Boiler Maintenance

PLTU Nagan Raya NAD 2X110MW
Boiler Maintenance Manual
Vol.1–6A
PT.PLN (PERSERO) JASA ENJINIRING
SINOHYDRO CORPORAION LIMITED
SHAANXI NORTHWEST POWER GENERATION CO., LTD

2013.3.30
Project Name PLTU Nagan Raya NAD 2X110MW
File Number YNYQ-01-21-006-A/2
Contract No. SAC/HTB/SC/060/11
Boiler Maintenance Manual
Sinohydro Corporation Limited
Shaanxi Northwest Power Generation Co., Ltd
Initial
Compiled Checked Translated
Checked Date Date Date
by by by
by
Peng Qi
First edition 2013.3.23
Zengping Zhiyong
Second
edition
Third edition
Fourth edition
Final edition approved by Edition
0
Maintenance Manual Vol.1–6A Boiler Maintenance Manual
CONTENTS
Introduction ............................................................................................................................................... 0
1 Boiler Main Design Parameters ............................................................................................... 1
1.1 Boiler Size ................................................................................................................................. 1
1.2 Main Technical Parameters of Boiler ....................................................................................... 1
1.3 Furnace Water Wall Loop Characteristics .............................................................................. 1
1.4 Flue Gas Temperature of Boiler ............................................................................................... 2
1.5 Fuel Coal Analysis .................................................................................................................... 2
1.6 Ignition and Combustion Aiding Oil ......................................................................................... 3
2 Boiler Main Equipment Structure ............................................................................................. 3
2.1 Boiler Overview ......................................................................................................................... 3
2.2 Steam Drum .............................................................................................................................. 4
2.2.1 Structure .................................................................................................................................... 4
2.2.2 Steam Drum Fixing ................................................................................................................... 4
2.2.3 Equipment Inside Boiler Drum ................................................................................................. 4
2.3 Downcomer ............................................................................................................................... 5
2.4 Water Level Monitoring Device ................................................................................................ 6
2.5 Combustion Chamber and Water Wall .................................................................................... 6
2.6 Superheater and Temperature Regulating System ................................................................ 7
2.6.1 overview..................................................................................................................................... 7
2.6.2 Superheated Steam Flow ......................................................................................................... 7
2.6.3 Superheater Introduction .......................................................................................................... 8
2.6.4 Superheater Fixing Device ....................................................................................................... 8
2.7 Economizer ............................................................................................................................... 9
2.8 Ait Preheater ............................................................................................................................. 9
2.9 Steam-cooled Cyclone Separator .......................................................................................... 10
2.10 Fuel Recyle Device ................................................................................................................. 10
2.11 Boiler Safety Control ................................................................................................................11
2.11.1 Rigid Beam ...............................................................................................................................11
2.11.2 Expansion Center ....................................................................................................................11
2.11.3 Safety Control ..........................................................................................................................11
2.12 Piping Within Boiler..................................................................................................................11
2.12.1 Feed Water Control Board ......................................................................................................11
2.12.2 Economizer Recirculating Pipe ...............................................................................................11
2.12.3 Spray Water Desuperheating Water Pipe ..............................................................................11
2.13 Sootblowing System ............................................................................................................... 12
2.14 Above Bed and Below Bed Ignition Burner .......................................................................... 12
3 Boiler Auxiliary Equipment Technical Specifications ............................................................ 12
3.1 ID Fan ...................................................................................................................................... 12
3.2 Secondary Air Fan Technical Specifications ......................................................................... 13
3.3 PA Fan ..................................................................................................................................... 13
3.4 HP Fluidized Air Fan Technical Specifications ...................................................................... 14
3.5 Technical Specifications of Coal Feeding System ................................................................ 15
3.5.1 Coal Feeder............................................................................................................................. 15
3.5.2 Technical Specifications of Coal Bunker Loosener .............................................................. 15
3.6 Technical Parameters of Slag Discharging Equipment ........................................................ 15
1
3.6.1 Paprameters of Water Cooling Barrel Slag Cooler .............................................................. 15

3.6.2 Embedded Scraper Conveyor ............................................................................................... 16
3.6.3 Technical Specifications for Bucket Elevator ........................................................................ 17
3.6.4 Slag Bunker Performance Parameter ................................................................................... 18
3.7 Limestone System .................................................................................................................. 19
3.7.1 Overview .................................................................................................................................. 19
3.7.2 Technical Specifications for Limestone System Equipment ................................................ 19
3.8 Air Compressor System ......................................................................................................... 22
3.8.1 Instrument Air Compressor System....................................................................................... 22
3.8.2 Maintenance Air Compressor System ................................................................................... 22
3.8.3 Technical Specifications of Ash Handling Air Compressor .................................................. 23
3.8.4 Technical Specifications of Refrigeration Dryer .................................................................... 23
3.8.5 Technical Specifications of Combined Dryer ........................................................................ 23
3.9 Bed Materials Conveying System.......................................................................................... 24
3.9.1 System Overview .................................................................................................................... 24
3.9.2 Technical Specifications of System Equipment .................................................................... 24
3.10 Boiler Blowdown System ........................................................................................................ 25
3.10.1 System Overview .................................................................................................................... 25
3.10.2 Technical Specifications of System Equipment .................................................................... 25
3.10.3 Sparts pars for Blowdown Flash Tank ................................................................................... 26
3.11 Fuel System ............................................................................................................................ 26
3.11.1 System Overview .................................................................................................................... 26
3.11.2 Technical Specifications of Equipment in Fuel System........................................................ 26
3.12 Electrostatic Precipitator (ESP) ............................................................................................. 28
3.12.1 System overview ..................................................................................................................... 28
3.12.2 Technical Specifications of ESP ............................................................................................ 28
3.13 Pneumatic Ash Conveying System ....................................................................................... 29
3.13.1 System overview ..................................................................................................................... 29
3.13.2 Technical Specifications of Equipment in Ash Conveying System ...................................... 29
3.14 Startup Boiler ........................................................................................................................... 30
3.14.1 Overview .................................................................................................................................. 30
3.14.2 Technical Specifications of Startup Boiler ............................................................................. 30
3.14.3 Technical Specifications of Boiler Auxiliaries ........................................................................ 31
4 Boiler Proper Maintenace....................................................................................................... 32
4.1 Steam Drum Maintenance...................................................................................................... 32
4.1.1 Safety Precautions for Maintenace ....................................................................................... 32
4.1.2 Maintenance Items ................................................................................................................. 32
4.1.3 Maintenance Process and Quality Standards ...................................................................... 33
4.1.4 Acceptance after Steam Drum Maintenance ..................................................................... 37
4.2 Water Wall and Furnace Maintenance .................................................................................. 38
4.2.1 Safety Measures during Maintenance................................................................................... 38
4.2.3 Edge Preparation of Tube Groove Processing and Butt-Welding ....................................... 38
4.2.4 Maintenance Processes and Quality Standards .................................................................. 39
4.2.5 Acceptance of Water Wall Maintenance ............................................................................... 42
4.3 Superheater Maintenance ...................................................................................................... 42
2
4.3.1 Maintenance Items for Low-temperature Superheater ........................................................ 42

4.3.2 Maintenance Items for High-temperature Superheater ....................................................... 42
4.3.3 Cut Pipe Inspection of Heating Surface ................................................................................ 42
4.3.5 Acceptance after Superheater Maintenance ........................................................................ 45
4.4 Economizer Maintenance....................................................................................................... 46
4.4.1 Safety Measures During Maintenance .................................................................................. 46
4.4.4 Economizer Acceptance After Maintenance ......................................................................... 48
4.5 Air Preheater Maintenance .................................................................................................... 49
4.5.2 Routine Maintenance of Equipment ...................................................................................... 49
4.5.4 Acceptance after Air Heater Maintenance ............................................................................ 51
4.6 Sootblower Maintenance ........................................................................................................ 51
4.6.1 Equipment Daily Maintenance ............................................................................................... 51
4.6.2 Sootblower Maintenance Process and Quality Standards .................................................. 51
4.6.3 Acceptance after Sootblower Maintenance .......................................................................... 54
4.7 Attemperator Maintenance ..................................................................................................... 54
4.7.1 Safety Measurements during Maintenance .......................................................................... 54
4.7.3 Acceptance after Attemperator Maintenance ....................................................................... 57
4.8 Fuel Oil System Maintenance ................................................................................................ 57
4.8.2 Preparation Before Maintenance ........................................................................................... 57
4.8.4 Acceptance after Fuel Oil System Maintenance .................................................................. 60
4.9 Maintenance of Steel Beam, Platform and Ladder .............................................................. 60
4.9.1 Overview .................................................................................................................................. 60
4.9.2 Maintenance Techniques and Quality Standards ................................................................. 61
4.10 Lifting Tools.............................................................................................................................. 62
4.10.1 Electric hoist Operation Rules ............................................................................................... 62
4.10.2 Routine Inspection Items and Requirements of Electric hoist ............................................. 62
4.11 Spare Parts .............................................................................................................................. 63
5 Boiler Auxiliaries Maintenance ............................................................................................... 66
5.1 ID Fan Maintenance ............................................................................................................... 66
5.1.1 Construction Overview ........................................................................................................... 66
5.1.2 ID Fan Maintenance Precautions .......................................................................................... 68
5.1.3 ID Fan Maintenance ............................................................................................................... 69
5.1.4 Spare Parts of ID Fan ............................................................................................................. 70
5.2 HP Fluidization Air Fans Maintenance .................................................................................. 70
5.2.1 Construction ............................................................................................................................ 70
5.2.2 Assembling Clearance ........................................................................................................... 71
5.2.3 Routine Maintenance.............................................................................................................. 71
5.2.4 Maintenance Techniques and Quanlity Standards ............................................................... 72
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5.2.5 Common Faults and Solutions ............................................................................................... 72

5.2.6 Spare Parts .............................................................................................................................. 73
5.3 Maintenance of Secondary Air Fan ....................................................................................... 73
5.3.1 Main Construction of Secondary Air Fan .............................................................................. 73
5.3.2 Fan Maintenance .................................................................................................................... 76
5.3.3 Precautions for Maintenance ................................................................................................. 76
5.3.4 List of Consumables and Replaceable Parts for Overhaul.................................................. 77
5.3.5 Spare Parts for Secondary Air Fan ........................................................................................ 77
5.4 PA Fan Maintenance .............................................................................................................. 77
5.4.1 Main Construction of P.A Fan................................................................................................. 77
5.4.2 Fan Maintenance .................................................................................................................... 79
5.4.3 Precautions for Maintenance ................................................................................................. 79
5.4.4 Disassembly of Rotor During Maintenance .......................................................................... 80
5.4.5 List of Consumables and Replaceable Parts for Overhaul.................................................. 81
5.4.6 Spare Parts of P.A Fan ........................................................................................................... 81
5.5 Coal Feeder Maintenance ...................................................................................................... 81
5.5.1 Construction Overview ........................................................................................................... 81
5.5.2 Maintenance Techniques and Quality Standards ................................................................. 82
5.5.3 Spare Parts of Coal Feeder.................................................................................................... 85
5.6 Maintenance for Loosening Machine of Coal Bunker .......................................................... 85
5.6.1 Installation Position for Loosening machine ......................................................................... 85
5.6.2 Technical Parameters for Coal Loosening machine............................................................. 85
5.6.3 Common Faults and Solutions for Coal Bunker Loosening machine ................................. 85
5.6.4 Spare Parts for Coal Bunker Loosening Machine ................................................................ 87
6 Maintenance of Boiler Auxiliaries System ............................................................................. 87
6.1 Slag Handling System Maintenance ..................................................................................... 87
6.1.1 Main Construction of HBSL Type Slag Cooler ...................................................................... 87
6.1.2 Maintenance Techniques of Slag Cooler .............................................................................. 88
6.1.3 Chain Bucket Conveyor Maintenance ................................................................................... 89
6.1.4 Slag Cooler Faults and Solutions .......................................................................................... 90
6.1.5 Common Faults and Solutions for Chain Bucket Conveyor ................................................ 91
6.1.6 Common Faults and Solutions for Steel Slag Bunker .......................................................... 92
6.2 ESP System Maintenance ..................................................................................................... 92
6.2.1 WT Series ESP Structure ....................................................................................................... 92
6.2.2 Safety Measures for Maintenance ......................................................................................... 93
6.2.3 Special Maintenance Items for ESP ...................................................................................... 94
6.2.4 Overhaul Items of WT Series ESP ........................................................................................ 94
6.2.5 Inspections and Acceptance after Maintenance ................................................................. 108
6.2.6 Spare Parts (for individual ESP) .......................................................................................... 108
6.3 Maintenance for Ash Handling Gasified Blower ................................................................. 109
6.3.1 Operation and Maintenance................................................................................................. 109
6.3.2 Common Failures and Solutions for Gasified Blower .........................................................110
6.4 Limestone System Maintenance .......................................................................................... 111
6.4.1 Operation and Maintenance of Limestone Air Blower......................................................... 111
6.4.2 Maintenance Process and Quality Standards of Limestone Air Blower ............................ 111
6.4.3 Operation and Maintenance of Limestone Bucket Elevator ...............................................113
4
6.4.4 Maintenance Process and Quality Standards of Limestone Bucket Elevator ...................113
6.4.5 Operation and Maintenance of Vessel Pump ......................................................................114
6.4.6 Maintenance Process and Quality Standards of Vessel Pump ..........................................115
6.4.9 Consumable Items and Spare Parts of Plate Chain Bucket Elevator ................................115
6.5 Air Compressor System Maintenance..................................................................................116
6.5.1 Maintenance Requirements for Combined Low-dew Compressed Air Dryer ...................116
6.5.2 Automatic Drainer Maintenance ...........................................................................................116
6.5.3 Electrical Drainer Maintenance .............................................................................................116
6.5.4 Water Filter Maintenance ......................................................................................................116
6.5.5 Unit Interior Maintenance ......................................................................................................117
6.5.6 Operation and Maintenance of Absorption Dryer ................................................................117
6.5.7 Spare Parts .............................................................................................................................118
6.6 Maintenance for Double Color Water Level .........................................................................118
6.6.1 Maintenance and Precautions for Water Level ...................................................................118
6.6.2 Maintenance Processes and Quality Standards of Water Level ........................................119
6.7 Maintenance for Boiler Wear-Resistance, Fire-Proof and Insulating Materials ............... 121
6.7.1 Refractory Inspection............................................................................................................ 121
6.7.2 Refractory Construction........................................................................................................ 121
6.7.3 Refractory Removing ............................................................................................................ 122
6.7.4 Preparations for Anti-wear and Heat Insulation Brick ........................................................ 122
6.7.5 Refractory Agitating .............................................................................................................. 122
6.7.6 Installation of Anti-wear and Heat Insulation Brick ............................................................. 122
6.7.7 Maintenance for Pipe Insulation .......................................................................................... 122
6.7.8 Heat Insulation Maintenance for Furnace Outer Wall ........................................................ 122
6.8 Boiler Maintenance ............................................................................................................... 123
6.8.1 Boiler Maintenance in Normal Operation ............................................................................ 123
6.8.2 Boiler Maintenance During Long-term Outage ................................................................... 123
7 Maintenance for Boiler Valve and Pipe ............................................................................... 124
7.1 Boiler Pipe ............................................................................................................................. 124
7.1.1 Main Steam Pipe and Main Feedwater Pipe ...................................................................... 124
7.1.2 Welding and Hot Treatment for Alloy Steel with Middle and Large Pipe Diameter .......... 124
7.1.3 Pipe Color System ................................................................................................................ 125
7.2 Valve Maintenance ............................................................................................................... 125
7.2.1 Electrical Valve Maintenance ............................................................................................... 126
7.2.2 Relief Valve Maintenance ..................................................................................................... 127
8 Thermal Mechanical Work Permit ....................................................................................... 132
8.1 Responsible person who fills the permit ............................................................................. 132
8.2 Reasons to Perform Work Permit ........................................................................................ 132
8.3 Purpose ................................................................................................................................. 132
8.4 Rules for Application ............................................................................................................. 132
8.5 Hot Work Permit Classifications .......................................................................................... 133
8.6 Safety Responsibilities of Permit Issuing Person ............................................................ 133
8.7 Safety Responsibilities of Responsible person................................................................ 134
8.8 Safety Responsibilities of Team Members .......................................................................... 134
8.9 Safety Responsibilities of Work Licensor ............................................................................ 134
8.10 Safety Responsibilities of Shift Supervisor ......................................................................... 134
5
8.11 Problems during Work Permit Application Process ......................................................... 135

8.12 Safety Rules for Personnel on Site ..................................................................................... 135
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Introduction
Boiler maintenance manual is complied based on maintenance instructions and
relevant P&ID supplied by manufacturers of Indonesia PLTU Nagan Raya NAD
2×110MW coal-fired power plant. This manual shall only be applied to Indonesia
PLTU Nagan Raya NAD 2×110MW coal-fired power plant
Content of this manual: boiler proper and auxiliary equipment system setup,
descriptions, technical specifications, equipment working principles, maintenance
methods, maintenance acceptance standards and safety requirements.
0
1 Boiler Main Design Parameters

1.1 Boiler Size
Table 1-1 Boiler Size
Items Unit Size
Furnace width (distance between centre lines on both sides of
mm 14370
water wall)
Furnace depth (distance between centre lines of front and rear
mm 7010
water wall)
Furnace roof tube elevation mm 43440
Center line elevation of boiler drum mm 47200
Highest point elevation of boiler (upper elevation of roof) mm 53300
Operating layer elevation mm 9000

Boiler width (distance between centre points of pillars on both
mm 29000
sides of boiler )
Boiler depth (distance between pillar Z1 and Z4) mm 34200
1.2 Main Technical Parameters of Boiler

Table 1-2 Boiler Technical Specifications
Items Unit Design Data
Steam flow t/h 430
First stage desuperheated water flow t/h 17.96
Second stage desuperheated water flow t/h 14.55
Steam drum pressure MPa 10.8
Outlet pressure of superheater MPa 9.81
Inlet temperatre of economizer °C 234
Steam temperature of superheater °C 540
1.3 Furnace Water Wall Loop Characteristics

Table 1-3 Furnace Water Wall Loop Characteristics
Front and Rear Water Wall
Loop Water Wall Side Water Wall Panel
Number of risers and
specifications n-Φ×s 2×179-Φ60×5 2×87-Φ60×5 5×28-Φ60×5
Number of water connecting
pipe and specifications n-Φ×s 2×12-Φ159×12 2×6-Φ159×12 5×1-Φ219×16
1
Number of steam and water

outgoing pipe and
specifications n-Φ×s 24-Φ159×12 2×6-Φ159×12 5×2-Φ159×12
Number of downcomer and
specifications n-Φ×s 4-Φ426×28 5-Φ219×16
Cross section ratio of water
connecting pipe and riser ％ 0.49 0.503 0.5
Cross section ratio of outgoing
pipe and riser ％ 0.49 0.503 0.521
1.4 Flue Gas Temperature of Boiler

Table 1-4 Flue Gas Temperature
Load 100% Load
Coal Design coal Verified coal
Furnace outlet °C 890 886
Economizer outlet °C 291.5 280.8
Steam-cooled separator outlet °C 886 881
LT superheater outlet °C 511.8 469.4
Platen superheater outlet °C 890 886
HT superheater outlet °C 711 676
Air prehetare outlet °C 141 136
1.5 Fuel Coal Analysis

Table 1-5 Boiler Fuel Coal Analysis
Design coal Standard coal
Items Symbols Unit
quality quality
As-received basis total water
Mt.ar % 30 35
content
Air as-dried basis water content Mad % 18 25
As-received ash content Aar % 5 6

As-dried ash-free basis volatile
Vdaf % 53.85 47.29
content
Low heat calorific value Onet.ar MJ/kg 15.16 14.21
Onet.ar Kcal/kg 3620 3395
As received basis carbon Car % 44.33 38.35
As-received basis hydrogen Har % 3.71 1.77
2
As-received basis oxygen Oar % 15.06 17.7
As-received basis nitrogen Nar % 0.73 0.32
As-received basis total sulfur St.ar % 1.17 1.3
Grindability index HGI 50 65
Deformation temperature DT 0C 1050
Softening temperature ST 0C 1100
Hemisphere temperature HT 0C 1150
Fluidizing temperature FT 0C 1200
1.6 Ignition and Combustion Aiding Oil

Table 1-6 Ignition and Combustion Aiding Oil Specification
No. Items Unit Data
1 Specific weight Kg/m3 815～870
2 Dynamic viscosity（37.8°C） mm2/sec 3.6～5.8
3 Flash point °C ≥60
4 Sulfur content %wt Max 0.5
5 Moisture content %Vol Max 0.05
6 Ash content %wt Max 0.01
7 Low heat calorific value Kcal/kg 10140
2 Boiler Main Equipment Structure

2.1 Boiler Overview
2.1.1 Boiler configuration: single horizontal steam drum, single furnace, natural circulation,
fully suspended structure, and full steel frame with π arrangement. The boiler is
installed outdoors and the grid is installed on 9m high operation platform. The furnace
uses membrane water wall. The volute steam-cooled cyclone separator is located in
the middle part of boiler. Two-stage three groups of convectional superheater is
arranged in vertical flue gas duct. Four groups of economizers and three groups air
heaters for primary air and secondary air are arranged in the lower part of
superheater.
2.1.2 Boiler uses CFB combustion technology. The coal feeder feeds the coal to the furnace
through coal chute, and air needed by combustion is supplied by PA fan and SA fan.
Air supplied from PA fan will be preheated by air heater, and enter water-cooled wind
box under the boiler through air duct on left and right side, and then enter combustion
chamber through air cap on water-cooled air distributor plate. The air supplied by SA
3
fan will be preheated by air heater and then sprayed to furnace through the nozzle on
front wall and rear-wall of furnace in order to make-up air and improve turbulence and
mixability. The fuel in furnace will be mixed and combusted with fluidized circulating
materials. When the density in bed reaches to a certain value, a large amount of
material will go upward in the middle and go downward along the wall and the heat
will be transferred along the height of furnace. The materials carried by the flue gas
will be separated by volute steam-cooled cyclone separator and return to the furnace
through U-beam solid separator to realize circulation combustion. The flue gas will be
discharged through turning room, HT superheater, LT superheater, economizer,
primary and secondary air heater and vertical flue gas duct. CFB combustion mode
promotes significant reduction of SO2 emissions in flue gas can be reduced greatly
through suppling lime stone. In addition The use of the low temperature and graded
air supply technology can suppress NOx emission. The equipment produces high
activity ash and slags, that are potentially available for comprehensive usage.
2.1.3 The feedwater enters the steam drum after being heated by four groups of
economizers arranged horizontally. The boiler water in steam drum enters through the
lower header of water wall, riser, water tube inside of furnace, upper heater and
downcomer. The steam and water separator is installed in steam drum. Saturated
steam enters steam-cooled cyclone separator through the steam connecting pipe on
the top of steam drum, and then through rear steam-cooled enclosed wall tubes, LT
superheater, firs-stage water sprays desuperheater, platen superheater,
second-stage water sprays desuperheater, HT superheater, and finally high-quality
superheated steam is supplied to turbine.
2.2 Steam Drum

2.2.1 Structure
2.2.1.1 The steam drum inner diameter is Φ1600mm, wall thickness is 100mm, the material is
SA-299. The direct section length of steam drum is 17500mm, the steam drum total
length is approximately 19350 mm and using two dome-head ends.
2.2.1.2 the top part of steam drum is welded with joints of steam outgoing pipe, safety valve
pipe and pressure gauge. The feedwater pipe joint is welded on the point formed 45°
angle with the horizontal surface. The water and steam mixture pipe joint is welded on
the form and rear horizontal part. The downcomer pipe joint with large diameter is
welded on the bottom of steam drum. The water level meter pipe joint, recirculation
pipe joint, emergency discharge pipe joint and others are also welded on steam drum.
The manhole, blowdown pipe seat and dosing pipe seat are arranged on seal head.
The pre-welding plate is also welded on the upper and lower surface of steam drum.
Thermocouples are welded on it to monitor upper and lower wall temperature.
2.2.2 Steam Drum Fixing
Steam drum is suspended under top beam by two U-shaped twist chain hanging
frames. Two suspending points are distributed symmetrically at two sides of boiler
drum with a distance of 11500 mm.
2.2.3 Equipment Inside Boiler Drum
The steam and water separator in steam drum adopts single-stage evaporation
4
system. The cyclone separator, cleaning orifice and louver-shaped corrugated plate
are arranged inside of steam drum. The steam and water mixture enters the cyclone
separator to achieve first-stage separation, the separated steam will go upward and
enter the corrugated plate to complete gravity separation. The steam also will enter
cleaning orifice to reduce salt and silicate content entrained in steam. The steam after
being cleaned will enter top louver separator and multi-orifice plate to achieve
second-stage separation. The separated water will enter the water space of steam
drum and the steam will go to the superheater system through steam outgoing pipe
on top of steam drum.
2.2.3.1 Cyclone Separator
72 axial flow cyclone separators of diameter Φ315mm are arranged into two rows
along the cylinder inside boiler drum, and the average steam load of each separator
under 6t/h in BMCR working condition.
2.2.3.2 Top Ladder and Wave-Shaped Separator
Steam and water mixture flows into cyclone separator along tangential direction for
first-stage separation, then the separated steam flows into steam space of drum for
gravity separation through ladder and wave shaped separator on the top of cyclone
separator, then the steam flows through cleaning hole plates to reduce salt and
silicate content. The cleaned steam flows to top blind window and multiple hole plates
for second-stage separation, and is finally led to superheater system through
saturated steam outlet pipe installed on the top of boiler drum.
2.2.3.3 Continuous blowdown pipe
The continuous blowdown pipe is arranged on the top part of boiler water space to
discharge boiler water with high salt content and maintain the salt content in the
permissible range. The continuous opening should face vertically upward and this
arrangement can avoid that chemicals being carried away immediately after dosing by
the continuous blowdown pipe.
2.2.3.4 Dozing Pipe
Phosphate is dozed to boiler drum water space along the whole dozing pipe to keep
the boiler water PH value within 9-10.5, therefore, the distributing coefficient of silicate
and dissolve carrier of steam will be decreased. To fully mix chemical and water, the
open hole of dozing pipe is in horizontal direction.
2.2.3.5 Emergency Discharging Pipe
When water level increases and exceeds the maximum allowable water level caused
by mismatch of boiler feedwater capacity and evaporation capacity, water must be
discharged by emergency discharging pipe to normal water level to prevent water
overfill.
2.3 Downcomer
Four downcomer pipe bundles with Φ426×28 mm are led out from steam drum bottom
water space and these four bundles will be led to 36 pipes with Φ159×12 mm to
supply water to water wall. The water wall lower header on two sides are led with 6
connecting pipes respectively and the water wall lower header on front wall and rear
wall are led with 12 connecting pipes. The upper header on two sides have 6
Φ159×12mm connecting pipes respectively to steam drum and the upper header on
5
front wall and lower wall respectively have 24 pipes with Φ159×12 mm. Water in five
water wall platen is supplied from one downcomer pipe with Φ219×16 mm and then
enter steam drum through 2 outgoing pipe with Φ159×12 mm.
In order to avoid swirling formed in downcomer caused by bubbles due to
non-unifrom/faster water flow speed, grating is installed on the upper part of
downcomer inlet.
2.4 Water Level Monitoring Device

In order to monitor and adjust water level of boiler drum, two high-reading bicolor
water level meters and two low-reading electric contact water level meters are
installed on seal head of boiler drum. Four groups of automatic control single chamber
balance container is also equipped with water level alarm which can be checked
visually at local or monitored on remote industrial TV.
2.5 Combustion Chamber and Water Wall
The cross section of combustion chamber is rectangular and the depth × width
=14370 mm×7010mm. Wall of combustion chamber use membrane water wall made
of plain tubes and flat steel. There are 179 pipes with Φ60×5 mm and 87 pipes with
Φ60×5 mm on front wall, rear wall and sidewall. The pipes on lower dense phase area
of front wall and rear wall form a angle with the vertical line and a cone-structure is
formed. the water-cooled air distributor plate is arranged on the bottom of cone and
the lower part of air distributor plate is formed by rear water wall and two sidewalls.
The height from air distributor plate to furnace top part is 35.5 m and the furnace flue
gas cross section flow speed is 5.22m/s. There is platen membrane superheater 14m
away from air distributor plate which is flushed by flue gas longitudinally. The
wearable high temperature casting materials is casted on the lower part of platen
superheater.
Two sides of pipes of rear cold water wall stretch out from furnace outlet to
separator and form flow guiding acceleration section. Pipes at lower part of cone
form two material returning orifices symmetrically. Four coal adding orifices are
arranged at lower part of front cold water wall and one maintenance manhole is
arranged at lower part of side cold water wall. Two rows of secondary air inlets are
arranged on the front and rear walls in furnace dense region.
The furnace and rear enclosed wall use membrane wall structure. There are heat
insulation material on the outer side covered with trapezoid corrugated guard plate.
There are manhole, inspection hole and measuring hole on furnace wall. The dense
phase area, separator, dip leg, U-beam solids separator and some other parts with
serious abrasion are covered with high temperature wearable casting materials,
plastic materials and liner. The separator outlet flue gas duct and economizer use light
guard plate. The rear wall and front wall header pipe diameter is Φ377mm, while
diameter of other wall pipes Φ273mm.
The water-cooled air distributor plate is formed by lower rear wall of furnace, the cross
section of air distributor plate is 14370×3360mm, pitch distance 160mm, the material
is SA210-C and the refractory casting material thickness of air distributor plate is 150
mm. there are 1700 reverse flow air caps mounted on and the air caps use high
6
temperature wearable alloy steel with leakproof function. The flue gas flow on air
distributor plate is 4-5 m/s. Due to wide bed surface area, during manufacture and
installation, the flatness of bed surface must be assured to avoid impact on fluidization
caused by uneven materials layer. There are manholes on two sidewalls of air
distributor plate for boiler internal maintenance.
2.6 Superheater and Temperature Regulating System

2.6.1 overview
The superheater system is composed of enclosed wall superheater, LT superheater,
first-stage platen superheater and HT superheater. Among LT superheater,
first-stage & second-stage platen superheater and HT superheater, first-stage and
second-stage water sprays desuperheater are arranged.
In order to keep the boiler evaporation at the range of 100%B-MCR, superheat steam
temperature shall reach 540°C and realize regulating ability under overload condition.
The maximum design water sprays flow of this boiler can reach 49t/h and the rated
load can reach appropriate 32.5t/h. When the load is less than 50%, on the premise of
keeping combustion stable, air flow can be increased appropriately and the furnace
outlet excess air coefficient shall be increased to meet the requirement of steam
temperature.
2.6.2 Superheated Steam Flow
Saturated steam from boiler drum is led to inlet header of flow guiding acceleration
enclosure wall in front of separator through 6 Φ159×12 mm pipes, then led to outlet
header through enclosure wall pipes of Φ51 mm. The steam is further led to lower
circular header of cyclone separator through steam leading pipe, after steam flows
upward to upper circular header through membrane wall, it is led to upper headers at
two sides of enclosure wall in back pass. The steam in enclosure wall flows downward
through superheater enclosure wall, front enclosure wall, top enclosure wall and rear
enclosure wall (all the pipes are Φ51×5 mm) to low temperature superheater with
pipes Φ42×5 mm distributed in order.
In order to reduce abrasion, flue gas flow speed shall be controlled and moreover,
install abrasion proof cover plate. The superheated steam from LT superheater enters
the first stage water sprays desuperheater after passing through connecting pipe for
coarse adjustment. Superheated steam enters platen superheater through the first
stage desuperheater and then to the second stage water sprays desuperheater after
passing through connecting pipe for fine adjustment. As last, the superheated steam
being heated by HT superheater will enter outlet header at first and then turbine
through main steam pipe.
7
Figure 2-1 Superheated Steam Flow
2.6.3 Superheater Introduction

2.6.3.1 Roof Superheater and Enclosure Wall Superheater
In order to simplify furnace wall structure, this boiler installed roof superheater and
enclosure wall superheater with Φ51×5mm pipe and δ=8mm flat steel being welded
together to form the membrane water wall. Pipe pitch: 90mm, pipe material:
SA213-T12, fin material: SA387Gr12CL2.
2.6.3.2 Low-temperature Superheater
Low-temperature superheater is in the back pass, and its four coils are laid
horizontally. They are 119 horizontal rows of coils. Pitch distance: 100mm, pipe
diameter: Φ42×5mm, material: SA213-T12.
2.6.3.3 Platen Superheater
Platen superheaters, which are arranged at upper part of combustion chamber, and
with vertical layout with front wall. Steam inlet terminal of screen is located at lower
part of front wall, and the platen and water wall are welded through sealing boxes. As
temperature of platen superheater and front wall is different, consequently the
expansions of them are not the same, so expansion joint is installed in seal box of
screen to compensate expansion difference.
Platen superheater uses membrane type which is only flushed longitunally by flue gas.
The anti-wear materials are casted on the lower part of platen superheater and it is
14m away from air distributor plate. The pipe diameter of platen superheater is
Φ42×6mm and the material is SA213-T22 and SA213-T91
2.6.3.4 High-Temperature Superheater
HT superheater is located in rear vertical flue gas duct which can be divided into two
stages, the lower stage uses reverse flow arrangement and the upper stage uses
direct flow arrangement. The first row pipe is equipped with abrasion-proof cover plate,
as well as for elbows. Pipe diameter: Φ42×5mm and uses SA213-T91 material.
2.6.4 Superheater Fixing Device
2.6.4.1 LT superheater is suspended with four rows steam-cooled suspender and hanged on
frame top plate with lifting rod.
2.6.4.2 Enclosed wall superheater is hanged on the top plate through front wall, rear wall and
enclosed walls of two sides with spring lifting rod.
2.6.4.3 Platen superheater: there are two lifting points on upper header of each platen which
8
is hanged on the top plate of frame with lifting rod. In order to solve the different
expansion problem between platen superheater and water wall, the constant spring
hanger is installed on lifting device of platen. The lower part of each platen is fixed on
the front water wall.
2.6.4.4 Superheater connecting pipe: the connecting pipe supports weight on column and
beam through lifting rod and corresponding constant hanger. The constant spring
hanger is applied to solve upper ward expansion of connecting pipe.
2.7 Economizer
There are four groups of plain-pipe economizer installed in boiler vertical flue gas duct
and pipe with Φ38×4.5 mm arranged in line with excellent anti-wear ability. The
transverse pitch is 70mm and the material of pipe is SA210-A1.
The top row of economizer is installed with abrasion-proof cover plate and every
elbow of coiled tubes and surrounding walls are equipped with abrasion-proof cover.
The average flue gas flow speed is controlled below 10m/s. There are recirculation
pipe installed between steam drum and the next economizer to guarantee necessary
cooling for economizer during startup.
There are manholes arranged among economizer groups in vertical flue gas duct for
maintenance. The vent pipe support and valves are arranged in the outlet header and
there is DN20 water discharge valve and acid cleaning pipe support connected in
series on inlet header of economizer.
2.8 Ait Preheater

There are three groups of air preheaters arranged below economizer which are used
to heat primary air and secondary air separately. 800mm space is left between every
two groups for maintenance and replacement.
The tubular air preheater uses horizontal type and it is arranged between primary air
and secondary air alternately along with flow of flue gas. The structure of air heater is
mainly composed of upper, middle and lower layer headers and its corresponding
primary air and secondary air connecting shell, frame, air duct joint, flue gas duct
connecting frame, cutting frame, expansion joint and etc. It has two stages arranged
horizontally in vertical flue gas duct. The upper stage is secondary air heater and the
lower stage is primary air heater. The air is supplied in boiler through PA fan and SA
fan respectively. The flue gas flows outside of pipe from top to bottom and the air
flushes inside of pipe transversely. The secondary air flows to secondary air pipe
through two process and the primary air flows through three processes. The pipe
diameter of air heater is Φ51×3.5mm, The flue gas flows outside of pipe from top to
bottom, the air flushes inside of pipe transversely and it is arranged reversely
compared with the flue gas. The air heater is arranged in-line in 6 groups so as to be
ease for cleaning by sootblower.
The weight of air preheater is transferred to steel beam through pipe plate. And the
preheater can expand freely in horizontal direction due to expansion plate between
pipe plate and steel beam. Moreover, the preheater is connected to economizer
through expanding head to compensate differential expansion and ensure good
sealing.
9
2.9 Steam-cooled Cyclone Separator

2.9.1 Separator is the main part of CFB. This boiler uses high-efficiency volute
steam-cooled cyclone separator. There are two steam-cooled cyclone separator
arranged in the outlet of furnace symmetrically and the diameter of separator is
Ф6620mm. the membrane wall composed of pipes with Ф38×6 and fin tubes is the
shell of cyclone separator and the inlet structure is volute type. The advantages are
high separation efficiency and high combustion intensity. The cyclone separator
separates the fuel carried by flue gas and returns it to furnace through fuel recycle
device, and the flue gas will flow to the rear convectional heating surface. The working
temperature of material separating and returning loop is around 900°C.
2.9.2 The steam-cooled heating surface of separator can effectively absorb the heat
produced after materials combustion, avoid high-temperature coking, enlarge the
adaptability of coal rank. Boiler startup time is shortened by using thin refractory layer.
2.9.3 The inner surface of separator is welded with closely spaced nails and casted with
one layer special wearable casting materials with 60mm thickness which can protect
the inner surface and prolong the lifetime of separator.
2.9.4 The outlet pipe of separator is high-temperature heat resistance alloy steel and the
material is 16Cr25Ni20Si2.
2.9.5 There is access door installed on the inlet and the sealness should be kept well.
2.9.6 The thermocouple hub and inspection port are installed on vertical pipe and fuel
recycle device to monitor the material fluidizing condition.
2.10 Fuel Recycle Device

The fuel recycle device is installed below the cyclone separator which is composed of
steel shell and refractory liner. The refractory materials can be divided into inner layer
and outer layer, and the inner layer is high-intensity anti-wear casting materials, and
the outer layer is insulation casting materials.
The loosening and returning air of fuel recycle device is HP cold air which is supplied
by small air cap. The number of holes and diameter of loosening air and returning air
is different. Returning air is larger, while loosening air is smaller and they are in
different air chambers. The material of air cap is ZGCr25Ni20Si2. the flowmeter,
pressure gauge and air flow regulating valve should be installed on air main pipe inlet.
During normal operation, the total air flow is 3576 Nm3/h and the total returning air
flow is 2384Nm3/h. Startup design air flow is 6384 Nm3/h and the total returning air
flow is 4256 Nm3/h. Bed material filling gate with φ219×5mm is set on fuel recycle
device and it can be taken as fly ash filling gate of fly ash recirculation pipe during
operation. There is one ash discharging φ108×6mm pipe installed on fuel recycle
device. Due to the low ash fusion point of this boiler, two layers air pipe are specially
set on recycle device to avoid coking and this pipe is connected to both returning air
and compressed air pipes. During normal operation, returning air is supplied. If there
is any coking problem, returning air will be cut off and the compressed air will be
supplied in stead.
10
2.11 Boiler Safety Control

2.11.1 Rigid Beam
In order to avoid heating surface being broken by boiler explosion and furnace wall
ruining by inside boiler pressure fluctuation, horizontal strip winding rigid beam is
placed on boiler to guarantee the safety of water wall and enclosure wall superheater
in all adverse conditions.
Strip winding rigid beam system consists of horizontal rigid beams that wrap furnace
and back pass. Rigid beams are fixed on water wall tubes by splint and connecting
board.
2.11.2 Expansion Center
Because there is expansion clearance among all parts of this boiler, expansion center
is designed to prevent deformation of heating surface when expansion is limited.
Multi-layer or single layer guide devices are installed on combustion chamber, rear
flue gas duct, cyclone separator and material returner and the seismic load, wind load
and nudie load can be transferred to the boiler frame through these guide devices.
2.11.3 Safety Control
Non-metal expansion joints with good performance are installed on the connection
passageways of flue gas and materials, which can eliminate seal problem caused by
thermal displacement. The sealing of heating surface parts which penetrate walls
adopts advanced design to ensure good tightness. Under normal operation and
emergency state, spring safety valves are installed on steam drum and superheater
outlet respectively to prevent pressure elements from damages caused by boiler
overpressure. Both boiler drum and superheater outlet are installed with two safety
valves. If boiler is over pressure, the safety valves will be opened to release pressure.
The total safety valve discharge capacity of steam drum and superheater is 567702
kg/h, and the safety valve discharge capacity of reheater is 567702 kg/h.
2.12 Piping Within Boiler

2.12.1 Feed Water Control Board
Feedwater control board supplies water to two pipelines: one is 100% main feedwater;
the other is 30% feedwater. Feedwater regulating valve is used in 30% feedwater, but
not for main feedwater. Feedwater is transferred to inlet head of economizer on right
side of boiler through feedwater control board.
2.12.2 Economizer Recirculating Pipe
During initial startup of the boiler, as the evaporation capacity is low, and steam &
water expansion is produced in cold water wall after ignition, boiler feed water is
stopped. In order to ensure certain flow velocity in economizer, circulating pipeline
and one electric check valve are installed between economizer and boiler. The check
valve is opened when feed water is stopped after ignition, and it is closed as soon as
feed water is started to prevent feed water from entering boiler.
2.12.3 Spray Water Desuperheating Water Pipe
Spray water desuperheating water is supplied by high pressure feed water. The main
spraying water pipe is equipped with one blocking valve and alternately supplies
11
water to two desuperheaters. The spray water pipeline is equipped with adjusting
valve, and there is a manual check valve in front of the adjusting valve and an
automatic check valve behind the adjusting valve. The adjusting valve can be isolated
if necessary. Besides, manual check valves are installed below the adjusting valves of
each pipeline for drainage during maintenance of adjusting-valve while pressure is
released. Use adjusting valve to control water spraying amount of each
desuperheater, and when the adjusting valve is closed, the blocking valve on main
water spraying pipeline must be closed correspondingly. Water spraying amount of
two superheaters are 17.96t/h and 14.55t/h respectively. Desuperheating water
adjusting range should be controlled within 50-150% of designed value. Main steam
electric gate valve is Pw5414V and DN250.
2.13 Sootblowing System

In order to guarantee the heat transfer efficiency of rear heating surface during
operation and reduce the heat losses of boiler exhaust flue gas, one set of sootblower
is installed on boiler rear heating surface (superheater, economizer and air heater).
HT superheater is equipped with 4 HXC-4 long retractable sootblowers, LT
superheater with 4 HXB-4 retractable sootblowers, economizer with 8 HXC-4 long
retractable sootblowers and 4 HXB-4 retractable sootblowers and 16 HX-B-4 half-long
retractable sootblowers at air preheater. The steam is sourced from the outlet of LT
superheater.
2.14 Above Bed and Below Bed Ignition Burner
This boiler is equipped with four below bed burners that are arranged in parallel at
rear side of furnace cooling water chamber, and four above bed burners arranged at
two sides of furnace dense region. The burner is composed of oil gun, high energy
electric burner and fire detecting device. Oil gun adopts mechanical atomization and
the fuel adopts light diesel oil. Each oil gun output of below bed burners is 800kg/h,
and each oil gun output of above bed burners is 1000kg/h, the oil pressure is 2.5 MPa.
The needed combustion air for above bed oil gun is secondary air, and the air for
below bed burner is primary air. As for below bed burners, after combustion of air and
oil, it produces hot flue gas with temperature of 850°C, which is conveyed into furnace
evenly through air distribution plates on cooling water chamber. The burner is
equipped with observation port for the convenience of inspecting ignition of oil guns.
This unit can also realize remote control ignition and is equipped with fire detecting
device. The fire detecting probe is cooled by primary air.
3 Boiler Auxiliary Equipment Technical

Specifications
3.1 ID Fan
Table 3-1 ID Fan Technical Specifications
Name ID fan
12
Model SFY27F-C5A
Quantity Each boiler with 2 sets, 4 sets in total
Drive mode Single suction double supporting centrifugal type
Arrangement Bilateral symmetry
Working rotating speed 995 r/min
Rotor critical speed 1295 r/min
Motor model YFKK630-6W
Rated power 1400kW
Motor voltage 6KV
Rated current 166A
Rated rotating speed 995r/min
Protection grade IP55
3.2 Secondary Air Fan Technical Specifications

Table 3-2 Secondary Air Fan Technical Specifications
Equipment name SA fan
Type Single suction double supporting centrifugal type

Left: 2 sets; right: 2 sets (seen from the motor end
Rotating direction side, clockwise direction as towards right, and vise
versa )
Number Four sets
Power 630kW
Power factor 0.88
Frequency 50HZ
Rotating speed 1492r/min
Votage 6000V
Rated current 73.7A
3.3 PA Fan
13
Table 3-3 PA Fan Technical Specifications

Equipment name PA fan
Type Single suction double supporting centrifugal type

Fan quantity/Rotating Left: 2 sets; right: 2 sets (seen from the motor end side, clockwise
direction direction as towards right, and vise versa )
Number Four sets
Power 1400kW
Power factor 0.88
Frequency 50HZ
Rotating speed 1494r/min
Votage 6000V
Rated current 162A
3.4 HP Fluidized Air Fan Technical Specifications

Table 3-4 HP Fluidized Air Fan Technical Specifications
Name HP fluidized air fan
Model SR25LC
Inlet cooling water working temperature <30°C
Cooling water flow 10-15L/min
Cooling water working pressure 1MPa
Motor model Y280M-4-90KW
Power 90KW
Voltage 380V
Rotating speed 1480 rpm/min
Rotating direction Clockwise
Power factor 0.87
Rated current 164A
14
3.5 Technical Specifications of Coal Feeding System

3.5.1 Coal Feeder
Table 3-5 Main Technical Specifications of Coal Feeder
No. Item Unit Parameters
1 Coal feeder model EG2490

Each boiler with 4 sets,
2 Quantity
8 sets in total
3 Output range t/h 4.5-45
4 Drive motor model M100LB4 / Y3-4P
5 Power Kw 4
6 Power source 400V, 3 Phase, 50 Hz
7 Cleaning chain motor model M80S6 / Y0.37-4P
8 Power Kw 0.37
9 Power source 400V, three-phase 50Hz
3.5.2 Technical Specifications of Coal Bunker Loosener

Table 3-6 Technical Specifications of Coal Bunker Loosener
Items Parameters
Model HT-SSJ-I-1/2
Thrust force 65000N
Loosening coal height >3m
Oil tank volume 40L
Power source requirement of control oil station Three-phase four-wire
Voltage 380V
Power 3.75KW
3.6 Technical Parameters of Slag Discharging

Equipment
3.6.1 Parameters of Water Cooling Barrel Slag Cooler
Table 3-7 Slag Cooler Parameters
15
No. Name Parameter
1 Model HBSL--Ⅳ
2 Rated slag discharge capacity 0-5T/H
3 Slag intaking temperature ≤900°C
4 Slag discharging temperature ≤100°C
5 Slag intaking size 0~30mm

Hardness lower than 0.003 softened water or
6 Cooling water quality
condensate
7 Water intake temperature ≤45°C
8 Water out –take temperature ≤90°C
9 Water resistance ≤0.15MPa
10 Water in-take pressure ≤1.6MPa
11 Cooling water flow/tons slag Demineralized water 3.5T/H, condensate 5T/H.
12 Water in-take and out take diameter 70mm
13 Drive mode Gear
14 Rotor rotation speed 0~2 rpm
15 Power assorted 1.5KW
16 Motor current 3.0A
17 Slag discharge port diameter 300×120mm
18 Slag in-take diameter ф219mm
3.6.2 Embedded Scraper Conveyor

Table 3-8 embedded scraper conveyor
Embedded scraper conveyor type and
MGB400×23
model
Equipment normal output 8.55t/h Maximum 41t/h
External dimension of embedded
（L×W×H） 24.12×0.71×1.15 m
scraper conveyor
Scraper width 400mm
Horizontal length 23.1m
Chain speed 0-0.8m/s
Chain type T shapped membrane chain
16
Chain material ZG450
Chain life service 35000/h --
Drive mode Chain driving
Reducer model XWD7.5-8-1/72
Motor model YVP132M-4--
Motor power 7.5kW --
Voltage 380/V
Motor protection level IP55
Total equipment weight 18520kg
3.6.3 Technical Specifications for Bucket Elevator

Table 3-9 Technical Specifications for Bucket Elevator
1 Bucket elevator type and model ZBT400×28
2 Equipment output Normal 8.55t/h，maximum 41t/h
3 Bucket elevator width 400mm
4 Bucket elevator height 28m
5 Chain speed 0.35m/s
6 Chain type Heavy plate chain
7 Chain material Nickel-chromium-molybdenum alloy
8 Chain surface hardness ≥ HRC50
9 Chain life service 35000/h
10 Chain wheel type Wheel edge-hub assembly type
11 Chain wheel life service 25000h
12 Chain wheel type Split type
13 Reducer model XWD11-8-1/59
14 Motor model YVP160M-4
15 Motor power 11kW
16 Voltage 380/V
17 Motor protection level IP55
18 Insulating level F
17
19 Total equipment weight 23240/kg
3.6.4 Slag Bunker Performance Parameter

Table 3-10 Slag Bunker Performance Parameter
1 Slag bunker diameter 8/m
2 Effective volume 300/m3
3 Minimum thickness of bunker wall 10/mm
4 Height of vertical cylinder 5.675/m
5 Height of cone part 4.644/m
6 Air gun quantity 3
7 Air comsumpion 0.3/m3/min
8 Pressure 0.4-0.8/MPa
9 Level gauge model CL4G1M400S1
10 Total weight of slag bunker 64500/Kg
Table 3-11 Technical Specifications of Exhaust Filter on the top of Bunker

Filter type Pulse bag
Filtering air flow 2160-4320m3/h
Filtering area ＞40m2
Filter efficiency 99.5%
Dust concentration in outlet exhaust ≤30mg/m3
Pulse blowing air flow 0.1～0.3m3/min
Pulse blowing air pressure ≥0.4MPa
Filtering resistance force 1200～1500Pa
Filtering air speed ≤0.8m/min
Usage life 25000h
Table 3-12 Technical Specifications of Rotary Feeder

Model DSG450
Output YVP112M-4
Quantity Each boiler with 1 set, 2 sets in total
Motor model YVP112M-4

18
Power 4KW
Table 3-13 Technical Specifications of Two-shaft Blender

Quantity Each boiler with 1 set, 2 sets in total
Output 100t/h
Main shaft speed 42.6r/min
Moisture content after commissioning ≤20%
Water consumption quantity 20-50m3/h
Water pressure 0.2~0.6MPa
Speed reducer power 30KW
Table 3-14 Technical Specifications of Air Cannon

Each boiler with 3 pieces, 6 pieces in
Quantity
total
Air consumption quantity 0.3m3/min
Pressure 0.4~0.8MPa
3.7 Limestone System

3.7.1 Overview
Finished limestone is transported to the factory for storage by vehicles. One storage
silo with an effective volume of 300m3 is built in the power plant. The limestone
powder in the silo is delivered to the daily-limestone silos of two boilers, each
daily-limestone silo is with an effective volume of 80m3. The powder from daily silo is
delivered to the inlet of boiler by air and thrown into combustion chamber. The pieline
from limestone silo to inlet of boiler is referred to as primary limestone delivery system
in which positive pressure pneumatic conveying system is employed. The pieline from
daily limestone silo to inlet of boiler is referred to as secondary limestone delivery
system in which positive pressure pneumatic conveying system is employed. The
compressed air for primary limestone delivery system is provided by air compressor
for ash remover and conveying medium for secondary limestone delivery system
provided by Roots fan.
3.7.2 Technical Specifications for Limestone System Equipment
3.7.2.1 Technical Specifications of bale breaker
Table 3-15 Technical Specifications of Bale Breaker
Items Unit Data
Primary bale breaking device KT bale breaker
19
Breaking type Blade cutting
Blade usage life h 3000
Motor power KW 0.55
Secondary breaking device Shaftless screw
Motor power KW 4
Rotary speed of separated sift cylinder r/min 8
Motor power KW 0.75
Conveying capacity of feeding convey belt m3/h 160
Belt speed m/s 1.2
Motor power KW 1.1
Filtering area of exhaust dust receiver m2 7
The number of filtering bag 个 9
Filtering air flow m3/h 800~1000
Fan outlet flow m3/h 1000
Fan outlet pressure MPa 0.25
Motor power KW 1.1
Screw conveyor output t/h 30
Motor power KW 2.2
Speed rpm 9
Motor power of waste bag recycling device KW 3
3.7.2.2 Technical Specifications of bucket elevator

Table 3-16 Technical Specifications of Bucket Elevator
Items Unit Data
Model ZBT300
Output t/h 35
Elevating height m 25
Motor power KW 11
Voltage V 380
3.7.2.3 Technical Specifications of Silo Pump

Table 3-17 Technical Specifications of Silo Pump
20
First stage conveying system Second-stage conveying system
Conveying model 20/8 420-120V
Quantity 2 4
Individual Volume (m3) 0.57 1
Individual Output (t/h) 12 5~10

Conveying distance (horizontal and
260 42
vertical) (m)
3.7.2.4 Technical Specifications of Bag-type Dust Remover

Table 3-18 Technical Specifications of Bag-Type Dust Remover
Model DMC-72II
Filtering area of each set (m2) 50
Filtering bag quantity 108
Resistance force of device 1200~1500Pa
Air supply pressure (MPa) 0.5~0.7
Filtering air speed 0.7m/s
Pulse control valve quantity 12
3.7.2.5 Technical Specifications of Limestone Fan

Table 3-19 Technical Specifications of Limestone Fan
Model BK7011
Air pressure 65KPa
Air flow 21m3/min
Shaft power 34KW
Voltage 380V
Motor power 37KW
Speed 1250 rpm
3.7.2.6 Technical Specifications of Motor-Driven Feeder

Table 3-20 Technical Specifications of Motor-Driven Feeder
Items Unit Parameters
Output t/h 5~10
Motor power kW 4
21
Main shaft speed r/min 11~22
Conveying distance m 50
3.8 Air Compressor System

3.8.1 Instrument Air Compressor System
3.8.1.1 Overview
This project is equipped with three oil-free screw-type air compressor to supply
compressed air for instruments. With the change of air consumption , air compressor
will load or unload automatically to meet air quantity requirement of conveying
system.
3.8.1.2 Technical Specifications of Instrument Air Compressor
Table 3-21 Technical Specifications of Instrument Air Compressor
Model D75-08W
Quantity 3
Voltage 380V
Power 75KW
Exhaust pressure 0.8MPa
Flow 11.25m3/h
Speed 2950rpm/min
Motor power of oil pump 15KW
Inlet water temperature <50°C
Outlet water temperature <90°C
3.8.2 Maintenance Air Compressor System

3.8.2.1 Overview
This project has three oil-spray screw-type air compressor (two in operation, one
standby) to supply compressed air for maintenance. With the change of air
consumption , air compressor will load or unload automatically to meet air quantity
requirement of conveying system.
3.8.2.2 Technical Specifications of Maintenance Air Compressor
Table 3-22 Technical Specifications of Maintenance Air Compressor
Model L110G-8.5W
Quantity 3
Voltage 380V
Power 110KW
22
Rated current 195.4
Flow 19.6m3/h
Speed 3000rpm/min
Bearing vibration 4.2mm/s
Inlet water temperature <55°C
Outlet water temperature <66°C
3.8.3 Technical Specifications of Ash Handling Air Compressor

Table 3-23 Technical Specifications of Ash Handling Air Compressor
Model L132G-7.5W
Quantity 3
Voltage 380V
Power 132KW
Flow 24.1m3/min
Speed 3000rpm
3.8.4 Technical Specifications of Refrigeration Dryer

Table 3-24 Technical Specifications of Refrigeration Dryer
Model SLAD-25NW
Quantity 3
Refrigerating agent R22
Voltage 380V
Power 4.4KW
Processing quantity 26.8Nm3/min
Inlet air temperature ≤45°C
3.8.5 Technical Specifications of Combined Dryer

Table 3-25 Technical Specifications of Combined Dryer
23
Model SLAD-10ZW
Quantity 3
Refrigerating agent R22
Working pressure 0.6~1.0MPa
Voltage 380V
Power 2.6KW
Dew point ≤-40°C
Inlet air temperature ≤50°C
3.9 Bed Materials Conveying System

3.9.1 System Overview
Bed materials conveying system is designed to convey bed materials to furnace
through pneumatic conveying system to meet the requirement of boiler operation
during boiler startup and operation. The granularity of bed materials should be less
than 0~2mm, such as quartz sand or similar materials. The plant is equipped with two
sand bunkers to store required bed materials, each of which is with volume of 50m3
for one boiler. These bunkers are outside of boiler compartment. Besides, pneumatic
conveyor is placed on the bottom of bunker. The bed materials in bunker are
transported to furnace through pneumatic conveying system with positive pressure.
Each boiler is arranged with two receiving ports on two sides of boiler. Compressed
air used in conveying system is supplied by ash handling compressor and whole bed
materials conveying system of each boiler is as one unit.
3.9.2 Technical Specifications of System Equipment
3.9.2.1 Technical Specifications of Transport Vessel
Table 3-26 Technical Specifications of Transport Vessel
Items Parameters
Model 12/8 conveying pump
Conveying output 10t/h
Conveying volume 0.34m3
Max. working pressure 0.7MPa
Max. working temperature 200°C
3.9.2.2 Technical Specifications of Bucket Elevator

Table 3-27 Technical Specifications of Bucket Elevator
Items Parameters
Output Normal 10t/h, Max. 20t/h
24
Width 350mm
Height 17.5m
Chain speed 0.35m/s
Chain working life 35000h
Motor power 7.5KW
Voltage 380V
Motor protection grade IP55
Insulation grade F
3.10 Boiler Blowdown System

Boiler blowdown system consists of continuous blowdown (CBD) and intermittent
blowdown (IBD). Continuous blowdown refers to water transferred to continuous
blowdown flash tank . Under working pressure and evaporation function, one part of
water becomes steam which is taken to deaerator with relative pressure for medium
and heat recovery, while the rest of water enters continuous blowdown flash tank.
Intermittent blowdown is that blowdown of downcomer header and drain water from
economizer, superheater and all headers enters periodic blowdown flash tank. After
processing inside flash tank, separated steam goes to atmosphere and blowdown
water enters cooling pond. Each boiler is equipped with one continuous and one
intermittent blowdown flash tank, two boilers in total for this project.
3.10.2 Technical Specifications of System Equipment
3.10.2.1 Technical Specifications for CBD Flash Tank
Table 3-28 Technical Specifications for CBD Flash Tank
No. Item CBD
1 Type Vertical
2 Volume 3.5m3
3 Design pressure 1.0MPa
4 Design temperature 350°C
3.10.2.2 Technical Specifications for IBD Flash Tank

Table 3-29Technical Specifications for IBD Flash Tank
No. Item IBD
1 Type Vertical
2 Volume 12m3
25
3 Design Pressure 1.0Mpa
4 Design Temperature 350°C
3.10.3 Sparts pars for Blowdown Flash Tank

Table 3-30 Sparts pars for Blowdown Flash Tank
Production place
No. Name specification Unit Quantity Remarks
Manufacturer
1 Manhole gasket DN500 Piece 2 WUXi Power Plant
2 Thermometer Piece 2 Changzhou I&C
3.11 Fuel System

This plant is equipped with 3 oil supply pumps, 2 oil unloading pumps, 1 sump pump
and one set of oil and water separator. One set of oil system is arranged for two
boilers and light diesel is adopted. Besides, the system only has one set of oil and
water separator. Two oil tanks with volume of 500m3 are placed in oil tank zone.
Under evaporation of oil tank, sewage with oil is transported to sump pool. After
separation of sewage under effect of gravity, clean water enters separated clean
water part for processing through oil and water separator. Finally, water is discharged
when quality meets requirement.
3.11.2 Technical Specifications of Equipment in Fuel System
3.11.2.1 Technical Specifications of Oil Supply Pump
Table 3-31 Technical Specifications of Oil Supply Pump
No. Items Unit Data
1 Quantity set 3
2 Head m H2O 420
3 Speed rpm 2950
4 Shaft power kW 7.35
5 Motor power kW 11
6 Rated voltage/current V 380V/22.8
7 Rated speed rpm 2950
8 Shaft vibration speed mm/s 2.8
9 Bearing type Rolling

Rotation direction (view from shaft end of
10 Counter-clockwise
motor)
26
3.11.2.2 Technical Specifications of Oil Unloading Pump

Table 3-32 Technical Specifications of Oil Unloading Pump
No. Items Unit Parameters
1 Quantity Set 2
2 Head m H2O 32
3 Speed rpm 2950
5 Motor power kW 30
6 Rated voltage and current V/A 380/57.9
8 Cooling mode Water cooling
9 Shaft vibration speed mm/s 2.8
10 Rotation direction (view from shaft end of motor) Clockwise
3.11.2.3 Technical Specifications of Sump Pump

Table 3-33 Technical Specifications of Sump Pump
No. Items Unit Parameters
1 Quantity Set 1
2 Head m H2O 37
3 Speed rpm 2950
5 Motor power kW 5.5
6 Rated voltage and current V 380V/12.1
8 Shaft vibration magnitude mm/s 2.8
9 Bearing type Rolling
10 Rotation direction (view from shaft end of motor) Counter-clockwise
3.11.2.4 Oil Storage Tank

Table3-34 Oil Storage Tank Parameter
Name Unit Parameter
Number of oil tank 2
27
Oil tank volume m3 500
Oil tank height m 8.5
Basic height m 0.5
Oil tank diameter m 9.6
3.12 Electrostatic Precipitator (ESP)

3.12.1 System overview
This plant is equipped with two sets of WT type of ESP with double-chanmber and
three electric fields. ESP mainly consists of anode system, cathode system, rapping
device for anode and cathode systems, trumpets of inlet and outlet, air flow
distribution device, HV power supply device, shell, hopper and etc. Anode plate row
includes hanging plate assemble, anode plate, limit plate and anti-sway fork. Anode
plate adopts top rapping to remove dust and rapping device is outside of shell.
Cathode system consists of corona wire, upper and lower horizontal tube, cathode
hanging beam, cathode suspension system and anti-sway device. Cathode plate also
takes top rapping mode. Each electric field is with 2 hoppers and each boiler is with 6
hoppers. The hopper is pyramid construction and the lower part is connected to
unloading and conveying ash device. The collected ash of ESP is transported through
hopper and unloading ash device. Besides, the lower part of hopper wall is equipped
with heating device. Hopper has ash poking hole and spoiler is installed in the middle
part of hopper to prevent short circuit due to flue gas.
3.12.2 Technical Specifications of ESP
Table 3-35 Technical Specifications ESP
No. Item Unit Value
Design efficiency % 99.5
1 Guaranteed efficiency % 99.5
Check coal quality and design efficiency % 99.5
2 Proper resistance Pa 200
3 Proper air leakage rate % 2
4 Chamber quantity/electric field quantity 2/3

157.2 (verified coal)
5 Flue gas inlet flow m3/s
194.4 (design coal)
139.2 (design coal)
6 Flue gas inlet temperature °C
134.3 (verified coal)
7 Flue gas flow rate m/s 0.72
8 Ash hoppers for each ESP Piece 6

High material level meter of ash hopper
9 Pieces 6
(each ESP)
28
10 Rectifiers equipped in each ESP Set 6
11 Rated power of each rectifier KVA 83
3.13 Pneumatic Ash Conveying System

3.13.1 System overview
This system is pneumatic ash conveying system of dense phase and positive
pressure. Collected ash of ESP falls into transport vessel which is arranged under
hopper of ESP, and then the ash is transported to ash silo through wear-resistant pipe
by using compressed HP air from air compressor. Fluidized board is arranged below
each hopper and also two ash silos. The air from pneumatic air fan acts as fluidized
air to ensure the ash in hopper enters transport vessel. Each boiler can be one unit in
conveying system and conveying output of each unit is 11t/h to meet the output
requirement of 150% ash under condition of B-MCR and design coal firing. The two
boilers are equipped with two sets of steel ash silo, each with available volume of
400m3 and diameter of φ8m. Besides, each ash silo has public platform and staircase
and two discharging ash port on the lower part. The one is connected to dry unloader
and each set output is 100t/h. the other is connected to dual-shaft blender and each
set output is 100t/h. The maximum distance from hopper of ESP to ash silo is 200m.
3.13.2 Technical Specifications of Equipment in Ash Conveying

System
3.13.2.1 Technical Specifications of Ash Conveying Pump
Table 3-35 Technical Specifications of Ash Conveying Pump
ESP second electric
ESP first electric field ESP third electric field
field
Conveying device model 10.0E/8 5.0E/8 5.0E/8
Quantity 2 2 2
Volume of each set (m3) 0.34 0.17 0.17
Output of each set (t/h) 4.58 0.79 0.79
Total Output (t/h) 9.163 1.573 1.573
Operation period (hour/shift) 8 8 8

Feed valve Pneumatic dome Pneumatic dome
Pneumatic dome valve
(type/specification) valve valve
3.13.2.2 Technical Specifications of Aeration Blower

Table 3-36 Technical Specifications of Aeration Blower
Model BK5003
Air flow 2m3/min
29
Air pressure 60KPa
Motor power 7.5KW
Shaft power 5.34KW
Voltage 380V
Speed 1150r/min
3.13.2.3 Technical Specifications of Aeration Blower

Table 3-37 Technical Specifications of Aeration Blower
Type DYK-8
Inlet air pressure 60KPa
Outlet temperature 150°C
Heater power 8KW
Voltage 380V
Air flow 2m3/min
3.13.2.4 Technical Specifications of Two-shaft Mixer

Table 3-38 Technical Specifications of Two-shaft Blender
Type XSJ-100
Quantity 2
Output 100t/h
Speed reducer power 22KW
Water content in ash after commissioning 15%～30%
Conditioning water quantity 15~30 t/h
Conditioning water pressure 0.4~0.6MPa
3.14 Startup Boiler

3.14.1 Overview
The boiler is D type furnace assembly construction and mainly consists of upper and
lower steam drums, convection heating surface, radiant heating surface, superheater,
economizer, furnace wall, platform staircase, steel frame and etc, with compact
construction and high thermal efficiency.
3.14.2 Technical Specifications of Startup Boiler
Table 3-39 Technical Specifications of Startup Boiler
Items Unit Design Data
30
Boiler model SZS10-1.27/270-Y
Rated output t/h 10
BMCR t/h 11
Steam pressure under rated working
MPa 1.27
condition
Steam temperature under rated working
°C 270
condition
Feedwater temperature °C 20
Outlet water temperature of economizer °C 89
Flue gas temperature °C 166
Rated oil consumption quantity t/h 733
Oil pressure of burner MPa 2.8~3.5
3.14.3 Technical Specifications of Boiler Auxiliaries

3.14.3.1 Technical Specifications of FD Fan
Table 3-40 Technical Specifications of FD Fan
Items Unit Data
Air flow m3/h 10800
Air pressure Pa 6000
Motor power/voltage KW/V 30/400
Current A 54.1
Speed rpm 2965
3.14.3.2 Technical Specifications of ID Fan

Table 3-41 Technical Specifications of ID Fan
Items Unit Data
Air flow m3/h 31554
Air pressure Pa 2041
Speed rpm 1450
3.14.3.3 Technical Specifications of Feedwater Pump

31
Table 3-42 Technical Specifications of Feedwater Pump

Items Unit Data
Quantity Set 2
Flow t/h 12.5
Head m 175
Current A 27
Speed rpm 2900
4 Boiler Proper Maintenance

4.1 Steam Drum Maintenance
4.1.1 Safety Precautions for Maintenance
4.1.1.1 Prepare work permit before maintenance.
4.1.1.2 After draining water from boiler for 48 hours, open the manhole for ventilation. Work
can not be carried out in boiler unless the temperature is below 40°C.
4.1.1.3 such valves for main pipe, feed pipe, back flush and neighboring boiler heating should
be isolated from the boiler before personnel enter the steam drum for work.
4.1.1.4 The personnel entering the steam drum for maintenance should wear special uniform
with the pockets being free from unnecessary articles. All tools and parts taken in shall
be recorded carefully. In case of lost, the missing item must be found.
4.1.1.5 When maintenance is conducted in the steam drum, personnel should be assigned at
manhole as guardian. If steam and water enter the steam drum, stay calm and get out
of it as soon as possible.
4.1.1.6 12V portable light should be used as lighting in the steam drum.
4.1.1.7 The voltage for electrical tools used in steam drum should not exceed 24V. if not,
relevant safety precautions should be taken and approved by supervisors.
Disconnecters of those electrical tools should be installed outside the drum and
operated by special personnel.
4.1.1.8 Before entering the drum for work, seal the downcomer to prevent objects from falling
into it.
4.1.1.9 record and check that the personnel entering the drum, tools and materials taken into
the drum, should be in correct number before finish work.
4.1.1.10 Before leaving the site, the personnel seal the manhole with special mesh enclosure
and lock or seal out.
4.1.1.11 After work completed, the personnel in charge should check the number of personnel
and tools are correct and after confirming nothing is left in the drum, close the
manhole for acceptance.
4.1.2 Maintenance Items
32
4.1.2.1 Manhole surface inspection and cushion replacement

4.1.2.2 Record the installation of steam and water separator devices.
4.1.2.3 Clean the sediments on both sides of steam drum (along with chemical workshop)
4.1.2.4 Inspect the seal joint visually or by means of dye testing.
4.1.2.5 Internal equipment inspection inside Expansion indicator
4.1.2.6 internal equipment inspection
a) Check the structure of devices in the steam drum for corrosion or other condition.
b) Inspection of seal joints on both sides of steam drum (visually and dye testing)
c) Cleaning of scaling in connection pipe of water level gauge (assisted by pipe
valves)
d) Disassemble water and steam separator for inspection (if necessary)
e) Check whether the feed pipe, dosing pipe, abd etc are damaged, the screws are
loosen.
f) Visual inspection of weld joint inside the indicator, penetration inspection and flaw
detection including pin head welding.
Note: Minor maintenance does not include maintenance work for steam drum.
4.1.3 Maintenance Process and Quality Standards
Table 4-1 Quality Standards for Maintenance
Maintenance
No. Processes and precautions Quality standards
items
a) Make good records of
expansion indicator before
a) Sampling should be
boiler shutdown.
conducted by chemical
b) Dismantle the protection
personnel.
1 Preparations cover of manhole.
b) Take out the sampling in
c) Prepare rubber and other
proper way, never hold it
tools.
with hand.
d) Install two 12V portable
lights.
a) Make good indication records
before boiler shutdown
a) The assembly is correct and
b) Compare the records of
Correction of secure.
expansion indicator before
2 expansion b) Zero calibration is correct.
and after boiler shutdown
indicator c) The indicator gives clear
c） Conduct the last complete
indication and clean surface.
inspection before hydrostatic
test.
a) Check the contact of part that a) The upper and lower tile
suspends the steam drum at pads should be complete.
lower part of hanger and b) Shaft pins and nuts should
Inspection of
steam drum. be fastened.
3 steam drum
b) When handling the removal c) The part that suspends the
hanger
of welding problem about steam drum at lower part of
16Mn steel sheet at spot hanger should be isolated
welding point, remove the from steam drum.
33
thermal insulation of steam

drum at first; normally,
grinding work should be
checked when checking the
welding joint on drum.
a) Prepare work permit after
boiler shutdown for 48-hour
discharging. Use special
spanner to unscrew the bolts
on manhole and mark the
bolts and gaskets for easy
a) The manhole surface should
reassembly.
be smooth, free from
b) Maintenance director or
noticeable straight flute and
special engineer, safety
corrosion pits. It should be
personnel and chemical
free from cracks and joint
personnel of power plant are
surface should be larger
required to be present at the
than 2/3 of total width.
site while opening the steam
b) Press the rubber gasket to
drum. One person keeps
make sure there is no lap,
monitoring and records the
the thickness is between 2
results when opening
and 4mm, equal to the
manhole. The operator
manhole, the gasket should
should wear glove and stand
be dry and free from
Manhole at one side of it, to avoid
softening by damp.
disassembly and scald and paste seal on
4 c) The pressure plate for
reassembly manhole after closing it.
manhole door should be free
c) Install ventilator to cool the
from counter-thread and
air in the steam drum to
galling, the nuts can be
reduce it below 40℃ before
fastened to the end by hand.
entering steam drum.
Coat lead powder or
d) After opening the steam
molybdenum disulfide on
drum, the chemical
one side of screw.
personnel should firstly enter
d) No water leakage after
it to inspect the scaling in the
assembly.
steam drum, corrosion and
e) Ignite to increase pressure
the completeness of devices
to 0.29—0.40MPa and
in it. Meanwhile, they should
tighten screws on manhole
make good records of
in hot state.
inspection before
maintenance. Give strict
inspection to the objects the
personnel carry on with them
when their entering steam
drum, record carefully and
take them out of steam drum
34
when leaving the drum.

e) 12V low voltage light is
equipped in the steam drum.
Cover the downcomer with
rubber before entering the
steam drum to prevent other
objects dropping into it.
f) Do not cut or weld on steam
drum unless approved by the
leaders concerned.
g) Do not close manhole even
after completing the task in
steam drum until the leve-3
acceptance is made.
h) Make good records of steam
drum after maintenance so
that comparison can be
made between two results.
a) Number the steam and water a) The corrosion depth of all
separating device and steam devices in the steam drum
cleaning devices that has should not be over 1/2 of
been dismantled in a left, original thickness.
right, front and back order. b) The error for overflow valve
Remove the rust and scaling threshold should not be over
from the devices in the steam 0.5mm and 4mm in length.
drum with brush, wire brush Make records of the
or sand cloth and place the measuring results. If the
small parts such as pins and error exceeds the given
screws in the same place. value and affects water and
b) Purge the water pipe, steam quality, take
feedwater distribution pipe, appropriate measures to
Internal cleaning
5 dosing sampling pipes, water solve it.
gauge connection pies (use c) The dosing pipe, blowdown
small hammer to knock the pipe, feedwater distribution
pipes unable to dismantle to pipe and sampling pipes
make them unblocked) with should be unblocked and
compressed air to remove installed firmly in correct
the rust and dirt. position. The connection
c) Bind up downcomer and pipe should be arranged at
cross-shaped damper and the height than normal water
cover them with rubber to level and bypass water
prevent tools and foreign pipes should be distributed
matters left in pipe. symmetrically in the correct
d) Install a temporary manhole direction and led near
and paste seal on it before downcomer orifice. Channel
35
leaving the steam drum after steel impact-absorbing shell

completing task. is firmly welded and the
emergency discharge pipe
should be installed at the
place higher than lowest
water level.
d) The eyehole of multi-orifice
plate and cleaning plate
should be clean and
unblocked.
a) Clean the joint surface of
manhole with horizontal
scrapper, polish it with sand
cloth and wipe with white
cloth. This should be done
around the manhole. There
should be free from straight
flute, especially corrosion
spot and straight flute lines. If
large and deep corrosion
spots are found, immediately Check the surface with
try to repair them by chipping special flat plate (tested)
Manhole surface away the spots and grinding and feeler gauge in circle,
6 measurement and them to smooth after giving 12-16 points around
maintenance overlapping welding the circle for each surface
(appropriate welding and making good records of
measures should be taken the results.
depending on the
performance of materials).
Be careful enough not to
damage the manhole surface
while dismantling parts of
steam drum.
b) Re-scrapping, grinding and
leveling should be conducted
with grinding paste and
scrapper.
a) Check the cracks of steam a) When the depth of dents
drum every time when and pits on the internal
Inspection of conducting overhauling. surface of barrel each as
cracks on external Check the cracks on outer 3mm—4mm, polish it until it
7
and internal walls surface every six years. becomes smooth. However,
of steam drum b) Check the cracks by coloring when the depth exceeds
method or ultrasonic wave 4mm, give repair weld and
and record the result. then polish it.
36
c) If the cracks on the steam b) Give repair to those surface

drum are larger than the with small cracks and bulges
given standard so that repair with the height of 3mm.
weld should be conducted, in
this case, detailed repair
weld measures should be
provided and approved by
the general engineer before it
is carried out.
The devices inside the steam
a) cross-damper is firmly
Port inspection of drum that are dismantled
welded.
8 large-diameter should be given careful
b) Port of downcomer is free
downcomer inspection before put back
from cracks.
into steam drum.
a) pay close attention to
chemical supervision and
a) Poor feedwater quality.
conduct blowdown
b) Insufficient blowdown
according to relevant
Internal corrosion capacity leads to
9 requirements.
and scaling deterioration of boiler water.
b) Give acid cleaning of steam
c) Failure to complete cleaning
drum and heating surface.
for long-term operation.
c) Give complete cleaning
during overhauling.
The rapid feeding or
discharging speed after
Work out measures to solve
Bending and boiler startup/shutdown gives
it.
10 cracks of steam rise to over 50℃ temperature
Strictly carry out the
drum differential of top and bottom
operation code.
wall of steam drum, which
results in too much stress.
a) Joint surface of manhole fails
to be tight enough. a) Grind the joint surface of
Steam drum
b) Cushion material fails to manhole of steam drum.
manhole leakage
11 meet the standards. b) Employ asbestos cushion
and internal parts
c) The pins inside the steam up to standards.
fall-off
drum fails to be firmly c) Firmly install the pins.
installed.
4.1.4 Acceptance after Steam Drum Maintenance

Table 4-2 Acceptance after Steam Drum Maintenance
Acceptance items Methods Standard
a) Supports and hangers a) site acceptance maintenance
b) Expansion indicator b) Reference acceptance quality for
37
c) Disassembly and reassembly of c) Selective inspection acceptance

manhole. acceptance through standard
d) Measure steam drum levelness, measurement.
bending, ovality and manhole
surface.
e) Internal cleaning of steam drum.
f) Cleaning of parts inside the steam
drum.
g) Disassembly of different equipment
h) Hydrostatic test
4.2 Water Wall and Furnace Maintenance

4.2.1 Safety Measures during Maintenance
4.2.1.1 The work permit is well prepared and safety measures are taken before work is
carried out.
4.2.1.2 For furnace work, keep the temperature below 60℃ and well ventilated
4.2.1.3 The personnel entering the furnace should wear necessary personnel protection
equipment.
4.2.1.4 At least two personnel are assigned to work together in the furnace with someone
monitoring outside.
4.2.1.5 The scaffolding set up in the furnace should meet safety requirements and be
accepted by relevant department.
4.2.1.6 Wear safety belt when working high above the ground.
4.2.1.7 The 36V (below) portable lamp should be used in lighting.
4.2.1.8 220V lighting lamp should be fixed firmly and have good insulation. The electric tools
must have good insulation and reliable grounding wire. The disconnectors should be
installed outside of furnace and operated by special personnel.
4.2.1.9 The electric tools must have good insulation and reliable grounding disconnectors
should be installed outside of furnace and operated by special personnel.
4.1.1.10 Personnel should seal the port that fails to be welded and given label before leaving.
4.2.2.1 Clean the coked ash on the external surface of pipe.
4.2.2.2 Conduct internal inspection of water wall as the requirements for chemical
supervision.
4.2.2.3 Measure the wall thickness of easily worn parts.
4.2.2.4 Inspect the cap of air distribution plate and clear the blockage.
4.2.2.5 Measure the wall thickness of water wall.
4.2.2.6 Give seal inspection and remove leaked ash.
4.2.2.7 Inspect fin and give repair weld.
4.2.2.8 Inspect water cooling air chamber.
4.2.2.9 Replace part of water wall depending on inspection results.
4.2.3 Edge Preparation of Tube Groove Processing and
Butt-Welding
4.2.3.1 The butt-jointed seam of heating surface tube should not be allowed to be installed at
38
the bend part and its location should meet the following requirements:
4.2.3.1.1 There should be at least a distance of 100mm between the central line of butt joint
and the point where bend begins (or steam drum,the external wall of header, the edge
of supporter and hanger).
4.2.3.1.2 There should be at least a distance of 200mm between the central line of two butt joint
of pipe port, which also should be no less than the pipe diameter.
4.2.3.2.3 The end angle derivation value of pipe port should be smaller than 1mm and does not
exceed 1.5mm at most. It can be inspected with angle square or sample plate.
4.2.3.2 After cut, the pipe can be machined into groove with a flat file or groove machine. The
groove size depends on the thickness of pipe wall.
4.2.3.3 Clean the oil dirt and rust within the range of 10-15mm on groove surface and inner
wall to make it shines before connecting pipes. The pipe with bigger diameter should
be polished to a large length.
4.2.3.4 When connecting pipes, keep the thickness derivation of two pipes not over 15% of
nominal thickness with the maximum not over 3mm, otherwise, give weld to make
them get even thickness and aligned according to weld regulations.
4.2.4 Maintenance Processes and Quality Standards
Table 4-3 Maintenance Processes and Quality Standard
No. Maintenance items Technology and notes Quality standards
a) Give careful inspection to a) The depth of peel off should
those parts including bending not exceed 10% of pipe
part of water wall, welding thickness.
joint and heating surface in b) Pit depth should not be over
dense zone. 0.5mm.
b) If such defects such as c) Expansion should not
cracks, bulging, pits, peel off, exceed 3.5% of original
bend corrosion and dents diameter.
happen during welding, d) The cracks should be
record them carefully and smaller than 1/3 of wall
give weld, alignment and thickness, length not bigger
replacement of tubes to than 50mm and the area not
Water wall tubes
eliminate the defects. over 100mm2.
1 inspection and
c) Before tube measuring, firstly e) Inspect pipe when it bends
measurement
polish the part where 30mm toward wall inside.
measuring point is installed f) The seal joint of fin should
with sand cloth and then be free from open weld.
measure with vernier caliper g) Check the new pipe to be
or special calipers. used to be up to standards
d) When conducting with length being not over
replacement of tubes by gas 200mm.
welding cut, experienced h) There should be at least a
welder should be assigned central distance of 150mm
and avoid molten iron and between weld joint of the
dioxide falling into tubes. replaced pipe and old weld
e) When aligning tubes by joint and 70mm away from
39
heating, keep the the point where bend

temperature between 600 to begins, outer wall of header
650℃ with the maximum not and support and hanger
over 800℃. edge.
f) The welding of water wall i) The ovality and arc degree
tubes should be carried out at bend part should meet the
by qualified high pressure standards when replacing
welders and should be the pipe with bends.
confirmed to pass the
standard before the heat
insulation material and
protective plate are restored.
a) Sampling location should be
determined by chemical
personnel and personnel from
workshop.
b) The place where to be cut
should meet the requirements
for butt welding to facilitate
welding and inspection of
weld joint.
c) Do not use hammer to knock a) The sampling section meets
the sampling section to avoid chemical requirements.
characteristic of inner wall b) Inspect the replaced new
Tube cut surface and seal the pipe port pipe to meet standard and
2
inspection as soon as the sampling pipe internal wall is cleaned with
is cut. acid.
d) When conducting c) Inspect the weld joint to
replacement of tubes by gas reach standards
welding cut, experienced
welder should be assigned
and avoid molten iron and
dioxide falling into tubes.
e) When cutting the upper and
lower fins on the weld joint, do
not cut the pipe and the fin to
be cut should be about
100mm.
a) Check the refractory around a) The air cap should be free
air cap to be free from from looseness.
Air cap and looseness. b) Give welding or
3 refractory b) Check the air cap to be free replacement of air cap
inspection from deformation. depending on wearing.
c) Check the refractory in c) The refractory should be
furnace to be free from cracks smooth, complete, and free
40
and falling off. from tilting and bubbling.

d) Check the air cap to be free d) The air cap is unblocked.
from blockage.
a) Check the refractory in the air a) The refractory in air
chamber to be free from chamber should be
Air chamber falling off. complete, smooth, free from
4
inspection b) Check whether ash deposits tilting and bubbling.
and leakage occurs in air b) Clean the deposited ash
chamber. and eliminate ash leakage.
a) Remove the heat insulation
material to give appearance
inspection.
b) Measure the bending of
a) the surface of header should
header and check whether
be free from cracks,
there present cracks and
corrosion and peeling off。
leakage marks at weld joint.
b) the bending of header
c) Check the hangers to be free
should not exceed 3mm per
from looseness and
meter.
experience uneven force. If it
c) The lower header
does, ascertain the causes
Header experiences normal
5 and make adjustment.
maintenance expansion, the expansion
d) Check the expansion of lower
indicators of it have clear
header and make records of
display and the pointer
it.
stands at zero, 3-5mm away
e) Make good records of the
from plate.
indication shown by
d) The internal header is free
expansion indicator of upper
from corrosion but presents
and lower headers and make
minor scaling.
zero correction.
f) Conduct inner corrosion
inspection as required by
chemical personnel.
a) Inspect furnace wall heat
a) Complete heat insulation.
insulation and inform
The temperature increase of
bricklayer if falling off
external surface should not
refractory is found.
over 50℃。
b) Inspect external protective
Furnace wall and b) External protective plate is
plate, add new one to those
6 steel beam complete and beautiful.
missing parts, weld the
maintenance c) The steel beam is reliable,
loosened parts and coat them
the cross beam is free from
with oil regularly.
damage and the connection
c) Give overall inspection to
piece at four corners is in
steel beam and make sure
good condition.
there are no defects.
7 Hydrostatic test Special safety technical a) The working pressure
41
measures should be decrease should not be

formulated for hydrostatic test more than 0.04-0.6MPa.
and super hydrostatic test. b) No leakage at weld joint.
4.2.5 Acceptance of Water Wall Maintenance

Table 4-4 Acceptance after Maintenance
Item Method Standard
a) Pipe cutting and a) Acceptance on site. Acceptance standards
sampling. b) Documents acceptance. correspond to
b) Hydrostatic test test. c) Selective inspection of measurement. maintenance quality.
c) Expansion system.
d) Expansion indicator.
e) Water wall
measurement and
inspection.
4.3 Superheater Maintenance

4.3.1 Maintenance Items for Low-temperature Superheater
4.3.1.1 Inspect inner scaling and corrosion condition by pipe cutting based on chemical
agreement.
4.3.1.2 Remove ash on the external wall of heating surface.
4.3.1.3 Pipe wear- and explosion-proof inspection and solutions.
4.3.1.4 Pipe lifting and pipe blockage inspection.
4.3.2 Maintenance Items for High-temperature Superheater
4.3.2.1 Clean the external of heating surface.
4.3.2.2 Pipe wear- and explosion-proof inspection and solutions.
4.3.2.3 Pipe clamps inspection and solutions.
4.3.2.4 Inner inspection by pipe cutting is determined by chemical and metal conditions.
4.3.2.5 Pipe measurement and corrosion inspection.
4.3.2.6 Supports ＆ hangers and pipe clamps inspection and repair. Replace the
damaged spacing iron comb type clips.
4.3.3 Cut Pipe Inspection of Heating Surface
4.3.3.1 The pipe-cut inspection of water wall, superheater pipe and economizer should be
conducted during overhauling.
4.3.3.2 The location and quantity of pipes to be cut should be determined through the
consultation of personnel from production and technology department, chemical
personnel and maintenance personnel in charge.
4.3.3.3 The new pipe by cutting should be sent to metallographic laboratory for assay and
then for chemical acid cleaning before welded.
4.3.3.4 It is better to use handsaw rather than oxyacetylene gas cutting to give pipe cutting
inspection of economizer and superheater. Oxyacetylene gas cutting of alloy-steel
pipe should be conducted as required of relevant regulations and pipes should be
replaced in accordance with relevant procedures after cut.
42
4.3.3.5 After cutting pipes of the economizer and superheater, check the scaling and
corrosion in them, make good records of the results and then send them for chemical
assay and metallographic analysis.
4.3.3.6 The pipe cutting of water tube wall includes the following:
a) Before cutting pipes, remove the corrugated pipe plate near all pipes and heat
insulating material and clean the neighboring area where pipes are cut.
b) Firstly use oxyacetylene gas cutting to cut the weld joint between fin and pipes.
Be careful not to damage the fins on both sides. Cut the lower port of vertical pipe
section with handsaw, insert baffle plate and make a hole with oxyacetylene gas
cutting.
c) When conducting pipe cutting as required, do not let welding spatter into pipes.
d) After pipe is cut, the maintenance personnel should make an internal inspection
by themselves and make records before send it to the chemical personnel.
e) After removing the section where pipes are cut, process groove as required and
temporary seal.
f) Length of the section where pipes are cut and check the length left for the
economizer that has been cut and prepare new pipes.
g) When connecting pipes, fix both ends of pipe and water wall with clamp and give
spot welding at three to four points. Then take out the clamp and weld the two
weld joints. After completing welding, it is not allowed to reinstall external
insulating material and corrugated plate until they are inspected by the personnel
in charge of metallographic examination and pass hydrostatic test.
Table 4-5 Maintenance Process and Quality Standards
Maintenance
No. Process and precautions Quality standards
items
a) The manhole can open and
close flexibly and the refractory a) The manholes is free from
is complete. defects and handles are
Manhole b) Close the manholes after complete.
1
maintenance everything is completed and b) Manholes enjoy flexible
make sure they are tightly opening and closing and are
closed. The handles are leakage-free after closed.
complete.
a) Contact with operation
personnel to start one ID fan a) There should not ash
and open its inlet damper to deposits falling down when
provide sufficient negative swaying the pipes.
pressure in furnace. Use b) The depth of ash on the pipe
Superheater compressed air to blow the ash should not exceed 0.3mm.
2
purging
deposited in horizontal flue gas c) There should be large
duct and ash on back heating coking block between pipes.
surface. d) Completely remove the ash
b) Wear safety helmet when from oblique bottom wall.
conducting ash cleaning in
43
furnace to prevent coked slag

from the top. If necessary, wear
safety belt, shawl hat,
dustproof mask, and safety
glasses.
a) Give overall inspection of pipe
to see whether it experiences
bend caused by heat, bulging,
peel-off, damage by colliding, a) Give overall inspection and
cracks and corrosion. there is defect-free.
b) Check whether there are b) No defects are found on
cracks and inspection holes on welding joints.
Pipe inspection welding joint. c) The wearing should not be
3 and
c) Check the wear thickness of over 1/3 of wall thickness.
measurement
pipes. d) The expansion of alloy steel
d) After abrading the ash pipe should not exceed
deposited on measuring points, 2.5% and that of carbon
measure the longitudinal and steel not over 3.5%.
horizontal straightness of pipe
with sand cloth or vernier
caliper and record them.
a) The weld joint where pipe
replacement made can be
welded and the sampling
section should meet the
metallographic examination
and chemical monitoring
requirements.
a) The pipe length should not
b) When changing pipes of HT
shorter than 200mm.
and LT superheater, removing
b) At least 70mm away from
comb plate and draw away the
the point where bend
pipes at both sides of them with
begins.
Pipe chain hoist for a distance of
4 c) Central mismatch is smaller
replacement 500-600mm and then remove
than 0.5mm.
the pipes to be replaced and
d) Meet standards.
place wooden block under
e) Tempering process should
them.
be with temperature
c) It is better to use handsaw to
730-750℃.
cut pipes. When using gas
cutting, firstly cut the pipe port
at lower part and prevent
welding slag from entering into
pipe.
d) Leave at least a length of
200mm when grinding 102#
44
pipe by gas cutting and then

the groove machine cuts the
section which influences heat.
e) the pipe groove should meet
the welding requirements
f) The pipe section should be
given optical spectrum
inspection and proved to be
correctly treated.
g) The weld joint after treatment
should take metallographic
examination and proved to be
free from defects.
h) Give high temperature
tempering treatment to weld
joint as required.
i) Reassemble clamps and comb
plate.
a) Check whether the lifting band, Lifting band, positioning
positioning clamp and comb clamp and comb plate are
Positioning plate experience damage and free from damage. When
5 comb plate of
falling off. If so, replace them. replacing new material,
superheater
b) Electric welding cutting of old inspect the material to meet
clamp. relevant standards.
a) Conduct overall inspection of
heat insulation every six years a) The bending of header
and make sure there is no should not exceed 3mm per
deformation, cracks and peel meter.
off. b) No corrosion cracks, etc.
b) Carry out internal inspection of c) The expansion indicator has
Header inspection hole as required by clear display and pointer
6
maintenance chemical supervision. stands at zero.
c) Expansion indicator is free from d) The hangers have no
defects. defects.
d) The hanger should bear even e) The heat insulation is in
load and fail to be loose. good condition and
e) The heat insulation for header complete.
is complete and undamaged.
a) Correctly and firmly
Expansion It should be carried out before installed.
7 indicator
hydrostatic test. b) Zero calibration, clean
maintenance
display and clear scale.
4.3.5 Acceptance after Superheater Maintenance

Table 4-6 Acceptance after Superheater Maintenance
45
Acceptance items Acceptance methods Acceptance standards

a) Pipe inspection
b) Expansion indicator a) Site acceptance
c) Coil pipe measuring records of b) Material acceptance acceptance standards
correspond to
superheater c) selective inspection
maintenance quality.
d) Internal inspection to the desuperheater on quality.
e) Hydrostatic test
4.4 Economizer Maintenance

4.4.1 Safety Measures During Maintenance
4.4.1.1 The work permit has been prepared before maintenance and safety measures are
taken.
4.4.1.2 Before entering economizer for ash removing and inspection, make sure the air duct
and flue gas duct of boiler are isolated, and then contact the operation foreman to cut
off the power supply for FD fan and coal feeder and hang warning board of “Do not
start”.
4.4.1.3 It is not allowed to conduct ash removing and maintenance in economizer before the
temperature is brought down below 60℃. Ash removal should be done in a up-down
order and protection devices should be used by personnel during the maintenance.
When everything is ready, start ID fan.
4.4.1.4 The portable light voltage should not exceed 36V.
4.4.2.1 According to chemical requirements, inspect the economizer inner scaling and
remove it.
4.4.2.2 Economizer hangers and supports inspection.
4.4.2.3 Replace some pipes on the two ends of the economizer according abrasion condition.
4.4.2.4 Calibrate and repair expansion indicator.
4.4.2.5 Economizer repair and heat insulation recovery.
4.4.2.6 Hydrostatic test.
Maintenance
No. process and precautions Quality standards
items
a) Prepare tools, materials and
portable lights according to
equipment defects records and
last maintenance records.
1 preparations b) When the temperature in
maintenance area drops below
60℃, do not enter the working
area unless approved by the
personnel in charge.
2 Cleaning, a) Check the ash deposited at the a) Clean the ash deposited at
46
inspection and outer surface of pipe and make the outer surface of pipe of
maintenance of records. The cleaning should economizer.
outer surface of be carried out in a top-bottom b) The economizer pipe
economizer pipe order from bypass economizer. expansion should not
b) Before purging, notify operator exceed 3.5% of original
to start one ID fan whose diameter. If not, replace it.
openness of damper should c) Partial corrosion depth
meet purging requirements. should not exceed 10% of
Use compressed air to purge pipe wall thickness and wear
the ash deposited on the outer should not exceed 1/3 of wall
surface of economizer or use thickness. If not, replace it.
NaOH solution to clean the ash, d) Anti-wear should be in good
but immediately put the air condition and pipe clamp
heater into operation after should meet the drawing
cleaning and start FD fan to dry requirements and firmly
the surface. fixed.
c) Use calipers to measure the e) if there is flue gas path,
creeping of economizer and make some improvement or
make records. install spoiler baffle.
d) Check whether the pipe surface f) The pipes should be orderly
presents peel off, corrosion, arranged, the clamp-fixed
changing of color, bulging, pipe has even space, the
cracks, etc. if necessary, error should not be over
replace with new pipe. ±5mm and the bending of
e) Check whether the anti-wear pipe should not exceed
cover and pipe clamp 20mm.
experience rolling over, falling
off, open weld, etc. Check
whether both sides suffer from
flue gas leakage.
f) Check the neatness of pipe,
adjust the pipes that bend. Use
fire welding to straighten but the
temperature should not exceed
700℃. Replace the serious
deformed ones if failing to
straighten them.
a) Check anti-wear cover plate
and protective cover to be free a) Anti-wear cover plate should
from burn-out, derivation, be placed on the right top of
Anti-wear device declining or bends. If so, use pipe, free from declining,
3
inspection gas welding to recover. bending and bulge.
b) If burn-out, falling-off or b) Anti-wear device can expand
seriously worn are found, do freely.
not weld the cover plate
47
protective cover on the pipe

when replacing.
c) use short cover plate to cover
the joints of two plates without
clearance.
a) Cut the inspection hole cover of
header for inspection according
to chemical requirements.
b) Before cutting, mark lines on
the original weld joint. After
a) Record the cut position.
cutting, notify the personnel
b) There is no water scale,
from chemical department,
sand deposits, etc.
metal test department and
Economizer c) The welding of inspection
production & technology
4 header hole cover of header should
department for inspection and
inspection be equal to the one of water
record the results.
wall header.
c) After polishing the groove,
d) Weld joint should pass flaw
clean the rust and impurity in
detection inspection.
the header.
d) If the shell cover that is cut fails
to be welded immediately,
apply temporary plug and paste
seal.
a) Expansion indicator should
Header
be installed in the proper
expansion The maintenance should be
position.
5 indicator completed before hydrostatic
b) The indicator gives clean
maintenance test.
display, clear indication and
zero calibration.
a) The manholes should be
flexible and the joint surface
Manhole should be flat with any leakage.
6
maintenance b) The cushion for manhole
should be complete. If not,
replace it.
a) The test should be carried out
together with whole-unit test.
b) Provide comprehensive
7 Hydrostatic test inspection for the header and
hanging pipe of economizer,
give emphasis on new weld
joints.
4.4.4 Economizer Acceptance After Maintenance

Table 4-8 Economizer Acceptance After Maintenance
48
Acceptance item Acceptance methods Acceptance

standards
a) Random inspection about pipe cut. a) Site acceptance. Acceptance
b) Hydrostatic test b) Material acceptance. standards
c) Random measurement inspection of c) Random measuring correspond to
coil tube. inspection for maintenance quality.
d) anti-wear inspection. acceptance.
4.5 Air Preheater Maintenance

4.5.1.1 Conduct necessary oxygen content monitoring before entering air preheater.
4.5.1.2 There should have sufficient illumination in the interior space.
4.5.1.3 Wear dustproof caps and masks.
4.5.1.4 Adjust the damper at air-facing side to ensure a certain negative pressure.
4.5.1.5 Do not carry out maintenance to two layers of air preheaters together. Otherwise,
inform the relevant personnel and perform protective measures.
4.5.2 Routine Maintenance of Equipment
4.5.2.1 Clean the ash deposited in the upper part of pipe.
4.5.2.2 Inspect and handle the abrasion of tubes and anti-abrasion sleeve.
4.5.2.3 Inspect and repair retractable joints.
4.5.2.4 Perform air leakage test and eliminate the leakage.
Maintenance
NO. Technical Methods and Precautions Quality Standards
Items
a) First, clean accumulated ash on
top of air preheater and do not
storage the ash in the boiler.
b) Pipe dredge
1) If using dry dredge method with
ID fan start, the top of the
equipment below upper and
lower stages air preheaters
must be covered with asphalt
1 Ash clean felt to avoid repeated ash
removing.
2) Dry type dredge: use steel rod
(diameter is 6mm) to poke ash
downward. If it fails, poke
upward. The steel rod should be
0.5-1m longer than air preheater
height.
3) Use mechanical device to
increase work efficiency, like
49
pipe washer driven by motor.

4) Wet type dredge: use several
rubber (oxygen) soft pipes with
proper length to connect with
header which is connected with
slag washing pipes. Then start
slag washing pump and keep
proper pressure, and then insert
soft rubber pipes to air
preheater pipe from top, if there
is water reversely flowing out, it
means the pipe is still blocked. If
using the wet dredge method,
before boiler ignition, dry air
preheater with hot air to prevent
it sticking to ash, resulting in ash
blockage, or wash it with HP
washer.
a) Check pipes at air side of air
preheater to see if there is
accumulated ash, if there is,
then conduct air leakage test.
b) Air leakage test: start FD fan
and maintain certain air
Air leakage
2 pressure for air preheater. Then
test
operator enters into air
preheater flue gas side to check
each pipe with paper. If the
paper swings, it means this
place has air leakage which
should be marked.
a) If only a few pipes get leaked,
use plugs to seal or use steel
plate to weld them. If many
experience leakage, resulting in
large area of leakage, it is
required to replace them. a) No air leakage.
Air leakage b) When replacing pipes, use b) If the leakage quantity
3
elimination special tools to remove welding exceeds 1/3 of whole set,
scan until the circle trace can be replace all.
seen on pipe plate and pipe
head. And then use pulse pipe
to push pipe out. Insert pipe into
its plate hole and carry out full
welding, if pipe cannot be
50
inserted fully, cut it into several

sections, and install individually,
and then weld them.
c) If the quantity of leaked pipes
exceeds the value required, the
pipe box should be replaced.
a) Inspect to see whether such
defects as open weld, cracks
and air leakage are found on the
welded junction of air
Inspection for connection box and expansion
air connection joint.
4 box and b) Conduct patch welding for the
expansion parts that present open-welding
joint and cracks.
c) Use steel plate to weld the part
with air leakage in large area
without affecting the function of
expansion joint.
4.5.4 Acceptance after Air Heater Maintenance

Table 4-10 Acceptance after Air Heater Maintenance
Acceptance
Acceptance Items Acceptance Methods
Standards
Acceptance
a) Air leakage test a) Spot acceptance
standards
b) Hydrostatic test b) Material acceptance
correspond to
c) Spot check of coil tube c) Acceptance for
maintenance
measurement measurement spot check
qualities.
4.6 Sootblower Maintenance

4.6.1 Equipment Daily Maintenance
4.6.1.1 Fasten the inlet and outlet flanges again in time during attemperator is being
pre-heated.
4.6.1.2 Frequently check equipment vibration and displacement to make sure the equipment
can expand freely with reliable support.
4.8.1.3 Actuators are firmly connected without looseness.
4.6.1.4 The safety valve must be popped up manually and periodically to make sure it can
reliably perform.
4.6.2 Sootblower Maintenance Process and Quality Standards
Table4-11 Sootblower Maintenance Process and Quality Standards
Maintenance
No. Process Measures, Precautions and Quality Standards
Items
51
a) Prepare necessary maintenance tools and spare parts.

Preparations b) Prepare lifting and lighting devices.
1 before c) Inspect one by one to ensure that related systems are all isolated,
maintenance and residual steam and water have been discharged.
d) Make sure power is cut off.
a) Disassemble inner pipe flange nuts.
b) Move forward inner pipe flange to expose the split ring, then remove
split ring and push inner pipe off the back end plate.
c) Remove inner pipe flange gaskets.
d) Put disassembling tools into inner pipe chase, and push inner pipe off
the walking stuffing box.
e) Remove outer pipe flange nuts, spring gaskets and stud bolts.
f) Use sling to blind inner pipe through crossing cover plate hole at top
Disassembly of big beam, and make sure inner pipe is completely kept in the pipe.
and g) Remove and discard the upper gaskets of outer pipe.
2 maintenance h) Slowly tighten ropes for supporting inner and outer pipes.
for inner and i) Move outer pipe until the flange is off walking stuffing box. Move inner
outer pipes and outer pipes forward the back end plate until outer pipe head is off
the furnace connection sleeve and the front pulley set.
j) Lay down inner and outer pipes, and push them off big beam bottom.
The sliding angle should not be large to avoid inner pipe sliding from
outer pipe.
k) Check if the inner pipe surface presents abrasion and scratches, if
severe abrasion or deeper scratches occur on inner pipes, they
should be replaced.
l) Check bend and corrosion of outer pipe, if severe, replace it.
Inner pipe The procedures are contrary to the above mentioned one. And when
3
reinstallation installing inner pipe, replace one set of flexible graphite stuffing.
a) The total stuffing adjustable amount is 9.6mm, when adjustment is
finished, add one round of flexible graphite stuffing.
b) Cut off steam source and power.
c) Disassemble lock nuts and stud bolts of stuffing gland, move
4 Stuffing adding backward stuffing gland and inner ring along the inner pipe.
d) Put the seal stuffing ring (by two half circles) coated with lube grease,
composed into stuffing chamber, and recover the top pressing ring.
e) Reinstall stuffing back cover, stud bolts, and lock the nuts.
f) Check distance between front and back stuffing glands.
a) Remove inner ring.
Stuffing b) Remove outer ring and replace seal gaskets.
5
removing c) Remove steam valve and replace seal gaskets.
d) Remove stuffing box.
a) Disassemble oil cup and gasket, loosen lock nuts, and remove front
Disassembly
gland, pressing ring, retaining ring and back gland.
6 and installation
b) Pad a wooden block under main shaft back terminal, use hammer to
of main shaft
slightly hit bearing, so as to make bearing off box casing. Replace oil
52
seal of bearing casing.

c) Check to see if bearing and liner experience severe scratches and
abrasion, if so, replace them.
d) After the walking box and inner pipe are installed at back of
sootblower, replace flexible graphite stuffing.
e) Install cross shaft in reverse order to the above-mentioned
procedures.
a) Check and replace oil seal, bearing, worm wheel and worm.
b) Cut off steam source and power before getting the permission of
operator.
c) Disassemble motor flange bolts, nuts, and gaskets, and then remove
motor.
d) Orderly remove bolts, gaskets, oil seal, and bearing in gearbox.
Remove primary stage worm wheel and worm components and
remove chain wheel, final stage worm wheel and worm components.
e) Use kerosene to completely wash residual oil in gearbox.
f) Check the two worm wheels, if they have severe abrasion, replace
7 Gearbox
them with new one.
g) Check the two worm wheels, if they have severe abrasion or other
problems, replace them.
h) Replace all oil seals.
i) Check all bearings, and replace the damaged one.
j) Based on the above-mentioned procedures, reinstall the gearbox.
k) Measure the meshing clearance between worm wheel and worm, and
make records. The clearance can be adjusted through adjusting
gaskets.
l) Reinstall the gearbox into sootblower.
Steam valve overhaul
a) Disassemble steam valve.
b) Isolate the valve opening mechanism from steam valve.
c) Remove bolts, nuts, and gaskets of steam inlet valve flange.
d) Remove valve outlet nuts and steam valve. The total weight of valve
is about 30 Kg, and place valve on working area.
e) Replace stuffing (as above mentioned).
f) Take out the valve lever, and check abrasion of valve lever and valve
disc sealing surface. If sealing surface abrasion is not severe,
8 Steam valve
conduct few mechanical processing. And use micrometer to align
valve lever on lathe, to ensure concentricity.
g) Check if the valve seat sealing surface presents abrasion or damage,
if it is severe, conduct minor mechanical processing to repair it.
h) Reinstall stuffing, valve lever, and valve seat according to procedures
reverse to disassembly ones.
i) Reinstall the steam valve to sootblower and replace red copper
gaskets at valve outlet.
j) Reinstall the steam valve on flange gasket, and evenly tighten flange,
53
bolts, nuts and gaskets.

k) Before reinstall the checked steam valve to sootblower, the
hydrostatic test should be conducted. The valve cover should be
given strength pressure test, and the hydrostatic test with 4.4 MPa
pressure after installation.
l) Reinstall valve opening actuator and set valve opening based on
nameplate.
The actuator has one valve opening lever, which rotates around
steam valve cover support. It connects with the support through
spherical surface bearing. The lever is welded on the shaft and one
end of shaft is with tenon, on which there is cam. When the walking
Valve opening stuffing box moves forward, the bump pin on the stuffing box will
9
actuator engage with cam to drive shaft and link to move. As the stuffing box
continues moving forward, the rod will pull the valve lever to open
valve to let steam flow in. Remove hex socket screw, tighten rod head
spherical bearing, or tighten screw joint to adjust valve opening at 10
mm.
4.6.3 Acceptance after Sootblower Maintenance

Table 4-12 Acceptance after Sootblower Maintenance
Acceptance Items Acceptance Methods Acceptance Standards
a) Inspection for inner and outer
a) Spot acceptance
pipes Acceptance standards
b) Spot acceptance
b) Stuffing supply correspond to
c) Material acceptance
c) Gearbox maintenance qualities.
d) Measurement acceptance.
d) Steam valve
4.7 Attemperator Maintenance

4.7.1 Safety Measurements during Maintenance
4.7.1.1 Main stop valve and its bypass, feedwater valve and emergency water discharging
valve should be tightly closed, locked or hanged with warning board ‘DO NOT OPEN,
IN MAINTEANCE’. Front blocking plates of the main periodical blowdown valve and
superheater main drainage valve should be blocked.
4.7.1.2 The place where the railing is cut off for lifting out attemperator core must be equipped
with temporary fence to avoid falling.
4.7.1.3 Under non-working condition, or before off duty, use plug to seal inlet and outlet pipes
of attemperator, and put the seal to avoid sundry falling into pipes.
4.7.1.4 When lifting attemperator core, try to maintain it in horizontal position without abrasion
and collision to avoid damaging attemperator cooling pipes.
4.7.1.5 Maintenance personnel should be careful during working to avoid high place falling.
4.7.1.6 The platform set up should be safe and reliable and able to bear the weight of
maintenance operator, maintenance tools and parts.
4.7.1.7 During maintenance, the tools and components of disassembled equipment should be
put in order.
54

Maintenance
NO. Process Methods and Precautions Quality Standards
Items
a) The platform should be
a) Set up maintenance platform safe, and reliable and
prepare tools, prepare material and capable of bearing the
lighting devices. weight of maintenance
b) Remove furnace protection plate. operator and
1 Preparations c) Remove heat insulation material for maintenance tools and
header other parts.
d) Check attemperator cylinder outer b) The disassembled
surface and water inlet pipe, and protection plates and
make records. bricks should be neatly
placed.
a) Conduct the inspection to header a) The header should be
and inner bushing after cutting end free from cracks, if not,
cover. ascertain causes and
b) Carefully check if the inner bushing report to relevant leader.
presents deformation, cracks and b) The inner bushing is free
damage. If damage is found, from deformation, crack,
Inspection of ascertain the causes and then and damage.
header and inner replace the bushing.
bushing c) Check if diaphragm and support of
bushing are complete.
d) The header inspection is carried out
based on bushing inspection and is
assisted by personnel from metal
supervision department if
necessary.
a) Measure and record the water spray a) When ripping supporting
device position in cylinder. plate, pay attention not
b) Rip the support sampling plate to damage header inner
welded on header. wall.
c) Install chain block pulley and use b) Do not pull out protection
pulley to conduct trial run. When the pipe too hard to avoid
protection pipe becomes loose, pull pipe damage.
Protection pipe
3 out the pipe and place it to given c) The pulled-out pipe
pull-out
position. should be placed
d) After pulling out protection pipe, the horizontally.
personnel in charge are required to
work with personnel from production
technology department and
workshop to check and come out
with maintenance method and make
55
identification records.
e) Before leaving working spot, seal
the header and put a seal on it.
a) Clean the protection pipe with steel a) The protection bushing
brush and abrasive cloth, and and water spray device
conduct macroscopic inspection. should not be subject to
b) If there is crack and deformation on cracks and deformation,
protection pipe and water sprayer, and water spraying hole
conduct patch welding or replace should be smooth
them when necessary. without blockage.
c) Check if supporting plate and hot b) Supporting plate and
source ring are good, complete, if retaining ring is straight
there has severe deformation, and complete without
replace it. If there is open welding blocking and damage.
Inspection of and carry out patch welding. c) The cylinder is free from
protection pipe d) Check if the cylinder interior cracks, and partial
4
and water spray presents cracks and deformation, if corrosion depth is not
device there is abnormality, timely report to more than 1.5 mm.
workshop so that measures can be d) Cylinder expansion of
taken. primary stage
attemperator should not
exceed 3.5% of original
cylinder diameter.
e) Secondary stage
attemperator should not
exceed 2.5%, and bend
is 1.5/1000 of header
length, overall length is
not more than 10 mm.
a) Use groove tools to make out a) Cylinder interior is clean
cylinder header groove based on without rusty and
requirements. sundries.
b) Thoroughly clean cylinder inner b) Cylinder butt size (see
sundries. chart).
c) Under designated personnel unite c) Protection pipe
command, conduct installation with installation direction and
block chain or special tools. position are correct.
5 Installation
d) After aligning water spray device d) Welding quality should
and protection pipe, reinstall screw meet requirements.
connection pipe. Welding strengthening
e) Use electric-welding to weld water surface height is higher
spray supporting plate on cylinder than 4mm, welding width
inner wall. is 2-6mm wider than
f) Conduct butt welding for cylinder groove, and welding
headers. surface is free from
56
cracks, un-melting, air

hole and dirt inclusion.
Partial undercutting does
not exceed 10% of total
welding length. Welding
is acceptable by
detection test.
4.7.3 Acceptance after Attemperator Maintenance

Table 4-14 Acceptances after Attemperator Maintenance
Acceptance
Acceptance Items Acceptance Methods
Standards
a) Header and inner bushing Acceptance
a) Spot acceptance
inspection. standards correspond
b) Spot acceptance
b) Weld quality inspection to maintenance
c) Spot acceptance
c) Hydrostatic test. qualities.
4.8 Fuel Oil System Maintenance

4.8.1.1 When disassembling and reinstalling oil gun, the operator should wear glove and
bundle sleeve to avoid scalding.
4.8.1.2 During oil gun disassembly, slowly loosen movable joint of oil gun to avoid abrupt
spray of hot oil. Before disassembling oil gun, the inlet oil valve and steam purging
valve should be closed.
4.8.1.3 When replacing and disassembling oil gun, pay attention to furnace air pressure to
avoid scalding by fire spray at positive pressure.
4.8.1.4 Pay attention to firefighting during maintenance and clean the oil stain on the ground.
4.8.2 Preparation Before Maintenance
4.8.2.1 Prepare work permit and contact operator to cut off fuel oil system operation and take
protection measures.
4.8.2.2 Prepare required tools and material.
Maintenance
No. Process Methods, Precautions and Quality Standards
Items
a) Periodically inspect bearing heating condition, bearing
temperature should not exceed the value in the chart below, and
check oil level of oil level indicator at properly time.
Daily
b) Do not use gate valve on suction pipe to adjust flow, so as to avoid
1 maintenance of
cavitation.
fuel oil pump
c) Do not keep running pump when the flow is lower than 30% of
design flow, if it is imperative, the bypass connection pipe should
be equipped at outlet and the flow should be higher than the
57
lowest value mentioned above.

d) Periodically pay attention to leakage and radiation of stuffing.
e) Periodically check foot bolt looseness, fluctuation of outlet
pressure gauge and pump vibration. And check if pump casing
temperature is corresponding with inlet oil temperature.
a) After pump disassembly, take out rotor and all components and
conduct cleaning.
b) Check components, measure their abrasion, corrosion and
washing degree, replace them if necessary.
c) During disassembly and reinstallation, use level-meter to measure
and adjust pump levelness, check and adjust coupling alignment
degree.
d) Check abrasion of bearing sleeve, gland, stuffing ring, balanced
Fuel oil pump drum, balanced plate, balanced sleeve, all sealing rings, and
2
maintenance check clearance between spare parts and carry out measurement,
replace them if necessary.
e) Check bearing (rolling one and sliding one), replace it if necessary.
f) Wash subordinate pipe lines, pipe fittings related with pump seal
fluid cooling water, and repress stuffing, calibrate pressure gauge
and replace lubricating oil.
g) Check and adjust shaft bending and rotor vibration condition.
h) During minor repair, if there is any problem, handle it depending on
the above conditions.
a) Periodically check bearing radiation and bearing temperature
should not exceed 80℃.
b) Check oil cup every eight hours every shift to see if oil level of oil
cup is normal.
c) Discharge and wash oil before adding new oil half a year which is
Daily
usually conducted in spring and autumn. For humid and dissert
maintenance of
3 area, outdoor spot and place where climate varies greatly, oil
oil unloading
should be replaced frequently.
pump
d) For equipment standby pump, periodically rotate rotor parts once
each week at angle of 90° to avoid deformation and at the same
time maintain bearing lubricating oil film in good condition.
e) A certain temperature of high temperature standby pump must be
maintained in case of emergency.
a) Check abrasion of casing sealing ring, impeller sealing ring, throat
liner, bearing sleeve, bearing, impeller, mechanic dynamic seal
ring and mechanic static seal ring.
Oil unloading b) Clean stain and blockage for cooling water pipe, oil seal pipe and
4 pump water cooling chamber.
maintenance c) Check and adjust shaft bend and rotor vibration.
d) Check damage and scratch of O seal ring, shaft sleeve pad, pump
cover pad, mechanical seal gland pad, and bearing gland.
e) Align the coupling to make sure its concentricity is in required
58
range.
a) Check manhole and lighting hole once for a month (do not open
them), and they should be complete.
b) Check oil measuring port at least once for a month to make sure
there is no damage and sundry.
c) Check breather valve two times for a month, if temperature is
lower than 0℃, conduct inspection before every work.
d) Check safety valve once for one quarter.
e) Check vent pipe once for one quarter to make sure there is no
Daily
damage and corrosion.
5 maintenance of
f) Inspection of valve operating device should be conducted together
oil storage tank
with oil tank washing.
g) Check water drain valve once for one quarter, when washing oil
tank, there is no oil leakage.
h) Check oil inlet and outlet valves at least once for a year, when
washing oil tank, the valve does not crack, and flange does not
leak oil.
i) Check tank once for a month to make sure it is free from cracks
and oil leakage.
a) General requirements of hot work maintenance. Before
maintenance, conduct spot observation and work out feasible work
operation and fire distinguishing plans. Before work, clean all
weeds, oil stains and other flammable objects surrounding hot
work place, and prepare necessary safety detection devices and
firefighting devices. Firefighting device and fire extinguishing
device for oil tank storage area should be secure and reliable. The
work should be done by experienced operator, and supervised by
full-time or part-time fire fighting operators on site to avoid
accident.
b) Oil tank hot work maintenance. Clean out oil in oil tank to be
maintained. Use firefighting water to wash oil stain on oil tank wall
Oil storage tank from man hole of oil tank, and pump the deposit water mixed with
6
maintenance oil. The waste oil and rusty slag from the tank should be buried in
proper place. The oil stain containing sulfur should be timely buried
in proper place out of tank in humid state. Before hot work, analyze
if there is explosion hazard through gas analysis, or using
explosion meter to measure oil gas at places of measuring hole,
lighting hole, tank bottom and ease of oil gas accumulation dead
space. Like riser and downcomer, center column. If the tank
bottom welding is poor, its bottom may deposit oil. It is better to
use more than 2 explosion measuring meters for convenience of
data calibration to prevent false phenomenon from failure meter.
c) Hot work maintenance of oil conveying pipe. Before hot work,
conduct disassembly after discharging pipe deposited oil, and
wash it completely by water, and then open its port for ventilation,
59
and move to designated spot. For oil tank line which is

disassembled for no reason, after discharging pipe deposited oil,
separately adapt relative safety firefighting measures to weld pipes
based on conveying oil dangerous degree. For oil tank with 20 m
away from pipe welding, move its light oil to other tanks and
charge water for tank. Two ends of maintenance pipe should be
disassembled and kept for opening. Ends of pipes which are not
repaired should be sealed with blind plates. If using steam to wash
pipe, vacuum should be prevented during pipe cooling, or the oil or
oil gas will flow into unopened pipe and there will break out a fire
during hot work.
a) Loosen soft pipe screw and remove soft pipe. During operation,
take care not to face the connection directly to avoid scalded by
residual steam.
b) Loosen nozzle pressing nut and remove atomizing disc.
c) Check oil gun swirl atomizing disc and nut, replace unacceptable
ones.
d) Check if oil returning plate is blocked and its cleanness.
e) When installing oil gun, planish swirl atomizing disc, tighten screws
to avoid oil leakage after startup.
Oil gun
7 f) Check whether the soft pipe has oil blockage, which should be free
maintenance
from distortion. When tightening header, pay attention to prevent
the soft pipe from being stressed from twisting.
g) When installing nozzle, oil returning plate and hole tangential
groove of atomizing disc should be smooth without sundry.
h) Tolerance of spraying hole oval degree should not exceed
0.01mm, and concentricity should not be larger than 0.02 mm.
i) The soft pipe service time should not exceed 4 years, before
replacing soft pipe (generally during major overhaul), firstly carry
out pressure test.
4.8.4 Acceptance after Fuel Oil System Maintenance

Table 4-16 Acceptance After Fuel Oil System Maintenance
Acceptance Items Acceptance Methods Acceptance Standards
a) Oil supply pump
b) Oil unloading pump a) Spot acceptance Acceptance standards
c) Oil pipe purging b) Spot acceptance. correspond to
d) Valve inspection c) Spot acceptance maintenance qualities.
e) Oil tank and firefighting inspection
4.9 Maintenance of Steel Beam, Platform and Ladder

4.9.1 Overview
4.9.1.1 The boiler is of outdoor arrangement. Boiler body adopts steel frame, which mainly
takes the following loads: whole suspending weights of boiler front and rear parts,
60
supporting weight of middle and rear parts, effective loads of body pipes and
maintenance, all steam water pipes and flue gas pipes in boiler room range, partial
load of operation floor platform, boiler water chamber, boiler roof light roof and furnace
top monorail hoist.
4.9.1.2 The platform and ladder are grid type with enough strength and rigidity. Live load of
big platform at operation floor is 8KN/m2, live load of maintenance platform is 4KN/m2,
and other floors live loads are 2.5KN/m2. Ladder live load is 2KN/m2. Platform width is
1m, handrail height is 1.2 mm. Toe guard height is ≥100mm. Ladder gradient is 45°,
ladder width is 800mm. The platform and stairs are set according to operation and
maintenance requirements, and it can be moved out for maintenance without
contacting boiler body pipe, flue gas duct and air heater.
4.9.1.3 This boiler steel frame is of whole steel construction which can be safely operated
under below 8-stage earthquake strength. Platforms are arranged for furnace top,
header, man hole, inspection hole for observation operation and maintenance.
Platforms are connected with each other through ladders.
4.9.1.4 There is certain expansion clearance between all boiler parts to prevent heating
surface from deformation caused by expansion.
4.9.2 Maintenance Techniques and Quality Standards
Table 4-17 Maintenance Techniques and Quality Standards
NO. Maintenance Items Techniques and Precautions Quality Standards
a) During overhauling, check the
vertical column gradient.
b) Measure main column gradient
in front back, left right
Inspection of a) Measuring direction is
directions with the suspending correct.
1 vertical column
perpendicular line method. b) Record is clear and
gradient complete.
When measuring, take center
lines of column end surface as
basis.
c) Make records.
a) During overhaul, inspect the
main column and cross beam
deflection.
b) Based on steel beam
construction, conduct a) Record should be clear,
Inspection of main
deflection inspection by part correct, and complete. Total
2 column and cross
c) Use steel wire pulling method length deflection should not
beam deflection
to measure beam deflection. exceed 10 mm.
d) Do not add platform ladder or
other loads on steel beam
without permission of relative
technical departments.
Outer inspection of a) Check surface rusty and crack. a) Steel plate is free from such
3 boiler roof steel b) Check weld of big beam. defects as, layering, spint,
beam c) Check steel beam peel-off, pitting and
61
deformation, such as net-shaped cracking.

deflection, pitting and twist. b) Weld meets manufacturer
standards.
d) There is no visible
deflection and twist.
a) Height of platform side
cabinet guard plate is 100
mm.
b) The gradient of ladder with
a) When construction requires
height higher than 5m
platform ladder to be
should not exceed 50°,
disassembled, temporary
when the gradient is 45-50°,
railing should be installed.
vertical distance between
After work, disassemble it.
footboards should not
b) When the guard plate
exceed 200mm, ladder
Maintenance of needs to be cut during
width should not exceed
4 platform and maintenance, give neat cut to
600mm.
ladder the original welding, and do
c) Railing vertical rod is
not cut in arbitrary. After work,
ф32mm and cross member
restore to original arrangement
is ф25mm.
immediately
d) The platform should have
c) The platform after
limit load remark to avoid
maintenance should be
accident.
repainted.
e) Platform should be welded
by 5mm thick checkered
steel plates or 36×100mm
steel plates.
4.10 Lifting Tools

4.10.1 Electric hoist Operation Rules
4.10.1.1 Do not use limit switch to shut down machine, do not adjust brake when lifting weight
for inspection and maintenance.
4.10.1.2 When weight approaches or reaches the rated load, first conduct trial lift with low
height and short travel, then lift weight with minimum height. Do not walk above when
conducting lifting.
4.10.1.3 The electric hoist without lower limit switch must have at least 3 circles of steel rope
around the reel when its hook is in lowest working position.
4.10.1.4 Do not disassemble and change electric hoist safety device.
4.10.1.5 If there is abnormal sound in use, follow this procedures: shut down, check, and
restart after eliminating faults.
4.10.2 Routine Inspection Items and Requirements of Electric
hoist
Table 4-18 Routine Inspection Items and Requirements of Electric hoist
62
Inspection Items Requirements
Working place No obstacle in operator’s walkway
Operation rail There is no abnormality on rail observed from ground

Button device (electric Up, down, left and right movements should be flexible and accurate.
control button) Pressing one set of buttons together will not activate the electric hoist.
When no-load hook reaches the limit position, the limit switch should
Limit switch
be accurate and reliable.
The hook should be able to rotate flexibly in the range of
circumference 360°, vertical 180° without bites and collision. The
Hook device
loose-proof device of hook nut is good and hook locking device is
normal.
Lifting, decreasing and operation brake reactions are flexible and
Brake
reliable.
Conductor rope device
Activation is normal, safe and reliable.
and other safety devices
4.11 Spare Parts

Table 4-19 Spare Parts
No. Name Quantity Material Weight
1 Pipe Φ42×5,L=40m 15CrMoG 182.5
2 Pipe Φ42×5,L=40m 20G/GB5310 182.5
3 Pipe Φ42×5,L=40m SA213-T91 182.5
4 Pipe Φ42×5,L=40m 12Cr1MoVG 182.5
5 Pipe Φ42×6,L=40m 12Cr1MoVG 213.1
6 Pipe Φ60×5,L=40m 20G/GB5310 271.3
7 Pipe Φ76×10,L=40m 20G/GB5310 651.1
8 Pipe Φ38×4,L=40m 20G/GB5310 134.2
9 Pipe Φ42×6,L=40m 15CrMoG 213.1
10 Pipe Φ159×12,L=15m 20G/GB5310 652.5
11 Pipe Φ51×5,L=40m 20G/GB5310 226.9
12 Pipe Φ133×10,L=2m 20G/GB5310 60.7
13 Pipe Φ159×12,L=2m 12Cr1MoVG 87
14 Pipe Φ325×20,L=2m 12Cr1MoVG 300.9
15 Pipe Φ325×20,L=2m 15CrMoG 300.9
63
16 Air cap 180 ZG40Cr20Ni9Si2NRe 800

Connection
17 180 ZG40Cr20Ni9Si2NRe 540
pipe
Bi-color water
level meter’s
18 4 sets
glass, cushion,
and circle mica
Consumables
of oil gun
19 2
retractable
consumable
20 kiln eye Φ80 2 Fitting 18.8
21 Cushion 10 Winding type pad

Check valve
22 4 Fitting 31.6
DN20; PN32
Corrugated
23 20 Color plate 200
plate L=2m
24 Oil gun lance 2
Anti-abrasion
device of
25 2 Fitting 43.6
suspending
pipe
Elbow
26 anti-abrasion 5 1Cr6Si2Mo 0.6
cover
Anti-abrasion
27 5 1Cr6Si2Mo 1.55
cover NO.1
Anti-abrasion
28 100 1Cr6Si2Mo 6
cover NO.2
Elbow
29 anti-abrasion 100 1Cr6Si2Mo 39
cover
Elbow
cover
Anti-abrasion
31 20 1Cr6Si2Mo 10
cover NO.3
Elbow
cover
33 Cover plate 100 1Cr6Si2Mo 20
64
Anti-abrasion
34 2 1Cr6Si2Mo 3.2
cover NO.4
Anti-abrasion
35 5 1Cr6Si2Mo 2.2
cover NO.5
Anti-abrasion
36 5 1Cr6Si2Mo 12.1
cover NO.6
Anti-abrasion
37 20 1Cr6Si2Mo 43.2
cover NO.7
Anti-abrasion
38 5 1Cr6Si2Mo 13.5
cover NO.8
Anti-abrasion
39 2 1Cr6Si2Mo 5.32
cover NO.9
Anti-abrasion
40 2 1Cr6Si2Mo 1.56
cover NO.10
Anti-abrasion
41 5 1Cr6Si2Mo 10.65
cover NO.11
Anti-abrasion
42 5 1Cr6Si2Mo 10.3
cover NO.12
Anti-abrasion
43 2 1Cr6Si2Mo 2.12
cover NO.13
44 Clip NO.1 20 1Cr20Ni14Si2 78
45 Clip NO.2 20 1Cr20Ni14Si2 94
46 Clip NO.1 10 1Cr20Ni14Si2 37
47 Clip NO.2 5 1Cr20Ni14Si2 20.5
48 Clip NO.3 5 1Cr20Ni14Si2 14
50 Clip NO.1 10 1Cr20Ni14Si2 44
53 Clip NO.4 5 1Cr20Ni14Si2 19.5
54 Cover plate 2 1Cr20Ni14Si2 19
55 Cover plate 2 1Cr20Ni14Si2 12.2
56 Pressure plate 100 1Cr20Ni14Si2 20
57 Pressure plate 100 1Cr20Ni14Si2 6

Anti-abrasion
58 10 1Cr20Ni14Si2 13
cover NO.1
Anti-abrasion
59 20 1Cr20Ni14Si2 38
cover NO.2
65
Anti-abrasion
60 2 1Cr20Ni14Si2 3
cover NO.3
Anti-abrasion
61 20 1Cr20Ni14Si2 28
cover NO.5
Anti-abrasion
62 2 1Cr20Ni14Si2 5
cover NO.7
Anti-abrasion
63 2 1Cr20Ni14Si2 1.4
cover NO.9
Anti-abrasion
64 2 1Cr20Ni14Si2 1.8
cover NO.10
Anti-abrasion
65 2 1Cr20Ni14Si2 5.2
cover NO.11
Anti-abrasion
66 5 1Cr20Ni14Si2 2
cover NO.13
All kinds of
1％ standby
67 high strength
amount
bolts
Applicable
68 20 kilos each
electrode
Oil gun standby
69 One
solenoid valve
All kinds of
5％ standby
70 through tube
amount
seals
Table4-20 Boiler special tools

NO Tool Name Unit Quantity
Big bolt wrench for steam drum
1 付/set 1
suspending
Bolt special wrench for steam drum man
2 付/set 1
hole
Inlet motorized wrench for high strength
3 付/set Each with three
bolt (primary tight and final tight)
4 Furnace maintenance platform
5 Boiler Auxiliaries Maintenance

5.1 ID Fan Maintenance
5.1.1 Construction Overview
5.1.1.1 This fan is composed of rotor set, supporting bearing, thrust bearing, casing, air inlet
box, air inlet port, adjustable valve, and inlet and outlet flexible connections. The
transmission part consists of a system in which motor drives the fans. (Refer to below
diagram)
66
1—casing; 2--- air inlet box; 3—air inlet port 4—rotor set
5—supporting bearing 6—thrust bearing 7—inlet flexible connection
8—outlet flexible connection 9—governor valve 10—transmission rod
11—actuator base 12—casing seal 13—air inlet seal box
14—air inlet box support 15—coupling protection cover 16—bearing base
17—governor valve main drive paddle 18-- motor
Figure 5-1 ID Fan Structure Diagram
5.1.1.2 The rotor set is composed of impeller set, hub, and main shaft. Impeller set is
composed of blades, wheel cap and wheel plate. 10 pieces of backward airfoil type
impellers are welded between arcuate wheel cap and plat plate type wheel plate.
Material of impeller, wheel cap and wheel plate is 15Mnv. The impeller set welding is
conducted with color detection test and aligned by static and dynamic balance, which
ensure the impellers can operate safely and stably. This impeller set has advantages
of high efficiency, low noise, and high strength. The main shaft material is 45 steel and
it is conducted with supersonic detection test and magnetic power detection test.
1—impeller 2—main shaft 3—hub 4—fix ring 5—key 45×280 6—key 63×450
Figure 5-2 ID Fan Rotor Set
67
5.1.1.3 Air inlet box is welded by Q235A steel plates. For convenience of disassembly, the
box is made as division structure. (When disassembling air inlet opening, the operator
should first enter air inlet box through man hole and remove bolts at connection of air
inlet port and air inlet box opening). Porcelain cordages should be equipped for trim
plate of air inlet box opening and aboral flange. In order to increase rigidity of air inlet
box, the supporting pipes are welded in box interior.
5.1.1.4 Governor valve is equipped with guide vanes, through which air fan characteristic and
air inlet flow can be adjusted by changing the opening of blade, so the governor valve
has good adjustable efficiency. The realization of angle adjustment of guide vane,
which connecting the transmission link with electrical actuator and governor valve,
enables the device to meet its requirements for working conditions. (Note: governor
valve bearing is insert ball bearing with base and its model is L90610)
Figure 5-3 ID Fan Governor Valve

1. Driving rod 2. Air flow 3. Close 4. Fully open
5.1.1.5 This air fan is equipped with inlet and outlet flexible connections, which not only helps
compensate expansion caused by fan pipe expansion but isolate vibration. It is also
equipped companion flanges at the inlet and outlet, enabling the users to weld the
inlet and outlet pipes with the companion flanges at the inlet and outlet.
5.1.2 ID Fan Maintenance Precautions
5.1.2.1 In order to prevent human Initiated failure and accident due to improper maintenance,
natural failure of air fan and motor and accidents should be prevented. To give full
play to equipment performance and prolong fan service life, give timely and careful
maintenance.
5.1.2.2 Periodically clean the accumulated ash, oil stain and water deposit in air fan.
5.1.2.3 Do not conduct maintenance during fan operation, when disassembling equipment,
first cut off power supply.
5.1.2.4 When disassembling spare parts which have corresponding and matching relations,
spare parts should be marked for convenience of reinstallation.
5.1.2.5 When lifting rotor, keep axial levelness to avoid spare parts damage.
5.1.2.6 When tightening bolts, first paint Vaseline grease on matching surfaces of nut and
thread.
5.1.2.7 Maintenance personnel should periodically patrol and inspect operating fan according
to the following chart, and record relevant operation data.
68
Table 5-1 ID Fan Inspection List

Every Every Every Every
Inspection Items
day week month half a year
Bearing temperature X
Bearing tank oil level X
Air fan, motor vibration X
Fan appearance inspection X
Anchor bolt locking condition X
Bearing tank lube oil replacement X
5.1.3 ID Fan Maintenance

The overall maintenance of ID fan is usually carried out after 8000 but more than
12000 hours ‘operation.
Table 5-2 List of ID Fan Main Maintenance Items
Test Period
Tested Time
Operatio Shutdow Main Test Parts
Items
n Period n Period Half a Every Above
year Year One Year
Bearing and oil-immersed
asbestos packing abrasion;
Bearing X inspection of oil level and oil
quality; oil adding or
replacement
Abrasion inspection, replace it
Oil seal X
if necessary
Ash accumulation inspection,
Impeller X
clean; welding inspection
Check based on motor
Motor X
instructions
Air inlet
Check ash accumulation and
port of
X deposits in the casing, and
casing air
clean them.
inlet box
Check to see if physical
parameters of lube oil are
Lube oil X
acceptable, replace it if
necessary
Connectio Check if the connection bolts
X
n bolts are loose, if so, tighten them.
Instrument
X Check calibration
s
69
Check membrane abrasion,

Coupling X
replace it if necessary
Table 5-3 List of ID fan Consumables and Exchange Items for Major Overhaul
Code Name and Model Material Quantity/Set
1105.28×1-3 Oil seal (top, bottom) ZL102 Two
1105.28×1-3-4 Oil seal (top, bottom) ZL102 One
C1104×2 Casing seal part One
C1104×3 Seal part of air inlet box One
22340CC/W333/C3 Spherical roller bearing Two
(SKF)
JMT380/180×180-350 Membrane coupling One
C1104.05 Inlet flexible connection One
C1104.06 Outlet flexible connection One
C1104.25 Rotor set One
ISO VG46 Steam turbine oil 60L
5.1.4 Spare Parts of ID Fan

Table 5-4 Spare Parts of ID Fan
No. Name Model Unit Quantity Remarks
1 Gland seal Set 2 One for two ID fans
2 Oil level sight glass Set 2 One for two ID fans
5.2 HP Fluidization Air Fans Maintenance

5.2.1 Construction
5.2.1.1 Air blower casing components mainly consist of left wall plate, casing and right
wall plate made of gray cast-iron after relieving stress. Rolling bearings, labyrinth
gland and oil seal are equipped in the left and right wall plate. The left wall plate
acts as positioning end and the impeller moves towards the left wall plate as a
result of expansion; two cylinder roller bearings are installed in the left wall plate
and self aligning roller bearings or four angle contact ball bearings installed in the
right wall plate. Based on different pressure, international top brands such as NSK
and TWB or national top brand bearings are applied to support the drive rotor
shaft and driven impeller shaft.
5.2.1.2 The air blower has two sets of impellers made of ductile cast iron. Its profile
surface is machined in special CNC machine center. It is installed on the drive
shaft and driven shaft of No.45 steel or 40Cr alloy steel.
5.2.1.3 The main lube parts for air blower are synchromesh gear, rolling bearing, skeleton
70
type rubber oil seal and others. The bearing end, with the help of drive bearing,
mainly throws out the lube oil in oil trough under oil tank and then lubricates the
parts mentioned-above. The brand of lube oil varies with seasons and
temperature where work is done. It is suggested that N68 is used in summer and
N46 in winter. The lube oil is injected through the refill opening of oil tank until it
reaches the central line of oil pointer. Make adjustment if there is too much or
insufficient oil. The dynamic input end is lubricated by grease with the brand of
ZL3# heat resistance lithium base grease which is regularly injected into through
the forced filling oil cup on the shaft cover by oil gun.
5.2.1.4 When the pressure rising ΔP≥49KPa, fill water to cool. The temperature of cooling
water inlet is lower than 30℃ and cooling water pressure: 49KPa-294KPa and
cooling water flow: 10-15L/min.
5.2.1.5 The Trefoil Roots Blower and motor mainly adopt rubbercushioned sleeve bearing
coupling. But when the rotation speed of blower does not adopt 730r/min、980
r/min and1450r/min, use effective width narrow V belt to transmit. Safety cover
should be installed outside the coupling arrangement to ensure safety.
5.2.1.6 When adopting rubber cushioned sleeve bearing coupling, align the concentricity
of the air blower drive shaft and motor shaft. The radial displacement should not
over 0.4mm and angle tilting should not exceed 10. the axial clearance of two half
couplings end surface should be between 5 and 10mm.
5.2.1.7 When adopting effective width narrow V belt to transmit, it is required to adjust the
tightness of narrow V belt by giving vertical loading of 57.86~85.32N/piece on
narrow V belt at the central part of l of two points of contact narrow V and belt
wheel when the deflexion is 0.016L. the external end surface of belt wheel of air
blower and motor should be on the same surface and use ruler to align the
tightness of tensioning force.
5.2.2 Assembling Clearance
5.2.2.1 The assembling clearance of blower is of great importance to guarantee its
performance and safety operation. Each blower, before going to the market, is
accurately adjusted about its assembling clearance in factory which should not be
changed in use without permission.
5.2.2.2 Assembling clearance of impeller is as shown in the following table:
Table 5-5 Assembling clearance of impeller is as shown in the following table:
Measuring parts Specified value
Between impellers 0.35-0.6
Impeller and casing 0.25-0.3
Impeller and left wall plate 0.28-0.4
Impeller and right wall plate 0.18-0.2
5.2.3 Routine Maintenance

5.2.3.1 Newly-built unit and blower after overhaul should be given oil replacement completely
71
after running for 4-8 hours. Keep close eye on the oil level in ball oil pointer and
immediately refill the lube grease. Inject grease into oil cup on bearing cover using oil
gun monthly. Normally, replace all grease seasonally or every 1000 hours. The quality
of lube oil and grease should meet with band requirements given.
5.2.3.2 Regulatly check the bearing temperature, vibration and sound, oil level, oil
temperature, air inlet and outlet pressure, ammeter reading, and cooling water
condition.
5.2.3.3 Regularly check the belt tightening of the belt-driven unit, check whether the anchor
bolt lossens. If so, immediately tighten them to ensure safety operation.
5.2.3.4 Regularly clean the dust on filter to avoid the blower overloaded or damaged caused
by filter screen being blocked or damaged by absorption.
5.2.3.5 Frequently check whether there is abnormal sound during operation, if partial frication
is found, immediately shut down for inspection and continue operating until the faults
are eliminated.
5.2.4.1 Give maintenance after running the device for 4000 hour or do it yearly, carefully
measure the main parts of original device and record the results and mark the
relevant parts during maintenance to make sure the performance of original device
can be recovered as soon as the reassembly is completed.
5.2.4.2 Carefully check the consumables during maintenance. Normally these should be
replaced. The assembling clearance of main parts should be adjusted to the range
specified in the MANUAL.
5.2.5 Common Faults and Solutions
Table 5-6 Common Faults and Solutions
No. Fault description Causes Solutions
a) blockage of filter
a) remove dirt
b) increase in rotor
1 Insufficient air flow b) readjust the clearance
clearance
c) replace or tighten belt
c) belt slippage
a) blockage of filter a) remove dirt
b) increase in resistance of b) remove the obstruction in the
2 Overload of motor inlet pipeline pipe
c) collision of moving parts c) readjust the rotor clearance
b) overheat belt d) adjust the tension of belt.
a) too large lateral
clearance of gear a) replace gear.
b) collision of rotor b) ascertain causes and adjust
3 Abnormal vibration c) looseness of anchor rotor clearance.
bolts c) tighten bolts
d) damage of rolling d) replace bearing.
bearing
a) too much or little lube oil
a) reduce oil level or replace oil.
4 Too high temperature in oil tank.
b) reduce outlet pressure.
b) High oil pressure.
72
a) failure of oil seal

a) replace oil seal
Oil contained in b) too much labyrinth seal
5 b) replace labyrinth shaft sleeve
conveying medium clearance.
c) clean or replace vent plug.
c) vent plug blockage
a) large gear clearance.
b) wearing of rolling a) replace gear.
Friction between bearing. b) replace bearing.
6
impeller c) dirt on rotor profile. c) remove dirt.
d) even-aged flat key d) use new flat key.
deformation.
a) change of orientation of a) readjust the axial clearance.
axes of bearing b) reduce outlet pressure.
Friction between b) too high pressure rising. c) ascertain causes and improve
7 impeller, wall plate c) Too high temperature. cooling conditions.
and casing d) deformation of casing, d) Check the unit installation
and wall plate change of accuracy and readjust the
positioning. position.
5.2.6 Spare Parts

No. Name Specification Unit Quantity
1 Oil seal Set 1
2 Oil pointer Piece 6

Coupling pin (including elastic
3 M16*24 Piece 12
ring)
4 Pressure gauge YN60 0-0.1MPa Piece 2
5.3 Maintenance of Secondary Air Fan

5.3.1 Main Construction of Secondary Air Fan
5.3.1.1 The air fan consists of rotor set, supporting bearing, thrust bearing, casing, air intake
box, air intake, guide valve, inlet and outlet hose. The running part forms drive system
in which motor drives fan to rotate.
73
9 5 2 3 1 4 8 6 7 14 15 16 13 17 10 11 12
1
1
1
1
1
1
1
1
Figure5-4 The construction of secondary air fan.

1.casting 2.inlet box 3.air intake 4.rotor set 5.thrust bearing 6.supporting bearing
7.bearing seat 8.seal 9.driven rod 10.driving rod 11.governing valve 12.inlet hose
13.outlet hose 14.coupling cover 15.coupling 16.motor 17.motor activator
5.3.1.2 The impeller consists of 12 pieces of backward plate blades welded at the middle part
between the front shroud and plate back should and provided with guard plate. The
reel adopts ZG230-450 material. The blade, front should, back shroud and stiffening
ring are made of 15Mn welded steel plate. The impeller has given static and dynamic
balance calibration so that it runs steadily. The weld joint of impeller has been given
dyed flaw detection test.
74
1.blade 2.shaft 3.fixed collar 4.bolt 5.key 63×250 6.key 40×280

Figure 5-5 Rotor set of secondary air fan
5.3.1.3 The casing is a volute welded by Q235A steel plate. it has two parts including the
upper part and the lower part which enables it to be easily installed and disassembled.
reinforcing plate is welded at both sides of casing to enhance the rigidity of casing.
5.3.1.4 The air inlet is an easy disassembly and assembly dissection made of Q235A steel
plate. bolt holes are drilled out of two flange plate so that the bolts can be fastened
inlet of fan casing and air intake box. The reinforcing rib is welded between inlet
flanges to increase the rigidity of air inlet.
5.3.1.5 The air intake box is an component to realize air change from radial flow to axial flow
and then deliver the air into air intake. The box is made of Q235A steel plate and
reinforcing rib is welded outside the air intake box to improve its rigidity. For easy
assembly and disassembly, air intake box is designed as dissection structure.
5.3.1.6 The bearing box adopts HT250 casting iron material. To prevent oil leakage,
aluminum oil seal is installed at both sides of the box, oil-immersed asbestos packing
and oil thrower wheel is used on main shaft. To monitor bearing temperature rising,
double platinum resistance thermometer sensor platinum bimetal thermometer are
installed on the box of two shafts. There is circulation cooling water passage for
bearing, that is to say, use circulation cooling water to cool bearing and thin oil to
lubricate. The quantity of cooling water used varies with the local temperature,
normally, 2-2.5tons/hour，water pressure 0.4Mpa and bearings are SKF bearings.
5.3.1.7 The guide vane installed on the governing valve adjusts opening of blade via actuator
driving transmission bar to adjust air intake flow and fan performance.
75
Figure 5-6 Governor valve device of secondary air fan

1.fully closed 2.fully open 3.driving rod
5.3.2 Fan Maintenance
To prevent man-made faults and accidents due to improper maintenance, natural
faults on fan and motor as well as accidents from happening and to give full play to
equipment efficiency and prolong life service of fan, it is necessary to provide close
maintenance to fans. The maintenance personnel should pay patrolling inspection of
the running fans as required in the above table, and record the data on operation.
Table 5-8 Record sheet of operation data
Every three
Inspection item Every day Every week Every month
months
Bearing temperature X
Bearing box oil level X
Fan and motor vibration X
External inspection of fan X

Locking conditions for
X
anchor bolt
Lube oil replacement in
X
bearing box
Wearing of blade X
5.3.3 Precautions for Maintenance

5.3.3.1 Regularly remove the ash deposits, oil dirt and accumulated water in fans.
5.3.3.2 Do not conduct maintenance during fan operation. Cut off power supply when
disassembling equipment to mark sure the motor can not be started up under
mis-operation condition.
5.3.3.3 Mark the parts that match each other when disassembling for easy assembly.
5.3.3.4 Keep the rotor level in axial direction when hoisting it to avoid damaging other parts.
5.3.3.5 Before tightening bolts, first apply some Vaseline grease on the matching surface of
screw thread and screw nut and then fasten nuts.
5.3.3.6 Conduct monthly inspection of oil pointer to avoid oil level hole blocked and observe
whether the oil level is equal to the actual oil injection.
5.3.3.7 Check the thermometer and vibration meter every year.
76
5.3.3.8 Normally, change the lube oil of bearing every three to six months. The lube oil is ISO
VG46. national brand GB11120-89，N46 turbine oil. The quantity is 30 liter for each
box.
5.3.4 List of Consumables and Replaceable Parts for Overhaul
Table 5-9 List of Consumables and Replaceable Parts for Overhaul
Name and specifications No. Material Quantity/set
Oil seal (top and bottom) 1914.10-2 ZL102 2
Oil seal (top and bottom) 1914.11-2 ZL102 1
Bearing lube oil N46 58litre
Inlet flexible connection C1121X1 Fluoresce 1
Outlet flexible connection C1121X2 Fluoresce 1
Seal parts C1121X3 2
Bearing 22238CC/W33 SKF 2
Coupling membrane 1Cr18Ni9Ti 2
Rotor set C1121.25 1
5.3.5 Spare Parts for Secondary Air Fan

Table 5-10 Spare Parts for Secondary Air Fan
No. Name Specifications Unit Quantity Remarks
One set for
1 Gland seal Set 2
two fans
One set for
2 oil level sight glass Set 2
two fans
5.4 PA Fan Maintenance

5.4.1 Main Construction of P.A Fan
5.4.1.1 The air fan consists of rotor set, supporting bearing, thrust bearing, casing, air intake
box, air intake, guide valve, inlet and outlet flexible connections. The running part
forms drive system in which motor drives fan to rotate in the figure as shown below.
77
1 14 12 13 2 7 6 8 18 10 11 9 3 4 9 5 15 17 16
参设
端
终
数位置0 0%.
OK请
按关定
0%确
到
SET
OCA L
RE MOT
ESC OK NE XT
L
E
OPE NS OPT CL OSE
Figure 5-7 The construction of primary air fan

1.casting 2.inlet box 3.air intake 4.rotor set 5.thrust bearing 6.supporting
bearing7.bearing seat 8.seal 9.driven rod 10.driving rod 11.governing valve 12.inlet
hose13.outlet hose 14.coupling cover 15.coupling 16.motor 17.motor activator
5.4.1.2 The impeller consists of 12 pieces of backward plate blades welded at the middle part
between the front shroud and plate back should and provided with guard plate. The
reel adopts ZG230-450 material. The blade, front should, back shroud and stiffening
ring are made of 15Mn welded steel plate. The impeller has given static and dynamic
balance calibration so that it runs steadily. The weld joint of impeller has been given
dyed flaw detection test.
78
Figure 5-8 Rotor set of primary air fan

5.4.1.3 The min shaft, made of steel 45 high quality forge piece, receives ultrasonic
inspection inspection and magnetic particle inspection after heat treatment.
5.4.1.4 The casing is a volute welded by Q235A steel plate. it has two parts including the
upper part and the lower part which enables it to be easily installed and disassembled.
reinforcing plate is welded at both sides of casing to enhance the rigidity of casing.
5.4.1.5 The air inlet is an easy disassembly and assembly dissection made of Q235A steel
plate. bolt holes are drilled out of two flange plate so that the bolts can be fastened
inlet of fan casing and air intake box. The reinforcing rib is welded between inlet
flanges to increase the rigidity of air inlet.
5.4.1.6 The air intake box is an component to realize air change from radial flow to axial flow
and then deliver the air into air intake. The box is made of Q235A steel plate and
reinforcing rib is welded outside the air intake box to improve its rigidity. For easy
assembly and disassembly, air intake box is designed as dissection structure.
5.4.1.7 The bearing box adopts HT250 casting iron material. To prevent oil leakage,
aluminum oil seal is installed at both sides of the box, oil-immersed asbestos packing
and oil thrower wheel is used on main shaft. To monitor bearing temperature rising,
double platinum resistance thermometer sensor platinum bimetal thermometer are
installed on the box of two shafts. There is circulation cooling water passage for
bearing, tht is to say, use circulation cooling water to cool bearing and thin oil to
lubricate. The quantity of cooling water used varies with the local temperature,
normally, 2-2.5tons/hour，water pressure 0.4MPaand bearings are SKF bearings.
5.4.1.8 The guide vane installed on the governing valve adjusts opening of blade via actuator
driving transmission bar to adjust air intake and fan performance.
Figure5-9 guide valve device of primary air fan

1. fully closed 2. fully open 3. driving rod
5.4.2 Fan Maintenance

To prevent man-made faults and accidents due to improper maintenance, natural
faults on fan and motor as well as accidents from happening and to give full play to
equipment efficiency and prolong life service of fan, it is necessary to provide close
maintenance to fans. The maintenance personnel should pay patrolling inspection of
the running fans as required in the above table, and record the data on operation.
5.4.3 Precautions for Maintenance
5.4.3.1 Regularly remove the ash deposits, oil dirt and accumulated water in fans.
79
5.4.3.2 Do not conduct maintenance during fan operation. Cut off power supply when
disassembling equipment to mark sure the motor can not be started up under
misoperation condition.
5.4.3.3 Mark the parts that match each other when disassembling for easy assembly.
5.4.3.4 Keep the rotor level in axial direction when hoisting it to avoid damaging other parts.
5.4.3.5 Before tightening bolts, first apply some Vaseline grease on the matching surface of
screw thread and screw nut and then fasten nuts.
5.4.3.6 If the flow is too high, which fails to meet with the relevant requirements or there is a
small flow required, use the guide valve to regulate until it is up to standards.
5.4.3.6 Conduct monthly inspection of oil pointer to avoid oil level hole blocked and observe
whether the oil level is equal to the actual oil injection.
5.4.3.7 Check the thermometer and vibration meter every year.
5.4.3.8 Normally, change the lube oil of bearing every three to six months. The lube oil is ISO
VG46. national brand GB11120-89，N46 turbine oil. The quantity is 30 liter for each
box.
5.4.4 Disassembly of Rotor During Maintenance
5.4.4.1 Careful inspection should be given to impeller, bearing, coupling membrane, bearing
and box seal during fan maintenance. This requires disassembling rotor which should
be carried out according to the following steps:
a) Dismantle the breaches on air intake box and casing.
b) Dismantle the breach at air inlet and throat bolts.
c) Remove the membrane coupling and middle part.
d) Remove bolts on divided surface of bearing box and bearing side cover,
dismantle bearing top cover, side covers on both sides and pull out of seal
laterally (refer to bearing box figure)
Figure 5-10 bearing box

1.supporting bearing 2.bearing upper casting 3.side cover 4.bearing seal
5.4.4.2 Before reassembly, wash the bearing box with kerosene and wash the cooling water
80
passage until it is clean and unblocked. Apply some lube grease or machine oil on
joint surfaces of bearing to prevent getting rust or reduce difficulty in disassembling.
When installing bolts, if there are stop bolts, first fasten them before tightening the
bolts.
5.4.4.3 Hoist the rotor parts out vertically and take care not to touch the rotor.
5.4.4.4 Two points must be noticed if it takes much work to repair the impeller: one is Weld
inspection, and the other is carrying out dynamic balance again. When reassembling,
align coupling again.
5.4.5 List of Consumables and Replaceable Parts for Overhaul
Table 5-11 List of Consumables and Replaceable Parts for Overhaul
Name and
No. Material Quantity/set
specifications
Oil seal (top bottom) 1914.10-2 ZL102 2
Oil seal (top bottom) 1914.11-2 ZL102 1
Bearing lube oil N46 58 liter

Inlet flexible
C1120.05 Fluoresce 1
connection
Outlet flexible
C1120.06 Fluoresce 1
connection
Seal parts C1120x1 2
Bearing 22238CC/W33 SKF 2
Coupling membrane 1Cr18Ni9Ti 2
Rotor set C1120.25 1
5.4.6 Spare Parts of P.A Fan

Table 5-12 Spare Parts of P.A Fan
No. Name specifications Unit Quantity Remarks
One set for two
1 Gland seal Set 2
fans
One set for two
2 Oil level sight glass Set 2
fans
5.5 Coal Feeder Maintenance

5.5.1 Construction Overview
5.5.1.1 It consists of enclosed housing, transporting system, purging system, metering
system, temperature control system, electrical valve and electrical control system.
5.5.1.2 The inlet gate is composed of shell body, gate and driving device. The shell is of
enclosed structure. The contacting surface with coal is with special design, which is of
relatively high anti-resistant and anti-corrosive performance.
5.5.1.3 The driving device for inlet gate is composed of gear shaft and motor-driven device,
81
which is with big driving toque and stable operation. It can be controlled from CCR.
5.5.1.4 Coal regulating device is equipped at the inlet hopper. Turn the regulating handle to
control coal thickness, which can further regulate coal flow. Besides, when the
passage is blocked by big-sized coal or foreign matter, raise gate to the highest
position to remove the faults.
Table 5-13 Maintenance Techniques and Quality Standards
Inspection
No. Techniques, precautions and quality standards
item
a) Fill bearings with ２＃lithium base grease every two weeks.
b) Conduct oil level inspection for gearbox half a year and this should
be done after the power is cut off and the gearbox cools down.
c) Check the no-load running of idler according to regulations. If the
idler fails to rotate freely, dismantle the idler and remove the labyrinth
collar. Check the bearings and replace the damaged ones if found. At
the same time, add calcium base grease and put back seal ring. To
Routine avoid damage, dip the seal ring into water to soften before
1 maintenance installation.
d) Check the tension of belt and give frequent inspection when the belt
fails to align during operation. Adjust the stretching device at the tail
of pulley to keep the belt tension in intermediate force state and run
smoothly.
e) Regularly remove the ash and dust deposited on weight-scale table.
Pay special attention to the rotation of weight-scale idler. Check to
make sure the weight-scale idler support and weight-scale table are
firmly fastened by bolts.
a) Unscrew the oil discharge hole and oil injection hole to
discharge oil from gearbox.
b) Use special spanner to remove the bolts connecting gearbox and
casing.
Disassembly c) Remove the fixing bolts on gearbox pedestal, use large-sized
of gearbox of screwdriver to move the fixed flange at connection parts, take out the
2
belt coal gearbox carefully and place it on the ground paved with rubber.
feeder d) Remove the motor of gearbox.
e) Remove the gaskets on both sides of drive shaft, oil seal, limit
clamp spring, drive gear and supporting bearing.
f) Remove the gaskets on both sides of driven shaft, oil seal, limit
clamp spring, driven gear and supporting bearing.
a) Clean the gearbox from inside to outside and check oil gauge. Make
sure the devices are in good condition, oil groove is unblocked, box
Maintenance
does not have serious deformation, cracks, joint surfaces are smooth
of gearbox of
3 and air flow is smooth after maintenance.
belt coal
b) The bearings give normal rotation sound without noticeable wear and
feeder
cracks. The oil seal is free from damaging and aging, if not, replace
it. The locating clamp ring f should be free from deformation and
82
cracks and have normal elasticity.

c) Shafts have no obvious deformation, wear and burrs and the
surfaces are smooth. The keys and key grooves are tightly matched
without damage.
d) The gear should be free from wear, cracks and broken tooth and the
engagement surface meets with requirements.
a) Repair bearing end cover and replace seal parts.
b) Use wash oil to clean all parts and then wipe up.
c) Apply antiseptic on the joint surface of bearing, gear and shaft
Disassembly before assembly.
of gearbox of d) Assemble bearing and other parts and place them in right place.
4
belt coal e) Adjust the clearance of different parts and cover it after accepted by
feeder professionals.
f) Apply fluid sealant evenly on joint surface （ not too thick ） and
symmetrically tighten the bolts.
g) Add proper quantities of accepted lube oil.
a) Clean both the inside and outside surface of belt feeder to make sure
there is no foreign matter.
b) The belt and roller sweeper are free from wear and the belt and
roller are contacted tightly
Belt
5 c) The belt presents no obvious scratches, overheated and aging
maintenance
phenomenon and corrugated ribbon on both sides of belt is in good
condition.
d) The belt is in proper tightness and the tension devices are easy to
adjust.
a) Completely loosen the tension device behind coal feeder to loosen
coal feeder belt.
b) Dismantle the maintenance holes at front, back and lateral side of
coal feeder.
c) Dismantle the measuring assembly in coal feeder
d) Dismantle the cleaning device and belt roller
e) Dismantle drive and driven roller.
f) Remove the old belt and replace with a new one. Install drive and
driven roller and upper idler.
Belt g) Adjust the shaft axis of drive roller is generally parallel to the driven
6
replacement roller and they are level. Fix roller if nothing abnormal.
h) Turn the device manually and adjust the belt tension and off-tracking
through belt tension device.
i) Install sweeper and measuring assembly of coal feeder
j) If nothing abnormal, start coal feeder to check the coal feeding.
Readjust the tension device to ensure the tension force is proper and
there is no belt off-tracking.
k) After finishing trial run, remove the foreign matters in the coal feeder
if nothing abnormal happens and then close all inspection doors.
l) It is required to use instrument to test measuring assembly.
83
a) The idler bearing is free from overheat, wear and cracks and the oil
Idler used is up to standards. If not, immediately replace it.
7
inspection b) The idler surface should be clean, without attachment and obvious
deformation.
a) After giving maintenance to the cleaning gearbox, add proper amount
of oil into it, there should be no abnormal sound or overheat after
running.
b) Manually turn the device to check the cleaning chain one by one for
open weld, broken chain and chain jamming. Replace the whole
Maintenance
chain if it stretches after long period of operation.
8 of scraper
c) Scraper cleaner bolts should be fastened well. Those loose or
cleaner
detaching bolts should be welded with electric arc firmly. The scraper
cleaner should be free from any noticeable wear and has good
contact with bottom casing.
d) The idler of cleaning chain should be free from wear and noticeable
deformation. It rotates flexibly and the bearing is well lubricated.
a) Screw tension is used in belt tension. First, loosen fixed nuts and
then use special tools to retract stretching screw.
b) Clean the slideway of driven roller and make sure there is no
sundries, burrs and deformation in slideway.
Maintenance
c) Use wash oil to clean stretching bolts and relevant internal thread
of belt
9 and make sure all threads are smooth without burrs.
tensioning
d) It is much better to add some black lead powder into slideway after
device
finishing cleaning. Do not install stretchning bolts before applying
some lube oil on them.
e) Clean the retaining nuts and relevant bolts with iron brush before
locking the tension device after adjusted.
a) The outlet expansion joint is free from damage and coal deposits and
the temperature-measuring and coal blocking device is checked to
work well.
b) The valve passage of outlet pneumatic valve should be free from
various power, the air cylinder moves normally and the flanges at
inlet and outlet present no leakage.
c) The front and back sight glasses of coal feeder (inspection glass)
should be given good cleaning and sealing so that the operation
Maintenance
10 inside the coal feeder can be clearly observed.
of other parts
d) The lighting shield in coal feeder should be clean and well sealed and
the lighting conditions meet with inspection requirements.
e) Check all inspection doors and manholes in coal feeder system are
tight and well sealed.
f) The coal regulating valve screw at the top of coal feeder should be
provided with lube oil and can be freely regulated vertically.
g) The oil filling pipe of coal feeder is in correct connection without
disconnection.
84
5.5.3 Spare Parts of Coal Feeder

Table 5-14 spare parts of coal feeder
No. Name Specifications Unit Quantity
个
1 Air switch 1
Piece
Scrapper cleaner chain 米
2 4
components Meter
个
3 Seal ring of belt tension bolt 8
Piece
5.6 Maintenance for Loosening Machine of Coal Bunker

5.6.1 Installation Position for Loosening machine
5.6.1.1 17.50 m floor of coal bunker and beside the steel coal hopper.
5.6.1.2 Each boiler is equipped with two rectangular coal bunkers and each of that has two
coal hoppers.
5.6.1.3 The maximum temperature of closed loop circulating cooling water system is 38℃，
pressure is 0.6～1.0MPa.
5.6.1.4 The maximum temperature of open loop circulating cooling water system is 32.5℃，
pressure is 0.5MPa.
5.6.1.5 Power: AC power. Voltage: 380/220V
5.6.1.6 Working pressure of compressed air: 0.6-0.8 MPa
5.6.2 Technical Parameters for Coal Loosening machine
Table 5-15 Technical Parameters for Coal Loosening machine
Name Parameters
Loosening machine model HT-SSJ-I-1/2
Pulling rod quantity 4
rib plate and blade material 1Cr13
Pushing force of loosening machine 65000N
Height of coal layer loosened ＞3m
Quantity of controlled oil station 1
Oil tank volume 40L
Power requirements for controlled oil station three-phase four-wire
Voltage 380V
Power 3.75KW
5.6.3 Common Faults and Solutions for Coal Bunker Loosening
85
machine
Table 5-16 Faults and Solutions for Coal Bunker Loosening machine
No. Failure description Causes and solutions
a) Check whether the indication light of power input
When the loosening machine is
half-wave rectification plug of solenoid overflow
supplied with power, the motor
valve is on or the adjusting pressure of overflow
runs normally and the coil of
valve is not enough.
solenoid valve is energized, but
1 b) Check the power input for the solenoid overflow
the hydraulic pressure gauge
valve is correct and the indication light is on. or
gives zero indication, and the
manually turn the overflow valve
dredger up and down travel
anticlockwise until the pressure rises. The
position does not move.
set pressure is between 5 and 6Mpa.
a) Check the light of any of the half-wave
rectification plug at both sides of electromagnetic
When the loosening machine is directional valve shines and then see whether
supplied with power, the motor the central axis experiences runout when the
runs normally and the half-wave light is on. The normal runout value (4mm).
rectification indication light of b) When gives power supply, the half-wave
2 solenoid valve is on, but the rectification plug indication light of solenoid valve
hydraulic pressure gauge gives should be on. When the light is on, if the coil of
zero indication, and dredger up solenoid valve does not have enough
and down travel position does not electromagnetic force or central axis fails to
move.. move, remove for cleaning.
c) The coil does not have enough electromagnetic
force and needs to be replaced.
a) Check whether the half-wave rectification plug of
electromagnetic directional valve is on when
supplied with power, the motor
supplied with power. If not, check the input
runs normally and the hydraulic
power or coil electromagnetic force or check
3 pressure gauge indication is
whether the central axis is jammed.
5-6Mpa but the oil cylinder can
b) When gives power, the indication light is on, but
only realize single direction
the central axis fails to move, remove it to clean
displacement.
or replace with a new coil.
a) Check the startup delay to see whether the
setting is reasonable.
b) Whether the pressure of overflow valve is
adjusted Appropriately.
c) Delay the startup delay of over current protection
supplied with power but the up
and adjust it to the proper value.
4. and down travel of dredger is not
d) Adjust the pressure of overflow valve to proper
moved to the proper position.
range from 5 to 6 Mpa, if the up and down travel
still fails to be in proper position, increase the
pressure accordingly until it meets the
requirements.
86
5.6.4 Spare Parts for Coal Bunker Loosening Machine

Table 5-17 Spare Parts for Coal Bunker Loosening Machine
No. name Specification unit quantity Remarks
Hydraulic oil pipe
1 Piece 8
joint
2 Filter cartridge Geared MF-04 Piece 8
3 Pressure gauge LB-70 0~16MPa Piece 1

Oil level
4 YWZ-100 Piece 1
thermometer
5 Button ADA Piece 2
6 Maintenance of Boiler Auxiliaries System

6.1 Slag Handling System Maintenance
6.1.1 Main Construction of HBSL Type Slag Cooler
6.1.1.1 The slag discharging temperature for CFB is around 1000℃. The high temperature
slag, after exchanging heat with cold water through slag cooler, can be brought below
100℃. (refer to figure 6-1)
Figure 6-1 Main Structure of HBSL Type Slag Cooler

1. Belt conveyor 2. slag outlet 3. speed reducer 4. outlet/inlet of water 5. lifting position
6. cylinder 7. direction of slag flow 8. outlet of water 9. slag-entering chamber 10. inlet
of water 11. front support bracket 12. back support bracket
87
6.1.1.2 The connection of water system is as shown in figure 3 attached. The cooling water is
provided for the inlet pipe of slag coolerф50mm-ф70mm. the pipe between this
section is equipped with flow controller, at the front and back end of which direct pipes
with one meter or 0.5 meter are allowed to ensure the precision of flow controller. For
easy maintenance, valves and bypass valves are also installed on the front and back
of slag cooler. Intake valve should be installed before slag cooler and pressure gauge
and blowdown valves used behind it. take one pipe with ф20mm from flow controller
and connect it with the inlet pipe of slag inhaling pipe of slag cooler.
6.1.1.3 The water heated by slag cooler is drained through slag cooler outlet where local
temperature gauge and remote temperature gauge are installed. The outlet of slag
cooler（Φ50-70mm）and outlet of slag intaking pipe（Φ20mm）after being in parallel,
are connected to drain manifold and then to deaerator. (refer to attached figure 6-2).
Figure 6-2 cooling water system of slag cooler
6.1.2 Maintenance Techniques of Slag Cooler

6.1.2.1 The roller slag cooler should be managed as pressure vessel.
6.1.2.2 Apart form the above-mentioned notes, filling into lube oil should also be noticed
when lube oil of the gearbox for slag cooler is lower than the lowest level in operation
and the brand of oil is as shown in operation instruction.
6.1.2.3 Cooling fan of the gearbox for slag cooler can not experience reverse rotation and
should keep normal running.
6.1.2.4 Regularly fill lube grease into support roller of slag cooler and inject #2 lithium base
grease with special oil gun through the oil holes on support roller.
6.1.2.5 The driving force between slag cooler and gearbox, slag conveyor and gearbox is
delivered by connecting the drive chain wheel and big sprocket. loose chain should
be tensioned properly to avoid decrease in transmission efficiency. When the
88
tensioning reaches its maximum and can not continue, cut off a few chains or change
chain. If the chain wheel is seriously worn, replace it with a new one.
6.1.2.6 The axial displacement of slag cooler roller is controlled by block wheel which,
enjoying fast wearing for a much smaller diameter than support ring, is considered to
be consumables and requires to be replaced regularly.
6.1.2.7 Except that the consumables for slag cooler require close patrolling inspection, other
parts do not need to be replaced. But leakage and rust should be inspected to ensure
normal operation.
6.1.3 Chain Bucket Conveyor Maintenance
6.1.3.1 Before starting the chain bucket conveyor, run it for a period of time without load and
feed material until it runs normally. Give feeding evenly and do not increase feeding
suddenly or operate it in overload condition.
6.1.3.2 Unless stated, do not shutdown with load. If shutdown is required, stop feeding and
then unload the materials in the conveyor before shutdown it.
6.1.3.3 When the chain bucket conveyor operates, do not clean and repair the moving parts
nor adjust the tension device.
6.1.3.4 As for the startup of the device that experiences emergency shutdown at full load, first
open the material unloading device of last stage until material is completely unloaded
and then open the devices of other stages one by one. The shutdown order is reverse
to the startup order.
6.1.3.5 If several sets of devices are connected in order. Start the one that unloads material
last when startup and then one by one to the first. The shutdown order is reverse to
the startup order.
6.1.3.6 During operation, do not let steel objects, large hard objects and foreign matter go into
chain bucket conveyor to damage belt or cause other accidents.
6.1.3.7 The operator should regularly observe the operation of chain bucket conveyor and
check whether the connection bolts at connection parts are tight, check the wearing of
middle rail, whether the chains are damaged, drive gears, drive and direction
changing gears experience wearing or not. If serious wearing is found on chain, chain
wheel, rail, chain roller or rail, immediately repair or replace them.
6.1.3.8 The chain bucket conveyor tends to accumulate too much material in the dead angle
of chain bucket conveyor, so they should be removed for they may affect chain bucket
conveyor operation and aggravate chain wearing.
6.1.3.9 Frequently adjust screw type tension device to keep a proper strength of chain. When
adjusting, move the screw bolts at both sides with even speed to keep the axial line of
tail shaft vertical to the central line of conveyor. Keep the surface of adjust screw bolts
clean and apply lube oil on it regularly.
6.1.3.10 Different parts of chain bucket conveyor should be given sufficient lubrication but note
that do not apply lube oil on chain and support rail contacting with it as well as on the
contact surface of carries roller and wheel.
6.1.3.11 Do not give reverse rotation of the chain bucket conveyor. Do not use it to convey dry
material or adhesive material. The open fields that totally enclosed from the outside
should have rain-proof precautions.
6.1.3.12 Regularly check the coal tub of chain bucket conveyor for deformation and supporting
roller for wearing and immediately replace any one that has problem.
89
6.1.3.13 Regularly check the chain bucket conveyor motor and gearbox operation.
6.1.4 Slag Cooler Faults and Solutions
Table 6-1 Slag Cooler Faults and Solutions
a) Close slag gate and
clean large coking from
emergency slag
a) Large piece of coking blocks the
discharging port.
slag intake port.
No slag or small b) Open emergency slag
b) Large piece of coking blocks the
1 amount of slag from discharging port to clean
slag discharging pipe.
discharging port large coking in slag pipe.
c) Cooling passage gets blocked or
c) Close slag gate and
part of it blocked.
dismantle slag intake
pipe for slag cooler to
remove the blockage.
Small temperature
difference between a) Slag intake pipe or cooling a) Do it as (1)
2 inlet and outlet passage gets blocked. b) Decrease cooling water
temperature of b) Too much cooling water flow appropriately.
cooling water
a) Increase cooling water
flow or decrease rotation
High temperature a) Cooling water flow is too small or
speed of slag cooler
of outlet cooling over the rated slag discharging
3 appropriately.
water (higher than amount.
b) Stop slag cooler
90℃) b) No cooling water
immediately and supply
cooling water.
a) No cooling water a) Pump cooling water
b) The cooling water is too small to b) Increase cooling water
reach the flow set by flow flow to make it exceed
controller (frequency converter the flow set by flow
Slag cooler failing
4 display Er16). controller
to start
c) The frequency converter is not c) Connect to power supply.
connected to power source. d) Set parameters as
d) The parameters for converter is required in instruction
not correctly set. manual of control box.
a) Friction exists at connection part
of static and dynamic parts.
a) Adjust clearance
b) Ash falls into back bearing or the
b) Clean bearing or fill oil.
5 Motor overload bearing is lack of oil
c) Repair or replace
c) Damage of gearbox and motor.
d) Fill oil or replace.
d) Support wheel bearing is lack of
oil or damaged.
90
6.1.5 Common Faults and Solutions for Chain Bucket Conveyor

Table 6-2 Common Faults and Solutions for Chain bucket conveyor
a) There are slag deposits or
a) Clean the slag at the
mixture of water and slag at
bottom.
1 Deactivation the bottom.
b) Replace the deformed
b) Slag bucket gets bites and
bucket.
deformation.
a) Add oil on chain
a) Oil for chain is insufficient B Adjust chain
b) Chain gets too loose or tight c) Check and take out foreign
c) Foreign matter falling inside matter.
2 Abnormal sound (large metal) d) Reassemble bucket
d) Bucket falling e) Fasten bolts
e) Bolts get loose f) Remove heavy hammer, jack
f) Chain falling off track up the main shaft to install
chain and then put it back.
a) Improper installation of
conveyor.
b) The unflatness of casing is
excessive.
a) Inspect the installation
Derivation of idler c) Front and back wheels fail to
3 quality
pulley be aligned.
b) Readjust
d) Derivation of front and back
wheel shaft
e) Tail shaft still derivates even
after adjusting tension device.
a) Hard matter falls into the
a) Clean it and prevent foreign
casing and obstructs chain.
Breaking of pin matter falling
b) Long-time usage leads to
4 shaft of chain b) Replace chain.
serious wear.
c) Feed evenly after
c) Full load startup or sudden
discharging manually.
excessive feeding.
Too much accumulated
material in the middle of
5 Fast wear of chain Clean accumulated material
casing accelerates wearing
of chain.
a) Hard matters falls into the
Sudden abnormal
casing and obstructs chain. a) Clean foreign matter
6 sound happened
b) Chain joints and support b) Fill lube oil, repair or replace.
on chain
wheel fail to rotate flexibly
a) The front and back wheel a) Adjust the front and back
Poor engagement
7 shafts derivate or are not wheel shafts.
of gear and chain
flat. b) Replace chain.
91
b) Chain pitch gets bigger after

long-term running.
a) The tension of chain is not a) Adjust tension device
enough which resulting in b) Correct chain wheel
8 Derail of chain
looseness. according to relevant
b) Chain wheel off-tracking measures for off-tracking
6.1.6 Common Faults and Solutions for Steel Slag Bunker

Table 6-3 Common Faults and Solutions for Steel Slag Bunker
a) Air supply pipe of
gasification tank is
Unsmooth material a) Remove blockage
1 blocked
delivering b) Remove blockage
b) Foreign matter exists in
bunker
a) Give maintenance of
a) Bag filter is damaged
High concentration of dust remover
b) Pneumatic conveying air is
2 dust in material b) Adjust the pneumatic
beyond bag remover
bunker conveying air
capacity.
appropriately
a) Gasification plate is broken
and fails to work.
b) Gasification plate and casing a) Replacement
Dust in air supply pipe
3 are not tightly sealed. b) Repair or replace
of gasification tank
c) Check valves on the pipeline c) Make replacement
are damaged and fail to work
normally.
6.2 ESP System Maintenance

6.2.1 WT Series ESP Structure
The WT series ESP proper mainly consists of the anode system, cathode system,
rapping devices in anode and cathode systems, inlet and outlet loudspeaker, gas
distribution devices, high voltage incoming devices, and ash hoppers.
The ESP housing mainly consists of the supporting steel, wall plate, upper and lower
end plates, top girder, bottom pressure parts, middle pressure parts, inclined strut,
and internal walkway. Its structure is as shown in figure 6-2.
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1 ash hopper 2 supporting steel 3 housing 4 inlet loudspeaker

5 gas distribution plate 6 anode 7 electromagnetic rapper
8 cathode 9 stairway 10 outlet groove plate 11 outlet loudspeaker
Figure 6-3 WT Series ESP Proper Structure
6.2.2 Safety Measures for Maintenance

6.2.2.1 Have a warning board noticing PERSONNEL WORK INSIDE NO SWITCHING ON
hanged at an obvious location on the control panel.
6.2.2.2 At least two maintenance personnel are required to enter the ESP interior at the same
time with one person supervising. The maintenance personnel must not only be
familiar with the structure of ESP and functions of different parts, but also have good
understanding of the characteristics of flue gas and dust. They must take adequate
protective measures in case of any potential risk.
6.2.2.3 Whenever conducting high position inspection, maintenance or testing on the housing
or climbing on to the anode or cathode parts, rapping parts, or distribution plates for
maintenance, personnel are required to wear the safety helmets and safety
harnesses with cables or self lockout device.
6.2.2.4 ESP is of high voltage requiring attention to the personal safety. When putting the high
voltage connection parts and insulator chamber near rectification transformer into
operation, personnel should stay within the safety scope.
6.2.2.5 As the ESP is of high temperature, negative pressure and dusty, it is forbidden to
touch the high temperature parts with hands or other body parts during operation. It is
not allowed to conduct work in ESP until the temperature reduces below 40℃ by
opening the manhole for cooling.
6.2.2.6 After shutdown, all personnel should wear safety helmets, protective uniform boots
and gloves with good seal.
6.2.2.7 Stop all the ESP rapping motors and safety switch of electric air lock for ash
conveying and lock them.
6.2.2.8 Disconnect the high voltage isolator of high-voltage silicon rectifier transformer and
93
lock it. Use the earthing device provided to connect the discharge electrode system to
earth.
6.2.2.9 Put the switches of I.D fan and F.D fan of ESP into CLOSE position and lock it.
6.2.2.10 Close the air dampers at inlet and outlet flue gas ducts. Turn off the electric operated
device for air damper and lock it.
6.2.2.11 Open all manholes to give ventilation to electric fields. Enter it only when the
temperature drops to below 40℃. If needing to accelerate temperature reducing,
open the air valve of the outlet flue gas duct and start the I.D fan. At this time,
manhole should be kept in OPEN position to avoid sudden close.
6.2.2.12 Personnel entering the electric field should pay attention to the temperature of
different parts to avoid being scalded.
6.2.2.13 After entering electric fields, check whether there is ash accumulative formation. If so,
try to remove it to avoid accident and check the causes of ash accumulation.
6.2.2.14 After completion, count the tools that are taken to the electric field to prevent it being
left in the electric field, affecting the functions of the field.
6.2.2.15 After completion, take a bath and wash protection clothes to prevent the flue gas
sticking to the clothes from infecting people.
6.2.3 Special Maintenance Items for ESP
6.2.3.1 The following points should be noted when giving first time maintenance to it after the
newly operated ESP shutdowns for the first time. This can help us take measures to
prevent the defects during installation getting worse and further threatening the
normal operation of equipment in the future.
6.2.3.2 The insulator and ceramic shaft installed at the top of ESP may soon have cracks
because of non-operation causes such as installation and equipment quality, so give it
an overall and careful inspection.
6.2.3.3 Check the connections at electrodes in electric fields and the frame structure. If there
are looseness, open weld and flaking off, tighten, spot weld, and reinforce the weld
according to relevant technical requirements.
6.2.3.4 Check whether the expansion of electrodes lower part deforms from resistance.
6.2.3.5 Observe the caging device on the anode electrode and spoiler of ash hopper to see
whether the spoiler suffers from open weld or the guide plate experiences falling off.
6.2.3.6 Check whether the manhole seal and rubber pedestal of rapper are aging and
immediately replace if there is any problem.
6.2.3.7 Other Maintenance Items for ESP
6.2.3.8 Regularly paint those surfaces such as, staircase, platform, rapper casing and other
exposed surfaces being easily worn by rust to prevent it from rusting.
6.2.3.9 Check the oil ring, oil mouth, oil dipstick, and oil pointer are in good condition. Deal
with it if any problem.
6.2.3.9 If the reducer oil deteriorates, or with too high or too low oil level, handle it
immediately to avoid false oil level.
6.2.3.10 Give adjustment test of top and bottom displacement of analyzer regularly (quarterly)
in terms of standard air and mechanical zero calibration, electric zero calibration and
full range test. Check the ash deposits and breaking of sampling head and clean
them.
6.2.4 Overhaul Items of WT Series ESP
94
Table 6-4 General Preparations

No. Overhaul Items Technical Process and Precautions Quality Standards
a) Check electric fields parameters (secondary
voltage, current, activation rate, operation
The plan should be
hours), equipment defects, the latest
approved by the
overhaul conclusions and all maintenance
technology
conducted since previous overhaul before
administration
operation of ESP and compile an overhaul
department. The
Compile plan by analyzing the various materials in
1 major safety
overhaul plan detail.
measures should be
b) Compile an overhaul control process,
examined and
technical process, labor organization plan,
approved by safety
and cooperation conditions.
supervision
c) Work out a detailed regulation for technical
department.
measures and safety precautions on major
and special items.
Safety tools should
be inspected by
safety personnel.
Use a portable
torch or 12V portable
Make
lamp in electric
preparation for Material preparations include the following: spare
fields. Knife switch
2 materials and parts, safety tools, construction tools, instruments
must be installed
filed and meters, lighting tools and so on.
high at a noticeable
arrangement.
place outside the
manhole, and
monitored by
designated
personnel.
Prepare the
a) Include: records form for measuring
forms of
electrode distance, record card for electric
3 related
field no-load energized voltage increasing
technical
test and the necessary items.
record.
a) Checked and
accepted by
a) Complete all kinds of work permits strictly
Take adequate relevant
according to the related safety operating
4 safety personnel and
regulations, and carry out all safety
measures. people in charge
measures.
of maintenance
at site.
Table 6-5 Mechanical Part Overhaul Items
95
No. Overhaul Items Technical Process and Precautions Quality Standards

a) After natural cooling for a certain a) Natural cooling time for
time, open all manholes in electric electric field in large-sized
field to accelerate cooling. When ESP is usually not less
the internal temperature than 8 hours.
decreases below 50℃, people
can enter the electric field for
work. Prevent cold air from
entering the electric fields which
may result in dramatic change in
temperature and further the
deformation of such metal parts
as shell, electrode cables and
electrodes.
b) Inspections before ash removing.
1) Observe the ash deposit condition
on anode plate and cathode wire
in first step, and then analyze the
causes and keep record of them.
2) Observe the ash deposit condition
on air distribution plate and trough
a) Clean up and dry the ash
plate, and analyze the causes and
deposit on components
Clean the electric keep record of them.
1 surfaces for two purposes:
field proper 3) Check the electrodes deformation
① convenient for
and deviation condition, cathode
inspection and
frame deformation, electrode wire
maintenance; ②
flaking off or getting loose and
prevention of equipment
conduct the macroscopic
corrosion.
inspection on electrode distance.
c) ash removing
1) Include: cathode and anode
electrodes, trough plates, ash
hoppers, inlet and outlet, guide
plates, air distribution plates, and
ash deposit on housing inner wall.
2) Remove ash from top to bottom
(from inlet to outlet in sequence),
and prevent operator and tools
from dropping to ash hopper.
3) When hopper experiences ash
blockage, don’t discharge ash
from hopper manhole. Open ash
flushing water and ash discharge
valve when removing ash deposit,
so that the ash is discharged in
96
normal way.
4) After flushing electric fields with
clean water, dry with hot air or air
fan when required conditions are
met.
a) Anode plate completeness
inspection
1) Inspect the anode plate for
deformation by visual or wire
drawing method.
2) Inspect the electrode plates for
rust corrosion or electrolytic
corrosion. Find out the causes
and eliminate them. Change the
plates that get perforated, or
those with bending caused by
deep and large area damage, and a) The connection and
those with failure to meet space welding of electrodes
standards. group is in good condition
b) Anode plate completeness without flaking off or
inspection unsoldering.
1) Inspect if the connection and b) The movable interval of left
welding of continuous anode plate and right can move slightly.
falling off, and deal with it. Adopt c) Figure out thermal
Anode plate AC welder to reduce the expansion according to the
2
overhaul influences on continuous plate height of electrode and
flatness. possible max temperature
2) Check if the electrode positioning of flue gas. One multiple
plate and guide U-steel have time of margin but not less
unsoldering and deformation. than 25mm. should be kept
Repair welding and adjust it when with left and right sides
necessary. smooth without stages.
3) Check if the guide bar and guide d) The table record is clear,
plate at the bottom of anode plate and the data is genuine.
have adequate thermal expansion
margin, and there is no blockage
and jamming at left and right
sides.
4) Check if the electrode plate falling
down or displacement along flue
gas direction. If some falling
downwards, inspect the welding
condition of lifting lugs on top
girder, suspended pin plate and
fixed plate. Deal with it when
97
necessary.
5) The whole electrode group is in
good arrangement without clear
concave-convex problem by
visual inspection.
c) Electrode distances detection
The electrode distance is
measured based on relative flat
anode plate in electric field center
section. Measuring parts of
distance can be at inlet and outlet
position of each electrode plate.
Measuring should be conducted
at the top, middle and bottom by
height. Make sure the measuring
should be taken at the same place
during each overhauling and the
data measured and adjusted
should be recorded into
equipment files.
d) Electrode integral adjustments:
1) Same electrode distance
adjustments: when the bending
deformation is severe, hammer
the part where maximum bending
happens by wood hammer or
rubber hammer, and use lighter
force to evenly hit towards both
sides. The knocking point should
be at both sides of plate. It is not
allowed to hammer the working
surface of the operating panel.
When it experiences too severe
deformation to adjust the
electrode distance in permitted
range, replace it.
2) When the electrode plate
experiences severe misalignment
or falling downwards, the distance
between same electrodes
exceeds the prescribed value and
fails to be eliminated at site, or
when replacement of electrode
plate is required, preparations
should be made to remove the top
98
caver before repairing, and

specific maintenance scheme
should also be provided at the
same time.
3) The newly replaced anode plate
should be measured in
accordance with manufacturer’s
regulations, and the error of plane
and diagonal line after electrodes
arrangement should be in
accordance with the
manufacturer’s requirements.
Lifting should follow the original
arrangement ways. Refer to the
other related chapters for the
replacement of electrodes.
a) Find out the electric field of
insufficient rapping and anode
plate based on inspections of
anode ash deposit for careful
inspection.
b) Inspect the center deviation of
rapping bar and rapping rod
during operation as well as the
wear of the two contact surfaces.
Inspect if the three fixed screw
rods of vibrator are loose or fallen
off. Adjust the screws to align the
center of rapping bar and rapping
rod, as well as the the length of
Anode rapping
3 exposed rapping rod. Inspect if Refer to the installation chapter.
device
the rapping height is same as
displayed height, by inserting a
45cm long and 2.5mm2 copper
core single-thread wire into the
hole, mark, and then pinch it. The
lifting height of copper core is
consistent with that of the rapping
rod. If the copper wire does not
fall freely, the height is considered
to be the actual value.
c) Add some rust inhibiting lube oil
on rapping rod to prevent the iron
rod from blocking its free gap due
to rust and check if the rapping
99
bar experiences bending and

deformation.
d) Check if the rapping coil leaks oil
and the two joints of output lead
wire are exposed or broken.
e) Check if rain-proof hypo (rubber)
is destroyed, if packing box
experiences air or water leakage
caused by aging and if the locking
screw of gland box is seized by
corrosion.
a) Inspections and maintenance of
cathode suspension device
1) Check if each pressure insulator
is placed horizontally.
2) Check if each suspension point of
cathode suspension beam is at
the same level. Adjust the screws
on insulator support flange to
maintain the suspension point a) The surface of support insulator
horizontal when error occurs. is free from no mechanical
3) Wipe the pressure insulator and damage or the insulator is
proclaim shaft with clean and dry broken.
soft cloth. Check if the surface of b) Test standards of newly
insulator has mechanical replaced HV insulator
damage, or if the insulator is components:
Maintenance of
broken, or if there is electric 1) 1.5 times of rated voltage AC
cathode rapping
discharging trace. Change the voltage withstand.
4 suspension
broken pressure insulator or 2) No puncture in one minute.
device, frame and
proclaim shaft. Conduct the c) The discharging electrode is
electrode wire
voltage withstand test before adequate without looseness,
replacing the insulator. When disconnection or falling off. The
replacing the pressure insulator, electric field heteros-electrode
take the corresponding fixed distance is ensured.
measures (move the suspension d) The table record is clear,
point to the temporary supporting measuring data is accurate,
point with temporary hook.). Make and data is genuine.
sure that the strength of each
suspension point is evenly for the
protection of other components
of supporting points from damage.
Adjust each suspension point is at
the same level, and fill the
insulator bottom surroundings
with asbestos rope to avoid air
100
leakage.
4) Check if the screws on frame
beam top is loose or experiences
displacement, and if the two ends
positioning elements on the
insulators are fallen off.
5) Refer to point 2-5 of anode
rapping equipment part.
b) Maintenance of cathode frame
1) Check if the integral flatness error
of cathode frame meets the
requirements, and adjust it if
necessary.
2) Check if the frame is partially
suffering deformation or
unsoldering or cracking. Adjust
and deal with them if necessary.
c) Maintenance of cathode wire
1) Give a thorough check on the
fixed condition of cathode wire to
see whether the cathode wire
experiences falling off, getting
loose, breaking of wire. If so,
ascertain the causes and
eliminate such defects. When the
wire drops to the position beyond
the reach of people, which has
little influence on the frame
structure (such as reduction on
strength and deformation) and
distance between different
electrodes is guaranteed, it is
possible to weld it by electric
welding. It is required to polish the
welding spots and burrs and
remove the wire if welding fails.
Take out the remaining part of
broken wire, ascertain the causes
(for example, mechanism
damage, electric erosion or
rusting) and take proper
measures to resolve the problem.
For loose electrode wires, shake
the frame for any abnormal sound
and observe the swaying, which
101
should be considered as as a
preliminary method for such
defect. The electrode wires that
get loose arising from loosening
of nuts should, in principle, be
given spot weld after the nuts are
fastened.
2) Check the performance of various
kinds of cathode wires and record
the results which will be used as
data for overall analysis of the
operation and performance of
equipment. In addition to checking
of cases as loose electrode wire,
falling off, breaking of electrode
wire and ash deposits, more
careful inspection should be given
to the following items: needle line,
inactivation of discharged end,
balling or falling off needle wire
and distance adjusting of both
points.
3) Replacement of cathode wire
Cathode wire of the same model
and specification should be used
and inspection should be
conducted before replacement to
see whether it is in good
condition. Calibrate the wire of
bending so that it meets the
requirements of manufacturer.
d) Test and adjustment of distance
between different electrodes
1) This test should be carried out
after the frame test is completed
and the distance between the
anode plates is adjusted within
the normal range. The distance
between different electrodes that
meets the requirements after
being adjusted should be marked
and the data before and after
adjustment should be recorded
into equipment file.
2) Measuring points distribution
102
For easy work, measuring points

are generally arranged on the first
electrode wire at the inlet and
outlet of electric field.
3) Based on the arrangement of
measuring points, personnel
should prepare the forms for
measuring which must include:
electric field name, quantity of
channels, measuring points code,
and number of cathode wire,
personnel for measuring,
measuring time, and measuring
data. Try to choose the same
measuring position for better
analysis and comparison.
4) As required, conduct
maintenance and calibration of
the distance between same
electrodes, frame and electrode
wire of the electric filed.
Theoretically, the distance
between different electrodes can
be controlled within the normal
range, but in fact, it fails to be
brought into the normal range
because of such factors as too
much work, intensive construction
schedule, improper measuring
method or equipment aging, then
partial adjustment should be
made to ensure all the measuring
points of the distance between
different electrodes meet the
requirements. Other parts
between the cathode and anode
electrodes should be given with
visual inspection by experienced
personnel or tested by specially
made T. Small quantity of needle
wires can be adjusted accordingly
by changing the derivation and
the distance between two points.
But this requires strict controlling
of the number of needle wires
103
within 2% of the total number,

otherwise, the changing of the
discharged center will make the
needle wire unable to
optimistically cooperate with the
electrode plates, thus weakening
the performance of discharging
wire.
a) Inspect the corrosion condition on
hopper inner wall, leakage from
flange joint surface, cracks at a) There is no leakage point
weld joint, ash leakage and or retained cicatricle on
corrosion during equipment hopper inner wall.
operation. Conduct repair welding b) Four corners of hopper is
to prevent leakage depending on smooth without dead zone.
the condition. Eliminate the c) The hopper is free from
welding deposits with grinder after deformation and the
repairing weld to avoid ash support structure is firm.
accumulation. d) The gate valve has no
b) Check arc plate on the corners of leakage, operation is
hopper is complete, and the flexible and reliable, and
welding condition on the side wall. insulation performance is
The arc plate should be smooth good.
without scar for avoid ash e) Ash falling chute is
accumulation after repairing weld. unblocked without leakage
Maintenance of
c) Check if the internal resistance point.
hopper and ash
5 guide plate in hopper experiences f) Ash discharging valve is
discharging
falling off or displacement. If so, free from blockage or ash
device
reset and weld it immediately. automatical flowing. The
d) When repairing the gate valve at reducer and bearing are in
bottom of the ash hopper, change good performance.
the sealing packing between gate g) Referential size of radial
valve and ash hopper flange. clearance is 0.7mm-.5mm,
Eliminate ash dropping point on and the referential size of
joint surface. Inspect the gate axial clearance is 1.5mm -
valve operating mechanism, and 4mm.
inspect if the gate valve has no h) Rotor rotates briskly and
leakage, the operation is flexible flexibly without jamming or
and reliable, and adjust and axial movement. The
protect with rust resistant grease coupling clearance is
applied. 4-6mm, and center error is
e) Ash dropping pipe maintenance: less than 0.05mm without
inspect and deal with the ash leakage.
blockage and unsmooth ash
dropping in ash dropping pipe.
104
Deal with the leak point at flange

joint surface in ash dropping pipe
and Y-shape ash poking hole.
f) Ash discharging valve
disassembly maintenance.
1) Check if there is crack or damage
on the housing.
2) Disassemble the coupling.
3) Disassemble and remove the
reducer base to carry out
maintenance of it. (Same model
as rapping reducer, refer to
rapping equipment maintenance.)
4) Disassemble the front and rear
end covers of ash discharging
valve, and draw out the rotor.
Check the wheels and outer
housing wear, and change them if
the blade has gap or is damaged
severely. Weld the impeller blade
that experiences minor breaking.
5) Disassemble the front and rear
bearings and bearing covers, and
check the lubricating grease
condition. Use industrial cleaning
agent to clean. Check the bearing
wear and clear up the blocked
lubricating grease.
g) Reassemble the ash discharging
valve in a reverse order of that of
the assembly and pay attention to
the following:
1) Use a feeler gauge to measure
the clearance between the
impeller and outer housing
diameter, and adjust it to be
equally distributed.
2) Adjust the axial clearance
between front and rear end
covers and impeller.
3) Coat a layer lubricating grease to
newly-replaced packing before
installation. Allow further
tightening after filling and
fastening, and maintain the gland
105
is not inclined.
4) Coat grease onto the rolling or
sliding surface to form a
preliminary lubricating condition
before installing bearings. The oil
filling hole of bearing should align
with the oilhole cup of end cover
during installation. Make sure that
air will not enter the bearing
during operation.
h) Mechanism integral assembly and
trial operation.
1) Spin the assembled ash
discharging valve coupler
manually.
2) Align the speed reducing center
based on ash discharging valve
coupler.
3) Supply power to run for an hour.
a) Check casing inner wall corrosion a) There is no leakage or
condition and conduct patch corrosion in housing inner
welding for water and air leakage wall with flatness and
parts. Observe the leaked ports smoothness.
using kerosene oil leakage b) Manhole has no leakage,
method if necessary. Check the and the safety marks are
inner wall dust accumulation complete.
condition. If the inner wall has c) Insulation layer should be
curve and deformation, find out filled with complete
causes and calibrate it, keep it coverage and even
Maintenance of straight to avoid eddy. thickness and the local
housing, external b) Check the sealing of all access heat insulation
devices, and inlet doors (ash hopper one, electrical requirements can be met.
6
and outlet maintenance one and The metal protection plate
loudspeaker temperature protection box one), is firm and reliable with the
U-type plate and replace the packing if ability to resist the
necessary. Calibrate the maximum wind (Typhoon
deformed manhole and replace in coastal area.)
the damaged bolt. The HV d) Speak louder at inlet and
dangerous mark on man hole outlet are free from
should be complete and clear. deformation or leakage or
c) Check the temperature insulation over wear.
condition of ESP outer housing. e) Change those when their
d) Check and record the wear worn area exceeds 30% of
condition of inlet and outlet inner the original size. (for
walls and the supports. Adjust or reference)
106
add guide flow damper in inlet flue

gas duct if necessary. Add
anti-wear liner on severe abrasion
parts. Perform patch welding for
water and air leakage parts.
Replace the support with severe
abrasion.
e) Check to see if flange connection
of inlet and outlet flanges and duct
are in good condition. Repair and
fasten the inner wall concave.
f) Check the U plate and wear of
flow distributor, and guide flow
suspending fixing parts. And
check the welding fixing condition.
Replace the damaged fixed parts
and bolts.
g) Check the distributor wear and
distribution flatness. For
distributor with large holes,
conduct patch welding in
accordance with the original
configuration. Replace the
severely worn distributor.
Distributor bottom and inlet
loudspeaker inner wall pitch
should meet requirements. For
electric filed which has low
efficiency caused by unbalanced
flue gas, before maintenance of
flow distributor and guide plate, a
flow distribution test should be
conducted. Meanwhile, based on
the results, adjust the guide angel
and air distribution hole until they
meet the relevant requirements.
h) Maintenance of distribution
rapping should refer to the
requirements of anode electrode
rapping system.
i) Check wear and deformation of
the U plate and conduct the
related patch welding, calibration
and replacement.
j) Check the wear of guide flow
107
plate, and perform replacement or

patch welding.
k) Conduct repair and maintenance
for stair, platform, handrail and
rain shield with antirust protection.
6.2.5 Inspections and Acceptance after Maintenance

Table 6-6 Inspections and Acceptance After Maintenance
No. Items Methods Standards
1 Anode plate In accordance with the technical

standards, and flexible
2 Anode rapping In accordance with the technical
standards, and flexible
3 Anode gearing In accordance with the technical
device standards, and flexible
4 Cathode frame and In accordance with the technical
wire standards, and flexible
5 Cathode rapping
6 Cathode gearing In accordance with the technical

device standards.
a) Working group
7 Housing Slight wear without deformation
self-inspection.
8 Ash hopper b) Material examine and Slight wear without deformation
acceptance.
9 Inlet and outlet gland In accordance with the technical
c) Local examine and
standards.
acceptance at site.
10 ESP top In accordance with the quality
standards.
11 ESP manhole Slight wear with no deformation
12 ESP flue gas duct Slight wear with no deformation
13 Air distributor In accordance with the technical

standards
14 Ash discharging In accordance with the quality
equipment standards
15 Trail operation In accordance with the parameter
standards
16 Hygiene on-site No foreign matters
6.2.6 Spare Parts (for individual ESP)

Table 6-7 Spare parts (for individual ESP)
No. Name Specification Mode Unit Quantity Notes
1 Indicator XB2-BVM3C Piece 8

108
2 Intermediate relay JQX-13F 2Z 220V Piece 8
3 Damping resistance ZG12-1200W-2KΩ Piece 5
4 Manifold block 4N39 Piece 6
5 Manifold block LM348 Piece 6
6 Electric heater WBT2.0-5 Piece 3
7 Shaft pin WBT15-9 Piece 10

只
8 Bush WBT15-12 10
Piece
9 Coupling bush bi-pyramid WBT4.0-25 Piece 10
10 Gasket WBT10.0-2 Piece 10
11 Electrode plate Piece 5
12 Electrode wire Piece 10
13 Pressure insulator WBT4.0-11B Piece 2
6.3 Maintenance for Ash Handling Gasified Blower

6.3.1 Operation and Maintenance
6.3.1.1 Gasified blower can only be operated when it is in completely good situation, and the
following conditions must be ensured: sufficient capacity for power supply facilities;
steady voltage; no open-phase operation; specific power supply circuit; temporary
circuit for power supply in a long time is not allowed.
6.3.1.2 Shut down the gasified blower for inspection when the following phenomena are
happened during operation: ① abnormal sound; ② overdue heating of motor; ③live
outer housing ④switch trip ⑤startup failure. For safety, it is not allowed to maintain
the the blower during operation. Perform trail operation for five minutes after
maintenance. Restart the machine after the blower is normal.
6.3.1.3 Keep the blower running in dry place to prevent the motor from being affected with
damp.
6.3.1.4 Check the fuel regularly, and keep it in normal oil level. (The proper oil level is at the
center top of red dot of the oil location observation window.)
6.3.1.5 Change fuel after 200h operation for the first time, and every 2000h or at least 3
months for once in the future.
6.3.1.6 Clean inlet filter once a week.
6.3.1.7 Paper filtering cartridge can be purged with air compressor, and the purging direction
is reverse to the air flowing direction that along cartridge during operation.
6.3.1.8 For metal mesh filtering cartridge, it shall be cleaned by cold water or warm water with
cleaning agent.
6.3.1.9 Check the temperature and vibration of the blower regularly.
6.3.1.10 Find out the causes for abnormal current and voltage variation during operation. Shut
109
down the blower when necessary.

6.3.1.11 Do not pry while replacing the belt. Adjust the regulating screw on the motor to reduce
wheel diameter to fit the belt on belt wheel.
6.3.2 Common Failures and Solutions for Gasified Blower
Table 6-8 Common failures and solutions for Gasified Blower
No. Failures Causes Solutions
a) Check the clearance
a) Rotors collide with each other, or the
between rotor and
rotor collides with housing.
housing.
b) Too much load for blower.
b) Check the operating
c) Blower housing experiences
The blower does pressure and
deformation due to the load on blower
1 not rotate or gets temperature of air.
added by pipeline or uneven
blocked. c) Check the inner of
foundation.
rotor and housing.
d) There is Foreign matter in blower.
d) The blower must be
e) The blower is chocked and blocked
replaced.
due to dust deposit.
e) Clean the blower.
a) Rotors collide with each other, or the a) Check the clearance
rotor collides with housing. between rotor and
b) The gear clearance is large. housing.
2 Abnormal noise
c) The rolling bearing clearance is large. b) Change the gear.
d) The rotor loses balance due to dust c) Change the bearing.
deposits. d) Clean the rotor.
a) The blockage of filter makes inlet flow
decrease.
a) Clean or change the
b) Large pressure differential causes too
filter.
much heating caused by
b) Check the pressure
compression.
Overheating of settings of pipeline
3 c) The oil level is too high, or the oil
Gasified Blower and relief valve.
viscosity is large.
c) Change oil and adjust
d) The clearances between rotor and
the oil level.
rotor, and between rotor and housing
d) Carry out overhaul.
inner wall are too big (abrasion). The
blower must experience overhaul.
a) Shaft end have oil leakage, and the oil
a) Change oil gland.
gland is damaged.
b) Repair the gland
b) There is oil leakage between end
sealing of joint.
cover and side plate.
c) Change the sealing
c) The oil level observation window s is
gasket, and fasten
4 Oil leakage damaged and presents oil leakage.
the glasses of
d) Oil leaks into compressor inner part,
observation window.
and the oil gland is abraded or
d) Carry out overhaul.
damaged.
e) Adjust the oil level.
e) Oil level is too high.
f) Carry out overhaul.
f) The action of capillary tube among
110
components causes oil leakage.
a) Inspect inlet pipeline

system (filter
a) Inlet resistance is large.
blockage).
b) The actual operating parameters are
5 Low inlet flow b) Inspect operating
different from the given parameters.
parameter. (pressure
c) Large clearance (abrasion).
and flow)
c) Carry out overhaul.
6.4 Limestone System Maintenance

6.4.1 Operation and Maintenance of Limestone Air Blower
6.4.1.1 For limestone air blower, the operation current and voltage must be inspected
regularly to make sure they are within the rated range and the following conditions
must be ensured: no open-phase operation; specific power supply circuit; temporary
circuit for power supply in a long time is not allowed.
6.4.1.2 Shut down the air blower for inspection when the following phenomena happened
during operation: ① abnormal sound; ② overdue heating of motor;③outer housing
live ④switch trip ⑤startup failure. It is not allowed to maintain during operation in
order to ensure safety. Perform trail operation for five minutes after maintenance.
Restart the blower until it is in good condition.
6.4.2 Maintenance Process and Quality Standards of Limestone
Air Blower
Table 6-9 Maintenance Process and Quality Standards of Limestone Air Blower
No. Items Process and Precautions Quality Standards
1 a) Remove the protective cover of a) Normally, the heating
couplings and measure the temperature of wheel hub
radial differential and distance and gear, should not exceed
between couplings. Make a 150℃ if not stipulated.
record. Heating evenly within limited
b) Thoroughly discharge the lube temperature requirement to
oil in oil tank. Remove the prevent deformation. Gear
fastening bolts on the upper side should be
connecting surface of casing polished to be free from
Air Blower
and gear box and take out burr.
disassembling
sealing gasket to measure its
thickness and make a record.
Lube oil should be placed in a
cylinder rather than overflowed
onto the base and ground. The
measurement of gasket should
be accurate.
c) Mark the matched drive and
driven gears, then remove
111
locking screw. Wheel hub and

gear can be disassembled by
heating, and the temperature
after heating should meet the
manufacturer’s regulation.
d) Make signs before removing
bearing cover. Measure and
record gasket thickness, and
then remove bearing.
e) Lift out rotors on special
working platform. Bearing side
screw should be packed well to
prevent damage after rotors
are lifting up.
2 a) Gear surface should be free
from mechanical pitting,
broken gear tooth or crack.
a) Wash all parts following the fire Screw is damage-free and
protection regulation. key slot is burr-free and
b) Check wear degree of gear, crack-free.
Air blower
gear surface and key slot. b) There is no obvious pitting,
inspection
c) Check bearing clearance. hole, or sink mark on
d) Repair and replace the worn bearing. The moving
and damaged parts. clearance of bearing should
meet the manufacturer’s
requirements (not more than
0.2mm)
3 a) Reinstall the air blower in the a) All parts are sealed well
reverse way of assembling. after replacement.
b) Measure radial clearance
between rotor and casing after
rotor is installed. Replace rotor
if clearance is obvious.
Air blower c) Gasket thickness= (Casing
reassemble axial width – rotor axial width) x
80%.
d) Verify the key slots on bearing
are 90° to each other and pay
attention to the matched mark
of the two gears.
e) Adjust rotor clearance.
4 a) After reassembling, if the Roots a) There is no abnormal noise
blower is normal after turning and vibration is within the
Test running
the gear manually, conduct test given value during
running. operation..
112
b) Perform test running for 2h..
6.4.3 Operation and Maintenance of Limestone Bucket Elevator

6.4.3.1 In operation, the bucket elevator should be guarded by certain operator who must
have the general knowledge of machinery and familiar with the bucket elevator
performance.
6.4.3.2 The guarder must follow the Safety Operation Regulations of Equipment Maintenance
and handover system worked out by elevator user.
6.4.3.3 The elevator guarder should inspect the operating conditions of each component and
the fasteners regularly and tighten them if necessary. Do not clean or repair the
operating elevator parts during operation.
6.4.3.4 The material should be fed into elevator evenly, and the feeder conveying volume
should be within the range available in elevator, or the material may block the bottom
section.
6.4.3.5 When the elevator is in operation, all inspection doors should be closed. If any fault
happened during operation, shut down the unit immediately to clear the fault. Keep
record of the failure that is not easy to be solved, and solve it during maintenance.
6.4.3.6 The working conditions of hopper and chain should be inspected routinely by the
guarding operators. For several damaged hoppers, remove them. Repair the removed
components during elevator maintenance. Replace those that beyond repair.
6.4.3.7 The elevator working conditions should be inspected, cleaned and lubricated routinely
by guarding personnel.
6.4.3.8 Do start up the elevator with no-load, and shut down it when all materials are
unloaded.
6.4.3.9 In addition to lubrication and some components replacement, carry out routine
maintenance for once every six months during normal operation,. Solve all faults
recorded during operation. Remove or replace the damaged components, and
change lube oil regularly. The users can make up periodic maintenance plan based
on the working condition of elevator.
6.4.3.10 Adjust the rubber tongue at the outlet of elevator regularly until the hopper does not
scrape the rubber tongue.
6.4.4 Maintenance Process and Quality Standards of Limestone
Bucket Elevator
Table 6-10 Maintenance Process and Quality Standards of Bucket Elevator
No. Items Process and Precautions Quality Standards
a) Disassemble the drive a) No break tooth or cracks on chain
device after motor shuts wheel.
down. b) No falling off and the activation
b) Disassemble the drive between chains is flexible.
device. Inspect and clean c) The chain hopper is free from
1 disassembling drive chain and wheel. deformation and bolts are from
c) Disassemble the cover of looseness.
bearing box and the upper d) The sealing packing on
and lower bearing cover, connecting bearing cover is
and unlock the coupling completely cleaned.
bolts. e) Coupling wheel is free from redial
113
movement and abrasion, and

loose-proof measures are
provided.
f) Do not crash the drive bearing
when lifting.
a) The size of inner wall meets
manufactures’ requirements,
normally, the deformation can not
exceed 10%. When the abrasion
reaches 2/3 thickness, change the
a) Inspect body deformation
box.
and damage after cleaning
b) Sight glass is clear and indicator is
the inner of box.
sufficient.
b) Clean and inspect the
c) There is no mechanical pitting,
bearing, and measure the
discolor, or cracks on bearing ball.
clearance between them.
The clearance between bearings
The heating temperature of
is less than 0.25mm. The bearing
2 Inspection hot installing bearing is not
inner housing is matched with
more than 120℃.
shaft in jf mode and the tension is
c) Check and make sure the
0.01mm-0.03mm.
upper and lower drive shaft
d) The drive shaft should be free
free from crack or bend.
from bend or abrasion, and the
Check the driven wheel
regulating device is free from
abrasion, and replace it if
blockage. The sealing is good.
seriously.
e) The elevator upper driving shaft
and the lower driven shaft should
be on the same vertical plane. The
two shafts should be installed and
adjusted to the same level.
a) Inspect to make sure the
hopper has no
deformation, abrasion or
looseness. Replace those
that are seriously
damaged.
Maintenance for b) There should be no
a) The changed hopper and housing
3 material hopper abrasion or looseness in
should have certain clearance.
conveying part transmission chain.
c) Tension applied to both
sides of transmission chain
should be balanced, the
verticality shall be ensured
when the transmission
chain is in operation.
a) Check the housing fixing
bolts are tightened, and the
a) Try to make all the center lines of
upper hanger is steady.
housing along the same line. The
b) Use fireproof coarse cloth
deviation of straight line is
Maintenance for or asbestos belt to connect
4 1000mm, its length is less than
housing the intermediate housing,
2mm, and the overall length
so as to ensure the
cumulative deviation is less than
tightness. Try to make all
8mm.
center lines of housing at
the same line.
6.4.5 Operation and Maintenance of Vessel Pump

114
6.4.5.1 All movable parts must experience periodical maintenance, inspection and lubrication.
Periodically inspect the fluidized pipe and material outlet pipe. If the fluidization
mechanism is damaged, it will lead to unsmooth material discharge or high conveying
pressure, or even pipe blockage. Conduct inspection once for each month.
6.4.5.2 Inspect material level indicator (or gravimetric module), valves and all pressure
gauges everyday, if there is abnormity, timely conduct treatment or replacement.
6.4.6 Maintenance Process and Quality Standards of Vessel
Pump
Table 6-11 Maintenance Process and Quality Standards of Vessel Pump
Maintenance Process and
No. Maintenance Items Quality Standards
Precautions
a) Make work permit.
b) Close inlet gate valve before a) The maintenance
Preparations for
1 making sure vessel material is system should be well
maintenance
emptied. isolated.
c) Close the air check valve.
a) The governor valve
a) Check and adjust flow,
can swiftly adjust
pressure governor valves.
parameter change
b) Inspect the check valve; if seal
Air system without time delay.
2 is poor, timely replace it.
maintenance b) Check valve is tight
c) Check the gasification
and reliable.
performance of fluidizing
c) Fluidized plate can
device.
breathe evenly.
a) Check the abrasion degree of a) Valve opening is
Maintenance of valve plate and valve seat, and flexible without stiffing.
material inlet valve, replace the worn parts. b) Clearance meets
3
outlet valve and bleed b) Measure and adjust the manufacturer
valve clearance between valve plate regulations (≤0.06
and valve seat. mm.)
Conduct pressure vessel
inspection based on periodical
Inspections of pump
4 maintenance schedule
body and fittings
regulated by boiler monitoring
station.
Valve switch is in right
5 Trial run Check valve activation position and activation
is normal.
6.4.9 Consumable Items and Spare Parts of Plate Chain Bucket

Elevator
Table 6-12 Consumable Items and Spare Parts of Plate Chain Bucket Elevator
No. Name Model Unit Quantity Remarks
115
1 Doom valve seal ring Pcs 2
2 Vessel pump air inlet valve Pcs 1
3 Solenoid valve Pcs 2
4 Copper control joint Pcs 6 6 for each model
6.5 Air Compressor System Maintenance

6.5.1 Maintenance Requirements for Combined Low-dew
Compressed Air Dryer
Maintenance for combined low-dew compressed air dryer is very necessary. Correct
use and maintenance can make the dryer meet operating requirements and prolong
its service life. The dryer has been tested and control functions are examined before
leaving plant. The dryer, if installed in the clean environment and run within the given
environmental temperature range, will be able to maintain long-term normal running.
The routine maintenance includes following items:
During equipment operation, check to see if the reading of refrigerant low pressure
meter is in normal range. In air system, too low pressure of secondary refrigerant will
lead to frost or ice formation, which will increase pressure loss or damage compressor.
Too high pressure will decrease system refrigerating amount.
6.5.2 Automatic Drainer Maintenance
6.5.2.1 Inspect the drainage condition of automatic drainer everyday, periodically clean
strainer to prevent blockage.
6.5.2.2 For primary operation, use working condition compressed air to wash pipe for 20
minutes, then install the drainer, or the drainer will be blocked.
6.5.3 Electrical Drainer Maintenance
6.5.3.1 When checking compressed air system, you are advised to give several presses on
the manual test button (TEST) on timer to check if the electrical drainer works
normally.
6.5.3.2 When starting or shutting down combined low dew compressed air dryer, conduct
blowdown by opening blowdown valve under adsorption tower. Conduct blowdown in
fixed time two times a day.
6.5.3.3 The only 2-3mm space between adjacent two fins of air-cooled condenser makes the
condenser easy to be blocked by air dust, which may cause poor radiation. The dirty
condenser will increase the condensing pressure of refrigerating system and the
compressor will stop running due to overload. Therefore it is necessary to conduct
periodical cleaning by compressed air spraying or by copper brush or by low pressure
water column spraying added with cleaning agent. And meanwhile, impurities, like dirt
and rust, in condenser should also be cleaned every year according to requirements.
6.5.4 Water Filter Maintenance
The main function of the water filter is to prevent the solid impurities in cooling water
from entering the condenser and further affecting heat exchange. So the filter net
should be periodically washed to avoid high condensate temperature caused by
116
inefficient water circulating.

6.5.5 Unit Interior Maintenance
6.5.5.1 During shutdown, periodically carry out vacuum cleaning for internal parts. Pay
attention to protecting refrigerating system from damaging.
6.5.5.2 Keep good ventilations all around the equipment, and prevent equipment from direct
sunlight and all hot sources.
6.5.5.3 Under full load condition, check the pressure loss of air flow passed dryer. If it is
higher than design value (0.035MPa), wash air pipes in reverse following the below
steps: isolate dryer from system, plug all water discharging pipes, then fill water with
cleaning agent to air system, next after being maintained for 4-6 hours, use pump to
fill water from air inlet and discharge from air outlet for circulating washing, finally use
warm water to clean up. If the pressure loss still exits, contact the manufacturer.
6.5.6 Operation and Maintenance of Absorption Dryer
6.5.6.1 Wash the condenser once every 12 months with compressed air or chemical agent.
Suggestion: if the box internal space is too small to conduct cleaning, enlarge it.
6.5.6.2 Wash the automatic blowdown device once a week.
6.5.6.3 The fronted and back filter strainers should be replaced after 10000-12000h operation.
It is advised to perform filter blowdown for 6 times in every 24 hours.
6.5.6.4 Refrigerant suction pressure: normal pressure is in the range of 0.38-0.46MPa. If
pressure is lower than 0.38MPa, turn the returning cool water smaller, adjust
expansion valve and thermal bypass valve bigger clockwise; If pressure is higher than
0.46MPa, turn the returning cool water bigger, adjust the valves on the contrary.
6.5.6.5 Check refrigerant (Freon) amount: if suction pressure gauge indication is higher than
0.9MPa, it means the Freon is sufficient, if pressure is lower than 0.3 MPa, then make
up timely.
6.5.6.6 Check silencer once 6 months, and replace it when necessary.
6.5.6.7 Check pneumatic switching solenoid valve every 12 months.
6.5.6.8 Carry out random inspection on absorbent every 24 hours.
6.5.6.9 If the pressure differential gauge of fronted filter pointed red, it means the strainer is
blocked.
6.5.6.10 When the outlet pressure of filter regulator is not within normal range, it must be
regulated following procedures as below: pull up the button at the top of filter regulator,
increase pressure by turning it clockwise, while decrease pressure by turning it
anti-clockwise, and push the button to lock after reaching required pressure. The filter
of the regulator should be periodically cleaned to ensure air quality.Following the
below methods for cleaning: rotate and pull down the bayonet-type cup at the bottom
of regulator, and use neutral cleaning solution to wash strainer and cup. The filter
regulator adapts automatic water drainage mode, the water drain pipe should be
installed in proper position.
6.5.6.11 When the regenerative air flow is too high or too low, the regenerative air governor
valve should be adjusted, which is usually located at device top. rotate it one or two
rounds each time to adjust. After dryer is operated for one or two periods, conduct
adjustment according to actual situation.
6.5.6.12 During dryer regeneration, the pressure in regenerative drying tower should not
exceed 0.02MPa, otherwise, it will be deemed that the silencer is blocked if the valve
117
are in good condition. Then remove the silencer and clean up obstructions. Replace
those silencers that can not be cleaned up.
6.5.6.13 After a period of operation, the drying bed layer may sink slightly, so it is necessary to
check and make up or replace the desiccant timely, as required. Before filling the
desiccant, it should be screened: remove dust and select even particles.
6.5.6.14 Periodically inspect working conditions and seal states of all valves.
6.5.6.15 Periodically check to see if all electrical parts are with good contact, and frequently
clean the inside and outside dust of electric box.
6.5.7 Spare Parts
No. Name Model Unit Quantity
1 Bag filter strainer E9-48 Pcs
2 Strainer of oil removal filter E5-48 Pcs 1
3 Automatic drainer NAH-402 Pcs 1
4 Ball valve 1/2″ Pcs 1
5 Oil separation core B98262-173 Pcs 3
6 Oil filtration core A04425274 Pcs 3
7 Air filter 100012149 Pcs 3
8 Lube oil 92130280/20 Barrel 6
9 Fuse 4A Pcs 6
10 Fuse 1A Pcs 6
6.6 Maintenance for Double Color Water Level

6.6.1 Maintenance and Precautions for Water Level
6.6.1.1 The red and green glass of this level is arranged on one same glass frame with the
green inside and red outside. Do not install them reversely, or it will lead to wrong
judgment for water level with the steam indicated in green and water in red.
6.6.1.2 Mica seal components of water level must be periodically replaced and even have to
be replaced once for half year under normal indication condition, to prevent explosion
caused by leakage. Under special situation, if mica experiences severe scaling which
can not be cleaned, the mica seal also have to be replaced immediately. Meantime,
thoroughly clean the light source box, clean cold light lamb, red and green glass, so
as to ensure clarity and good transmittance.
6.6.1.3 Precautions for replacement of mica seal of water level
a) Close primary valve and secondary valve of water level and open drain valve.
Remove water level,and horizontally place it on working table or platform for
maintenance after cooling down in case of stud thread biting and break due to hot
expansion rate of level, stud and nut. Before disassembling nut and stud, first
spray loose liquid for full permeation. During disassembly, first make it vibrate
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repeatedly with outer force, and then loosen them gradually with more strength,
last, remove the nut. Do not remove by lengthening the sleeve or applying
excessive force at one time, which will lead to stud thread biting and break. Mark
all cover plates after they are removed for convenience of reinstallation.
b) When cleaning seal surface, pay attention not to scratching seal surface. seal
surface should be free from pit and groove trace, otherwise, it must be repaired
and processed.
c) Gland studs should be bright and clean without burr and disordered installations.
If there is elongation or deformation, replace them. If two of four studs on gland
are damaged, replace all studs. If the stud is broken, use driller to take it out
without damaging hole and thread. If nuts are wrongly installed with irregular
hexagon and uneven surface, replace them.
d) The sight glass, asbestos pad and terminal protection belt must be installed on
gland following regulated sequence. Strictly control sight glass prominence in
relative to gland seal surface. The prominent length must be in the range of
0.14mm—0.18mm. If it is longer than 0.18 mm, use file and sand cloth to adjust
asbestos pad thickness. Only when they are acceptable, can the seal ability and
service life be ensured.
e) The asbestos pad should be complete without fold and rip, and mica corner is
neat without peeling, crack and fold. Note: the seal components can only be used
once.
f) Install mica seal components according to top, bottom sequence. (The medium
contact side is at bottom.)
g) Reinstall gland based on marks made during disassembly. First manually tighten
nut, then diagonally fix nut with even force. Conduct four times tightening with
90N.m, 120N.m, 150N.m, 180N.m torque wrenches respectively. At last, tighten
all nuts again with 80N.m torque wrench by one operator, so as to ensure even
tightening force. The tightening sequence is diagonal tightening.
6.6.1.4 After one minor repair (one year) or disassembly of nut for 3-5 times, timely replace
new stud and nut to improve seal performance of water level and decrease
maintenance during normal operation.
6.6.1.5 Under normal condition, if the water level has been used for 4 years, it should be
replaced timely.
6.6.2 Maintenance Processes and Quality Standards of Water
Level
Table 6-14 Maintenance Processes and Quality Standards of Water Level
Maintenance
No. Processes and Precautions Quality Standards
Items
a) Use strong rope to hang the water
level meter on beam or pipe.
b) Remove the flange welded at boiler
1 Disassembly side, which connects water level and
valve.
c) Move water level along removing
direction and relieve its connection
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with flange.
d) Remove illuminator.
e) Disassemble terminal glands at both
ends of illuminator.
f) Manually remove bolts connected with
gland.
g) Remove screws of water level cover.
h) Remove cover.
i) Remove glass, lining belt and buffing
pad.
j) Remove surface and internal rust with
iron brush.
a) Check to see if outer bolt, bolt cap and
welding parts have severe
deformation and rust. If not severe,
cleaning with steel brush, otherwise,
replace it.
b) Check outer rusty condition, if there is
rust, apply one layer of paint on rusty
parts to avoid further deterioration.
c) Check rust conditions of inner and
outer surfaces. a) Bolt and bolt cap do not
d) Check liner contact surface of solution present such defects as
chamber. deformation, crack and
1) Check to see if there is corrosive spot. severe rust.
2) When there is leakage, check to see if b) Remove inner rust as far
there is erosion produced by steam as possible.
Spare parts
2 and hot water. c) If there is defect,
maintenance
3) Check to see if the pad has defect. eliminate with sand
e) Check to make sure the bolt and bolt paper or perform
cap have no crack and rust, and they mechanical process.
are properly engaged and easy of Replace the pad.
rotation. d) Replace those that have
f) Check ash accumulation on the glass defect.
of illuminator.
1) Loosen four screws at the bottom
plate of illuminator and extract the
mirror bracket.
2) Use soft brush to remove ash on
glass.
3) Use clean fine cloth dipped with
alcohol to clean glass.
4) Reinstall.
Assembly and a) Apply protection agent on bolt. a) No fingerprint on glass.
3
installation b) Apply protection agent on gland and b) Do not bend padding
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buffing pad contact parts. ring or leave fingerprint

c) Fill glass and pad to gland. on mica.
1) Install buffing pad, lining belt and glass
in sequence.
2) Touch to feel that they are higher than
the gland.
3) Clean the main body and use linen to
clean pad contact surface.
4) Install pad into water level in sequence
with seal pad first and mica pad next.
5) Install gland and bolt into water level
proper, and tighten bolt in diagonal
sequence.
6) Installation for opposite side should be
conducted as sequence 4-6.
7) Illuminator installation: use screw to
connect the illuminator with water level
proper through connection plate.
6.7 Maintenance for Boiler Wear-Resistance, Fire-Proof

and Insulating Materials
6.7.1 Refractory Inspection
6.7.1.1 Check the refractory to be free from falling off, looseness and serious cracks.
6.7.1.2 Check the forcers to be free from falling off and oxidation.
6.7.2 Refractory Construction
6.7.2.1 Clean the parts that need repairing and remove loose parts before refractory
construction.
6.7.2.2 The fixed forcers should be installed as the size and material given in the drawing.
6.7.2.3 The float coat should be smooth, with neat edges. Its flatness should not be more
than 3mm/m and the surface should be free from cracks in cold condition.
6.7.2.4 Directions for Mixing Refractory
a) The mixing of refractory is a very important step. It should be mixed by powerful
paddle mixer. Four bags of aggregate and one bag of bonding agent are
considered as one site mixing unit which should be filled with water about
50-55kg for each unit.
b) Before filling water, give dry mixing of materials for 30 seconds to eliminate the
particle segregation. The amount of water injected is of great importance for too
much water will prolong the coagulation process and reduce the mechanical
strength of the refractory and insufficient water will make it impossible to conduct
manual trowelling, resulting in low mechanical strength. Therefore, the water
required should be controlled within a certain range depending on the refractory
temperature which is in proportion to the water injected.
c) Conduct dry mixing of the materials for 30 seconds every time, then slowly fill
construction water to the mixture and measure it with a container with scale. Mix
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it for about 5-8 minutes. Excessive mixing will cause mixture overheat, shorten
the coagulation time, form quick setting cement, reduce construction strength
and heat insulation effect.
d) Note: the amount of mixing material should not exceed the amount that can be
used up within 40 minutes since water filling.
6.7.3 Refractory Removing
6.6.3.1 Special tools should be used to remove the refractory (such as hammer, chisel and air
pick)
6.6.3.2 Even force should be given during the disassembling, to avoid damage to pipes at
heating surface.
6.7.4 Preparations for Anti-wear and Heat Insulation Brick
6.7.4.1 Prepare the refractory and heat insulating material for the parts repaired for resume
according to manufacturer’s drawing.
6.7.4.2 The size and integrity of insulating brick should meet the relevant requirements in the
drawing.
6.7.5 Refractory Agitating
6.7.5.1 Use the specialized electrical agitating device to stir wear-resistant and heat
insulation mud.
6.7.5.2 The required mixing material must be calculated at each time in case of excessive.
6.7.5.3 The proportion of refractory adhesion should be prepared based on manufacturer
requirements.
6.7.6 Installation of Anti-wear and Heat Insulation Brick
6.7.6.1 The brick construction is performed based on manufacturer’s requirements.
6.7.6.2 Use trowel to smear the brick connection surface according to requirements.
6.7.7 Maintenance for Pipe Insulation
6.7.6.1 When medium temperature is lower than 450 ℃ , welding supporting part and
tightening supporting ring should be selected as support.
6.7.6.2 When support is not allowed to be welded directly on equipment or pipe, the
tightening ring should be used.
6.7.6.3 When support is directly welded on stainless steel pipe, stainless steel pad is
required.
6.7.6.4 Supporting surface width should be 10mm less than heat insulation layer. The space
between adjacent supports should be 1.5-2m.
6.7.8 Heat Insulation Maintenance for Furnace Outer Wall
6.7.8.1 Heat insulation layer and soft heat insulation material should be fixed by dowel and
self-locking tightening plate.
6.7.8.2 The dowel for heat insulation should made of carbon round steel.
6.7.8.3 Based on its physical dimension, the hook nail and dowel, installed in slit, should be
used as stake to fix heat insulation layer during heat insulation with insulation device.
During heat insulation with soft material, the space between adjacent dowels should
not exceed 350mm and the number of dowel not less than six per square meter at
side wall and eight at bottom wall.
6.7.8.4 When wall thickness is less than 4mm, conduct hook nail welding and fixation before
device leakage test.
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6.7.8.5 Carry out heat insulation layer installation from bottom to top, beginning with
supporting plate. The material thickness should meet design requirements and the
packing between slits should be sealed tightly. Each heat insulation material should
be bundled with at least two 14# galvanized iron wires, with well-proportioned space
and consistent tightness. The material consists of two or more layers should be
bundled layer by layer with same layer staggering each other and adjacent layer
having break joints. If there is hole, use small particles to stuff.
6.7.8.6 If there is no heat insulation supporting ring and welding is not allowed on site,
demountable ring can be fabricated.
6.7.8.7 When installing galvanized iron nets, two nets, which should be fastened firmly and
reliably to hook nails, should be welded by butt joint and firmly contacted against heat
insulation layer.
6.7.8.8 With construction completion, there should be free from broken iron end exposed on
iron net surface, bulging and empty layer. The iron net usually adopts open lap
galvanized iron net with 1.6mm diameter and 20mm×20mm net hole.
6.8 Boiler Maintenance

6.8.1 Boiler Maintenance in Normal Operation
6.8.1.1 Periodically check if following components have leakage: water level indicators,
valves, pipelines, flanges and so on.
6.8.1.2 Keep burner clean and governing system flexible.
6.8.1.3 Periodically remove water scaling inside boiler and flush with clean water.
6.8.1.4 Check inside and outside of boiler, if any serious corrosion is detected in pressurized
welding clearance and inside and outside of steel board, repair immediately; if the
defect is not severe, it can be repaired in next shutdown period. When suspicious
defects are found but won’t affect safety operation, just record them for reference in
future.
6.8.1.5 Outside shell and insulation layer can be removed for convenient inspection if
necessary. If some parts are severely damaged, do not use until they are repaired. At
the same time, record inspection and repair condition in boiler safety technical book.
6.8.2 Boiler Maintenance During Long-term Outage
Two maintenance methods: dry maintenance and wet maintenance. The first is used
when outage time is more than one month, while the second is is used when outage
time is less than one month.
6.8.2.1 Dry maintenance
After boiler is shut down, discharge water and remove inside dirty and scaling, then
flush with clean water. Next, dry the cleaning part with cooling air (compressed air).
Distribute quick lime with diameter of 10-30mm on different plates and put them into
boiler drum (make sure the quick lime has no contact with metal). The weight of lime
is calculated based on 8kg/m3 .in boiler drum. Close all manholes, handholes and
valves on pipeline and carry out inspection in every three months. If the lime becomes
powerdery lime, replace immediately. And the lime and plate should be taken out
when boiler is started again.
6.8.2.2 Wet maintenance
After boiler is shut down, discharge water and remove inside dirty and scaling, then
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flush with clean water. Refill water to the drum till it is full, and heat the water to 100℃
to exhaust air in the drum, then close all valves. Wet maintenance cannot be used in
the cold place to prevent boiler damage due to water freezing.
7 Maintenance for Boiler Valve and Pipe

7.1 Boiler Pipe
7.1.1 Main Steam Pipe and Main Feedwater Pipe
7.1.1.1 Two main steam pipes are led out from superheater outlet (one side one pipe), and
converge to one pipe before furnace, then divided into two branches before steam
turbine, which are separately connected to the left and right main steam valves of HP
casing.
7.1.1.2 Main feedwater pipe system is equipped with two electrical feedwater pumps with
pumping capacity of 100%, one for operation and the other for standby. Main passage
is equipped with only one electrical valve, while bypass is equipped with one
feedwater governor valve and two gate valves, so as to reduce throttle flow loss and
increase operation economy.
7.1.2 Welding and Hot Treatment for Alloy Steel with Middle and
Large Pipe Diameter
7.1.2.1 Preconditions before work
a) The welding should be conducted by the same one qualified operator, so as to
minimize the influence on welding quality due to human factors. During welding,
strictly conform to regulated parameters and make records by designated person.
b) The welding appearance inspection must be accepted and signed by welding
qualified inspector.
c) There are no flammable objects around working spot.
d) Scaffolding on working spot is stable and reliable enough to meet the standards.
e) Strictly control temperatures among layers during preheat welding. When
temperature reaches 400℃, inform operator to stop working. When temperature
decreases within the range of preheat temperature, inform operator to continue to
work.
a) Back Welded with Flux-cord Wire

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b) Back Welded with Solid Wire

Figure 7-1 Dimension of Bevels Back Welded with Flux-cord Wire and Solid Wire
7.1.2.2 Standards of bevel process and welding material
a) Bevel angle: flux-cord wire 27°±0.5, solid wire 30°±0.5
b) Clean bevel until it presents metallic luster. Use Polisher to remove iron rust and
dirt on inner and outer walls within the range of10-20mm, and polish until it has
metallic luster.
c) Interface-gap of flux-cord wire welding is in the range of 2.6-2.8mm.
d) Interface-gap of solid wire welding is in the range of 2.3-2.5mm.
e) Before welding, clean oil rust and dirt of wires until it shows metallic luster.
f) Use 350℃ constant temperature to dry electrode for 2 hours before using.
g) Mismatch amount: ﹤0.5mm.
h) Angle deformation: ﹤2°.
7.1.3 Pipe Color System
Table 7-1 Pipe Paint Color
No Medium Pipe Color
Ⅰ Steam Red
a Wet steam Silver with red and green strips
b Superheated steam Silver with red and white strips
c Exhaust steam Silver with red and black strips
Ⅱ Water Green
a Feedwater Green with red strip
b Condensate Green with yellow strip
c Cooling sea water Green with orange strip
Ⅲ Fuel oil and lube oil Brown
a Process air
b Control air source Blue
Ⅴ Water treatment
a Acid (hydrochloric acid ) Orange
b Alkali (sodium hydroxide) White
Ⅵ Vacuum Gray
7.2 Valve Maintenance

The valve is the control part of pipe flow conveying system, a device to change
passage section, medium flow direction and conveying medium movement, it has the
following functions: flow guide, check, adjustment, throttle, non-return, flow division or
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pressure relief under overload.

7.2.1 Electrical Valve Maintenance
7.2.1.1 Electrical valve disassembly
a) Mark corresponding valve body and valve cover, and open valve rod.
b) Remove and disassemble the transmission device.
c) Remove stuffing gland and clean padding.
d) Remove valve cover and clean padding.
e) Take out valve rod, remove valve head and take care of it.
7.2.1.2 Seal surface maintenance
a) Seal surfaces of valve head and seat are easy to be corroded and damaged. If pit
depth is shorter than 0.5mm, eliminate by griding. If the depth is above 0.5mm,
lathe first before grinding.
b) For valve connected by welding, it can only be grinded on site. In special
condition, disconnect lathe and then grind.
c) If the sealing surface has severe damage, repair in the manner of overlaying
welding. Depending on different seal surface material, the welding bar can adopt
‘overlaying welding 547’ alloy electrode or cobalt-base alloy electrode.
7.2.1.3 Valve body and seat maintenance
a) If the valve body has crack or sand hole, use mechanical method to eliminate and
then carry out repair welding.
b) If the valve seat welding has crack, conduct repair welding. Check valve stem
and measure it if necessary. If the bent is excessive, calibrate or replace it.
7.2.1.4 Packing and pad maintenance
a) During major and minor overhaul, the valve packing should usually be replaced.
Choose different packing based on valve type and specifications.
b) If the teeth of metal teeth-type pad experience deformation and poor seal,
replace the pad. Copper pad can be used for several times after washing and
anneal. Asbestos cushion should be replaced. During installation, the connection
surface and pad should be cleaned and smoothed with lead powder applied.
7.2.1.5 Valve maintenance precautions
a) Valve stem bent is less than 0.1-0.25mm, ovality is less than 0.2-0.25mm, and
rusting pit depth is less than 0.1-0.2mm.
b) Clearance between stuffing gland and stuffing box should be 15-20mm for
retightening, and valve stem clearance should be 0.1-0.2mm.
c) Stuffing ring interface angle is 45º and should be placed in stagger way with
angle of 180º. The black lead powder should be used.
d) After installation, conduct hydrostatic test for valve and proper supporting heating
surface.
7.2.1.6 Notices of self-seal valve maintenance
a) During disassembly, first remove the transmission device and its support, then
remove gland (use wheel puller if necessary). Take out the split ring from valve
circumferential hole with special tool, and at last take out valve cover and valve
stem.
b) The dimension and shape of expansion ring should meet diagram requirements.
The ring should be complete without damage, especially the sharp corner, or it
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will be difficult to be installed.

7.2.2 Relief Valve Maintenance
7.2.2.1 Precautions for valve maintenance
a) Relief valve adjustment should be conducted under the guidance of the
manufacturer. Personnel at site should work together under unite command. All
personnel for relief valve adjustment should carry out the safety technical
disclosure and make a sign.
b) Constructions are not allowed before the relief valve adjustment. Stability of each
fixed point must be confirmed before adjustment.
c) When adjusting steam pressure, the adjustment of combustion rate is considered
as rough adjustment and the adjustment of HP and IP bypasses is considered as
fine adjustment. Increase pressure slowly when it is close to relief valve
popping-up value.
d) Workers who set and operate relief valve must wear protective devices (to
prevent scald, noise, falling from high place etc.). Do not set the relief valves
when it is close to popping-up value.
e) When relief valve pops up and reseats, supervise water level of steam drum and
adjust the amount of feedwater timely to prevent high level or low level.
f) When leakage occurs during test running, isolate the area and hang warning
signs to prevent injury.
7.2.2.2 Set Procedures for Relief Valve
a) Set relief valves one by one from HP side to IP side.
b) During setting, pay attention to the change of steam pressure.
c) When steam pressure is up to about 80% of setting pressure, open relief valve
manually for purging. Conduct purging to each valve for about 5 minutes. Check
the discharging pipes of relief valves and the expansion, as well as installation
quality of other parts.
d) When steam pressure reaches about 85% of setting pressure, lower the screws
on the top of relief valves (which are not under commissioning) to make it
pressed against valve stem. Press the stem slightly so as not to bend the hot
valve disc and stem.
e) Manual opening devices must be assembled so as to exhaust steam during trial
test if necessary.
f) After purging, if the valve experiences leakage, it is possibly because there are
foreign matter accumulates on the sealing ring or the lower governing ring prop
against the disc. In this condition, decrease the steam pressure to 85% of setting
pressure and manually open valve for purging. If this does not work, leakage can
be stopped by manually rotating the governing stem clockwise, and lowering the
governing ring. If the leakage still exists, purge again. and fail again, disassemble
for maintenance.
g) Continue to increase pressure until the pressure is up to setting value, then relief
valve will pop up and at the same time achieve full travel. After discharging steam,
the pressure declines to make the valve reseat. If popping-up meets operation
requirements, hold down stem softly on the top of stem with screw and then
conduct commissioning to all relief valves orderly. After commissioning, reduce
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steam pressure to 80% of setting value, and restore all screw to their original
places, which are locked by self-provided lock. Adjust the the lead sealing of
stem up or lower and them put them into operation.
h) Whenever steam pressure is below 75% of setting pressure, do not lower the
screw but loosen the cover in reverse direction to keep hot disc from being
damaged by excessive pressing force.
i) Compare the result of commissioning with setting pressure on nameplate. If valve
pops up in advance, tighten the screw slightly clockwise. If valve does not pop up
at setting pressure, unscrew it slightly counter-clockwise to make it pop up.
j) If the relief valve fails to pop up when there is steam leakage under set pressure,
turn the adjusting rod counter-clockwise to make it pop up. Usually, adjust it for
semi-circle and a whole circle is the maximum. Regulate the adjusting ring for two
teeth while turning the adjusting rod for one turn.
k) When the blowdown pressure of relief valve is small or the valve pops up, adjust
the stem clock-wise to make the lower adjusting ring move downward. Do not
adjust it for more than 2 turns. If it failed, turn the upper adjusting lever to lower
the upper adjusting ring. In this way, the blowdown pressure will be increased so
that valve pop-up can be solved.
l) If the blowdown pressure of relief valve is big, turn the upper adjusting lever to
make the upper adjusting ring rise to reduce the blowdown pressure.
m) Adjust upper adjusting ring to regulate the blowdown pressure. It is best for us to
reduce the blowdown pressure under the condition of full travel. Usually, the
proper blowdown pressure can be obtained by lowering the upper adjusting ring.
Only when the proper blowdown pressure fails to be reached by regulating the
upper adjusting ring, can the adjusting sleeve be regulated. Turn the adjusting
sleeve clockwise to increase the back pressure of valve disc and reduce the
blowdown pressure. Do not regulate the upper adjusting lever for more than 5
turns each time. Regulate the adjusting sleeve within 1/4 turn.
n) A relief valve may pop up frequently while releasing gas or when it is ready to
close valve. Both of the two phenomena are caused by small blowdown pressure.
Do not reduce the pressure when it meets the requirements of operation. When it
pops up frequently along with gas releasing, solve it by lifting the position of
adjusting sleeve or lowering the upper adjusting ring which can increase
blowdown pressure. If it pops up frequently because the valve is ready to be
closed, lower the low adjusting ring.
o) If there is slight leakage after disc reseats, purge manually to remove the foreign
matter. If the leakage still exists, lower the pressing screws to pin against the
stem and even the disc temperature to stop leakage. If failed again, grind sealing
surface.
p) It is not necessary to adjust small error between popping pressures and reseat
pressure. Try to reduce times of adjustment. Adjust in every half an hour when
the temperature of all the parts drops to a stable value. .
q) When setting relief valves, take records of the following items timely: pressure,
temperature and expansion of boiler, water level of steam drum, popping
pressure, reseat pressure and time etc.
r) Sign witness report after the settings of all relief valves meet the requirements.
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7.2.2.3 Procedures for disassembly inspection

a) Remove rod jaw pin, rod jaw, bonnet, stem nut cotter pin and stem nut.
b) Ring setting record. Remove fixing nut in nozzle ring and check its location.
Nozzle ring settings are done by removing lifting device and identifying the
number marked on bonnet processing surface which perches on the lifting
device.
7.2.2.4 Maintenance Techniques & Quality Standards of Safety Valve
Table 7-2 Maintenance Processes & Quality Standards of Safety Valve
Maintenance
No. Techniques & Precautions Quality Standards
Items
a) Prepare the hoisting tools and
special tools.
Preparations
b) Mark components
1 Before
correspondingly.
Maintenance
c) Check pressure of steam
header.
a) Saw through drainage pipes of
safety valve.
b) Remove flange screws of
steam exhaust pipes and clean
the joint surface of flanges. a) Screw and screw cap should
c) Remove the screws connecting be complete.
2 Disassembly
flange of steam header and b) Material & specifications
main valve. Clean and send it should meet the standards.
for metallographic examination.
d) Lift out the whole safety valve
and send it to maintenance
room.
a) Disassemble rod jaw pin, rod a) Spring surface should be
jaw, bonnet, stem nut cotter pin smooth without cracks.
and stem nut. b) Bearing on both sides of
b) Ring setting record. spring must be parallel with
1) Disassemble the fixing nut of each other, whose axial
nozzle ring, and check its verticality with shaft center
location. The setting of nozzle should be smaller than
ring is achieved through 1.5mm.
Disassembly
3 removing lifting device and c) Heat retreatment hardness
Maintenance
identifying the number marked (HRC) =45.50.
on bonnet processing surface d) The misalignment of spring
which perches on the lifting inner and outer circle should
device. be smaller than 0.5mm.
2) Remove the fixed nut on e) Casing surface should be
adjustment ring. smooth, without rust, crack,
c) Remove spring without scratch etc. Surface
changing its compression. roughness is above 0.16.
129
1) Disassemble the paddle, rod f) Junction surface of valve

jaw and screw cap seat, valve case is smooth
2) When removing the fixed nut of and clean, without corrosion,
adjustment ring, the adjustment or cracks. Roughness of
ring should be rotated left or surface should be above
right as required. When the 0.18mm.
bottom surface of adjustment g) Sealing contact of valve sea
ring and disk or disk seat is on and valve plug is
the same level, the adjustment well-distributed, and the
ring is in horizontal location. width is no less than 2/3 of
The location of adjustment ring the sealing surface. Make
is recorded by the teeth number sure it is free from defects.
of negative (-) downward or h) Appearance of valve body:
positive (+) upward from the no sand hole no cracks.
horizontal position. l) Inspection of spring:
3) Measure the distance from the appearance has no layers,
bottom surface of bottom spring and the surface of two
gasket to the top surface of terminals is vertical to the
bonnet flange, and record its central line of spring. The
size. Then cut the length of appearance and size should
three pieces of steel bars which meet the requirements of
are 1/8 inch longer than record technical documents.
size as sizing block. j) Inspect the junction surface
4) Load the jack and lift stem then of disk and valve seat with
fit into the sizing block. color printing which should
5) Put away hydraulic jack then lift be in good joint conditions
out the upper part of valve body and no pit or groove.
carefully.. k) Check the bend of stem with
6) Put the upper part in horizontal dial indicator, which should
position. Caution not to damage be smaller than 0.1/1000.
the components. l) Check the clearance of all
7) Take out the inner parts parts by feeler and caliper.
cautiously. As one assembly, Make sure it meets the
parts like disk seat, disk, guide requirements.
holder, guide ring and stem
should be separated from
spring and bonnet.
d) Remove spring without holding
its compression.
1) Remove the fixed screw of
adjustment ring and the fixed
screw nozzle ring.
2) Measure the surface distance
from the top of compressing nut
to machining bonnet, and make
130
records for reassembly.

3) Unscrew compressed nut, and
loosen spring.
4) Remove the bonnet screw nut.
5) Vertically hoist the spring and
bonnet assembly over the stem.
6) Remove disk seat, disk, guide
seat, guide ring and stem from
the valve body.
a) Check whether the disk and
sealing surface of valve seat
has pit, groove, and cracks. If
a) Surface should be grinded
the defect is serious, perform
when it is horizontal.
lathe processing or welding
b) Grinding plate must be
(Conduct heat treatment if
processed precisely, whose
Grinding for necessary.) before
end face should be even.
4 Sealing refashioning. Grind if it
c) Sealing roughness should be
Surface experiences common faults.
above 0.5. The contact area
b) Valve core should be grinded by
of joint surface should be
grinding miller. Valve seat is
more than 2/3, without radial
fixed by plate and grinded by
cracks.
abrasive paper, which should
be checked at any time. Correct
it timely when grinding deviates.
a) Clean all components and
install them in the reversed
sequence of disassembly. a) Reassemble the parts
b) When assembling, tighten the carefully. Do not miss any
nuts for disk and stem, stem part or install it incorrectly.
and draw rod, firmly seal lock b) Do not damage the sealing
pad. surface when assembling.
c) When installing the casing c) Apply lead powder oil on
5 Assembling
cover, manually check the draw screw thread. Fasten the
rod is flexible, without jamming. diagonal screws with even
Then reassemble the spring force. Keep the same
which should be tightened to clearance around flange.
the original position. d) Stroke of piston is around
d) The packing material should be 20mm.
filled properly, neither too tight
nor loose..
a) Check if there are foreign a) The size of tooth pad is
Place main objects in steam header, and proper and is not deflective.
6 valve in right clean junction surface of flange, b) Apply lead powder oil on
position. then put tooth pad into the inlet bolts evenly. Keep the same
flange. clearance around flange.
131
b) Hoist the installed safety valve

to its position, and put them
back according to the original
marks.
c) Apply acceptable lead powder
oil on bolts and fasten them
evenly.
d) Weld the pulse lines which are
cleaned by washing.
8 Thermal Mechanical Work Permit

8.1 Responsible person who fills the permit
Work group members who fill the permit
Fill in task descriptions, locations, and scheduled time.
Fill in safety measures necessary, such as cut off power, isolate system, etc.
Fill in the control measures for hazardous points
After finishing the work permit content, hand it over to Issuing personnel.
After issuing, the work permit will be handed over to shift leader for permission.
The work will be performed after work approver approves the work permit..
Perform following affairs after work is finished.
Apply for extension if work is not finished in permitted duration.
8.2 Reasons to Perform Work Permit
The work permit is used to better maintain working order during daily operation,
reduce equipment damage and ensure employee safety..
Strictly obey the work permit regulations means to carry out measure during operation
process. Measures in the work permit, such as power supply cutoff, power testing,
isolation, discharging, purging, cleaning, maintenance and other works are called
technical measures or safety testing made to ensure personnel and equipment safety.
8.3 Purpose
Be clear about the organizations and responsibilities.
Raise the tasks and make relevant safety measures.
Specify working scope and time.
8.4 Rules for Application

Work permit is necessary in each inspection, maintenance, test and other works.
All the divisions should control the management of work permit conduction process.
Everyone should work with the work permit.
The application and management of work permit should be standardized while the
procedures should be fixed.. In this way, safe operation performance can be improved.
After work permit standardized, how to input the content and use the work permit
correctly will be the substance for personnel training.
132
8.5 Hot Work Permit Classifications

Level 1 hot work area: It means places where fire will probably happen and will cause
severe result, such as fuel oil bunker (cylinder), fuel oil pump and fuel oil system,
transformer, cable room, channel, oil port, chlorine station, hydrogen system, turbine
oil system, battery room, control room, dispatching room, flammable & explosive
material storage area and other areas and sites confirmed as level 1 hot work area by
power generating enterprises.
Level 2 hot work areas: when hot work needs to be carried out, use level 2 hot work
permit and the valid duration is 7 days.
When the hot work belonged to level 2 hot work classification is performed initially,
personnel for approving and issuing hot work permit from all departments should go to
the site to check whether firefighting measures are correctly done, flammable gas
content or dust concentration of flammable gas and flammable fluid is acceptable or
not. Also carry out flame test with the under supervision, make sure there is no
problem, and then perform the hot work.
When performing level 2 hot work, designated personnel should supervise on site
through the whole process. Before next day’s hot work, recheck the firefighting safety
measures, and check to make sure combustible gas content or dust concentration of
combustible gas and flammable fluid is acceptable then start the work.
Apart from the level 1 hot work area, all key fire-fighting areas and places where open
flame is forbidden are level 2 hot work areas.
When hot work needs to be carried out in level 1 area, level 1 hot work permit is a
necessity.
The valid duration of level 1 hot work permit is 48 hours. During level 1 hot work
process, test the flammable gas and dust concentration every 2-4 hours (if the hot
work interval exceeds 4 hours, carry out the test every time before hot work start). If
abnormal symptom appears, stop the work immediately. Don't start the hot work until
causes are found or faults are eliminated. The test result for the first time should be
filled on the permit and the results tested later should be attached in work permit. The
format should be the same.
Thermal mechanical work permit: When carrying out maintenance or installation on
site, in order to guarantee safety working conditions and operation, all departments of
power plant should strictly obey the work permit regulation to avoid accidents.
For the whole unit maintenance, apart from responsible person of every shift, one
leader of relative field should be designated for all maintenance work. The thermal
mechanical work permit must be signed by field director or vice director, or the work
permit can be proposed by field director and then signed by personnel designated by
plant leaders. Work permit signed by other personnel is considered to be invalid.
Only after getting shift leader’s permission and operator has taken effective protection
measures, can maintenance operator start work.
8.6 Safety Responsibilities of Permit Issuing Person

To determine whether the work is necessary and can be performed; whether the work
will be performed in accordance with analysis of hazardous points..
Make sure that safety measures and control measures for hazardous points are
133
correct and complete.

Make sure the number of responsible person and members as well as technicians of
work group is sufficient; and the work can be performed safely. .
8.7 Safety Responsibilities of Responsible person

Organize work correctly and securely.
Before work, convene and preside over the hazardous points analyzing and control
measures planning based on working contents.
Before work, discuss precautions with working group personnel.
Provide necessary guidance for working group personnel.
Check to make sure that working group members obey safety operation code and
beware of the safety measures at all times. .
Check to make sure if the safety measures listed in work permit are correct and
complete; whether safety measures taken by operators match with site practical
safety conditions.
Correctly carry out ‘self-maintenance’ safety measures, and restore the site after
work.
During work organization, the work responsible person should pay much attention to
working personnel’s physical and psychological conditions, which should be taken as
the first influencing factor.
8.8 Safety Responsibilities of Team Members

Before starting the work, study Power Industry Safety Code as well as relevant rules
and requirements in Operation and Maintenance Technological Regulations.
Participate in hazardous points analysis of the team and raise control measures;
Be familiar with and strictly perform the control measures in Hazardous Points Control
Measures to specify the operations and ensure personnel and equipment safety.
Supervise the performance of Power Industry Safety Code, site safety measures and
control measures.
8.9 Safety Responsibilities of Work Licensor

Check all measures listed in the work permit to ensure they are correct and complete.
Also, these measures should meet the safety conditions on site.
Conduct all safety measures listed on work permit and one should be responsible for
safety measures which are carried out by oneself.
Make sure all safety measures have been carried out correctly. Also, ensure
maintenance equipment and operation equipment has been separated.
Remind responsible person of the equipment with voltage, pressure, high temperature,
explosive danger and dangerous factors in working area.
For the safety measures for maintenance self-management, organize operator to
carry out accident prediction.
8.10 Safety Responsibilities of Shift Supervisor

Be responsible of confirmation of the necessity of work; and ensure actual
134
maintenance duration matches approved duration; safety measures listed in work

permit are correct and complete.
Be fully responsible for approved maintenance duration, work permit content as well
as safety measures.
Will not approve work permit without hazardous points control measures (except
thermal mechanical, I&C and hydraulic mechanical work permits) and operation
permit.
8.11 Problems during Work Permit Application Process

Personnel still fail to have a clear understanding of the principles, functions, aims and
range of work permit; perform work without work permit, unfamiliar with work permit
regulations and unable to understand management standards,;fail to implement it
seriously..
Work permit content is not input properly; without clear work tasks and complete
safety measures. Thus the acceptable rate of work permit is low.
Responsible person fails to perform his duty while responsible person and permitting
person fail to confirm safety measures on site. The on site acceptance after work
permit is finished becomes mere formality.
Work permit calculation and analyzing is not up to standards and the safety
supervision personnel fail to perform their duties.
8.12 Safety Rules for Personnel on Site

When working, do not damage the overall equipment. Protect it well.
Wear safety helmet properly before entering the construction site.
Safety belt is a must for personnel working at a certain height, which should be hung
on the fixed structure over head.
When working at a certain height, do not drop objects from height.
Do not smoke on site. Go to the designated place for smoking.
Do not work after drinking.
Do not wear high-heel, slippers or sandals when working at high place.
Operators should concentrate on operation. Do not enter operating room without
permission.
Reading or chatting is not allowed while performing duties. Shut the window and cut
off power supply before leaving.
Check the electric tools are free from leakage and the power wirings are not damaged
before using them.
Personnel who weld and cut will only take his post after trained to be qualified
Do not walk on the beam.
135

Boiler Maintenance

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Boiler Maintenance

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PLTU Nagan Raya NAD 2X110MW

Boiler Maintenance Manual

PT.PLN (PERSERO) JASA ENJINIRING

SINOHYDRO CORPORAION LIMITED

SHAANXI NORTHWEST POWER GENERATION CO., LTD

File Number YNYQ-01-21-006-A/2

Contract No. SAC/HTB/SC/060/11

Boiler Maintenance Manual

Sinohydro Corporation Limited

Shaanxi Northwest Power Generation Co., Ltd

Final edition approved by Edition

3.6.1 Paprameters of Water Cooling Barrel Slag Cooler .............................................................. 15

4.3.1 Maintenance Items for Low-temperature Superheater ........................................................ 42

5.2.5 Common Faults and Solutions ............................................................................................... 72

8.11 Problems during Work Permit Application Process ......................................................... 135

1 Boiler Main Design Parameters

Center line elevation of boiler drum mm 47200

Highest point elevation of boiler (upper elevation of roof) mm 53300

Operating layer elevation mm 9000

1.2 Main Technical Parameters of Boiler

Steam flow t/h 430

First stage desuperheated water flow t/h 17.96

Second stage desuperheated water flow t/h 14.55

Steam drum pressure MPa 10.8

Outlet pressure of superheater MPa 9.81

Inlet temperatre of economizer °C 234

Steam temperature of superheater °C 540

1.3 Furnace Water Wall Loop Characteristics

Number of steam and water

1.4 Flue Gas Temperature of Boiler

Coal Design coal Verified coal

Furnace outlet °C 890 886

Economizer outlet °C 291.5 280.8

Steam-cooled separator outlet °C 886 881

LT superheater outlet °C 511.8 469.4

Platen superheater outlet °C 890 886

HT superheater outlet °C 711 676

Air prehetare outlet °C 141 136

1.5 Fuel Coal Analysis

As-received ash content Aar % 5 6

Onet.ar Kcal/kg 3620 3395

As received basis carbon Car % 44.33 38.35

As-received basis hydrogen Har % 3.71 1.77

As-received basis oxygen Oar % 15.06 17.7

As-received basis nitrogen Nar % 0.73 0.32

As-received basis total sulfur St.ar % 1.17 1.3

Grindability index HGI 50 65

Deformation temperature DT 0C 1050

Softening temperature ST 0C 1100

Hemisphere temperature HT 0C 1150

Fluidizing temperature FT 0C 1200

1.6 Ignition and Combustion Aiding Oil

1 Specific weight Kg/m3 815～870

2 Dynamic viscosity（37.8°C） mm2/sec 3.6～5.8

3 Flash point °C ≥60

4 Sulfur content %wt Max 0.5

5 Moisture content %Vol Max 0.05

6 Ash content %wt Max 0.01

7 Low heat calorific value Kcal/kg 10140

2 Boiler Main Equipment Structure

2.2 Steam Drum

2.4 Water Level Monitoring Device

2.6 Superheater and Temperature Regulating System

Figure 2-1 Superheated Steam Flow