Contract drg. in
mm of Wate r Column

As me as ure d in
mm of Wate r
Column

33
1610 - 1611 VOL - C1 TAB - 8 - 226

13-C CHECK SHEET: SEAL AIR PRESSURE


FOR PRESSURISED BOILERS

S 1.N o.

Type of s oot
Blowe r

Blowe r No.

Se al Air Pre s s ure

As in. Contract
drg.in mm of
Wate r Column

As me as ure d
in mm of
Wate r Column

Sl. No.

Type of Soot
Blowe r

Blowe r No.

Se al Air Pre s s ure

As in Contract drg. in
mm of Wate r Column

As me as ure d in
mm of Wate r
Column

34
1610 - 1611 VOL - C1 TAB - 8 - 227

13-C CHECK SHEET: SEAL AIR PRESSURE


FOR PRESSURISED BOILERS

S 1.N o.

Type of s oot
Blowe r

Blowe r No.

Se al Air Pre s s ure

As in. Contract
drg.in mm of
Wate r Column

As me as ure d
in mm of
Wate r Column

Sl. No.

Type of Soot
Blowe r

Blowe r No.

Se al Air Pre s s ure

As in Contract drg. in
mm of Wate r Column

As me as ure d in
mm of Wate r
Column

35
1610 - 1611 VOL - C1 TAB - 8 - 228

13-D CHECK SHEET:


WALL DESLAGGER NOZZEL SETTING

S 1.N o.

Blowe r.No.

Dime ns ions in mm
'A'

'B'

'C'

SI. No. Blowe r.No


'B-C'

Dime ns ions in mm
'A'

'B'

'C'

'B-C'

36
1610 - 1611 VOL - C1 TAB - 8 - 229

13-D CHECK SHEET:


WALL DESLAGGER NOZZEL SETTING

S 1.N o.

Blowe r.No.

Dime ns ions in mm
'A'

'B'

'C'

SI. No. Blowe r.No


'B-C'

Dime ns ions in mm
'A'

'B'

'C'

'B-C'

37
1610 - 1611 VOL - C1 TAB - 8 - 230

13-D CHECK SHEET:


WALL DESLAGGER NOZZEL SETTING

S 1.N o.

Blowe r.N o.

D ime ns ions in mm
'A'

'B'

'C'

SI. N o. Blowe r.N o


'B-C'

D ime ns ions in mm
'A'

'B'

'C'

'B-C'

38
1610 - 1611 VOL - C1 TAB - 8 - 231

13-D CHECK SHEET: WALL DESLAGGER NOZZEL SETTING

S 1.N o.

Blowe r.No.

D ime ns ions in mm
'A'

'B'

'C'

SI. No. Blowe r.No


'B-C'

D ime ns ions in mm
'A'

'B'

'C'

'B-C'

39
1610 - 1611 VOL - C1 TAB - 8 - 232

40
1610 - 1611 VOL - C1 TAB - 8 - 233

41
1610 - 1611 VOL - C1 TAB - 8 - 234

42
1610 - 1611 VOL - C1 TAB - 8 - 235

43
1610 - 1611 VOL - C1 TAB - 8 - 236

44
1610 - 1611 VOL - C1 TAB - 8 - 237

45
1610 - 1611 VOL - C1 TAB - 8 - 238

46
1610 - 1611 VOL - C1 TAB - 8 - 239

47
1610 - 1611 VOL - C1 TAB - 8 - 240

48
1610 - 1611 VOL - C1 TAB - 8 - 241

49
1610 - 1611 VOL - C1 TAB - 8 - 242

50
1610 - 1611 VOL - C1 TAB - 8 - 243

51
1610 - 1611 VOL - C1 TAB - 8 - 244

52
1610 - 1611 VOL - C1 TAB - 8 - 245

53
1610 - 1611 VOL - C1 TAB - 8 - 246

54
1610 - 1611 VOL - C1 TAB - 8 - 247

55
1610 - 1611 VOL - C1 TAB - 8 - 248

56
1610 - 1611 VOL - C1 TAB - 8 - 249

57
1610 - 1611 VOL - C1 TAB - 8 - 250

58
1610 - 1611 VOL - C1 TAB - 8 - 251

59
1610 - 1611 VOL - C1 TAB - 8 - 252

60
1610 - 1611 VOL - C1 TAB - 8 - 253

61
1610 - 1611 VOL - C1 TAB - 8 - 254

62
1610 - 1611 VOL - C1 TAB - 8 - 255

63
1610 - 1611 VOL - C1 TAB - 8 - 256

64
1610 - 1611 VOL - C1 TAB - 8 - 257

65
1610 - 1611 VOL - C1 TAB - 8 - 258

66
1610 - 1611 VOL - C1 TAB - 8 - 259

67
1610 - 1611 VOL - C1 TAB - 8 - 260

68
1610 - 1611 VOL - C1 TAB - 8 - 261

69
1610 - 1611 VOL - C1 TAB - 8 - 262

70
1610 - 1611 VOL - C1 TAB - 8 - 263

71
1610 - 1611 VOL - C1 TAB - 8 - 264

72
1610 - 1611 VOL - C1 TAB - 8 - 265

73
1610 - 1611 VOL - C1 TAB - 8 - 266

74
1610 - 1611 VOL - C1 TAB - 8 - 267

75
1610 - 1611 VOL - C1 TAB - 8 - 268

TAB - 9

1610 - 1611 VOL - C1 TAB - 9 - 269