Soot Blower PDF

1
IK545 CONTENTS
SECTION TITLE PAGE
1 GENERAL DESCRIPTION 19
1.1 General 19
1.2 Opening Controls 19
1.3 Application 19
1.4 Cleaning Principle 19
1.5 Operating Cycle 20
1.6 Identification 20
2 COMPONENT DESCRIPTION 21
2.1 ELECTRICAL 21
2.1.1 Electrical Components 21
2.1.2 Function 21
2.2 MOUNTING 23
2.2.1 Beam 23
2.2.2 Front Support Plate 23
2.2.3 Wallbox 24
2.2.4 Pressure Regulating Valve (When Applicable) 24
2.2.5 Rear Support 25
2.2.6 Auxiliary Support 26
2.3 MECHANICAL 26
2.3.1 Carriage 26
2.3.2 Electric Drive Motor 27
2.3.3 Expanda Cable 27
2.4 BLOWING MEDIUM 28
2.4.1 Poppet Valve 28
2.4.2 Poppet Valve Operation 29
2.4.3 Air Relief Valve 30
2.4.4 Feed Tube 30
2.4.5 Lance Tube 31
2.4.6 Nozzle 31
2.5 OPERATING SWITCHES 32
2.5.1 Limit Switches / Pressure Switch 32
2.6 MANUAL OPERATION 33
2.6.1 Emergency Retract Air Tool 33
3 INSTALLATION INSTRUCTION 34
3.1 Location 34
3.2 Mounting 34
3.3 Lifting the Sootblower 34
3.4 Blowing Medium Supply Pipework 34
3.5 Scavenging Air 34
3.6 Lubrication 35
3.7 Electrical Connections 35
2
IK545 CONTENTS (Continued)
SECTION TITLE PAGE
4 COMMISSIONING 36
4.1 Stage 1 - Inspection 36
4.2 Stage 2 - Functional Checks 36
4.3 Stage 3 - Pre-Operational Checks 36
5 OPERATION INSTRUCTIONS 38
5.1 Operation Precautions 38
5.2 Blowing Schedule 38
6 MAINTENANCE INSTRUCTIONS 39
6.1 Operational Checks 39
6.2 Periodic Inspection 39
6.3 Annual Maintenance 39
6.4 Major Overhaul 40
6.5 Manual Operation 40
7 LUBRICATION 41
7.1 Initial Operation 41
7.2 Carriage Assembly 41
7.2.1 Gearbox 41
7.3 Lance Hub 41
7.4 General Lubrication 41
7.4.1 Grease Fittings 41
7.4.2 Bolt Heads and Threads 41
7.5 List of Recommended Lubricants 41
8 MAINTENANCE SCHEDULE 43
8.3 Routine Maintenance 43
9 OPTIONAL TOOLS 45
10 PARTS IDENTIFICATION 55
11 RECOMMENDED SPARES LIST 97
12 JOB SHEETS 101
13 FAULT FINDING 160
3
IK545 CONTENTS (Continued)
SECTION TITLE PAGE
14 STORAGE, HANDLING, & INSPECTION DURING STORAGE 163

14.1 STORAGE 163
14.1.1 Initial Receipt At Site 163
14.1.2 Stacking Sootblowers 163
14.1.3 Feed Tube and Poppet Valve Packing 163
14.2 HANDLING 163
14.2.1 Handling Packed Equipment 163
14.2.2 Handling Unpacked Equipment 164
14.3 INSPECTION DURING STRAGE 164
14.3.1 Frequency 164
14.3.2 Protective Lubrication 164
4
IK545 ILLUSTRATIONS
FIGURE TITLE PAGE
1 IK - 545B Sootblower - Overall View 18

2 Nozzle Cleaning Pattern 19
3 Electrical Components - Schematic Diagram 21
4 Front Support Roller Arrangement 23
5 Wallbox 24
5A Sealing Air Connection (Positive Pressure) 24
6 Rear Support Arrangement 25
7 Auxiliary Support 26
8 Carriage Operation 26
9 Expanda Cable Operation 27
10 Poppet Valve 28
11 Popper Valve Linkage 29
12 Air Relief Valve 30
12A Feed Tube Packing Arrangement 30
13 Operating Switches 32
14 Emergency Retract Air Tool 33
15 Checking the Blowing Pressure 37
16 Location of Square Tang for Manual Operation 40
17 Typical Slinging Arrangement 164
5
IK1M CONTENTS
SECTION TITLE PAGE
1 GENERAL DESCRIPTION 174

1.1 General 174
1.2 Operating Controls 174
1.3 Application 175
1.4 Cleaning Principle 175
1.5 Operating Cycle 175
1.6 Identification 175
2 COMPONENT DESCRIPTION 176

2.1 ELECTRICAL 176
2.1.1 Electrical Components 176
2.1.2 Function 176
2.2 MOUNTING 178
2.2.1 Beam 178
2.2.2 Front Support 178
2.2.3 Wallbox 178
2.2.4 Rear Support 179
2.3 MECHANICAL 180
2.3.1 Carriage and Drive Mechanism 180
2.3.2 Guide Assembly 180
2.3.3 Leadscrew 181
2.4 BLOWING MEDIUM 182
2.4.1 Poppet Valve 182
2.4.2 Poppet Valve Operation 183
2.4.3 Air Relief Valve 183
2.4.4 Feed Tube 184
2.4.5 Lance Tube 184
2.4.6 Lance Tube Support 185
2.4.7 Element / Nozzle / Rake Arrg’t 185
2.5 OPERATING SWITCHES 186
2.5.1 Limit Switches 186
2.6 MANUAL OPERATION 186
3 INSTALLATION INSTRUCTION 187

3.1 Location 187
3.2 Mounting 187
3.3 Lifting the Sootblower 187
3.4 Blowing Medium Supply Pipework 187
3.5 Lubrication 187
3.6 Electrical 187
6
IK1M CONTENTS (Continued)
SECTION TITLE PAGE
4 COMMISSIONING 188
4.1 Stage 1 - Inspection 188
4.2 Stage 2 - Functional Checks 188
4.3 Stage 3 - Pre-Operational Checks 188
5 OPERATION INSTRUCTIONS 190

5.1 Operating Precautions 190
5.2 Blowing Schedule 190
6 MAINTENANCE INSTRUCTIONS 191

6.3 Annual Maintenance 191
6.5 Manual Operation 192
7 LUBRICATION 193
7.1 Carriage 193
7.2 Drive Chain 193
7.3 Leadscrew and Square Shaft 193
7.4 General Lubrication 193
8 MAINTENANCE SCHEDULE 195

8.3 Routine Maintenance 195
9 OPTIONAL TOOLS 197
10 PARTS IDENTIFICATION 205
11 RECOMMENDED SPARES LIST 231
12 JOB SHEETS 234
13 FAULT FINDING 279
7
IK1M CONTENTS (Continued)
SECTION TITLE PAGE
14 STORAGE, HANDLING, & INSPECTION DURING STORAGE 282

14.1 STORAGE 282
14.1.1 Initial Receipt At Site 282
14.1.2 Stacking Sootblowers 282
14.1.3 Feed Tube and Poppet Valve Packing 282
14.2 HANDLING 282
14.2.1 Handling Packed Equipment 282
14.2.2 Handling Unpacked Equipment 283
14.3 INSPECTION DURING STORAGE 283
14.3.1 Frequency 283
8
IK1M ILLUSTRATIONS
FIGURE TITLE PAGE
1 IK1M Sootblower - Overall View 173

2 View on Rear of IK1M looking towards Boiler 174
3 Cleaning Pattern 175
4 Electrical Components-Schematic Diagram 176
5 Front Support Arrangement 178
5A Scavenging Air Arrangement 179
5B Adjustable Rear Support 179
6 Drive Arrangement 180
7 Guide Assembly 181
8 Leadscrew Arrangement 181
9 Sectional View of Popper Valve 182
10 Poppet Valve Linkage 183
11 Air Relief Valve 183
12 Feed Tube and Packing 184
13 Lance Tube Support 185
14 Limit Switch Operation 186
15 Square Tang for Manual Operation 186
16 Checking the Blowing Pressure 189
17 Manual Operation 182
18 Typical Slinging Arrangement 283
9
INSTRUCTION MANUAL
DIAMOND IK-545B
SOOTBLOWER
ELECTRIC MOTOR DRIVEN
(Customised to suit) Contract No. N10865
IM123
Diamond Power Specialty Limited

Glasgow Road Dumbarton Scotland G82 1ES
Tel: Dumbarton (01389) 744000 Fax: Dumbarton (01389) 762669
FORM 14164
10
EQUIPMENT IDENTIFICATION FORM
Diamond Contract No :- N10865
Customer Order No :- 07461-49100-A610-00
Blowing Pressure :- 12.9 kg/cm2 (2nd SH Inlet))

12.6 kg/cm2 (2nd SH (HT) Outlet)
10.0 kg/cm2 (2nd SH (LT) Outlet)
Equipment Supplied :- 27 - Diamond IK545B (Electric Motor Driven)

Long Retractable Sootblower.
Site :- Rabigh, Saudi Arabia
POSITION SERIAL UNIT CUSTOMER TAG

No No No No
LSB A B66494 1 B1HCB01AN301
LSB B B66495 1 B1HCB01AN302
LSB C B66496 1 B1HCB01AN303




NOTE
When ordering Instruction Manuals for the above equipment please quote
the Diamond Contract number and the following I.M. number:-123
(PAGE 1 of 2) FORM 13519
11
Blowing Pressure :- 12.9 kg/cm2 (2nd SH Inlet))

12.6 kg/cm2 (2nd SH (HT) Outlet)
10.0 kg/cm2 (2nd SH (LT) Outlet)
Equipment Supplied :- 27 - Diamond IK545B (Electric Motor Driven)

Long Retractable Sootblower.
POSITION SERIAL UNIT CUSTOMER TAG

No No No No



NOTE
12
------ IMPORTANT ------
READ THIS MANUAL

BEFORE
COMMISSIONING OPERATING
INSTALLING MAINTAINING
THIS EQUIPMENT
WARNING
This equipment may be operated by remote control
WARNING
Isolate from power and blowing medium supply before working on

equipment
WARNING
To avoid personal injury or damage to equipment during installation,

commissioning, operation or maintenance, follow the instructions given
on the Job Sheets.These instructions are of a general nature and do
not cover every circumstance.
WARNING
To maintain the safety and efficiency of the equipment, follow the maintenance
schedule instructions and use only Diamond Spare Parts as described in the
Parts Identification and Recommended Spares sections of the manual.
OCTOBER 1993 FORM 14148
13
CONTENTS
SECTION TITLE
1 GENERAL DESCRIPTION
1.1 General
1.2 Operating Controls
1.3 Application
1.4 Cleaning Principle
1.5 Operating Cycle
1.6 Identification
2 COMPONENT DESCRIPTION
2.1 ELECTRICAL
2.1.1 Electrical Components
2.1.2 Function
2.2 MOUNTING
2.2.1 Beam
2.2.2 Front Support Plate
2.2.3 Wallbox
2.2.4 Pressure Regulating Valve (When Applicable)
2.2.5 Rear Support
2.2.6 Auxiliary Support
2.3 MECHANICAL
2.3.1 Carriage
2.3.2 Electric Drive Motor
2.3.3 Expanda Cable
2.4 BLOWING MEDIUM
2.4.1 Poppet Valve
2.4.2 Poppet Valve Operation
2.4.3 Air Relief Valve
2.4.4 Feed Tube
2.4.5 Lance Tube
2.4.6 Nozzle
2.5 OPERATING SWITCHES
2.5.1 Limit Switches / Pressure Switch
2.6 MANUAL OPERATION
2.6.1 Emergency Retract Air Tool
3 INSTALLATION INSTRUCTIONS
3.1 Location
3.2 Mounting
3.3 Lifting the Sootblower
3.4 Blowing Medium Supply Pipework
3.5 Scavenging Air
3.6 Lubrication
3.7 Electrical Connections
OCTOBER 2002 (PAGE 1 OF 3) FORM 14274
14
CONTENTS (Continued)
SECTION TITLE
4 COMMISSIONING
4.1 Stage 1 - Inspection
4.2 Stage 2 - Functional Checks
4.3 Stage 3 - Pre-Operational Checks
5 OPERATING INSTRUCTIONS
5.1 Operating Precautions
5.2 Blowing Schedule
6 MAINTENANCE INSTRUCTIONS
6.1 Operational Checks
6.2 Periodic Inspection
6.3 Annual Maintenance
6.4 Major Overhaul
6.5 Manual Operation
7 LUBRICATION
7.1 Initial Operation
7.2 Carriage Assembly
7.2.1 Gearbox
7.3 Lance Hub
7.4 General Lubrication
7.4.1 Grease Fittings
7.4.2 Bolt Heads and Threads
7.5 List of Recommended Lubricants
8 MAINTENANCE SCHEDULE
8.3 Routine Maintenance
8.4 Major Overhaul
9 OPTIONAL TOOLS
10 PARTS IDENTIFICATION
11 RECOMMENDED SPARES LIST
12 JOB SHEETS
13 FAULT FINDING
15
SECTION TITLE
14 STORAGE, HANDLING, & INSPECTION DURING STORAGE

14.1 STORAGE
14.1.1 Initial Receipt At Site
14.1.2 Stacking Sootblowers
14.1.3 Feed Tube and Poppet Valve Packing
14.2 HANDLING
14.2.1 Handling Packed Equipment
14.2.2 Handling Unpacked Equipment
14.3 INSPECTION DURING STORAGE
14.3.1 Frequency
14.3.2 Protective Lubrication
16
ILLUSTRATIONS
FIGURE TITLE
1 IK-545B Sootblower - Overall View

2 Nozzle Cleaning Pattern
3 Electrical Components - Schematic Diagram
4 Front Support Roller Arrangement
5 Wallbox
5A Sealing Air Connection (Positive Pressure)
6 Rear Support Arrangement
7 Auxiliary Support
8 Carriage Operation
9 Expanda Cable Operation
10 Poppet Valve
11 Poppet Valve Linkage
12 Air Relief Valve
12A Feed Tube Packing Arrangement
13 Operating Switches
14 Emergency Retract Air Tool
15 Checking the Blowing Pressure
16 Location of Square Tang for Manual Operation
17 Typical Slinging Arrangement
NOVEMBER 1999 FORM 14275
17
SECTION 1
FORM 15018/1 JULY 1999
18
SECTION 1
SECTION 1
GENERAL DESCRIPTION
Introduction
This instruction manual covers the IK-545B long retractable sootblower supplied by
Diamond Power Specialty Limited; the main features are illustrated in Fig.1.
1.1 General
The IK-545B is a fully-retractable sootblower incorporating a travelling carriage and
dual rack-and-pinion drive. Power is transmitted, through an expanding cable
arrangement, from a fixed power connection on the beam to an electric motor on
the carriage. The motor moves the carriage to project a cleaning nozzle into the
boiler. Blowing medium flow is controlled by an integral poppet valve, which is
mechanically operated by the carriage.
The IK-545B sootblower is normally operated from a remote control panel or from
an individual starter box. Alternative controls are available to suit specific
applications. Upon completion of the cleaning cycle, the controls automatically
reset ready for the next cycle. No further action is required by the operator unless
a fault develops. A manual override allows the sootblower to be retracted at any
point in its forward travel.
Additional information on the operating controls is given in Section 2.
1.3 Application
The IK-545B is designed for cleaning the heating surfaces of the boilers fired with
ash-producing fuels, and is used principally to remove slag and ash deposits from
slag screens, superheaters, reheaters, and economisers. It is also used to clean
deposits from the underside of furnace arches.
The Model IK-525B is supplied for travels over 7.6m (25ft) and up to 13.7m (45ft)
1.4 Cleaning Principle (Fig.2)
The basic function of the sootblower is to clean the heating surfaces of the boiler
by the impact energy of high-pressure air, or steam, which is delivered from two
opposing nozzle openings located at the end of a translating and rotating lance
tube.
FIG.2 CLEANING PRINCIPLE
The lance tube advances on a 100 mm (4 in.) helix; therefore, the opposing nozzle
openings provide cleaning at 50 mm (2 in.) intervals.

19
SECTION 1
1.4 Cleaning Principle (Fig.2) (Continued)

A 25 mm (1 in.) shift of blowing pattern for reverse travel bisects the blowing
pattern for forward travel, thus producing a cleaning helix every 25 mm (1 in. )
Other helices are available for specific applications.
1.5 Operating Cycle
The operating cycle begins with the unit in the retracted position. When power is
applied to the electric motor, the carriage moves forward by rack-and-pinion drive
to project the lance tube into the boiler. When the nozzle is inside the boiler, the
carriage operates a cam which, in turn, opens the blowing medium valve to start
the cleaning operation. The carriage then continues to project the rotating lance
tube into the boiler until it reaches its extreme forward travel. At this point, the
carriage reverses its direction and, at the same time, indexes the lance tube to
return on a different nozzle path.
The carriage continues to retract until the nozzle is near the boiler wall, at which
point the blowing medium is shut off. The operating cycle is completed when the
carriage returns to its retracted position.
1.6 Identification
Each sootblower in an installation is identified by a serial number and a position
number, both of which are marked on the sootblower nameplate.
A list of the serial numbers of the sootblowers in the installation is given on the
Equipment Identification Form; the position of each sootblower is indicated against
the relevant serial number. Any features which vary from sootblower to sootblower
are also indicated against the serial number.
A more detailed specification of the equipment covered is given on the Equipment
Identification Form at the front of this manual.
FORM 14729 OCTOBER 2000

20
SECTION 2
SECTION 2
COMPONENT DESCRIPTION
General
The IK-545B sootblower comprises a number of sub-assembly components. This
Section describes the function of these components and their relationship to each
other. A comprehensive breakdown of the components is given in Section10
('Parts Identification').
2.1 ELECTRICAL
2.1.1 Electrical Components (Fig.3)
Electrical components on the sootblower comprise a drive motor, forward and reset
limit switches and terminal box containing start and reverse pushbuttons. The
wiring between the drive motor, limit switches and terminal box is part of Diamond
Power supply. The interconnecting wiring from the sootblower to the electric
control panel is not part of Diamond Power supply. To complete the electrical link
up between the sootblower and the control panel a typical or customised
interconnecting schematic diagram is normally supplied by Diamond Power for this
purpose.
2.1.2 Function
When the drive motor is energised from the control panel or local start push-button
it drives the carriage forward. As the carriage approaches the limit of its forward
travel, a limit switch trip arrangement on the carriage, makes contact with the
forward limit switch. This action reverses the drive motor
FIG.3
ELECTRICAL COMPONENTS - SCHEMATIC DIAGRAM
As the carriage approaches its fully retracted position, the limit switch trip
arrangement again makes contact, this time with the reset limit switch. This action
stops the drive motor. The sootblower can also be retracted at any point during
forward travel by pressing the local retract push-button.
JULY 2005 FORM 14332/2
21
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2. A CABLE HELIX OR OTHER MEANS OF CABLE MOVEMENT MUST BE ALLOWED BETWEEN
STANDING STEELWORK AND SOOTBLOWER TO ALLOW FOR BOILER EXPANSION. I 1 841420-0002 Pushbutton Assy, Start, 'F', Green
( I 1 841420-0001 Pushbuton Assy, Reverse, 'R', Red
3. ANY CABLE VOLTAGES SHOWN ARE ACTUAL VOLTS CARRIED BY CORES, THEY DO NOT 28 4 879011-3200 Washer, Serrated, M5 C
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5. INTERNAL WIRING ON SOOTBLOWER IS BY DPSL. ! "#$ %& " '
INTERCONNECTING CABLE AND GLANDS TO SOOTBLOWER IS NOT BY D.P.S.L. ( (! #$ ) *$ %& " ' 055D2CI !0"85 2/1D
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1 2 3 4 5 6
22
SECTION 2
2.2 MOUNTING
2.2.1 Beam (Fig.1)

The beam comprises a pressed steel canopy to which are welded a front support
plate and a rear bulkhead plate. The front support plate arrangement provides the
mounting for two roller bracket assemblies which incorporate lance support rollers.
The rear bulkhead plate carries a mounting bracket for the poppet valve. Four
longitudinal angles, welded to the canopy sides, support the carriage, via rollers
and gear racks.
The beam is supported at the front by a wallbox and wallsleeve. Support pins
connect the wallbox to the front support plate. Rear suspension is provided by a
rear support assembly mounted to the installation structural steelwork. This
method of suspension allows the sootblower to take the expansion and contraction
of the boiler in three planes.
2.2.2 Front Support Plate (Fig.4)

The front support plate c/w integral support pads is welded to the beam at the
forward end of the sootblower. Two roller bracket assemblies mounted onto the
pads support and guide the rotating lance tube as it travels.
FIG.4 FRONT SUPPORT ROLLER ARRANGEMENT
The arrangement of the support rollers is shown above. The roller bracket
assemblies are positioned so that the axis of rotation of each roller is at right
angles to the helical contact path of the lance tube.
APRIL 2002 FORM 14728/1
23
SECTION 2
2.2.3 Wallbox (Fig.5)

The basic function of the wallbox is to provide a seal where the lance enters the
Boiler through the wallsleeve. Since the gas pressure inside the boiler is above
atmospheric pressure, the wallbox is pressurised to prevent the flue gasses
escaping into the wallbox. Seal air is introduced into the wallbox via a nipple
connection located on the underside of the wallbox.
FIG.5 WALLBOX
The wallbox assembly consists of a fabricated steel housing which incorporates a
seal plate and seal arrg't. The seal plate and seal arrg't are seated against the
cover plate and housing by means of cap screws located through nuts welded to
the cover plate.
2.2.4 Pressure Regulating Valve (Fig.5D)
A pressure regulating valve is provided at the sealing air entry to the wallbox. The
valve must be connected to the sealing air line and adjusted to maintain adequate
sealing air within the wallbox.
FIG.5D PRESSURE REGULATING VALVE

A connection from the sealing air line also runs to the air relief valve to provide a
scavenging function. The pressure regulating valve can be installed in two
alternative positions as shown above.
FORM 14498 FEBRUARY 1995
24
SECTION 2
2.2.4 Pressure Regulating Valve (Fig.5D) (Cont'd)

On recovery boilers, an additional steam purge arrangement is supplied. In this
case, a connection from the sootblower poppet valve is piped to the wallsleeve.
Two inlet pipes are inserted through the wallsleeve facing towards the boiler. When
the sootblower operates, steam is blown from these inlets to clean the lance tube.
2.2.5 Rear Support (Fig.6)

The sootblower is supported at the rear by a tube and support plate assembly
welded, on-site, to the structural steelwork. A support pin, secured at each end,
runs through the tube of the assembly and through two side plates welded to the
sides of the beam.
FIG.6 ADJUSTABLE REAR SUPPORT
Each side plate incorporates an elongated hole to assist positioning and to allow for
boiler expansion in the horizontal plane.The supporting steelwork is not supplied by
Diamond Power, but design information is given on the Installation drawing.
SEPTEMBER 1999 FORM 12951/1
25
SECTION 2
2.2.6 Auxiliary Support (Fig.7)
The IK545B sootblower is fitted with an auxiliary support near the mid-point of the
beam. This arrangement supports the lance tube during the first half of forward
travel, and when the sootblower is in the rest position. It also supports the feed
tube during the last half of forward travel. The auxiliary support is mounted on a
channel bolted to both sides of the beam. The assembly incorporates a roller
bracket arrg’t similar to that of the front support and a feed tube support
arrangement which is linked to the roller bracket by a trigger and lever
arrangement.
FIG.7 AUXILIARY SUPPORT
An actuator arrg’t, mounted on the carriage, trips the trigger arrg’t when the
carriage reaches mid-point and the roller bracket arrg’t is lowered by the linkage.
The feed tube support arrg’t swings up to support the feed tube during the
remainder of the forward travel. On the return travel, the linkage operates in
reverse, leaving the roller bracket arrg’t supporting the lance tube.
2.3 MECHANICAL
2.3.1 Carriage (Fig.8)
The carriage drives the lance tube into and out of the boiler and also rotates the
lance tube as it travels. The assembly consists of a drive motor, a gearbox, and a
lance hub which contains the packing to confine the blowing medium in the lance
tube and feed tube.
FIG.8 CARRIAGE OPERATION
The primary spur gears are externally mounted for changing the travel speeds of
the carriage, when required. The output shaft from the second of the primary spur
gears engages a worm gear in the main gearbox for the major gear reduction. The
worm gear output shaft, in turn, operates spur gears for translation and bevel gears
for rotation of the lance tube.
SEPTEMBER 2000 FORM 15280
26
SECTION 2
2.3.1 Carriage (Fig.8) (Cont’d)

The translational spur gears operate the main drive shaft which incorporates two
drive pinions. The pinions engage with gear racks located on each side of the
sootblower beam and enable the carriage to travel along the rack to project the
lance tube into the boiler. The main drive shaft also contains two support rollers
which run on angles welded to the sides of the beam.
Indexing of the lance tube is effected during reversal at full travel by a 90° keyway
in the lance hub bevel gear. The carriage hub contains a mounting flange for the
lance tube and a packing gland to seal around the feed tube
2.3.2 Electric Drive Motor (Fig.1)

The standard electric drive motor is a fixed-speed 1.1kW (1.5hp) unit, mounted on
a flange on the carriage. Power is supplied to the motor through an expanding
cable arrangement (para.2.3.3), which is attached to the underside of the beam.
Alternative motors are available on application.
The carriage is also available with differing primary gearing to give carriage travel
speeds of: 15mm/sec.(35in/min), 30mm/sec.(70in/min), 40mm/sec.(100 in./min)
and 60mm/sec.(140in/min).
2.3.3 Expanda Cable (Fig.9)

The expanda cable arrangement transmits power from the terminal box located at
the rear of the sootblower beam to the drive motor mounted on the moving
carriage (Fig.9). The arrangement consists of a loop control arrangement supported
by a support rod and tow bar arrangement located under the sootblower beam.
FIG.9 EXPANDA CABLE OPERATION
As the sootblower carriage travels forward, the coils of the expanda cable start to
come off, one at a time, from the loop control arrangement fixed to the tow bar
arrangement.
FORM 14882 MAY 1997
27
SECTION 2
2.3.3 Expanda Cable (Fig.9) (Cont’d)

This action continues until the sootblower reaches its full extent of full forward
travel. Each expanda cable arrangement covers a range of sootblower travels,
therefore all the coils may not come off the loop control arrangement.
As the carriage retracts, the coils begin to contract and are pushed back by the
loop control arrangement until the sootblower is nearing the rear rest position, once
resistance builds up, a very rapid flow of coils over the loop control arrangement
takes place until the sootblower comes to rest.
2.4 BLOWING MEDIUM
2.4.1 Poppet Valve (Fig.10)

The poppet valve controls the flow of blowing medium to the nozzle and is
operated by a cam and trigger arrangement, as described in paragraph 2.4.2.
Sootblowers may be fitted with either 4.0, 6.0 or 12.0 MPa (40 bar, 60 bar, or
120 bar series) poppet valves, depending upon the pressure of the blowing
medium. The valve is supplied in carbon steel for standard applications, or in
chrome molybdenum for high-temperature applications.
FIG.10 POPPET VALVE
Each poppet valve is fitted with an air relief valve which allows scavenging air to
be drawn into the poppet valve between blowing cycles, thus preventing corrosive
gases from the furnace being drawn into the poppet valve, feed tube, and lance
tube.
MAY 1997 FORM 14883
28
SECTION 2
2.4.1 Poppet Valve (Fig.10) (Cont’d)

The poppet valve seat is of flexible construction to allow for distortion due to
uneven temperature distribution. The valve disc is loosely attached to the valve
stem by a screwed locknut and retaining washer; the loose fit allows the disc to
seal positively against the hard-faced valve seat.
The valve stem is positioned by the valve stem guide which is screwed into the
valve body. A pressure control disc is screwed onto the lower part of the guide
which extends into the valve body and is locked in position by a lockpin which is
an integral part of the air relief valve coupling. The upper part of the stem guide
contains the valve stem packing which seals around the stem to prevent leakage of
the blowing medium. A packing nut, screwed onto the stem guide, compresses the
packing through a packing washer. The packing nut also supports the valve spring
which acts on the stem through a valve yoke. The valve yoke secures the spring
retainer and is located in a recess on the upper part of the stem.
An integral inlet flange, cast on the poppet valve body, mates with the associated
companion flange and gasket supplied. The valve outlet has a square flange which
is bolted to a mounting bracket on the sootblower. This connection secures the end
of the blowing medium feed tube. A gasket, in the valve outlet, seals the
connection.
2.4.2 Poppet Valve Operation (Fig.11)

The poppet valve is operated mechanically via a cam and trigger arrangement. An
adjustable trip stud mounted on the carriage actuates the cam. As the carriage
moves forward, the stud pivots the cam, thus pulling the valve trigger forward.
FIG.11 POPPET VALVE LINKAGE
The valve trigger pivots on a lug which forms part of the valve body and depresses
the valve stem, thus opening the valve and admitting blowing medium to the feed
tube.
FORM 14884-1 AUGUST 2003
29
SECTION 2
2.4.3 Air Relief Valve (Fig.12)

The air relief valve performs a scavenglng functlon which prevents corroslve boiler
gases from entering the sootblower when it is not operating. On positive pressure
installations, a connection from the sealing air line to the wallbox is piped to the air
relief valve to overcome the furnace pressure. On negative pressure installations,
the atmospheric pressure provides sufficient flow of air through the air relief valve
into the sootblower.
FIG.12
AIR RELIEF VALVE
In either case, the action of the air relief valve prevents the blowing medium from
escaping from the sootblower into the sealing air line, or to atmosphere, when the
sootblower is operating.
2.4.4 Feed Tube (Fig.12A)

The feed tube supplies the blowing medium from the poppet valve to the lance
tube. The rear end of the feed tube is located in the poppet valve outlet and is
keyed to the feed tube plate which is bolted to the valve mounting bracket. The
feed tube gasket is compressed in the poppet valve outlet by the feed tube to seal
the blowing medium.
FIG.12A FEED TUBE PACKING ARRANGEMENT
At the front end, the feed tube is telescoped into the lance tube and is sealed by
the packing in the lance hub. After renewing or adjusting the feed tube packing,
care should be taken not to overtighten the gland nuts. The maximum torque
applied should not exceed 10 Nm (7 lbs.ft). The feed tube is made of highly-
polished stainless steel to provide a leak-free sealing surface for the packing.
APRIL 2002 FORM 14885/1
30
SECTION 2
2.4.5 Lance Tube (Fig.1)

The lance tube is flange-mounted to the lance hub on the carriage and is projected
through the sootblower wallbox and the wall sleeve into the boiler when the
sootblower operates. The lance tube and nozzle are designed to withstand the high
temperatures encountered in the boiler; the standard lance material is of low allow
steel and the nozzle of stainless steel. For higher temperature applications
alternative lance tube materials may be used.
2.4.6 Nozzle (Fig.1)

The nozzle is welded to the end of the lance tube and incorporates either two or
four venturi-type openings, arranged in a leading or lagging configuration,
depending upon the cleaning application. On large-diameter lance tubes, the nozzle
openings are directly opposite each other. The size of each nozzle throat is
determined by the type of blowing medium and the pressure required to clean a
particular heating surface. The nozzles are balanced at the factory to ensure equal
reaction from the opposing jets, thus preventing lance whip. The standard nozzle
material is stainless steel, but alternative materials are available for specific
applications.
FORM 14885/1 APRIL 2002
31
SECTION 2
2.5.1 Limit Switches (Fig.13)

Limit switches, mounted on the sootblower beam, control forward and reverse
travel.
FIG.13 OPERATING SWITCHES
The limit switches are actuated by a limit switch trip arrangement mounted on the
sootblower carriage.
JULY 2005 FORM 14886/1
32
SECTION 2
2.6.1 Emergency Retract Air Tool (Fig.14)
During maintenance, or in an emergency, the sootblower carriage can be operated

by turning the square tang on the rear of the carriage with the emergency retract
air tool. The tool consists of a vane-type air motor with motor mounting and shaft
coupling, a 30 m (100 ft.) length of PVC hose, and a manual shut-off valve. The air
motor operates on a clean, dry supply of air at 0.5 to 0.7 MPa (5.5 to 6.9 Bar)
pressure, and can be operated in reverse, if required.
FIG.14 EMERGENCY RETRACT AIR TOOL
The tool is secured by engaging the motor mounting with the flange on the
carriage. Turning the square tang clockwise results in the carriage travelling
forwards and the lance tube going into the boiler. Conversely, turning the square
tang anti-clockwise results in the carriage returning towards the normal fully-
retracted position.
NOTE : Blowing medium pressure should be ‘ON’ when the sootblower is operated
manually to cool the lance tube until it is retracted.
JANUARY 1997 FORM 14802
33
SECTION 3
SECTION 3
INSTALLATION INSTRUCTIONS
General
Installation drawings are supplied with each set of sootblowers. These drawings
show the location of the sootblowers in the installation, the blowing medium
pressure, overall dimensions, method of mounting, extent of Diamond Power
equipment supplied, and connections to be made.
3.1 Location
Each sootblower is identified on the appropriate installation drawing by a serial
number; this number is marked on the sootblower nameplate. Care must be taken
to ensure that each sootblower is installed in its correct location, by referring to the
relevant drawing.
3.2 Mounting
The sootblower is mounted on the boiler at two points, front and rear. At the front
mounting point, the wallbox is welded on-site to a boiler wall sleeve, normally
provided by the customer, and, at the rear, by a rear support on the sootblower
which is site-welded to the installation supporting steelwork. For condensate
drainage, reference should be made to the relevent installation drawings for full
mounting details.

When lifting the sootblower into position, the lifting lugs provided on top of the
beam should be used (Section 14).
NOTE: Do not use a sling around the beam or the protruding lance tube, as this
may cause damage and subsequent malfunctioning.

The supply pipework is site-welded to the companion flange which is bolted to the
poppet valve flange. The pipework arrangement must not strain the sootblower
mounting.
The supply pipework must be blown out to remove all scale, weld bead, etc, upon
completion of installation work. A sheet metal deflector must be inserted between
the sootblower poppet valve inlet and the companion flange before this operation
to ensure that debris does not reach the valve seat.
3.5 Scavenging Air

As described in Section 2, a scavenging air supply is used for removing the
corrosive furnace gases from the sootblower when it is inoperative. On positive
pressure installations, pressurised purge air should be used to overcome furnace
pressure.
APRIL 1995 FORM 12957
34
SECTION 3
3.6 Lubrication
Reference should be made to the Lubrication Chart in Section 7.
3.7 Electrical Connections

Power and control connections must be made to the terminal box. Reference
should be made to the electrical control details in Section 2 for the correct
connections required.
FORM 12957 APRIL 1995
35
SECTION 4
SECTION 4
COMMISSIONING
General
Commissioning should be carried out in three stages: (1) Inspection; (2) Functional
Checks; and (3) Pre-Operational Checks, as briefly described in the following
paragraphs. Reference should be made to the Job Sheets in Section 12 for more
detailed instructions, and to the commissioning check list (Job Sheet No.3) for a
summary and further references .

Immediately prior to operating the sootblower for the first time, an inspection
should be made to ensure that it has been properly installed, that all connections
(electrical, steam or air, where appropriate) have been made, that it has been
lubricated as specified in the installation instructions, and that it has not sustained
any damage since installation.
Once the above inspection has been made and any further work required
completed, the sootblower can be operated as described in paragraph 4.2.

Functional checks should be made before the boiler comes on-load, (i.e. without
blowing medium) to ensure that the sootblower mechanism is operating correctly .
The sootblower should initially be operated manually to check for freedom of
movement and correct functioning of the mechanism, as described in Job Sheet 7.
It should then be operated from the local control to check for correct direction of
motor rotation and correct operation of the limit switches. Power consumption
should also be compared (where possible) with the normal starting and full load
current, as stated on the motor rating plate.
The sootblower is now ready to be checked with the boiler on-load, as described in
the following paragraphs.
4.3 Stage 3 - Pre-Operational Checks (Fig.15)

The final stage in commissioning involves checking for blowing medium leakage,
setting the blowing pressure, and setting the wallbox sealing pressure, where
applicable. This can only be carried out with the boiler on-load and all services
available (i.e. power, blowing medium, and sealing air).
The check for leakage is particularly important where superheated steam is used as
the blowing medium, and should be made before, and during, initial operation of
the sootblower. Any leakage must be eliminated before moving to the next stage
of commissioning.
MAY 1998 FORM 14536
36
SECTION 4
4.3 Stage 3 - Pre-Operational Checks (Fig.15)(Continued)

The recommended blowing pressure is given on the Equipment Identification Form
at the front of this manual. The actual blowing pressure must be checked under
normal operating conditions, i.e. with blowing medium available at normal pressure
and temperature, nozzle in place, and the air relief valve in good working order.
Blowing pressure can be checked by connecting a suitable pressure gauge to the
air relief valve, as shown in Fig.15 below.
FIG.15 CHECKING THE BLOWING PRESSURE
The blowing pressure is controlled by raising or lowering the pressure control disc,
thus increasing or decreasing the gap between the valve seat and the disc. The gap
is set at approximately 2.5mm (0.1in.) on assembly. Adjustment is made by
withdrawing the lock pin and rotating the pressure control disc. The pressure
control disc must be locked in position after adjustment, by replacing the lock pin.
The end of the lock pin must engage one of the deep grooves in the pressure
control disc; each groove represents approximately 0.2mm (0.008in.) vertical
movement of the pressure control disc.
The sootblower should be operated through several complete cycles, with the
blowing medium on, to check that it is functioning correctly before finally putting it
into service.
FORM 14536 MAY 1998
37
SECTION 5
SECTION 5
OPERATING INSTRUCTIONS
General
The sootblower can be operated from a remote panel or from push-buttons
mounted on an individual starter box. Once started, it automatically completes its
operating cycle and returns to the rest position ready for a further cycle.
Provision is made,also, for manual operation (Section 6).

Retractable sootblowers are generally used on boilers of relatively high steaming
capacity, but they can also be used on smaller boilers.
When the sootblowers are installed on a small boiler, the steaming capacity should
be maintained at over 50% and the draft fans should be operating at a high rate of
flow during the sootblowing period. This ensures that the amount of cleaning
medium blown in is small compared to the amount of gases passing through the
boiler, and also that the deposits removed by the sootblowers are carried through
the boiler. If the firing rate is low, the sootblowing may agitate combustibles in the
furnace and cause puffing.
On larger boilers,these precautions are not normally necessary, as the amount of
cleaning medium blown in is usually small compared to the amount of gases
passing through.

When a steam generator is first placed into service, the tube surfaces have an
immunity to ash and slag adherence. Consequently, it will appear, at first, that the
recommended blowing pressures are higher than required. During this period,
lasting for a few weeks, it may not be necessary to operate the sootblower very
often. Later, after the tube surfaces have acquired a coating of residual slag, the
deposits of slag and ash will be more difficult to clean and the recommended
blowing pressure will more than likely be required.
Before commencing blowing, reference should be made to the operating
precautions given in the previous paragraph. Normal recommended practice is to
clean the boiler in the direction of the gas flow. The units nearest to the furnace
operate first, followed by the superheater and economiser units. If heavy
accumulations are to be removed, a few of the units in the rear passes of the boiler
should be operated interchangeably with those in the first pass. This eliminates a
heavy accumulation in the boiler output area. If a 'straight-through' schedule is
employed, it is possible that accumulation removed from the super-heater region
will pile up in the economiser area. These recommendations are general ones -
operating experience with the individual boiler is the most accurate guide.
38
SECTION 6
SECTION 6
MAINTENANCE INSTRUCTIONS
General
Maintenance instructions in this Section are grouped under the following headings
for convenience: Operational Checks; Periodic Inspection; Annual Maintenance; and
Major Overhaul. A maintenance schedule for each group is provided in Section 8,
and Job Sheets, detailing the action to be taken, are provided in Section l2.
Lubricants, which should be kept readily available for maintenance purposes, are
listed in Section 7.

Checks should be made when the sootblower is operating to detect malfunctioning
or blowing medium leakage.

The sootblower should be inspected periodically to ensure that:
(a) All mechanisms are functioning correctly.
(b) All moving parts on the carriage are adequately lubricated with
recommended lubricants.
(c) Blowing medium is not leaking.
(d) Nozzle is in good condition.
(e) Feed tube surface is in good condition.
(f) Lance tube surface is in good condition.
The frequency of inspection will depend on operating conditions, but should be at
least once a month.

The IK-545B sootblower should be inspected annually for deterioration of all critical
parts; these should be renewed, where necessary. Packing and lubricants should be
renewed and mechanisms checked and adjusted, where necessary.
NOTE: Components on the carriage which are sealed for life should only be re-
lubricated if dismantling has taken place. This does not apply to bearings
and similar parts, which should be discarded.
When renewing a negative pressure wallbox, care should be taken to
ensure that the wallbox is correctly orientated, with the word 'TOP'
uppermost.
39
SECTION 6
6.3 Annual Maintenance(Continued)

Critical parts include the following:
(a) Poppet Valve, including Air Relief Valve.
(b) Feed Tube.
(c) Lance Tube, including Nozzle.
(d) Support Rollers.
(e) Limit and Pressure Switches.
(f) Expanda Cable.
6.4 Major Overhaul

The IK-545B sootblower should be dismantled every three years for inspection and
renewal of all wearing parts, as indicated in the Recommended Spares List (Section
11). Seals, packing, and lubricants should be renewed at this overhaul. Wall
sleeves and supporting steelwork should also be checked, and rectified if
unserviceable.
NOTE: Components on the carriage assembly which are sealed for life should only
be re-lubricated if dismantling has taken place. This does not apply to bearings and
similar parts, which should be discarded.
6.5 Manual Operation (Fig.16)

During maintenance, or in an emergency, the sootblower carriage can be operated
manually be attaching a ratchet wrench to the square tang on the carriage. Turning
the square tang in a clockwise direction results in the carriage travelling forward
with the lance tube going into the boiler. Turning the square tang counter-
clockwise results in the carriage returning towards the normal fully-retracted
position. Alternatively, the emergency air retract tool (Section 9) can be used to
move the carriage manually.
FIG.16 LOCATION OF SQUARE TANG FOR MANUAL OPERATION
NOTE: The blowing medium supply should be 'ON' when the sootblower is
operated manually to cool the lance tube until it is retracted.
40
SECTION 7
SECTION 7
LUBRICATION
General
Prior to shipping, IK500 Series gearboxes are run with a protective oil and then
drained. For prolonged storage, the gearbox should be filled with a similar
protective oil, such as Esso Rustban 335. This must be drained and thoroughly
cleaned out before use. It is the responsibility of the maintenance Inspector to
ensure that this is done before operating the equipment.
To maintain the efficiency of the Sootblower, it is essential that periodic checks are
carried out at the lubrication points listed in this Section.
7.1 Initial Operation
When IK500 Series Sootblowers are operated initially, it is essential that the
lubrication procedures given in the following paragraphs are strictly adhered to.
7.2 Carriage Assembly
7.2.1 Gearbox
In compliance with transportation requirements, IK500 Series Sootblowers are
shipped with dry gearboxes. Before operating the equipment, the following must be
observed,
The carriage gearbox must be filled to the level indicated on the sight gauge on the
carriage with the lubricant specified in the Lubrication Chart. The vent filler plug is
located on top of the carriage and is accessible by removing the cover plate on the
top of the beam. The capacity of the gearbox is 7.33 litres.
The gearbox should be drained and refilled as specified in the lubrication chart. All
external moving components of the carriage which contain sealed bearings do not
require lubrication.
7.3 Lance Hub
The lance hub is lubricated during the initial fill of the gearbox via the vent filler
plug
7.4.1 Grease Fittings

The general grease fittings should be lubricated as specified in the Lubrication
Chart.
7.4.2 Bolt Heads and Threads
If any bolts are temporarily removed from the sootblower, the heads and threads
should be coated with an anti-seize compound, such as Molykote G or Thread-
Gard, before replacement.
7.5 List of Recommended Lubricants
Reference should be made to the Lubrication Chart for the correct lubricants to be
used on all IK500 Series Sootblowers.
JUNE 2002 FORM 14526
41
SECTION 7
IK545 SERIES LUBRICATION CHART
COMPONENT LOCATION LUBRICATION PART TO BE FREQUENCY MEANS OF LUBRICANT

POINT LUBRICATED LUBRICATION
Gearbox Mobil 600W Cyl Oil
Mineral Oil 6-Monthly Or
(Above 0°C) Shell Valvata J 460
Gearbox Vent Filler Plug Fill to middle of
Synthetic Oil Carriage on top of Gearing 18-Monthly site glass with Mobil SHC 634
(Above 0ºC)
Carriage 7.33 Litres of oil
Gearbox
Synthetic Oil 18-Monthly Mobil SHC 626
(Below 0ºC)
Grease Gun
Front Support At each Two Grease Bearing Shell
3-Monthly through Alvania EP-1 or EP-2
Rollers Roller Nipples Shafts
Lub Fittings
APRIL 2003 FORM 14418/4

42
SECTION 8
SECTION 8
MAINTENANCE SCHEDULE
General
Sootblower controls are normally arranged to protect the plant and the sootblower
from damage in the event of a fault developing, by rendering the sootblower
inoperative until the fault is rectified.
The Maintenance Schedule, in the following paragraphs, is designed to minimise
loss of use of the sootblower by forming the basis of a system of preventive
maintenance which identifies parts of the sootblower requiring attention before
they deteriorate to such an extent as to render the sootblower inoperative.
Action to be taken in the event of a fault developing is given against each item,
either directly, or by reference to a Job Sheet in Section 12.

Points to be checked are as follows:
1. Check the amperage as each sootblower operates and compare the readings
obtained with the full load current as shown on the motor rating plate.
Excessive current consumption, or fluctuating readings, indicate a sootblower
fault which should be investigated as soon as possible.
2. Check that the sootblower operates through its full cycle - failure to do so may
be due to either a mechanical fault in the sootblower itself, or an external fault,
such as inadequate blowing medium supply.

Frequency of this inspection will depend on operating conditions, but should not be
less than once per month. Points to be checked are:
1. All mechanisms are functioning as described in Section 2.
2. Blowing pressure is correct; refer to Job Sheet 5.
3. Blowing medium is not leaking; refer to Job Sheet 6.
4. All moving parts on the carriage are adequately lubricated; refer to Section 7.

Routine maintenance should be carried out annually, with the sootblower in situ
and with all services connected, but isolated where specified on the relevant Job
Sheet.
The sootblower should be inspected and dismantled as required for renewal, if
necessary. As a preliminary to this operation, the sootblower should be run and
checked for any malfunctioning, as described in paragraphs 8.1 and 8.2.
Dismantling and Reassembly instructions are given on the relevant Job Sheets in
Section 12.
43
SECTION 8
8.3 Routine Maintenance (Continued)

Gaskets and packing seals should be renewed at this stage; the parts involved are
listed in Section 10. Reference should be made to Section 7 for details of
lubrication required.
Critical parts, which should be examined in more detail at this overhaul. are as
follows:
1. Lance Tube - Check for corrosion. surface damage, and straightness.
2. Nozzle / Rake Arrg't - Check for cracking and corrosion .
3. Feed Tube - Check for corrosion, surface damage and straightness.
4. Carriage - Check for overheating and noisy running.
5. Poppet Valve - Dismantle.
Valve Stem and Disc Assembly - Check for wear and renew if necessary.
Valve Seat - Check for wear, and lap if necessary.
Reassemble using new packing and gaskets
6. Air Relief Valve - Pressure Test. Ensure that the disc, spring and seat are in
good condition
7. Limit / Proximity Switches - Check for correct operation (Job Sheet 33)
8. Motor - Check for overheating and freedom of movement.
9. Expanda / Looped Cable - Renew if necessary (Job Sheet 31)
Upon completion of Routine Maintenance, the sootblower should be
recommissioned as described in Section 4.
8. 4 Major Overhaul
The sootblower should be inspected every three years and dismantled for renewal
of all wearing parts if necessary. As a preliminary to this operation, the sootblower
should be run and checked for any malfunctioning, as described in paragraphs 8.1
and 8.2. Dismantling and Reassembly instructions are given on the relevant Job
Sheets in Section 12.
Gaskets, packing, seals, and lubricants, when required, should be renewed at this
stage; the applicable parts are listed in Section 10.
The procedure for examining critical parts is similar to that given for Routine
Maintenance.
Upon completion of a Major Overhaul, the sootblower should be recommissioned as
described in Section 4.
FORM 14247 SEPTEMBER 2003
44
SECTION 9
SECTION 9
OPTIONAL TOOLS
Certain Jobs described in the Maintenance Section can best be accomplished

using the optional special-purpose tools developed by Diamond Power.These
tools are listed below and are available from the Company.To order, quote the
relevant part number and quantity required.
Lapping Equipment for Poppet Valve

Valve Seat Protector Assembly
Poppet Valve Maintenance Tool (Spanner)
Poppet Valve Maintenance Tool (Depressing Tool)
Feed Tube Packing Tool Assembly
Emergency Retract Air Tool
Carriage Hub Oil Seal Locating Tool (For Lance Flange End)
Carriage Hub Oil Seal Locating Tool (For 2.375” Feed Tube)
Carriage Hub Oil Seal Locating Tool (For 2.750” Feed Tube)
MARCH 2004 FORM 12964/2
45
SECTION 9
LAPPING EQUIPMENT FOR POPPET VALVE
Item No. Part No. Description No. Off
1 395111-1123 Wobble Stick 1
2 313641-1125 Lapping Disc, Serrated Face (Series 40) 1

314718-1121 Lapping Disc, Serrated Face (Series 60) 1
3 313641-2123 Lapping Disc, Plain Face (Series 40) 1

314718-2129 Lapping Disc, Plain Face (Series 60) 1
46
SECTION 9
VALVE SEAT PROTECTOR ASSEMBLY
(PART No. 310925-1029 - SERIES 40)

(PART No. 310925-2026 - SERIES 60)
(PART No. 392443-1129 - SERIES 120)
1 863015-2800 Nut 1
2 311938-1113 Stem 1
3 311936-1115 Spacer (Series 40) 1

311936-2113 Spacer (Series 60) 1
393444-1128 Spacer (Series 120) 1
4 311937-1114 Disc (Series 40) 1

311937-2112 Disc (Series 60) 1
Not Applicable Disc (Series 120) -
AUGUST 1996 FORM 11828
47
SECTION 9
POPPET VALVE MAINTENANCE TOOL

(SPANNER)
1 312227-1129 Valve Packing Nut Spanner 1
48
SECTION 9

(DEPRESSING TOOL)
1 307025-1024 Valve Spring Depressing Tool 1
49
SECTION 9
FEED TUBE PACKING TOOL ASSEMBLY
(Part No. 308191-1012 - Graphite Foil Packing)

(Part No. 308191-2010 - Teflon Packing
1 307762-0114 Spring Clip (2-3/8"in o/d Feed Tube) 1
2 306761-0117 Body (Graphite Foil Packing) 1

3 327425-1127 Body (Teflon Packing) 1
MARCH 1995 FORM 12720
50
SECTION 9
EMERGENCY RETRACT AIR TOOL
(Part No. 395333-1026)
1 395368-1032 Motor and Motor Mounting Assy 1

2 393088-1036 Hose Assembly 1
51
SECTION 9
CARRIAGE HUB OIL SEAL LOCATING TOOL

(FOR LANCE FLANGE END)
1 TD2492-2 Carriage Hub Oil Seal Locating Tool 1
52
SECTION 9

(FOR 2.375” FEED TUBE)
53
SECTION 9

(FOR 2.750” FEED TUBE)
54
SECTION 10
SECTION 10
PARTS IDENTIFICATION
The correct part number for spares ordering can be identified by referring to the Parts
Lists included in this manual. Please quote the contract number and the sootblower serial
number when ordering spares.
The main assemblies and sub-assemblies of the Parts Lists are arranged in the following
order within Section 10:
Main Assembly (IK-545B)

Progressive helix Mechanism Assembly (When Applicable)
Expanda Cable Control Assembly
Carriage Assembly
Roller Assembly (Carriage)
Bracket Assembly, with Webb (Carriage)
Bracket Assembly (Carriage)
Trip Bar Assembly (Carriage)
Limit Switch Trip Assembly
Roller Bracket Assembly (Front Support)
Roller Assembly (Front Support)
Lance Joint and Packing Assembly
Blowing Medium Turn-on Assembly
Poppet Valve Assembly
Air Relief Valve Assembly
Electric Control Assembly (When Applicable)
Electric Control / Wiring Assembly
Terminal Box Assembly (When Applicable)
Auxiliary Support Assembly
Roller Bracket Assembly (Auxiliary Support)
Roller Assembly (Auxiliary Support)
Wallbox Assembly
Wallbox Piping Assembly (When Applicable
Scavenge Air Line and Piping Assy (When Applicable)
Pressure Switch and Piping Assembly (When Applicable)
Rear Support Assembly
Guard Assembly (When Applicable)
JULY 2005 FORM 14890/4
55
SECTION 10
SECTION 10
PARTS IDENTIFICATION (CUSTOMISED)
CONTRACT No.N10865
Assy Desc / Part No Item No Part No Form No
IK545B (EMD) MAIN ASSY 1 N1086514-C004 14991/2
N10865-2-1 (RH) 1A 875005-5639 "
1B 879006-5600 "
1C 879016-5600 "
2 398281-A100 "
3 398067-R260CAA "
3A N10865-811 "
3B 398694-000B "
4 FF2JA0-0963 "
Lance with 1.25” dia (31.8mm) Jets 5 L4AQ1D-0983 "
Lance with 1.125” dia (28.6mm) Jets 5 L4AN1D-0983 "
6 398071-AB00 "
7 398337-R6B0 "
7A 397802-F1A2 "
7B 396775-000G "
8 350256-010A "
9 397556-DDN1 "
10 397473-J120 (6-off) "
11 397474-010A (12-off) "
12 397447-3A10 "
12A 398041-1D00 "
13 398038-1003 "
14 Not Applicable "
14A N10865-2-615 "
15 398176-RAB0 "
16 398179-000B "
17 397940-000B "
EXPANDA CABLE CONTROL ASSY 1 396922-000B 15393

398281-A100 2 396950-000B "
3 TB1E-1030 "
4 398206-62L11 "
6 Not Applicable "
CARRIAGE ASSEMBLY 1 397408-010A 15198

(2-ROLLER ARRANGEMENT) G1 393222-1124 "
398067-R260CAA (RH) 2 397382-010A "
G2 323428-1123 "
3 350174-010A "
4 306037-2111 "
5 306038-1112 "
G5 323435-1124 "
56
SECTION 10
SECTION 10
CONTRACT No.N10865
CARRIAGE ASSEMBLY (Cont’d) 6 901110-0136 15198
(2-ROLLER ARRANGEMENT) G6 324125-1127 "
398067-R260CAA (RH) 7 Not Applicable "
G7 323434-1125 "
8 908502-0043 "
G8 323423-1136 "
9 Not Applicable "
10 323439-1120 "
11 305654-0127 "
12 304160-0119 "
13 Not Applicable "
14 875005-4836 (1-off) "
15 - 21 Not Applicable "
22 324124-1029 "
23 324128-1124 "
28 397385-010A "
29 397576-000A "
30 397578-000A "
47 Not Applicable "
49 907920-0010 "
59 875005-4437 "
63 Not Applicable "
67 875005-4430 "
91 350180-010A "
92 Not Applicable "
94 Not Applicable "
96 879006-4400 "
97 Not Applicable "
BRACKET ASSEMBLY (CARRIAGE) 1 397577-010A 14937

397578-000A
TRIP BAR ASSEMBLY 2 397491-010A 14250

397080-000C 3 879068-8901 "
5 876004-8907 "
LIMIT SWITCH TRIP ASSEMBLY 2 398693-010B 15435

398694-000B *3 Not Applicable "
(With Mechanical Limit Switch) **3 875005-4438 "
*4 Not Applicable "
**4 Not Applicable "
ROLLER BRACKET ASSEMBLY 1 323403-6022 15093

397940-000B
57
SECTION 10
SECTION 10
CONTRACT No.N10865
ROLLER ASSEMBLY 1 323404-2129 12761
323403-6022 5 323405-2128 "
6 901110-0024 "
LANCE JOINT & PACKING ASSY 1 346160-1134 15197

398071-AB00 1A 396741-010A "
2 316893-1123 "
3 316896-1021 "
4 397473-G085 "
5 879006-4800 "
6 873008-4800 "
7 305656-0117 "
8 876004-0006 "
9 Not Applicable "
BLOWING MEDIUM TURN-ON ASSY 10 398305-0750 15341

398337-R6B0 11 397481-010A "
12 398303-000A "
14 397480-010A "
23 304634-0117 "
POPPET VALVE ASSEMBLY 1 *398580-FAA0 14895

397802-F1A2 2 344381-1033 "
(*Welded with Item 1) 3 309786-1128 "
(*Fitted with item 1) 4 394197-1123 "
11 393802-1122 "
22 397474-010A "
23 397473-J090 "
24 Not Applicable "
25 398325-010A "
26 Not Applicable "
TERMINAL BOX ASSEMBLY 1 875003-3525 (4-off) 15486

398348-S0001 2 Not Applicable "
3 Not Applicable "
6 Not Applicable "
AUXILIARY SUPPORT ASSEMBLY 1 394664-010A 15251

398176-RAB0 19 871014-4837 "
20 334404-2126 "
24 398178-000B "
58
SECTION 10
SECTION 10
CONTRACT No.N10865
ROLLER BRACKET ASSEMBLY 6-9 Not Applicable 15252
398033-000A
WALLBOX ASSEMBLY 1 396944-000C 14497

397447-3A10 2 396940-010A "
3 397448-000A "
5 396938-010A (1-off) "
SCAVENGE AIR LINE & PIPING ASSY 1 397737-1003 15175

398038-1003 14 Not Applicable "
WALLBOX PIPING ASSEMBLY 1 394171-1032 15174

398041-1D00 2 394330-4034 "
3 Not Applicable "
REAR SUPPORT ASSEMBLY 1 Not Applicable 15287

398179-000B
59
SECTION 10
IK545B MAIN ASSEMBLY. DRG. NO.

PART. NO.
Item No. Part No. Description No.Off
1 Beam Arrg't 1
1A Bolt, Front Bulkhead Arrg’t 4
1B Washer, Front Bulkhead Arrg’t 4
1C Lockwasher, Front Bulkhead Arrg’t 4
2 Expanda Cable Assembly 1
3 Carriage Assembly 1
3A Electric Motor 1
3B Trip Pin, Carriage, Limit Switch (Not Illustrated)
4 Feed Tube 1
5 Lance Tube 1
6 Lance Joint and Packing Assembly 1
7 Blowing Medium Turn-on Assembly 1
7A Poppet Valve Assembly 1
7B Air Relief Valve Assembly 1
* 8 Gasket, Companion Flange 1
* 9 Companion Flange 1
* 10 Stud As Req’d
* 11 Nut As Req’d
12 Wallbox Assembly 1
12A Wallbox Piping Assembly 1
13 Scavenging Air Line and Piping Assembly 1
14 Electric Control Assembly 1
14A Electric Control / Wiring Assy (Not Illustrated) 1
15 Auxiliary Support Assembly 1
16 Rear Support Assembly 1
17 Roller Bracket Assembly (Front Support) 1
18 391750-1128 Warning Tag 1
* 30 909305-0021 Ratchet Wrench (Not Illustrated)** 1
* Items supplied loose ** Per Boiler Set
MARCH 2005 FORM 14991/2
60
SECTION 10
EXPANDA CABLE CONTROL ASSEMBLY (RH) & (LH) DRG. NO. 398281-0040
PART. NO.
Assembly Notes:
1. Engage fork of tow bar between flanges of loop control assembly before fitting the two
retaining screws
2. Attach the expanda cable at the towbar fork and at the rear of the beam using cable clips.
3. Cut off excess cable length, prepare ends and connect directly to the terminal box and the
motor.
4. Paint to be removed from under grounding strap (Item 10) to provide electrical continuity.
5. Support rod tensioning nuts to be torqued to 10-11 Nm (90 - 100 lb. in). Use vice grips or
similar tool to prevent rotation of the rod).
6. Coat thread of gland (Item 6) with hylomar prior to fitment to the motor.
MAY 2003 FORM 15393
61
SECTION 10
EXPANDA CABLE CONTROL ASSEMBLY (RH) & (LH) DRG. NO. 398281-0040
PART. NO.
1 Tow Bar Assembly 1

2 Loop Control Arrg't 1
3 Suspension Rod 1
4 Expanda Cable 1
5 395400-1123 Spacer 1
6 Gland, Cable 1
7 875005-4425 Screw, Hex Hd M10 x 25 lg As Req’d
8 879068-8900 Schnorr Safety Washer 6
9 879010-4400 Lockwasher, Shakeproof M10 1
10 395747-1026 Grounding Strap Arrg’t 1
11 873038-4400 Nut, Hex Brass M10 5
12 879007-4400 Washer M10 1
13 849515-8909 Clip 4
14 875005-3516 Screw, Hex Hd M6 x 16 lg 3
15 873015-3500 Nut, Hex M6 4
16 879016-3500 Lockwasher, Split Type M6 4
17 875005-3533 Screw, Hex Hd M6 x 35 lg 1
18 865022-2732 Screw, Hex Hd 3/8” - 16 x 1” lg As Req’d
FORM 15393 MAY 2003
62
SECTION 10
CARRIAGE ASSEMBLY DRG. NO. 398067-0040
(2-ROLLER ARRANGEMENT SHOWN) (RH)PART. NO.
(LH)PART. NO.
MAY 2005 (PAGE 1 OF 6) FORM 15198
63
SECTION 10
(4-ROLLER ARRANGEMENT SHOWN) (RH)PART. NO.
(LH)PART. NO.
MAY 2005 (PAGE 2 OF 6) FORM 15198
64
SECTION 10

(NON-ROTATING ARRANGEMENT SHOWN) (RH)PART. NO.
(LH)PART. NO.
NOTE – HUB OIL SEALS (DETAIL 8) MUST BE FITTED

WITH THE FOLLOWING TOOLS:
TD2492-2 FOR LANCE FLANGE END
TD2493-2 FOR GLAND END, 2.375” FEED TUBE
TD2494-2 FOR GLAND END, 2.750” FEED TUBE
DO NOT USE 351606-010A FOR THESE SEALS
MAY 2005 (PAGE 3 OF 6) FORM 15198
65
SECTION 10

(RH)PART. NO.
(LH)PART. NO.
1 Lance Hub 1
G1 Spur Gear,Motor 1
2 Housing, Carriage 1
G2 Spur Gear,Worm 1
3 Retainer,Bearing 1
G3 332429-1131 Worm Shaft(40:1) 1
4 Key, 1/4” Sq X 1” long 1
G4 349428-010A Gear,Worm(40:1) 1
5 Key, 3/8”Sq x 17/16” long 1
G5 Spur Gear 1
6 Ball Bearing/Spacer 2
G6 Spur Gear 1
7 Spacer 1
G7 Bevel Gear,Pinion 1
8 Oil Seal, Lance Hub 2
G8 Bevel Gear,Lance Hub 1
9 Oil Seal, Drive Shaft 1
G9 324188-1121 Pinion(12 Teeth) 2
10 Drive Shaft 1
11 Hub, Flange 1
12 Key, Hub Flange 1
13 Bracket, Non-Rotating 1
14 Screw, Hex Hd M12 As Req’d
15 Screw, Hex Hd M12 1
16 Spacer, Bracket, Non-Rotating 1
17 Lockwasher M12 1
18 Plain Washer M12 1
19 Bracket, Top Cover 1
20 Roller Assembly 4
21 Washer, Lock Stub Shaft 4
22 Roller Assembly 2
23 Spacer Roller 2
24 350178-010A Shim, Worm Shaft(.005 Blue) As Req'd
350178-010B Shim, Worm Shaft(.0075 Transparent) As Req'd
350178-010C Shim, Worm Shaft(.020 Yellow) As Req'd
25 350176-010A Shim,Bearing Carrier(.005 Blue) As Req'd
350176-010B Shim, Bearing Carrier(.0075 Transparent) As Req'd
350176-010C Shim, Bearing Carrier(.020 Yellow) As Req'd
26 350611-010A Shim,Bearing Retainer(.005 Blue) As Req'd
350611-010B Shim,Bearing Retainer(.0075 Transparent) As Req'd
350611-010C Shim,Bearing Retainer(.020 Yellow) As Req'd
27 398072-010A Shim, Roller Bracket As Req’d
28 Cover, Top 1
MAY 2005 (PAGE 4 OF 6) FORM 15198
66
SECTION 10

(RH)PART. NO.
(LH)PART. NO.
29 Bracket Assembly 1
30 Bracket Assembly 1
31 335592-1127 Caution Plate 1
32 397080-000C Trip Bar Assembly 1
33 306038-4116 Key 3/8”Sq x 17/8” long 1
34 306037-7110 Key 1/4”Sq x 15/8” long 3
35 306037-3119 Key 1/4”Sq x 13/8” long 1
36 395461-1129 Key 8mm x 7mm x 16mm long 1
37 323441-1126 Key 3/16”Sq x 1” long 1
38 901110-0062 Ball Bearing, Worm Shaft 2
39 901110-0130 Ball Bearing, Pinion Shaft. 1
40 901110-0049 Ball Bearing, Pinion Shaft 1
41 901110-0070 Ball Bearing, Pinion Shaft 1
42 901110-0060 Ball Bearing, Bevel Pinion Shaft 1
43 901110-0052 Ball Bearing, Bevel Pinion Shaft 1
44 907920-0136 Retaining Ring, Housing 1
45 907920-0069 Retaining Ring, Pinion Shaft 1
46 907920-0066 Retaining Ring, Housing 1
47 Retaining Ring, Pinion Shaft End 2
48 907920-0080 Retaining Ring, Pinion Shaft 2
49 Retaining Ring, Pinion Shaft End 2
50 907920-0078 Retaining Ring, Worm Shaft 1
51 908502-0044 Oil Seal, Worm Shaft 1
52 901416-0007 Oil Seal, 35x72x10 Viton 1
53 901416-0008 Oil Seal, 40x80x10 Viton 1
54 395539-1119 Oil Level Window 1
55 875005-4412 Screw, Hex Hd M10x12mm long 1
59 Screw, Hex Hd M10x45mm long 2
65 866004-9000 Screw, Hex Hd M8x16mm long(Tuflok) 1
66 875007-4420 Screw, Socket Hd M10x20mm long 4
68 871014-4436 Bolt, Hex Hd M10x40mm long 3
69 873015-4400 Nut, M10 3
70 879016-4400 Lockwasher, Split Type M10 As Req’d
71 879016-4800 Lockwasher, Split Type M12 As Req’d
MAY 2005 (PAGE 5 OF 6) FORM 15198
67
SECTION 10

(RH)PART. NO.
(LH)PART. NO.
72 879071-4800 Washer Plain Copper M12 3

73 869006-8901 Washer, Steel 5/16”x11/4”x14swg 1
74 906902-0027 Air Vent, 3/8”xNPT 1
75 936309-8600 Plug, Square Hd. 3/4” NPT 1
76 907656-0002 Plug, Expansion 3/4” 2
77 907941-0152 “O” Ring 1
78 907310-0009 Magnet 2
79 901099-0005 Locknut Bearing 1
80 901089-0005 Lockwasher, Bearing 1
81 397233-010A Housing, Change Gear 1
82 350108-010A Gasket, Change Gear 1
83 393728-1123 Gasket, Motor 1
84 332198-1122 Spacer, Worm Shaft 1
85 393221-1125 Distance Piece 1
86 350477-010A Mounting Flange 1
87 863651-2520 Pin, Steel 1/4”Dia x 5/8” long 4
88 397393-010A Carrier, Bearing 1
89 398399-010A Retainer, Bearing, Worm, Motor End 1
90 350613-010A Retainer, Bearing, Carrier End 1
91 Shaft, Pinion 1
92 Shaft, Pinion 1
93 350189-010A Gasket, Bracket Top 1
94 Gasket, Bracket Top 1
95 350175-010A Gasket, Bearing Retainer 2
96 Plain Washer M10 2
97 Breather Plug ¾”NPT 1
MAY 2005 (PAGE 6 OF 6) FORM 15198
68
SECTION 10
ROLLER ASSEMBLY (CARRIAGE) DRG. NO. 324124-1029

PART. NO. 324124-1029
1 324129-1123 Roller 1
2 901110-0045 Ball Bearing 1
3 907920-0062 Retaining Ring 2
69
SECTION 10
BRACKET ASSEMBLY(CARRIAGE) DRG. NO. 397576-0029

(With Web) PART. NO. 397576-000A
1 397570-010A Bracket, Reaction Roller 1

2 863651-1934 Roll Pin 1
3 316944-1122 Guide Roller 1
70
SECTION 10
BRACKET ASSEMBLY(CARRIAGE) DRG. NO. 397578-0028

PART. NO.
1 Bracket 1
2 863651-1934 Roll Pin 1
3 316944-1122 Guide Roller 1
71
SECTION 10
TRIP BAR ASSEMBLY DRG. NO. 397080-0025

PART. NO.
Item No Part No Description No Off
1 397079-010A Trip Bar 1

2 Trip Stud 1
3 Washer M12 1
4 305390-0118 Locking Washer 1
5 Hex Hd Screw 1
72
SECTION 10
LIMIT SWITCH TRIP ASSEMBLY DRG. NO. 398694-0025

PART. NO.
1 398699-010A Angle, Limit Switch Trip 1

2 Spacer, Limit Switch Trip Angle 2
* 3 Screw, Hex Hd M10 x 1.5 – 25 lg 2
**3 Screw, Hex Hd M10 x 1.5 – 50 lg 2
WITH MECHANICAL LIMIT SWITCH
* for 4 Roller Carriage

** for 2 Roller Carriage
73
SECTION 10
LIMIT SWITCH TRIP ASSEMBLY DRG. NO. 398694-0025

PART. NO.
1 398699-010A Angle, Limit Switch Trip 1

2 Spacer, Limit Switch Trip Angle 2
3 398768-010A Trip Plate, Proximity Switch 1
* 4 Screw, Hex Hd M10 x 1.5 – 25 lg 2
**4 Screw, Hex Hd M10 x 1.5 – 50 lg 2
5 875007-3208 Screw, Soc Hd M5 x 0.8 x 8 lg 2
WITH PROXIMITY LIMIT SWITCH
* for 4 Roller Carriage

** for 2 Roller Carriage
FORM 15435 MARCH 2005
74
SECTION 10
ROLLER BRACKET ASSEMBLY DRG. NO. 397940-0029

(Front Support) PART. NO.
Item No. Part No. Description. No. Off.
1 Roller Assembly 1
2 397938-000A Bracket, Roller 1
3 397939-010A Shaft, Roller 1
4 906902-8911 Lubrication Fitting 1
5 324210-2121 Spacer, Roller 2
6 863631-2238 Groove Pin 1
7 875005-5639 Hex Hd Screw M20 2
8 879006-5600 Washer M20 2
9 879016-5600 Lockwasher M20 2
10 876006-4410 Grub Screw 1
75
SECTION 10
ROLLER ASSEMBLY DRG. NO. 323403-1023

(Front Support) PART NO.
1 Roller 1
5 Spacer 1
6 Ball Bearing 2
9 316910-2112 Seal 2

76
SECTION 10
LANCE JOINT AND PACKING ASSEMBLY DRG. N0. 398071-0044
PART. N0.
77
SECTION 10
LANCE JOINT AND PACKING ASSEMBLY DRG. N0. 398071-0044

PART. N0.
1 Packing (Solid Ring)(Set) 1

1A Packing (Split Ring)(Set) 1
2 Bushing 1
3 Gland Arrg’t 1
4 Studbolt 2
5 Washer, Plain 2
6 Nut 4
7 Gasket 1
8 Hex Hd Bolt/Screw 6
9 Spring Assembly, Live Loaded Gland 2
10 Spring Assembly, Live Loaded Gland, Recovery 2
78
SECTION 10
BLOWING MEDIUM TURN - ON ASSEMBLY (RH) & (LH) DRG. NO.398337-0044
PART. NO.
79
SECTION 10
BLOWING MEDIUM TURN - ON ASSEMBLY (RH) & (LH) DRG. NO.398337-0044

PART. NO.
1 876004-8903 Hex Hd Bolt M16x2.0x65lg 1

2 398301-010A Spacer, Poppet Valve Trigger 2
3 907948-8900 Rod End 1
4 875005-4837 Hex Hd Screw M12x45lg 2
5 873024-5200 Hex Nut M16x2.0 1
6 871014-4840 Hex Hd Bolt M12x1.75x60lg 4
7 879006-4802 "C" Washer M12 8
8 873631-3536 Groove Pin Ø6x40 2
9 873015-5200 Hex Nut M16x2.0 1
10 Adjusting Rod 1
11 Clamping Plate, Feed Tube 1
12 Cam Arrg’t 1
13 398306-000A Pivot Block Arrg’t 1
14 Mounting Bracket 1
15 879016-4800 Lockwasher M12 6
16 869068-0012 Washer 2
17 907920-0007 External Retaining Ring 1
18 879016-4400 Lockwasher M10 2
19 875005-4436 Hex Hd Screw M10x1.5x40lg 2
20 398302-010A Spacer, Poppet Valve Cam 1
21 907948-8901 Rod End 1
23 Gasket, Feed Tube 1
24 873015-4800 Hex Nut M12x1.75 4
Notes :
1. Assemble adjusting rod and rod ends with equal thread engagement at each end. For reference
the nominal engagement will be 23mm.
2. Adjustment at final assembly is achieved by loosening the locking nut and rotating the
adjusting rod. Re-tighten the locking nut when adjustment is correct.
3. Apply Molykote Gn+ to threads and head of screws and torque to 41Nm (30 lb.ft.).
4. Apply Molykote Gn+ to threads and faces of poppet valve nuts and torque to 75Nm (55
lb.ft.). For each nut, bend up only ONE tab of the locking washer.
5. When poppet valve is correctly aligned with the feed tube, drill 06 through the bulkhead (via
existing 06 holes in mounting plate) and fit 06 groove pins.
6. Assemble all threads (including feed tube details) with Molykote Gn+.
7. Assemble Rod Ends with Molykote GN+ on the bores.
8. When valve is fully open ensure there is a minimum gap of 0.25mm between valve spring
coils.
80
SECTION 10
POPPET VALVE ASSEMBLY. DRG. NO. 397802-0042
PART. NO.
81
SECTION 10
POPPET VALVE ASSEMBLY. DRG. NO. 397802-0042

PART. NO.
Item No. Part No. Description. No. Off
1 Valve Body 1
2 Valve Stem and Disc Arrg't 1
3 Flexible Valve Seat 1
4 Pressure Control Disc 1
5 398300-000A Trigger Arrg’t 1
6 301235-0116 Valve Yoke Pin 1
7 863603-1716 Cotter Pin 1
8 301158-0119 Trigger Pin 1
9 863603-1934 Cotter Pin 1
11 Lock Pin Plug 1
12 930711-9034 Copper Washer 1
13 301142-0118 Valve Yoke 1
14 301808-0113 Valve Spring Retainer 1
15 302051-0115 Valve Spring 1
16 302032-0119 Packing Nut 1
17 302027-0116 Packing Washer 1
18 398443-010A Valve Stem Packing 1
19 342928-1136 Valve Stem Guide 1
20 301167-2114 Valve Stem Washer 1
21 396774-0121 Adjustable Pressure Tag 1
22 Nut 4
23 Stud / Hex Soc Hd Screw 4
24 Adaptor 1
25 Locking Washer, Poppet Valve Nut 2
26 Plug, G3/4 1
NOTES:
1. Valve Stem Guide, Lock Pin and Plug threads to be coated with ‘Molykote Gn Plus’
(907145-0002)
2. Torque Valve Stem Guide to 80Nm (60lb.ft)
3. Valves to be hydro tested to procedure – QA 002
6. This clearance dimension should be set between the bottom face of the packing
nut hex and the top face of the valve stem guide hex. Increasing this dimension
above 8mm can cause the spring to hard stop when the valve is fully open.
Decreasing this dimension below 3.5mm may cause problems with the valve stem
packing.
7. Ensure valve stem packing rings are assembled as shown.
82
SECTION 10
AIR RELIEF VALVE ASSEMBLY DRG. NO. 396775-1037

PART. NO. 396775-000G
Item No Part No. Description No.Off
1 341501-1026 Air Relief Valve Arrg't 1

5 937817-8600 Tee 1
6 935923-8600 Nipple 1
7 936220-8600 Plug 1
8 935924-8902 Nipple 1
10 349569-010E Adapter 1
11 930711-9034 Washer 1
83
SECTION 10
ELECTRIC CONTROL / WIRING ASSEMBLY (REV B) DRG. NO. N10865-2-615
PART. NO. N10865-2-615
SEPTEMBER 2006 (CONTRACT N10865)
84
SECTION 10
ELECTRIC CONTROL / WIRING ASSEMBLY (REV B) DRG. NO. N10865-2-615

PART. NO. N10865-2-615
Item No. Part No. Description Qty.
1 * Electric Motor -
2 * Entry, M25 -
3 841402-0071 Cable Gland M25 2
4 * Entry, 25.4mm (for M25) -
5 841402-0079 Locknut, M25 1
6 * Cable, Motor, 4-Core -
7 841405-0116 Limit Switch, Roller Crank (LSR & LSF) 2
8 * Entry, M20 -
9 848300-9784 Terminal Cross Connector, 3 Way 1
10 875007-3236 Screw, Soc Hd M5 x 0.8 – 40 lg 4
11 879006-4002 Washer, Plain M8 4
12 398744-A000 Rail & Fixings Assy 2
13 * Entry, 20.4mm (for M20/Pg13.5) -
14 841402-0067 Cable Gland, M20 2
15 841402-0078 Locknut, M20 2
16 841404-0014 Cable, Limit Switch, 3-core 1
17 841404-0015 Cable, Limit Switch, 5-core 1
18# 398348-S0001 Terminal Box Assy RH c/w fixings 1
19 907506-8901 Warning Label, “Steam Sootblower” 1
20 * Entry 44mm dia clearance hole -
21 * Cable Gland By Others
22 * Locknut By Others
24 * Cable Gland By Others
25 * Locknut By Others
26# 841420-0002 Pushbutton Assy, Start, ‘F’, Green 1
27# 841420-0001 Pushbutton Assy, Reverse, ‘R’ Red 1
28 879011-3200 Washer, Serrated, M5 4
29 847313-9208 VCI Foam Square 2
30# 398743-AA10 Terminal Block Assy 1
31# 841420-0010 Pushbutton Insert, RED 1
32# 841420-0011 Pushbutton Insert GREEN 1
N10865-2-615 Electrical Parts Assembly, RH Sootblower

N10865TB TB Assy, populated, RH Sootblower
* Shown for ref only

# assy of parts only
(CONTRACT N10865) SEPTEMBER 2006
85
SECTION 10
TERMINAL BOX ASSEMBLY (RITTAL) DRG. NO. 398348-0140

PART. NO.
1 Screw, Slt Hd Csk M6 x 1.0 - 25lg As Req’d

2 Screw, Slt Hd Csk M6 x 1.0 - 30lg 1
4 873015-3500 Hex Nut M6 8
6 Nylon Spacer 4
7 875006-3500 Washer, Form A, M6 4
8 841406-0009 Terminal Box 1
86
SECTION 10
AUXILIARY SUPPORT ASSEMBLY DRG. NO. 398176-0048
PART. NO.
87
SECTION 10
AUXILIARY SUPPORT ASSEMBLY DRG. NO. 398176-0048

PART. NO.
1 Channel (RH) 1
Channel (LH) 1
2 395991-000A Bearing Housing, Auxiliary Support 4
3 879006-4400 Washer Form ‘A’ M10 24
4 875007-4436 Screw, Hex Soc Hd M10x1.5 - 6gx40lg 8
6 873015-4400 Nut, Hex M10x1.5 - 6H 12
7 395403-1138 Support Block, non-Fork Side 1
8 395402-1139 Support Block, Fork Side 1
9 879006-4800 Washer Form ‘A’ M12 4
10 875007-4430 Screw, Hex Soc Hd M10x1.5 - 6gx30lg 4
11 398589-000B Auxiliary Shaft Arrg’t 1
12 398590-000A Lever/Shaft Arrg’t 1
13 334393-1022 Lever Arrg’t 1
14 863607-1932 Split Pin, Ø3x25 2
15 869068-0013 Washer, 27odx16idx13g 4
16 395387-1146 Bracket Arrg’t, Centre Support 1
17 398033-000A Roller Bracket Assembly 2
19 Bolt, Hex Hd M12x1.75 4
20 Shim, Centre Support Roller 4
21 869068-0026 Washer, 1.625” odx0.5” id x 0.83”lg 2
22 876006-4410 Set Screw, Hex Soc Hd M10x1.5 - 6g x10lg 2
23 398177-000A Tube Arrg’t, Centre Support 1
24 Support, Feed Tube 1
25 873008-5600 Lock Nut, M20x2.5 - 6H Hex 1
26 875005-4830 Screw, Hex Hd M12x1.75 - 6gx30lg 6
27 873015-4800 Hex Nut M12x1.75 - 6H 6
28 331696-2020 Actuator Arrg’t 1
29 875005-4438 Screw, Hex Hd M10 x1.5 - 6g x 50lg 2
30 398578-010A Spacer, Auxiliary Support Actuator 2
31 901118-8907 Bush 4
88
SECTION 10
ROLLER BRACKET ASSEMBLY DRG. NO. 398033-0025

(AUXILIARY SUPPORT) PART. NO.
1 398032-010A Roller Bracket 1

2 317061-1127 Shaft, Roller 1
3 317059-1022 Roller Assembly 1
4 317062-1126 Spacer 2
5 863651-2534 Roll Pin 1
6 Lockwasher, Split Type M12 2
7 Washer, 1.625”odx0.5”idx0.083” 2
8 Bolt, Hex Hd M12x1.75 - 45lg 2
9 Bolt, Hex Hd M12x1.75 - 40lg 2
89
SECTION 10
ROLLER ASSEMBLY DRG. NO. 317059-1022

(AUXILIARY SUPPORT) PART. NO. 317059-1022
1 317060-1128 Roller 1
2 901110-0058 Ball Bearing 1
90
SECTION 10
WALLBOX ASSEMBLY DRG. NO. 397447-0043
PART. NO.
91
SECTION 10
WALLBOX ASSEMBLY DRG. NO. 397447-0043

PART. NO.
1 Housing Arrg't 1
2 Seal Plate 1
3 Seal Arrg't 1
4 869006-3600 Washer As Req'd
5 Spacer As Req'd
6 396939-010B Cover Plate 1
7 907920-9001 Spirolox Retaining Ring 1
8 396937-010A Support Pin 2
9 873607-4841 Split Pin 4
10 875005-4444 Hex Hd Screw 4
11 941401-0012 Plug 1
12 398068-010A Label, Wallbox Adjustment 1
NOTE
SPARE PARTS WILL ONLY BE SUPPLIED IN THE FOLLOWING
SOLID AND SPLIT KITS : COMPRISING ITEMS 2,3,6,7 & 10.
PART NUMBER DESCRIPTION

397447-0A00 (SOLID) SEAL KIT - (3.5" Lance) (For IK500 Series S/B’s)
397447-0B00 (SOLID) SEAL KIT - (4" Lance) (For IK500 Series S/B’s)
397447-0C00 MOUNTING KIT -- Comprising Items :- 4,5,8 & 9
397447-0D00 (SOLID) SEAL KIT - (2..875" Lance) (For IK4M S/B’s)
397447-0E00 (SOLID) SEAL KIT - (2.375" Lance) (For IK4M S/B’s)
397447-0F00 (SOLID) SEAL KIT - (3" Lance) (For IK1M S/B’s)
397447-0G00 (SPLIT) SEAL KIT - (3.5" Lance) (For IK500 Series S/B’s c/w NPC Nozzles)
397447-0H00 (SPLIT) SEAL KIT - (4" Lance) (For IK500 Series S/B’s c/w NPC Nozzles)
397447-0J00 (SPLIT) SEAL KIT - (2.875" Lance) (For IK4M S/B’s)
397447-0K00 (SPLIT) SEAL KIT - (2.375" Lance) (For IK4M S/B’s)
397447-0L00 (SPLIT) SEAL KIT - (3" Lance) (For IK1M S/B’s)
397447-0M00 (SOLID) SEAL KIT - (3.5" Lance) (For TP500 Thermoprobes)
397447-0N00 (SOLID) SEAL KIT - (2.375" Lance) (For TP500 Thermoprobes)
FORM 14497 MARCH 2000
92
SECTION 10
SCAVENGE AIR LINE AND PIPING ASSEMBLY DRG. NO. 398038-0020

PART NO.
93
SECTION 10
SCAVENGE AIR LINE AND PIPING ASSEMBLY DRG. NO. 398038-0020

PART NO.
1 Galvanised Tube 1
2 941422-0001 Socket (¾” BSPT) As Req’d
3 941400-0018 Elbow 1
4 RT020025TI-0085 S.S. Tube 1
5 941402-0025 Male Stud Coupling 1
6 941408-0008 Elbow, ¾” BSPT Female 1
7 841414-0063 Adaptor, ¾” BSPP X ¾” BSPT 1
8 931403-0011 Elbow, Hosetail, ¾” BSPP X ¾” Hose 1
9 902210-8911 Hose Clip, Screw and Band 2
10 931403-0006 Hose As Req’d
11 931403-0010 Hosetail, ¾” BSPT X ¾” Tube 1
12 934008-8600 Street Elbow 1
14 Pipe, Rear End, Scavenge Air 1
94
SECTION 10
WALLBOX PIPING ASSEMBLY DRG. NO. 398041-0025

PART. NO.
1 Tee Valve Spindle Arrg't (2” BSPT) 1

2 Nipple Arrg't 1
3 Plug (2” BSPT) 1
4 941414-0003 Tee (2” BSPT) 1
95
SECTION 10
REAR SUPPORT ASSEMBLY DRG. NO. 398179-0029

PART. NO.
1 Plate, Blower Support As Req’d

3 397157-010A Pin, Blower Support 1
4 873607-4841 Split Pin M13x65lg 2
5 398180-000A Channel Arrg’t 1
6 869006-3600 Plain Washer 2
7 879006-6000 Washer M24 6
8 873015-6000 Hex Nut M24x3.0 8
9 RZ240130KC-0250 Screwed Rod M24 2
FEBRUARY 2001 FORM 15287
96
SECTION 11
SECTION 11
RECOMMENDED SPARES LIST
It is recommended that stocks of the items listed in this Section be maintained as

follows:
1. Running Maintenance
Quantities shown in column 1 should be regarded as a minimum initial stock level
until actual usage is established through operating experience.
2. Incurred Maintenance
Diamond sootblowers are designed to operate for long periods with the minimum of
maintenance and spares usage; component parts do not normally require replacement
unless a breakdown occurs due to accident or misuse. It is recommended, however,
that a stock of the items listed be maintained to minimise downtime should a
breakdown occur, recommended quantities are shown in column 2.
3. Major Overhaul
When the boiler is off-load for a major overhaul, sootblowers should be inspected for
wear or damage as indicated in Section 8, and parts replaced as necessary. Items
which are normally replaced at this stage are indicated by a quantity in column 3.
The items listed in this Section should be adequate for normal use but the
quantities stocked may have to be adjusted to take account of severe usage or
delays in obtaining replacements .
The assembly headings indicate where the items listed are used. Since headings
and items appear in the same order as shown in the Parts Identification Section of
the Instruction Manual, part numbers of related items can be readily identified.
The quantities recommended have been calculated per ten sootblowers. These
quantities may require to be adjusted to correspond with the actual number of
sootblowers in use.
97
SECTION 11

( Per 10 Sootblowers )
EQUIPMENT TYPE :- IK545B SOOTBLOWER 1. Running Maintenance

(Electric Motor Driven) 2. Incurred Maintenance
CONTRACT No :- N10865 3. Major Overhaul
DESCRIPTION PART NO. QUANTITY

1 2 3
MAIN ASSEMBLY (RH) N10865-2-1
Electric Motor N10865-811 - 1 -
Feed Tube FF2JA0-0963 - 1 -
Lance Tube c/w 1.25” dia (31.8mm) Jets L4AQ1D-0983 - 1 -
Lance Tube c/w 1.125” dia (28.6mm) Jets L4AN1D-0983 - 1 -
Gasket (Companion Flange) 350256-010A - 2 10
EXPANDA CABLE CONTROL ASSEMBLY 398281-A100

Expanda Cable 398206-62L11 - 1 10
CARRIAGE ASSEMBLY 398067-R260CAA

Spur Gear (Motor) 393222-1124 - 1 -
Spur Gear (Worm) 323428-1123 - 1 -
Key 306037-2111 - 1 10
Gear (Worm) (40:1) 349428-010A - 1 -
Key 306038-1112 - 1 10
Spur Gear 323435-1124 - 1 -
Ball Bearing 901110-0136 - 2 20
Spur Gear 324125-1127 - 1 -
Gear (Bevel Pinion) 323434-1125 - 1 -
Oil Seal 908502-0043 - 2 20
Bevel Gear (Lance Hub) (56 Teeth) 323423-1136 - 1 -
Oil Seal 908502-0051 - 1 -
Pinion 324188-1121 - 2 -
Key 304160-0119 - 1 10
Roller Assembly 324124-1029 - 2 20
Key 306038-4116 - 1 10
Key 306037-7110 - 3 30
Key 306037-3119 - 1 10
Key 395461-1129 - 1 10
Key 323441-1126 - 1 10
Ball Bearing 901110-0062 - 2 20
Ball Bearing 901110-0130 - 1 10
Ball Bearing 901110-0049 - 1 10
Ball Bearing 901110-0070 - 1 10
Ball Bearing 901110-0060 - 1 10
Ball Bearing 901110-0052 - 1 10
(Page 1 of 3) FORM 13123
98
SECTION 11



1 2 3
CARRIAGE ASSEMBLY (RH) (Cont’d) 398067-R260CAA
Oil Seal 908502-0044 - 1 10
Oil Seal 908502-0039 - 1 10
Oil Seal 908502-0038 - 1 10
Gasket (Change Gear) 350108-010A - 1 10
Gasket (Motor) 393728-1123 - 1 10
Gasket, Bracket Top 350189-010A - 1 10
Gasket (Bearing Retainer) 350175-010A - 2 20
BRACKET ASSEMBLY (With Web) 397576-0029

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

Guide Roller 316944-1122 - 2 20
TRIP BAR ASSEMBLY 397080-000C

Trip Stud 397491-010R - 1 10
ROLLER ASSY (Front Support) 323403-6022

Roller 323404-2129 - 1 -
Ball Bearing 901110-0024 - 2 20
LANCE JOINT & PACKING ASSEMBLY 398071-AB00

Packing (Solid Ring) 346160-1134 - - 10
Packing (Split Ring) 396741-010A 10 10 -
Bushing 316893-1123 - 1 10
Gland Arrg't 316896-1021 - 1 -
Gasket 305656-0117 - 1 10
BLOWING MEDIUM TURN-ON ASSY 398337-R6B0

External Retaining Ring 907920-0007 - 1 10
External Retaining Ring 907920-0005 - 1 10
Gasket, Feed Tube 304634-0117 - 2 10
99
SECTION 11



1 2 3
POPPET VALVE ASSEMBLY 397802-F1A2
Valve Stem and Disc Arrg't 344381-1033 - 2 10
Flexible Valve Seat 309786-1128 - 2 -
Pressure Control Disc 394197-1123 - 2 -
Valve Yoke Pin 301235-0116 - 2 10
Cotter Pin 863603-1716 - 2 10
Trigger Pin 301158-0119 - 1 10
Lubrication Fitting 906902-8910 - 4 -
Lock Pin Plug 393802-1122 - 2 -
Lock Pin Washer 930711-9034 - 2 10
Valve Yoke 301142-0118 - 2 10
Valve Spring Retainer 301808-0113 - 2 10
Valve Spring 302051-0115 - 2 10
Packing Nut 302032-0119 - 2 -
Packing Washer 302027-0116 - 2 -
Packing (Valve Stem) 351523-010A 10 10 10
Valve Stem Guide 342928-1136 - 2 -
Valve Guide Washer 301167-0118 - 2 10
Nut 397474-010A - 4 -
Stud 397473-J090 - 4 -
Locking Washer 398325-010A - 2 20
AIR RELIEF VALVE ASSEMBLY 396775-000G

Air Relief Valve 341501-1026 - 2 -
Copper Washer 930711-9034 - 1 10
ELECTRIC CONTROL / WIRING ASSY N10865-2-615

Limit Switch (Rear & Front) 841405-0116 - 2 -
ROLLER BRACKET ASSY (Aux Support) 398033-000A

Roller Assembly 317059-1022 - 2 20
Spacer 317062-1126 - 4 -
Roll Pin 863651-2534 - 1 10
WALLBOX ASSEMBLY 397447-3A10

Mounting Kit 397447-0C00 - 1 -
Split Seal Kit 397447-0G00 - 1 -
100
SECTION 12
SECTION 12
JOB SHEETS
JOB SHEET TITLE

NO
1 IK545B Installation Procedure

2 Site Erection of Rear Support
3 Commissioning Check List
4 Blowing Medium Turn-On Linkage - Adjusting Procedure
5 Poppet Valve - Checking / Setting the Blowing Pressure
6 Pressure Sealing Points - Checking Procedure
7 Functional Checks (Prior to Electrical Operation)
8 Pre - Operational Checks (With Power ON)
9 Manual Operation
10 Feed Tube Packing (Split Ring) Adjusting the Packing Gland
11 Feed Tube Packing - Renewal
12 Poppet Valve - Removal from Sootblower
13 Poppet Valve - Dismantling
14 Poppet Valve - Valve Stem Packing: Adjusting Procedure
15 Poppet Valve - Valve Stem Packing: Renewal
16 Poppet Valve - Tools and Equipment for Lapping the Valve Seat
17 Poppet Valve - Valve Seat Lapping Procedure
18 Poppet Valve - Seat Renewal
19 Poppet Valve - Reassembly Procedure
20 Poppetr Valve - Replacing on the Sootblower
21 Lance Tube Gasket - Adjusting Procedure
22 Lance Tube Gasket - Renewal
23 Lance Tube and Feed Tube - Removal
24 Carriage - Removal
25 Carriage Dismantling (1) - Motor and Primary Gear Change Assy
26 Carriage Dismantling (2) - Roller and Rack Pinions
27 Carriage Dismantling (3) - Pinion Shaft, Pinion, Spur Gear & Roller Assy
28 Carriage Dismantling (4) - Lance Hub and Bevel Gear Assembly
29 Carriage Dismantling (5) - Shaft and Bearing Assembly
30 Carriage Dismantling (6) - Shaft and Bearing & Drive Shaft Assembly
31 Expanda Cable - Removal and Renewal
32 Wallbox Dismantling
33 Limit Switches - Renewal and Adjustment
34 Not Applicable
35 Support Rollers - Adjustment
101
TECHNICAL DATA SHEET
(SERIES ONE CARRIAGE GENERAL NOTES)

DRAWING No. 398067-0040
NOTE
To be read in conjunction with Job Sheets 24 - 30
1. NUMERIC CRISS-CROSS TIGHTENING PATTERN OF M10 SCREWS SHOWN ON

APPROPRIATE PART TO BE USED.
(A) USE ’MOLY-G’ LUBRICANT UNDER SCREW HEAD AND ON THREADS.
(B) TORQUE TO 30 ± 5 lb-ft IN ONE PASS.
2. NUMERIC CRISS-CROSS TIGHTENING PATTERN OF M12 SCREWS SHOWN ON

APPROPRIATE PART TO BE USED.
(A) USE ‘MOLY-G’ LUBRICANT UNDER SCREW HEAD AND ON THREADS.
(B) TORQUE TO 30 ± 5 lb-ft IN ONE PASS.
(C) TORQUE TO 70 ± 5 lb-ft IN SECOND AND FINAL PASS.
3. SHIM BETWEEN HOUSING (2) AND MOUNTING FLANGE (86) TO GIVE 0.076 TO 0.20
WORM SHAFT ENDPLAY. PER DPS STANDARD QC79.
4. FOR CORRECT PINION ALIGNMENT ENSURE THAT THE STAMPED PINION FACING
ARE FACING THE SAME DIRECTION (I.E. BOTH LEFT OR BOTH RIGHT.
5. ALL SURFACES TO BE CLEANED AND DE-GREASED PRIOR TO THE APPLICATION OF
SEALANT OR ADHESIVES.
6. WORM GEAR (G4) TO BE INSTALLED WITH LARGER DIAMETER HUB NEXT TO SPUR
GEAR (G5).
7. REFER TO SHOP BOM FOR SPECIFIED TRVEL BEFORE TURN-ON.
8. FOR SHOP TEST ON FULLY FLOODED CARRIAGES ONLY, FILL GEAR CASE WITH
RECOMMENDED LUBRICANT TO SIGHT GAUGE LEVEL, AND COMPLETELY DRAIN
AFTER TEST. FILLER PLUG AND BREATHER TO HAVE ‘LOCTITE 572’ APPLIED TO
THREADS PRIOR TO FITMENT. FILLER PLUG MUST BE RE-SEALED WITH ‘LOCTITE
572’ AFTER OIL CHANGE.
NOTE, AT THE BREATHER HOLE, A SLAVE ‘BLANK’ PLUG WILL NEED TO BE FITTED
WHEN THE CARRIAGE IS INVERTED DURING ASSEMBLY.
9. WORM GEAR SHIMMING PROCEDURE IS TO BE USED TO OBTAIN PROPER
CONTACT PATTERN. SEE DPS STANDARD QC79.
10. ALL GASKETS TO HAVE ‘DOW CORNING SILASTIC 744’ APPLIED THINLY AND
EVENLY ON BOTH SIDES OF THE GASKET (OR BOTH FLANGES).
11. ASSEMBLE BEARING CARRIER (88), BEARING RETAINER (90) AND BALL BEARING
(43) WITHOUT SHIMS. MEASURE THE GAP BETWEEN CARRIER AND RETAINER, ADD
SHIMS (26) MEASURING 0.0 TO 0.064 GREATER THAN GAP. SEE DPS STANDARD
QC 79.
JULY 2003 (PAGE 1 of 2) FORM 15201
102
TECHNICAL DATA SHEET
(SERIES ONE CARRIAGE GENERAL NOTES)

DRAWING No. 398067-0040
NOTE
To be read in conjunction with Job Sheets 24 - 30
12. FOR THE 4 ROLLER CARRIAGE ONLY - APPLY ‘MOLYKOTE-Gn PLUS’ TO THE
THREADS AND SHOULDER OF THE ROLLER SHAFT AND TORQUE TO 90 lb-ft
MINIMUM.
13. FOR THE 4 ROLLER CARRIAGE ONLY, BEND LOCK WASHER (21) ONE PLACE
AGAINST FLAT ON ROLLER SHAFT (PART OF 20) AND ONE PLACE AGAINST CAST
FLAT ON BOTTOM OF TOP COVER BRACKET ARM (19).
14. EXPANSION PLUG (76) TO HAVE ‘DOW CORNING SILASTIC 744’ APPLIED PRIOR TO
PRESSING INTO HOLE SO OUTSIDE EDGE IS 0.03 TO 0.06 BELOW CASTING
SURFACE.
15. INSTALL CHANGE GEAR HOUSING (81) PRIOR TO TOP COVER SO THAT TWO TOP
SCREWS (NUMBERED 6 AND 7 IN BOLT TIGHTENING PATTERN) CAN BE USED TO
PULL TOP COVER INTO CONTACT WITH CHANGE GEAR HOUSING GASKET (82) TO
PREVENT LEAKAGE.
16. ALL OIL SEAL LIPS TO BE LUBRICATED ON ASSEMBLY WITH MOBIL SHC 634 ONLY.
OIL SEALS SHOULD BE FITTED WITH APPROPRIATE TOOLING.
17. ALL SHIMS TO HAVE ‘LOCKTITE GASKET ELIMINATOR 518’ APPLIED SPARINGLY
TO BOTH SIDES.
18. ALL BORES FOR OIL SEAL LOCATIONS TO HAVE ‘DOW CORNING SILASTIC 744’
APPLIED THINLY AND EVENLY PRIOR TO PRESSING SEALS INTO THE BORE.
19. OIL SIGHT GLASS TO BE FITTED WITH ‘LOCKTITE 225’.
20. STAMP THE CONTRACT NUMBER AND THE SPEED IN THE AREA AS SHOWN.
21. MOUNTING FLANGE (86) TO BE INSTALLED WITH PINS UP AS SHOWN.
22. FOR 2 ROLLER CARRIAGE ONLY, BRACKET (29) TO BE SHIMMED TO SUIT
APPLICATION.
23. SET HUB PROJECTION TO DIMENSION SHOWN. FINAL ADJUSTMENT OF LANCE
HUB PROJECTION TO BE CARRIED OUT WHEN FITTING LANCE TO BLOWER.
24. LUBRICATION – TABLE 6 ON DPS MANUFACTURING CARRIAGE DRAWING
INCLUDES APPROPRIATE MOBILITH SHC 007 GREASE (HARDWARE NUMBER 0903-
834) AND OIL QUANTITIES FOR THE VARIOUS BUILD POSSIBILITIES. AS THE OIL IS
DRAINED FROM THE CARRIAGE BEFORE DESPATCH, OIL QUANTITIES ARE FOR
REFERENCE ONLY. NOTE – kg IS THE UNIT OF MEASURE FOR GREASE.
25. FIT BREATHER PLUG WITH HOLE FACING DOWNWARD (USE LOCTITE 572 ON
THREAD). NOTE – A SLAVE ‘BLANK’ PLUG WILL NEED TO BE FITTED WHEN THE
CARRIAGE IS INVERTED DURING ASSEMBLY.
JULY 2003 (PAGE 2 of 2) FORM 15201
103
JOB SHEETS
The information within the job sheets are
of a general nature and are not intended to
cover every individual sootblower system.
WARNING
Before all adjustments, repairs and tests
are undertaken the control room should be
notified. The appropriate local permits
should be taken out and all safety
precautions taken.
NOTE
Refer to the yellow coloured warning sheet
at the front of the Instruction manual for
general information regarding important
Installation, Commissioning, Operating and
Maintenance instructions.
FORM 15325
104
SECTION 12
DIAMOND POWER JOB SHEET No.1

SOOTBLOWER TYPE : IK500 Series (Electric Motor Driven) SHEET
JOB SHEET TITLE : INSTALLATION PROCEDURE 1 of 3

STEP ACTION REF./INFO.
1. Remove all straps and packing from the sootblower.
2. Inspect for damage from shipment or storage.
3. Check that the equipment to be installed is complete as Packing List

specified
4. Determine the location and mounting position of the sootblower Installation

on the boiler. Drawing
5. Ensure that a wallsleeve has been welded to the boiler wall. Inst'n Drg.
6. Remove the wallbox from the sootblower.
7. Position and weld the wallbox to the wallsleeve.
NOTE
On positive pressure installations ensure that the wallbox has
been correctly orientated with the inlet hole on the bottom.
NOTE
On negative pressure installations also ensure that the wallbox
has been correctly orientated.
8. Fit guards (When Applicable) Job Sheet 35
9. Lift the sootblower into position using the lifting lugs provided Installation Drg
on top of the beam. Fit the sootblower to the wallbox, locating
the pivot pins correctly.
Note
For condensate drainage refer to the installation drg.
10. Position and weld the rear support to the supporting steelwork Installation Drg
and to the sootblower. Job Sheet 2
11. Connect the purge air pipework to the wallbox.

(For positive pressure applications only)
12. Connect a syphon tube to the pressure switch & air relief valve When Applicable
13. Bolt the companion flange to the poppet valve inlet flange.
105
SECTION 12


14. Position and weld the customers blowing medium supply Installation Drg
pipework to the companion flange.
Note
Any customer designed arrangement must be carefully installed
to prevent any undue stress on the sootblower.
15. Unbolt the companion flange from the poppet valve flange.
16. Install a sheet metal deflector between the companion flange

and the sootblower inlet flange.
17. Blow out the blowing medium supply pipework to remove all
scale, weld bead etc.
18. Remove the deflector and insert the companion flange gasket.
19. Bolt the companion flange to the sootblower inlet flange, and
compress the gasket evenly between them.Tighten the studs in
the sequence shown below.
NOTE
The use of a torque wrench is not mandatory but approximate
torque value of a properly tightened stud is as follows:-
80 - 100 Nm for M20 studs (40 and 60 Bar Valves)
125 – 140 Nm for M24 studs (120 Bar Valves)
STUD TIGHTENING SEQUENCE

NOTE
Series 40 Bar poppet valve installations have six flange studs.
Series 60 and 120 valve installations have eight flange studs.
.
20. Observe the alignment of the beam arrangement: check for any
bends, twists or other distortions.
FORM 12683 NOVEMBER 2000
106
SECTION 12


21. Lubricate the sootblower. Section 7
22. Make the power and control connections to the sootblower

terminal box ; ensure there are no loose terminals or wiring.
23. Leave the sootblower ready for commissioning, with the local
isolation switches off and the blowing medium supply isolated.
107
SECTION 12

SOOTBLOWER TYPE : IKSD-E / IK500 SERIES SHEET
JOB SHEET TITLE : SITE ERECTION OF REAR SUPPORT 1 of 1
1. Assemble the rear support (Items supplied loose) to the Job Sheet 1
lugs welded to the sootblower beam.
2. Position the sootblower to the boiler-mounted wallbox. Inst Drawing
Assemble the rear support screwed rod arrangements to

3.
the supporting steelwork.
108
SECTION 12

SOOTBLOWER TYPE : IK500 SERIES SHEET
JOB SHEET TITLE : COMMISSIONING CHECK LIST
1 of 1
NOTE
Steps 1 to 5 should be taken before the boiler comes on-
load and without the blowing medium on.
1. Check that the sootblower is complete as specified in the

equipment identification form at the front of the manual. It
is particularly important to ensure that the correct soot-
blower has been installed ; this can be checked by
reference to the equipment identification form and the serial
number typed on the sootblower nameplate.
2. Check that the mounting and connecting bolts are secure Job Sheet 1
and that all connections have been properly made as
specified in the installation section of the manual.
3. Check that all moving parts are free to move & have been
lubricated as specified in Section 7, and that there are no
obstructions on the rack or track.
4. Operate the sootblower manually and check that all of the Job Sheet 7
mechanisms function correctly.
5. Operate the sootblower from the local push-button (When Job Sheet 8
fitted) to check the direction of travel and the operation of
the limit switches; repeat from the remote control panel.
6. Operate the sootblower with the blowing medium 'ON'. Job Sheet 6
Check for leaks and rectify as necessary.
7. Operate the sootblower with the blowing medium 'ON'. Job Sheet 5
Check the blowing pressure and reset as necessary.
109
SECTION 12
DIAMOND POWER JOB SHEET No.4A

JOB SHEET TITLE : BLOWING MEDIUM TURN-ON LINKAGE
1 of 1
ADJUSTMENT PROCEDURE
CAUTION
Do not operate the blowing medium turn-on linkage by
hand with the poppet valve under pressure.
1. Check the amount of adjustment required by reference to

the illustration shown below.
2. Loosen the locking nut and rotate the adjusting rod. Re-
tighten the locking nut when adjustment is correct.
AUGUST 2003 FORM 12686/1

110
SECTION 12

JOB SHEET TITLE : POPPET VALVE:-
1 of 2
Checking/Setting the Blowing Pressure
NOTE
The Blowing pressure can only be set under normal working
conditions, i.e. with blowing medium available.
1. Check that the sootblower is in the fully-retracted position.
2. Check that the poppet valve is in the closed position.
3. Isolate the poppet valve from the blowing medium supply.
4. Isolate the sootblower from the power supply.
5. Determine the blowing pressure.
6. Disconnect the syphon tube from the air relief valve. When Applicable
7. Remove the 3/8"in BSPT blanking plug from the air relief
valve.
8. Connect a suitable pressure gauge to the air relief valve Section 4

outlet.
9. Remove the lock pin plug from the poppet valve, and coat the
threads with an anti-seize compound, replace the lock pin.
111
SECTION 12

2 of 2
Checking/Setting the Blowing Pressure
10. Turn on the blowing medium supply.
11. Reconnect the power supply.
12. Open the poppet valve by running the sootblower carriage As Applicable
forward from the “LOCAL/MANUAL” control position, and
note the pressure gauge reading.
13. Run the sootblower back to the fully-retracted position,

ensuring that the poppet valve closes.
14. Remove the lock pin plug.
15. Using a screwdriver inserted through the tapped lock pin

side hole, rotate the pressure control disc clockwise to
lower or anti-clockwise to raise, thus decreasing or
increasing the blowing pressure between the valve seat and
the valve disc.
16 Replace the lock pin plug after adjustment has been

completed, ensuring that it seats in one of the deep flutes
in the disc.
17. Repeat steps 12-16 until the recommended blowing

pressure is obtained.
19. Remove the pressure gauge.
20. Reconnect the syphon tube to the air relief valve. When Applicable
21. Replace the blanking plug.
24. Test run the sootblower.
FORM 12687 JANUARY 2004
112
SECTION 12

JOB SHEET TITLE : PRESSURE SEALING POINTS :-
1 of 1
Checking Procedure
NOTE
A check should be made for leakage at the pressure sealing
points listed below. This should be carried out by operating
the sootblower with the blowing medium on.
1. Poppet Valve to Companion Flange :

Tighten the gasket - if leakage persists, remove the poppet Job Sheet 12
valve and renew the gasket.
2. Feed Tube to Poppet Valve :

3. Lance Tube :
If leakage is detected, tighten the retaining bolts which Job Sheet
secures the lance tube flange to the lance hub. If leakage 21 and 22
persists after further tightening, renew the gasket.
4. Feed Tube Packing :

Check for leakage. If leakage is detected, tighten the Job Sheet 11
packing gland to eliminate the leakage. Do not tighten the
packing gland more than is necessary as this will shorten
the packing life and increase the load on the motor. If the
leakage persists, renew the packing.
5. Poppet Valve Stem Packing :

Check for leakage. If leakage is detected, tighten the brass Job Sheet 15
packing nut beneath the valve spring by turning it in a
clockwise direction until the leakage has been eliminated. If
the leakage persists, renew the packing.
113
SECTION 12

JOB SHEET TITLE : FUNCTIONAL CHECKS :-
1 of 1
Prior to Electrical Operation
1. Ensure that both the power and blowing medium supply

have been isolated from the sootblower to be checked.
2. Ensure that the limit switch lever arms are in the correct Job Sheet 33
position to receive the trip pin as the carriage moves
forward.
3. Ensure that the blowing medium valve turn-on cam is in the Job Sheet 4
correct position to receive the trip stud as the carriage
moves forward.
4. Move the carriage forward manually and check the points Job Sheet 9
as follows :
(a) Trip stud on the carriage engages the blowing medium Job Sheet 4
valve turn-on cam correctly, adjust if necessary.
(b) The position of the nozzle jets as the blowing medium

valve opens. The jets should be at least 50mm clear of
the boiler wall. Refer to the contract drawings for the
design dimensions. Adjust the position of the trip pin if
necessary.
(c) Indexing (If Applicable) - The lance should not rotate Equipment I.D.
during the first 50mm of forward travel. Form
(d) Oscillating movement (If Applicable) and blowing arc. Job Sheet 34
(e) Operation of the forward Limit switch by the trip pin on

the carriage.
5. Reverse the carriage travel and check the following :

(a) Indexing (If Applicable) - The lance should not rotate
during the first 50mm of forward travel.
(b) The forward limit switch is reset by the carriage trip pin.
(c) Trip stud engages the cam on the blowing medium turn
on linkage smoothly & closes the blowing medium valve.
(d) Carriage trip pin operates the rear limit switch.
114
SECTION 12

JOB SHEET TITLE : PRE-OPERATIONAL CHECKS 1 of 1
(WITH POWER ON)
1. Ensure that the sootblower to be checked is isolated from

the blowing medium and that it has been checked as
specified in Job Sheet 7.
2. Move the carriage forward manually until the trip pin on Job Sheet 9
the carriage clears the rear limit switch.
3. Switch ON the power supply - refer to the control panel

instruction manual if in doubt.
4. Press the local 'START' push-button and observe the

direction of travel - if the carriage travels towards the rear
limit switch switch OFF, isolate the sootblower from the
power supply, remove the terminal box cover, and switch
two of the three-phase supply wires to correct the travel
direction. Replace the terminal box cover and press the
'START' push-button again - direction of travel should now
be towards the forward limit switch.
5. Trip the forward limit switch and check that the carriage Job Sheet 33
retracts. If the forward limit switch is a stay-put type (i.e.
not spring-return), manually return the carriage to the
correct position to accept the trip pin.
6. Ensure that the carriage stops when the trip pin operates
the rear limit switch – if it does not stop, switch OFF and
investigate the fault.
7. Press the local 'START' push-button again and allow the

soot-blower to run through a complete cycle - observe the
amperage as it operates and compare it with the motor
rating plate figure to determine if overloading is occuring.
Rectify if necessary.
115
SECTION 12
DIAMOND POWER JOB SHEET No.9B

JOB SHEET TITLE : MANUAL OPERATION 1 of 1
NOTE
If a fault develops with a set of sootblowers during auto-
matic sequential operation, those in use should retract
automatically. If they fail to do so for any reason, such as
power failure, motor stalled, etc., immediate action must be
taken to withdraw the sootblowers involved.
IK500 sootblowers can be operated manually by attaching the Section 9

ratchet wrench supplied to the square tang on the carriage.
Alternatively, the optional emergency retract air tool can be
used to move the carriage manually. The air tool consists of a
vane-type air motor, shaft coupling, hose, quick-release
coupling, and manual shut-off valve. The motor operates on a
clean dry supply of blowing medium at 0.55 MPa - 0.69 MPa
pressure (5.5 - 6.9 Bar).
2. Attach the ratchet wrench, or emergency retract air tool, to Section 9

the square tang on the end of the carriage. The location of
the square tang is shown in the illustration below.
3.
Rotate the square tang in an anti-clockwise direction to return
the carriage towards the normally fully-retracted position.
NOTE
(a) It is essential to keep the blowing medium supply ‘ON’ to
cool the lance tube until it is retracted.
(b) The sootblower must always be returned to the fully
retracted position after manual operation to reset the limit
switches.
116
SECTION 12

JOB SHEET TITLE : FEED TUBE PACKING - SPLIT RING: 1 of 2
ADJUSTING THE PACKING GLAND.
2. Shut off the blowing medium supply.
3. Tighten the two packing gland nuts, just enough to prevent

leakage. The position of the packing gland nuts is shown in
the illustration below.
NOTE: The feed tube packing, which provides a seal

between the stationary feed tube and the
translational lance hub, is compressed in the
stuffing box by the adjustable packing gland
surrounding the feed tube.
The gland can be tightened until the gland shoulder butts

against the end of the lance hub.
On applications where superheated steam is used as the

blowing medium, tighten the packing gland when the feed
tube is at its hottest condition, as described in Step 3. This
procedure will increase the life of the packing and prevent
over-tightening due to thermal expansion.
4. If persistant leakage occurs, and further tightening does

not stop it, add additional packing up to a maximum of
three rings.
117
SECTION 12

JOB SHEET TITLE : FEED TUBE PACKING - SPLIT RING: 2 of 2
5.0 Adding Additional Packing
5.1 Remove the two nuts which secure the packing gland to
the lance hub. Slide the packing gland towards the rear
bulkhead.
5.2 Fit new additional split-ring packing into the stuffing box Section 9
using a packing tool.
5.3 Replace the packing gland.
5.4 Replace the packing gland nuts, and hand-tighten them

only.
8. Test-run the sootblower.
9. Adjust the packing gland, if necessary, to ensure a tight

seal, by tightening the nuts evenly.
118
SECTION 12

JOB SHEET TITLE : FEED TUBE PACKING - RENEWAL 1 of 3
(SOLID RING)
2. Shut off the blowing medium supply isolating valve.
3. Remove the four nuts which secure the poppet valve to the
sootblower via the mounting bracket and feed tube
clamping plate.
Remove the two bolts and lockwashers which secure the

4. feed tube clamping plate to the mounting bracket.
Slide the feed tube clamping plate forward along the feed
5. tube to expose the feed tube flange.
Slide the feed tube forward (towards the nozzle).

6.
Remove the gasket, key, and feed tube flange and
7. clamping plate.
Remove the two nuts, locknuts, and washers which secure

8. the packing gland to the hub assembly; slide the packing
gland towards the valve mounting bracket and put the
packing gland aside for re-use.
Remove the old packing

9.
119
SECTION 12

(SOLID RING)
10. Clean out the stuffing box and ensure that all associated
components are also clean and free from damage.
11. Inspect the packing bushing and renew it if required
12. Carefully unwrap the replacement packing set and arrange

it on a suitable surface parallel to the feed tube, ensuring
that the angle of the intermediate packing. rings is
positioned as shown below.
13. Slide the front graphite fibre header ring onto the feed
. tube, pushing it firmly home against the stuffing box
bushing.
14.
Fit each intermediate ring separately, ensuring at all times
that the correct direction of the packing slope is
maintained relative to the front of the sootblower. Push
each ring fully home before fitting the next one.
15.
Fit the rear fibre header ring, ensuring that the flat face is
outermost.
16.
Replace the packing gland
17.
Replace the packing gland nuts loosely, so that the packing
gland is just in contact with the packing.
FORM 12693/2 AUGUST 2003
120
SECTION 12

(SOLID RING)
18. Reassemble the key, feed tube flange nut, and feed tube
clamping plate, and install a new gasket. Slide the feed tube
back towards the mounting bracket.
19. Hand-tighten the packing gland nuts.
20. Reassemble the feed tube clamping plate to the mounting

bracket. Torque the two M10 bolts c/w lockwashers as
indicated. The function of the two bolts is to keep the feed
tube in position while the poppet valve is being fitted to the
sootblower.
21. Secure the poppet valve to the sootblower via the mounting
bracket and feed tube clamping plate, using the four M20
nuts.
NOTE:- Adjust the feed tube flange nut to establish a nominal
3mm gap between the faces of the poppet valve and
mounting bracket. This adjustment should be carried out
before torque is applied to the four poppet valve retaining
nuts and is necessary to guarantee a satisfactory sealing
point between the poppet valve and feed tube.
22.
Turn on the blowing medium supply.
23.
Reconnect the power supply.
24.
Test-run the sootblower.
25.
Adjust the packing gland, if necessary, to ensure a tight seal,
by tightening the nuts evenly.
CAUTION
After several operations of the sootblower, newly installed
packing should be re-adjusted. Re-tighten the gland nuts until
the gland is firmly seated against the packing. The maximum
permissible torque is 10Nm (7lbs ft.).
If, during normal operation, steam leaks are observed further
packing adjustment will be necessary.
Warning:- Do not over-tighten.
121
SECTION 12

(SPLIT RING)
3. Move the carriage forward, manually, a short distance, to

obtain working clearance.
4. Remove the two packing gland nuts and two locknuts

holding the packing gland in position.
5. Slide the packing gland to the rear of the feed tube.
6. Remove the old packing rings with a flexible packing hook.

Direct the hook at the bore of the stuffing box to avoid
damaging the feed tube.
7. Carefully clean the carriage hub stuffing box, packing

gland, and all components. A solvent may be required to
remove any traces of gum.
8. Inspect the feed tube and stuffing box for scratches, nicks,
or wear.
9. Repair or renew any damaged parts.
10. Lay out each packing ring in the correct sequence and
direction for installation.
11. Using both hands, and with the diagonal cut held upward,
fit the first packing ring on the feed tube.
122
SECTION 12

(SPLIT RING)
12. Gently insert the packing ring into the stuffing box.
13. Clamp the feed tube packing tool around the feed tube,
with the bevelled end towards the stuffing box; gently
press the packing ring into place.
14. Repeat the procedure with the remaining packing rings,

indexing each diagonal cut 90° with the preceding ring.
15. Insert the last packing ring, and reverse the packing tool,
placing the square end towards the stuffing box; firmly
press the packing ring into position.
16. Remove the packing tool and slide the packing gland into
position.
17. Tighten the gland nuts evenly until the packing is slightly
compressed; maximum torque is 10Nm (7 lbs.ft.).

CAUTION
After several operations of the sootblower, newly installed
packing should be re-adjusted. Re-tighten the gland nuts until
the gland is firmly seated against the packing. The maximum
permissible torque is 10Nm (7lbs ft.).
If, during normal operation, steam leaks are observed further
packing adjustment will be necessary.
Warning:- Do not over-tighten.
FORM 12694 JUNE 2000
123
SECTION 12

JOB SHEET TITLE : POPPET VALVE :- 1 of 1
REMOVAL FROM SOOTBLOWER
1. Isolate the sootblower from the power supply to prevent

automatic operation of the unit.
3. Disconnect the air relief valve from the scavenging air line
and siphon tube (when fitted).
4. Remove the nut, bolt and spacer, from the cam assembly
at the poppet valve trigger.
5. Disconnect the poppet valve at the companion flange.
6. Disconnect the poppet valve at the mounting bracket.
7. Remove the poppet valve from the sootblower.
124
SECTION 12

SOOTBLOWER TYPE : IK-500 SERIES SHEET
JOB SHEET TITLE : POPPET VALVE: DISMANTLING
1 of 1
NOTE
This Job Sheet covers partial dismantling of the poppet
valve in preparation for valve seat lapping or renewal.
1. Remove the poppet valve from the sootblower. Job Sheet 12
2. Remove the yoke cotter pin and withdraw the valve yoke
pin from the yoke.
3. Remove the trigger cotter pin and withdraw the trigger pin
from the valve.
4. Remove the trigger and replace the trigger pin only.
5. Depress the valve spring just enough to allow removal of Section 9

the yoke; use the optional valve spring depressing tool.
6. Remove the yoke and release the spring tension.
7. Lift off the valve spring retainer and the valve spring.
8. Remove the valve stem and disc assembly.
9. Remove the packing nut and packing washer.
10. Remove the valve stem packing.
125
SECTION 12

JOB SHEET TITLE : POPPET VALVE :
1 of 2
(Valve Stem Packing Adjustment Procedure)
NOTE
If leakage occurs at the valve stem at the top of the poppet
valve body, this is an indication that the valve stem packing
nut requires tightening, or that the valve stem packing should
be renewed.
1. Using the valve packing spanner, turn the brass packing nut Section 9
beneath the valve spring in a clockwise direction, tightening
just enough to prevent leakage. Overtightening will shorten the
packing life and may cause the valve stem to bind. The
packing nut should be torqued to 23 NM (17 lbs.ft.) maximum.
Refer also to note 6.
2. If persistant leakage occurs, and further tightening does not Job Sheet 15
stop it, renew the packing.
126
SECTION 12

2 of 2
NOTES:
1. Valve Stem Guide, Lock Pin and Plug threads to be
coated with ‘Molykote Gn Plus’.(907145-0002)
6. This clearance dimension should be set between the

bottom face of the packing nut hex and the top face of
the valve stem guide hex. Increasing this dimension
above 8mm can cause the spring to hard stop when the
valve is fully open. Decreasing this dimension below
3.5mm may cause problems with the valve stem
packing.
7. Ensure valve stem packing rings are assembled as

shown.
127
SECTION 12

1 of 2
(Valve Stem Packing Renewal)
1. Isolate the sootblower from the power supply to prevent the

automatic operation of the sootblower.
3. Remove the yoke cotter pin and withdraw the valve yoke pin Job Sheet 13
from the valve yoke.
4. Remove the trigger cotter pin and withdraw the trigger pin
from the valve.
5. Remove the trigger and replace the trigger pin only.
6. Depress the valve spring just enough to allow removal of the Section 9
yoke : use the valve spring depressing tool.
NOTE
To prevent the valve stem and disc assembly from falling into
the poppet valve, the valve stem should be held up during this
operation.
8. Lift off the spring retainer and the spring; then remove the
packing nut, packing washer, and old packing from the valve
stem.
9. Insert the new packing, staggering the splits in the rings by Section 10
90°. Use only the packing specified in the Parts list.
10. Seat each ring separately.

128
SECTION 12

2 of 2
11. Reassemble the poppet valve in the reverse order to that given
for dismantling.
CAUTION
Tighten the packing just enough to ensure that the spring is
not coil bound when the valve is fully open. A valve packing
spanner, for turning the packing nut, is available for this
operation. The packing nut should be torqued to 23 NM (17
lbs. ft) maximum. Refer also to note 6.
NOTES:
1. Valve Stem Guide, Lock Pin and Plug threads to be coated
with ‘Molykote Gn Plus’.(907145-0002)
the valve stem guide hex. Increasing this dimension above
8mm can cause the spring to hard stop when the valve is
fully open. Decreasing this dimension below 3.5mm may
cause problems with the valve stem packing.

129
SECTION 12

SOOTBLOWER TYPE : IK500 Series SHEET
JOB SHEET TITLE : POPPET VALVE : Tools and Equipment
1 of 1
Required for Lapping the Valve Seat.
NOTE
The tools and equipment required for lapping are as follows:-
1. One disc is serrated, for rough lapping, and the other disc is
plain, for finishing and burnishing. The surfaces of both discs
must be kept lapped flat; a lapping machine, or surface plate ,
can be used to maintain the disc surfaces.
2. Lapping Compounds:- Section 9

Diamond Compound, Hyprez 45.
3. Lapping Equipment:- Section 9

Wobble stick, manually-operated valve grinder, or small
capacity air motor with flexible shaft.
4. Inspection Equipment:-
Blue block - for checking flatness. An unused lapping disc,
which is absolutely flat, can also be used.
Prussian blue - to determine high and low markings.
JULY 1996 FORM 12699
130
SECTION 12

1 of 2
VALVE SEAT LAPPING PROCEDURE
1. Dismantle the poppet valve. Job Sheet 13
2. Charge an unused serrated lapping disc with Hyprez 45 Section 9

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

surface at the end of each cycle.
4. Clean off any traces of compound from the seat.
5. Charge an unused plain lapping disc with Hyprez 14

compound.
6. Finish lap for two-five minute cycles, checking the valve seat
surfaces at the end of each cycle.
8. Charge the plain lapping disc with Hyprez 3 compound Section 9
9. Burnish-lap for five minutes.
11. Cover the surface of a blue block with a very thin uniform
coating of Prussian blue.
12. Place the blue block carefully on the lapped seat.
13. Applying finger pressure only, move the blue block back and
forth slightly.
14. Carefully remove the blue block.
15. Inspect the lapped seat. If the dye transfer is uniform, the seat
is satisfactory; if not uniform, then the seat is not flat and the
complete lapping procedure must be repeated.
16. After the lapping procedure is completed, clean the valve body
with white spirit, using a small bristle brush.
131
SECTION 12

2 of 2
17. Dry the body with air, or by wiping. Special care should be
taken to remove all minute particles of fuzz and paper shreds.
18. Reassemble the valve in the reverse order to that given for Job Sheet 19
dismantling.
FORM 12700 JULY 1996
132
SECTION 12

JOB SHEET TITLE : POPPET VALVE : SEAT RENEWAL 1 of 2
2. Remove the old seat by machining the weld away. Avoid Poppet Valve Assy
removing material from the shoulder under the seat, as this Section 10
shoulder positions the new seat to the correct depth in the
body.
3. Assemble and position the new seat into the body, using a Section 9
seat protector. The protector, in addition to preventing
injurious material from reaching the seat, locates the seat
correctly in relation to the valve stem guide. Care should be
taken to ensure that the pressure control disc is correctly
orientated. Tighten the locknut finger-tight to hold down the
seat during welding.
4. Select an approved welding rod and hold it at

approximately85°, to deposit more metal on the seat than on
the body. Two 2.4mm (3/32in) diameter rods should be used
per seat.
* Equivalent to AWS 5.18 Class ER-70s-G or BS2901 Part1(1970) A18. *MIG wire
* Equivalent to AWS E7028 or BS639 (1976) E5144H. * Welding Rod
133
SECTION 12

5. Using D.C. welding equipment set at 82-92 amperes (reverse

polarity), start welding at 90° from the point of least
clearance between the body and the seat. Make a single pass
weld only, with no initial tacking. Proceed towards the point of
least clearance.
6. Overlap 13-19mm (1/2in-3/4in) between rod applications.

Clean the slag from the welded area between applications.
7. Upon completion of welding, chip off any remaining slag from

the weld.
8. Ensuring that the sealing surfaces are protected, carefully wire

brush the valve body.
9. Lap the valve seat to ensure a flat surface. Job Sheet 17
10. Reasemble the valve in the reverse order to that given for Job Sheet 19
dismantling.
134
SECTION 12

1 of 1
REASSEMBLY PROCEDURE
NOTE
This procedure covers reassembly after partial dismantling for
seat-lapping or renewal. The valve should be reassembled in
clean conditions to reduce the possibility of grit being trapped
between the sealing faces.
The reassembly procedure is as follows :
1. Place the poppet valve on its side.
2. Instal the stem and disc assembly, taking care to ensure that
the sealing faces are clean and undamaged.
NOTE
Maintain firm contact between the sealing faces during the
subsequent steps.
3. Insert the new valve stem packing, staggering the splits in the
rings by 90°; seat each ring separately.
4. Replace the packing washer.
5. Replace the packing nut and screw it down hand tight only;
adjust on assembly.
6. Place the valve body in an upright position.
7. Replace the valve spring, valve spring retainer and valve yoke.
NOTE
If the valve is not to be put into service immediately, the inlet
and outlet should be sealed to protect the internals.
8. Replace the trigger and trigger pin.
9. Replace the yoke pin and yoke cotter pin in the valve yoke.
10. Replace the poppet valve on the sootblower. Job Sheet 20
135
SECTION 12

1 of 2
REPLACING ON THE SOOTBLOWER
1. Ensure that the sootblower is isolated from the power supply and
that the blowing medium supply is shut off.
2. Ensure that the valve inlet and outlet sealing surfaces are clean
and undamaged.
3. Fit a new feed tube gasket to the poppet valve outlet.
4. Position the poppet valve on the sootblower with the four studs
projecting through the mounting bracket and rear bulkhead. (rear
bulkhead not shown in illustration below).
5. Ensure that the feed tube retaining ring groove is clean and the
edges free from burrs.
6. Ensure that the retaining ring is fully seated in the groove of the
feed tube with the sharpest edge of the retaining ring installed
towards the rear bulkhead.
7. Push the feed tube with the associated clamping plate through
the rear bulkhead until it makes contact with the feed tube
gasket.
8. Slide the feed tube clamping plate along the feed tube ensuring
that the counter bore in the clamping plate engages squarely over
the retaining ring.
NOVEMBER 2001 FORM 12703/1

136
SECTION 12

2 of 2
REPLACING ON THE SOOTBLOWER
9 Loosely fit the locking washers and securing nuts which retains
the poppet valve to the rear bulkhead via the clamping plate.
10. Locate and tighten the two screws of the clamping plate in turn
by torquing them in small increments to 41NM (30 lb.ft.)
maximum. This procedure will ensure that the clamping plate is
pulled squarely on to the retaining ring, compressing the feed
tube gasket between the poppet valve and the end of the feed
tube.
11. Tighten the poppet valve locking washers and securing nuts in
turn by torquing them in small increments to 75NM (55 lb.ft.).
For each nut, bend up only one tab of the locking washer.
12. Fit a new companion flange gasket.
13. Reassemble the companion flange to the poppet valve.
14. Reassemble the cam and arm assembly to the poppet valve
15. Reassemble the air relief to the poppet valve.
16. Reconnect the scavenging air line and syphon tube When fitted
19. Test run the sootblower, checking for leaks.
20. Reset the blowing pressure
FORM 12703/1 NOVEMBER 2001

137
SECTION 12

JOB SHEET TITLE : LANCE TUBE GASKET:- 1 of 1
ADJUSTING PROCEDURE
NOTE
The lance tube flange gasket is compressed between the
lance hub and the lance tube flange by tightening the
retaining bolts as follows:
1. Tighten the six bolts in the sequence shown in the

illustration below and observe the gap recommendation.
The bolts should be torqued to 136Nm (100 lbs.ft).
NOTE
The torque figure given applies to bolts coated with anti- Section 7
seize compound. Higher torque may be necessary when re-
tightening in service.
2. If persistant leakage occurs and further tightening does not Job Sheets
stop it, renew the gasket. 22 & 23
138
SECTION 12

JOB SHEET TITLE : LANCE TUBE GASKET - 1 of 2
RENEWAL
1. Ensure that the carriage is in the fully-retracted position.
4. Remove the four nuts which secure the poppet valve to

mounting bracket, and remove the two cap screws and
lockwashers which secure the feed tube clamping plate to the
mounting bracket.
5. Slide the feed tube clamping plate forward on the feed tube,
and remove the key from the feed tube keyway.
6. Remove the two nuts and locknuts holding the packing gland
in position.
7. Slide the packing gland to the rear of the feed tube. Job Sheet 23
8. Remove the feed tube packing. Job Sheet 11
9. Push the feed tube foward and remove the flange.
10. Continue pushing the feed tube forward until the end is well
into the carriage lance hub stuffing box.
11. Remove the auxiliary support assembly. (IK545B only)
12. Support the lance tube and feed tube securely, using slings
and a hoist.
13. Remove the six bolts from the lance tube hub flange.
14. Move the lance tube and feed tube forward far enough to
clear the carriage lance hub.
15. Lower the flange end of the lance tube, along with the feed
tube, enough to gain easy access for renewing the lance tube
gasket.
139
SECTION 12

JOB SHEET TITLE : LANCE TUBE GASKET - 2 of 2
RENEWAL
16. Remove the existing gasket.
17. Examine the locating face of the lance hub and the lance
flange.
18. Clean the locating face and remove any loose particles of
dirt, or existing gasket, as applicable.
19. Insert a new gasket in position.
20. Reassemble in the reverse order to that given for

dismantling.
NOTE
Job Sheet 21
(a). Coat the threads of the six lance hub flange bolts with &
anti-seize compound before reassembly, and torque to Section 7
136 Nm (100 lbs.ft.)
(b). Screw the feed tube into the feed tube flange far
enough to provide approximately 3 mm (1/8 in.) gap
between the face of the poppet valve and the mounting
plate.
(c). The torque figures given apply to bolts coated with

anti-seize compound. Higher torque may be necessary
when re-tightening in service.
140
SECTION 12

JOB SHEET TITLE : LANCE TUBE AND FEED TUBE :
1 of 2
(REMOVAL)
1. Ensure that the carriage is in the fully retracted position.
mounting bracket, and remove the two cap screws and
lockwashers which secure the feed tube clamping plate to
the mounting bracket.
5. Slide the feed tube clamping plate forward on the feed tube
and remove the key from the feed tube keyway.
6. Remove the two nuts and locknuts holding the packing

gland in position.
8. Remove the feed tube packing. Job Sheets 11A /11B
9. Push the feed tube forward and remove either the flange or
the retaining ring, as applicable.
10. Continue pushing the feed tube forward until the end is well
into the carriage lance hub stuffing box.
11. Remove the auxiliary support assembly. (IK-545B Only)
12. Support the lance tube and feed tube securely, using slings
and a hoist.
13. Remove the six bolts and lockwashers from the lance tube
hub flange.
14. Move the lance tube and feed tube forward far enough to
clear the carriage lance hub.
15. Lower the lance tube and feed tube clear of the sootblower.
141
SECTION 12

JOB SHEET TITLE : LANCE TUBE AND FEED TUBE :
2 of 2
(REMOVAL)
16. Install new lance and feed tubes, if required. Job Sheet 22
17. Reassemble in reverse order to that given for dismantling.
142
SECTION 12

JOB SHEET TITLE : CARRIAGE - REMOVAL
1 of 1
1. Ensure that the carriage is in the fully retracted position. Job Sheet 9
4. Support the lance tube by blocking up from the lower

flange of the beam.
5. Disconnect the lance and feed tubes. Job Sheet 23
6. Disconnect or Unplug the expanda cable from the motor

terminal box.
7. Remove the limit switch trip pin located on the carriage.
8. Remove the cover plate, screws and lockwashers from the

access hole on top of the beam.
9. Remove the loop control tow bar from the carriage.
10. Remove the two short carriage support angles at the rear of
the beam.
11. Lower the carriage clear of the sootblower.
12. Reassemble in the reverse order to that given for removal.
CAUTION:- It is extremely important that the carriage drive

pinions are in alignment with the two gear racks
to prevent abnormal stress loads at the lance
hub joint and to keep rack wear to a minimum.
Carriage alignment may be checked by removing
the inspection plates on both sides of the beam
and measuring from the rear of the beam to the
tooling centre holes in both ends of the pinion
shaft. If the variance is greater than 6mm (¼
in), the pinions are not engaged correctly with
the corresponding adjacent rack teeth.
143
SECTION 12
DIAMOND POWER JOB SHEET No.25C

SOOTBLOWER TYPE : IK500 SERIES / IKSD-E SHEET
JOB SHEET TITLE : CARRIAGE DISMANTLING (1)
1 of 1
(Motor & Primary Gear Change Assy)
(FOR SERIES ONE CARRIAGE DRG NO. 398067-0040)
1. Remove the drain plugs from the bottom of the carriage

housing and completely drain the oil from the carriage
sump.
2. Remove the three nuts ,screws and lockwashers which

secure the motor to the change gear housing.
3. Remove the motor and gasket from the change gear

housing
4. Remove the seven cap screws and lockwashers and remove

the change gear housing .
5. Remove the cap screw, washer , motor, spur gear, key and
distance piece from the motor shaft.
6. Remove the retaining ring and key and slide the spur gear
from the shaft and bearing assembly.
7. Check the gears for wear or damage.
8. Renew any components, if necessary.
9. Coat the gear teeth with the recommended lubricating oil. Section 7
NOTE
(a) Cap screws should be lubricated to assist removal.
(b) Raise the motor and change gear assy to the uppermost
position, within the clearance of the cap screw holes, to
ensure maximum running clearance between the motor spur
gear and the worm shaft spur gear before tightening the six
cap screws.
11. Replace the drain plugs and refill the carriage sump with oil
to the correct level shown on the oil level window.
144
SECTION 12

1 of 1
(Rollers and Rack Pinions)
1. Remove the retaining rings from both ends of the pinion

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

pinion shaft.
3. Check the condition of the bearings for flat spots, etc, by

rotating the inner race relative to the outer race.
4. Check the pinion teeth for wear.
5. Renew any components, if necessary.
6. Coat the gear teeth with a recommended lubricating oil. Section 7

dismantling.
NOTE
One face of each rack pinion is marked with an 'X' to
maintain the origional tooth wear patterns. Make sure that
the pinions are re-installed on the same end of the shaft
and
that the marks on the pinions are facing in the same
direction as they were before removal.
145
SECTION 12

SOOTBLOWER TYPE : IK500 Series / IKSD-E SHEET
1 of 2
(Pinion Shaft, Pinion, Spur Gear & Roller Assy's)
1. Remove the motor and gear change housing. Job Sheet 25
2. Remove the carriage rollers and pinions. Job Sheet 26
3. Remove the cap screws and lockwashers and lift off the
cover plate and gasket.
4. Remove the seal and retaining ring which secures the

bearing to the outer carriage support hub.
5. Spread the retaining ring and slide it back along the shaft
away from the spur gear to the end of the keyway. Do not
stretch the retaining ring out of shape.
6. With a rawhide mallet, drive the pinion shaft towards the

lance hub side of the carriage. As the shaft is removed, the
outboard bearing, seal, inboard bearing and key will
accompany it, leaving the spur gear in the carriage housing.
7. As the end of the pinion shaft passes through the the gear,
remove the retaining ring before it drops to the bottom of
the carriage housing.
8. Check the gears, bearings and seals for wear or damage.
10. Reassemble in the reverse order to that given for dismantling.

NOTE
When the shaft passes through the gear, position the key- Section 7
ways of the shaft and gear upward, install the retaining ring
and move it towards the near end of the keyway. When the
shaft is in position, lubricate the seal lip & the mating shaft
with a recommended light oil.
11. Insert key in the keyway and slide it into the gear. Move
the retaining ring into the groove next to the gear hub;
ensure that the ring is seated correctly.
146
SECTION 12

SOOTBLOWER TYPE : IK500 Series / IKSD-E SHEET
2 of 2
(Pinion Shaft, Pinion, Spur Gear & Roller Assy's)
12. Replace the support bearing retaining ring, pinion, spacer,

roller, housing cover, and gasket. Ensure that the retaining
ring is seated in the groove correctly.
13. Reassemble the carriage rollers and pinions. Job Sheet 26
FORM 14682/2 SEPTEMBER 1999
147
SECTION 12

1 of 2
(Lance Hub & Bevel Gear Assembly)
1. Remove the carriage from the sootblower.
2. Drain oil from carriage via the two drain plug holes.
3. Remove the key and hub flange from the lance hub and
bevel gear assembly.
4. Remove the four cap screws and lockwashers which secure

the front bearing retainer and packing assy to the carriage
housing.
5. Remove the bearing retainer, packing assy and gaskets

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

7. Remove the bearing and lance hub spacer from the

threaded end of the lance hub and bevel gear assy.
8. Remove the bevel gear and retaining ring from the threaded
end of the lance hub and bevel gear assy.
9. Remove the four cap screws and washers which secure the
rear bearing retainer and packing assembly to the carriage
housing.
10. Remove the bearing retainer and packing assembly, gasket

and the second lance hub bearing.
11. Remove the key and bevel-pinion gear from the lance drive
shaft assembly.
12. Check the bevel-pinion gear for wear and damage and
check the condition of both lance hub bearings.
148
SECTION 12

2 of 2
(Lance Hub & Bevel Gear Assembly)
13. Re-new any components, if necessary.
14. Lubricate the bearings through the grease nipples. Section 7
NOTE
Cap screws should be lubricated to assist removal. Section 7
149
SECTION 12

1 of 1
(Shaft and Bearing Assembly)
1. Remove the motor and change gear assembly. Job Sheet 25
2. Remove the four cap screws and lockwashers which secure

the bearing retainer to the carriage housing.
3. Withdraw the bearing retainer, worm shaft spacer and the

shaft and bearing assembly from the carriage housing.
4. Remove the four cap screws and lockwashers and

withdraw the emergency retract flange oil seal and shims
5. Check the condition of the bearings and worm teeth and

inspect the shaft oil seal.
6. Re-new any components, if necessary.
7. Re-assemble in the reverse order to that given for

dismantling.
NOTE
(a) Replace all shims to allow 0.025mm to 0.127mm
(0.001 to 0.005 in) axial movement of the worm shaft.
(b) Use a light oil on the seal lip and mating shaft. Care Section 7
should be taken not to damage the seal lip.
(c) Thrust bearings must be installed on the worm shaft

with the thrust side towards the end of the shaft, as
shown in the illustration below. The thrust side can be
determined by observing the thickness of the outer
bearing race from the side; the thicker of the two sides
is the thrust side.
8. Replace the motor and change gear assembly. Job Sheet 25
150
SECTION 12

1 of 1
(Shaft & Bearing & Lance Drive Shaft Assy)
1. Remove the drain plugs which are located in the bottom of

the carriage housing and drain off the oil.
2. Remove the key and the bevel-pinion gear from the Job Sheet 25
carriage housing.
3. Remove the shaft and bearing assembly from the carriage Job Sheet 27
housing.
4. Remove the six cap screws and lockwashers which secures

the lance drive shaft assembly and withdraw the complete
assembly.
5. Inspect the bearings, seals and gear teeth for wear, paying
special attention to the bronze worm gear.
6. Re-new any component, if necessary.
8. Re-assemble in the reverse order to that given for

dismantling.
NOTE
(a) Re-assemble retainer, carrier and ball bearing without
shims. Then measure the gap between the retainer and
carrier and add shims measuring (0.076mm to
0.127mm).
(b) The worm wheel should be blued and run in with the
worm shaft. To establish the correct alignment
between wheel and shaft, add shims to ensure that the
contact area of the worm is as near as possible to the
centre line of the worm wheel.
(c) All cap screws should be lubricated to assist removal. Section 7
9. Replace the drain plugs & refill with oil to the correct level.
151
SECTION 12
DIAMOND POWER JOB SHEET No.31E

JOB SHEET TITLE : EXPANDA CABLE - 1 of 2
REMOVAL AND RENEWAL
1. Select the correct size and handing of expanda cable to Section 10

suit the particular sootblower
NOTE
(a) A right-hand sootblower is one with the motor on the
right-hand side when looking from the rear of the
sootblower towards the boiler wall; similarly, a left-
hand sootblower has the motor on the left-hand side
when viewed from the same position.
(b) A right-hand sootblower uses an expanda cable coiled

in the direction of a left-hand thread; a left-hand
sootblower has the expanda cable coiled in the
direction of a right hand thread.
Disconnect the sootblower from the power supply.

2.
Disconnect both ends of the existing expanda cable.
3. Remove the tow bar arrg’t retaining screws, washers etc

on the Carriage.
4. Remove all the clips holding the expanda cable to the

beam.
5. Remove the support rod nuts at the front end of the

sootblower.
6. Loosen the locknut at the rear end of the support rod.
7. Remove the support rod from the rear of the bulkhead

plate.
8. Remove the expanda cable from the support rod.
8A Alternatively omit steps 5 and 6 and remove the expanda

cable towards the front of the sootblower after having
pushed the support rod through the front bulkhead plate.
152
SECTION 12
DIAMOND POWER JOB SHEET No.31E

JOB SHEET TITLE : EXPANDA CABLE - 2 of 2
REMOVAL AND RENEWAL

dismantling.
NOTE
The new expanda cable as supplied, has a line marked
along all the coils which is intended to assist in ensuring
that the correct coil diameter is achieved when fitting a
new cable. The position of this line around the
circumference of the coil is not important, although it must
appear on the same side of the coils in all instances as a
straight line or a wavy line, On no account should this line
spiral around the cable anywhere along the total length of
the cable.
10. Ensure that the support rod does not protrude through the
rear bulkhead plate.
11. Tension the support rod by fitting the tensioning nut to the
rear of the support rod and torque to 10 to 11 Nm (88.5 to
97.4 lb/in) approx, use a vice grip or similar, on the rod to
prevent it from turning during this operation. Fit the
locknut and torque to the above figure.
12. Re-assemble the tow bar arrg’t to the carriage. Replace all
the clips holding the expanda cable to the beam.
NOTE
Check the action of the expanda cable during the forward
travel, to see if this is satisfactory over the full length of
travel. Check during reverse travel that there is no
bunching or snagging all the way back to the rest position.
If there is a problem, check the rubber-lined clips at both
ends of the cable to see if they are holding the expanda
cable in a twisted position. Adjust, if necessary, and re-
test to check that the cable is now operating satisfactorily
throughout the total travel
153
SECTION 12
DIAMOND POWER JOB SHEET No.32P

SOOTBLOWER TYPE : IkSD-E & IK500 SERIES SHEET
JOB SHEET TITLE : WALLBOX - DISMANTLING:
1 of 3
(POSITIVE PRESSURE)

4. Attach a sling around the lifting lugs at the front and rear of
the sootblower.
5. Remove the split pins and washer(s) from the wallbox

support pins.
6. Check that there is enough slack on the control and power

cables to allow the sootblower to be pulled back until the
lance is clear of the wallbox. If not, it may be necessary to
disconnect the cables at the sootblower terminal box.
7. Remove the spacer(s) from the support pins.
8. Remove the spirolox retaining ring.
9. Remove the cover plate and seal arrg't.
FEBRUARY 2001 FORM 14500/1
154
SECTION 12

SOOTBLOWER TYPE : IKSD-E & IK500 SERIES SHEET
2 of 3
(POSITIVE PRESSURE)
10. Lift the seal plate out of the wallbox.
11. Re-assemble the wallbox using existing/new parts parts as

necessary.
NOTE 1
At assembly apply hylomar sealant to the periphery of the
cover plate, the bore of the housing, adjacent to the cover
plate and the retaining ring groove. Remove excess sealant
after assy.
This is a corrosion prevention measure.
NOTE 2
During assembly adjust screws evenly until there is no play
in the seal arrgt then turn the screws back by one half turn
each.
12. Wallbox Renewal
12.1 Disconnect the sealing air supply from the wallbox.
12.2 Remove the weld between the wallbox and the wallsleeve
12.3 Remove the wallbox housing.
12.4 Position and weld a replacement wallbox to the wallsleeve.
12.5 Check the clearance at the seal arrg't refer to 'NOTE 2'.
FORM 14500/1 FEBRUARY 2001
155
SECTION 12

SOOTBLOWER TYPE : IKSD-E & IK500 SERIES SHEET
3 of 3
(POSITIVE PRESSURE)
13. Re-install the sootblower in the reverse order to that given

for removal.
156
SECTION 12

JOB SHEET TITLE : LIMIT SWITCHES (Telemechanique):
1 of 2
RENEWAL AND ADJUSTMENT.
3. Unscrew the cable gland and connecting cable from the faulty
limit switch, noting the correct wire termination points.
4. Remove the two mounting screws, lockwashers and nuts

which secure the faulty limit switch to the beam; remove the
complete limit switch from the beam.
5. Select a new limit switch and install it in the reverse order to

that given for removal; ensure that the wires are fitted to the
same termination points.
6. Adjustment Procedure
6.1. Check that the contact roller engages correctly with the trip
bar on the carriage. The angular position of the roller crank can
be altered by loosening the adjustment screw, turning the
crank until the roller makes contact, and then tightening the
screw.
6.2. Operate the sootblower manually to check that the limit Job Sheet 9
switches operate correctly when tripped by the carriage trip
bar.
DECEMBER 2003 FORM 15394/2
157
SECTION 12

JOB SHEET TITLE : LIMIT SWITCHES (Telemechanique):
2 of 2
RENEWAL AND ADJUSTMENT.
FORM 15394/2 DECEMBER 2003
158
SECTION 12

SOOTBLOWER TYPE : IK545B SHEET
JOB SHEET TITLE : SUPPORT ROLLERS:- 1 of 1
ADJUSTMENT
(FOR SERIES ONE CARRIAGE)
3. Adjust the angle of rolling contact of the rollers to the

lance tube by altering the position of each roller bracket
assembly on the roller support bracket. An elongated hole
in each support bracket allows adjustment to be made by
loosening the two securing screws.
Check that the axis of rotation of each roller is at right

4.
angles to the helical path at the contact point
NOTE
The helical path can be found by holding a piece of chalk
on the lance tube as it is rotated manually.
After adjustment is complete, tighten the securing screws.

5.
Turn on the blowing medium supply.
6.
Reconnect the power supply.
7.
Test run the sootblower.
8.
NOTE
The above procedures apply to both front and auxiliary
support roller assemblies.
159
SECTION 13
SECTION 13
FAULT FINDING
SYMPTOM POSSIBLE CAUSE REMEDY
Sootblower fails to (1) No power voltage:

start. a. No power to starter. Check power supply.
b. Overload heater has Renew heater.

burned out.
c. Open circuit between Check continuity.

starter and motor.
(2) Motor winding open or Test and rectify circuit.

shorted.
(3) One power line open:

a. Overload relay has Re-establish continuity.
operated without the
motor starting due to
single phase condition
(4) Forward contactor fails Check continuity.

to operate.
a. No voltage from panel
on lines A and B.
b. No signal from panel

on line D.
c. If operated manually,
'START' pushbutton
fails to make contact.
d. Overload contacts are

open.
e. Coil is burned out.
f. Loose wire in forward

coil circuit.
MARCH 1995 (PAGE 1 of 3) FORM 12969
160
SECTION 13
SECTION 13
FAULT FINDING
Sootblower jams or Drive motor overloaded.

fails to travel. (1) Front rollers are not Re-align rollers.
set correctly.
(2) Lance is fouling in Check the orientation of wallbox

the wallbox. on the boiler wall.
(3) Lance is fouling on Adjust the mounting angle of the

the boiler internals. sootblower.
(4) Dirt or swarf in the Clean the wallbox using compres-

wallbox. -sed air.
(5) Feed tube packing is Adjust the packing gland.

too tight.
(6) Pinion is jamming on Inspect the rack for alignment and

the rack. clean the pinion teeth.
(7) Valve stem binding in Dismantle the poppet valve and

valve guide. inspect the valve stem. Re-new
the stem if it is damaged.
(8) Pipework incorrectly Inspect pipework and re-run if it is

supported - strain necessary.
transmitted to the
sootblower.
Sootblower fails to (1) Limit switch has not Tighten the trip lever.
stop. operated - trip lever
may be loose.
(2) Limit switch has Free or re-new the limit switch.

jammed.
Blowing medium (1) Poppet valve stem is Dismantle the poppet valve and
fails to turn off. sticking in the guide. inspect the valve stem. Re-new
the stem if it is faulty.
FORM 12969 (PAGE 2 of 3) MARCH 1995
161
SECTION 13
SECTION 13
FAULT FINDING
Blowing medium (2) Valve yoke is broken Dismantle the poppet valve.
fails to turn off. or detached from the Re-new the valve yoke.
(Continued) valve stem.
(3) Valve spring broken. Dismantle the poppet valve and

re-new the spring.
(4) Valve disc loose on Dismantle the poppet valve and

the valve stem. inspect the disc.
Re-new the disc if necessary.
(5) Operating pin broken. Re-new the pin.
(6) Cam and pin out of Re-align and re-new, if necessary.

alignment.
Lance tube fails to (1) Bevel gear teeth are Dismantle the gearbox and re-new
rotate although the stripped. the bevel gear.
motor runs.
Boiler tube abrasion (1) Blowing pressure is Re-set to establish recommended

or baffle erosion is to high. blowing pressure.
present upon internal
inspection. (2) Excess moisture is Increase temperature of blowing
present in blowing medium.
medium.
(3) Operating cycle out Check operation of poppet valve

of phase. and linkage.
MARCH 1995 (PAGE 3 of 3) FORM 12969
162
SECTION 14
SECTION 14
STORAGE, HANDLING, AND INSPECTION
DURING STORAGE
General
Damage resulting from improper handling on site, site storage, or storage
maintenance is not the responsibility of the equipment supplier. Because of the
many variables involved in site storage, however, there is always the possibility
of some damage occurring, particularly to electrical equipment on sootblowers.
This risk can be minimised by observing the instructions given in the following
paragraphs and the handling details given in paragraphs 14.2.1 and 14.2.2
14.1 STORAGE
14.1.1 Initial Receipt at Site

On receipt at site, it is recommended that IK-545B sootblowers should be
removed from their crates or boxes, all polythene wrappings removed, and the
equipment then stored in a dry building where temperature and humidity are
controlled to prevent condensation. Sootblowers should be stored the correct
way up and not on their sides.

Each sootblower should be placed on timber battens of sufficient thickness to
keep all parts of the equipment well clear of the ground. The battens should be
placed under the main beams at approximately one third of the length in from
each end. Equipment may be stacked up to three units high, in double rows, by
placing timber battens across each pair directly above the ground support
battens. To allow for inspection, electrical boxes should face outwards.

The feed tube packing and the poppet valve stem packing should be removed
and, if undamaged by removal, stored for reinstatement prior to commissioning.
The method of doing this and the part numbers for replacements are included in
the relevant sections of this manual.
14.2 HANDLING

Sootblowers which are packed in boxes or crates must be handled by slinging the
boxes. using two slings. Boxes and crates supplied are specially reinforced for the
purpose. A fork lift truck should not be used for handling IK-545B sootblowers .
163
SECTION 14
14.2.2 Handling Unpacked Equipment (Fig 17)

Sootblowers should only be moved by slinging from the four lifting lugs provided
on the top of the beam. Use of a two-point sling or fork lift truck is likely to
cause damage and prevent proper operation when installed.
FIG.17 TYPICAL SLINGING ARRG'T
14.3.1 Frequency
IK-545B sootblowers should be inspected at monthly intervals. with particular
care being given to ensuring that the closures (tape, caps. etc.) on all openings
remain intact.
14.3.2 Protective Lubrication

Prior to shipping, all gearboxes in mechanical equipment are run with a protective
oil and then drained. For prolonged storage. the gearboxes should be filled with a
protective oil. such as Esso Rustban 335. This must be drained prior to use. It is
the responsibility of the Maintenance Inspector to ensure that this is done before
operating the equipment.
FORM 14493 JUNE 2000
164
INSTRUCTION MANUAL
DIAMOND IK-1MTE
SOOTBLOWER
ELECTRIC MOTOR DRIVEN
(Customised to suit) Contract No.N10865
IM133
Diamond Power Specialty Limited

Glasgow Road Dumbarton Scotland G82 1ES
Tel: Dumbarton (01389) 744000 Fax: Dumbarton (01389) 762669
FORM 14165
165
Blowing Pressure :- 11.6 kg/cm2
Equipment Supplied :- 36 - Diamond IK1M-TE (Electric Motor Driven)

Multi-Nozzle Rotating Element Sootblower
POSITION SERIAL BOILER CUSTOMER TAG

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




166
Blowing Pressure :- 11.6 kg/cm2
Equipment Supplied :- 36 - Diamond IK1M-TE (Electric Motor Driven)

Multi-Nozzle Rotating Element Sootblower
POSITION SERIAL BOILER CUSTOMER TAG

No No No No



NOTE
167
------ IMPORTANT ------
READ THIS MANUAL

BEFORE
COMMISSIONING OPERATING
INSTALLING MAINTAINING
THIS EQUIPMENT
WARNING
This equipment may be operated by remote control
WARNING
Isolate from power and blowing medium supply before working on

equipment
WARNING
To avoid personal injury or damage to equipment during installation,

commissioning, operation or maintenance, follow the instructions given
on the Job Sheets.These instructions are of a general nature and do
not cover every circumstance.
WARNING
To maintain the safety and efficiency of the equipment, follow the maintenance
schedule instructions and use only Diamond Spare Parts as described in the
Parts Identification and Recommended Spares sections of the manual.
168
CONTENTS
SECTION TITLE
1 GENERAL DESCRIPTION
1.1 General
1.3 Application
1.4 Cleaning Principle
1.5 Operating Cycle
1.6 Identification
2 COMPONENT DESCRIPTION
2.1 ELECTRICAL
2.1.1 Electrical Components
2.1.2 Function
2.2 MOUNTING
2.2.1 Beam
2.2.2 Front Support
2.2.3 Wallbox
2.2.4 Rear Support
2.3 MECHANICAL
2.3.1 Carriage and Drive Mechanism
2.3.2 Guide Assembly
2.3.3 Leadscrew
2.4 BLOWING MEDIUM
2.4.1 Poppet Valve
2.4.2 Poppet Valve Operation
2.4.3 Air Relief Valve
2.4.4 Feed Tube
2.4.5 Lance Tube
2.4.6 Lance Tube Support
2.4.7 Element / Nozzle / Rake Arrg't
2.5.1 Limit Switches
3 INSTALLATION INSTRUCTIONS
3.1 Location
3.2 Mounting
3.5 Lubrication
3.6 Electrical
169
SECTION TITLE
4 COMMISSIONING
4.3 Stage 3 - Pre-Operational Checks
5 OPERATING INSTRUCTIONS
6 MAINTENANCE INSTRUCTIONS
6.4 Major Overhaul
6.5 Manual Operation
7 LUBRICATION
7.1 Carriage
7.2 Drive Chain
7.3 Leadscrew and Square Shaft
8 MAINTENANCE SCHEDULE
8.4 Major Overhaul
9 OPTIONAL TOOLS
10 PARTS IDENTIFICATION
11 RECOMMENDED SPARES LIST
12 JOB SHEETS
13 FAULT FINDING
170
SECTION TITLE
14 STORAGE, HANDLING, & INSPECTION DURING STORAGE

14.1 STORAGE
14.1.1 Initial Receipt At Site
14.2 HANDLING
14.2.2 Handling Unpacked Equipment
14.3.1 Frequency
171
ILLUSTRATIONS
FIGURE TITLE
1 IK1M Sootblower - Overall View

2 View on Rear of IK1M looking towards Boiler
3 Cleaning Pattern
4 Electrical Components - Schematic Diagram
5 Front Support Arrangement
5A Scavenging Air Arrangement
5B Adjustable Rear Support
6 Drive Arrangement
7 Guide Assembly
8 Leadscrew Arrangement
9 Sectional View of Poppet Valve
10 Poppet Valve Linkage
11 Air Relief Valve
12 Feed Tube and Packing
13 Lance Tube Support
14 Limit Switch Operation
15 Square Tang for Manual Operation
16 Checking the Blowing Pressure
17 Manual Operation
18 Typical Slinging Arrangement
MAY 2004 FORM 13649/2
172
SECTION 1
173
SECTION 1
SECTION 1
GENERAL DESCRIPTION
Introduction
This instruction manual covers the operation and maintenance of the IK-lM
sootblower(s) supplied by Diamond Power Specialty Limited; the main features are
illustrated in Fig. 1 opposite.
Where the manual is supplied for a specific contract, details of the equipment
covered are shown on the Equipment Identification Form at the front of the
manual. In addition, the Parts Identification (Section 10) is customised to reflect
the parts actually fitted.
1.1 General (Fig’s.1 & 2)
The IK-lM is a one-metre travel sootblower incorporating a travelling motor drive
which, through reduction gearing and a leadscrew, drives a carriage along a
supporting guide tube. A lance tube, attached to the carriage, propels an element
across the boiler. Blowing medium, controlled by an integral poppet valve, is fed to
the element via a feed tube to provide cleaning jets. The complete mechanism is
supported and protected by a rigid beam. The arrangement of the main
components of the sootblower is shown in the illustration below.
FIG.2 VIEW ON REAR OF IKlM LOOKING TOWARDS BOILER

The basic IK-lM sootblower is normally operated from a remote panel in the control
room. Control options available include local push-buttons on the terminal box, and
operation from an individual starter box adjacent to the sootblower. It can also be
arranged to operate automatically in a pre-determined sequence.
174
SECTION 1
1.2 Operating Controls Cont’d)
Where the controls are supplied by Diamond Power, the electrical instruction
manual gives more specific details. Once started, the lK-lM goes through its
cleaning cycle automatically. Limit switches control the extent of travel and are
automatically reset at the end of the cleaning cycle.
The IK-lM can also be operated manually in the event of power failure and for
maintenance purposes.
1.3 Application
The IK-lM is designed to clean the back-end section of coal and oil-fired boilers and
other industrial units.
1.4 Cleaning Principle (Fig.3)
The IK-1M functions by blasting the surfaces to be cleaned with jets of high-
pressure air or steam. Nozzles are positioned in a travelling element which
traverses the area to be cleaned and then returns to the reset position ready for the
next cleaning cycle. The element is permanently situated inside the boiler and is
designed, on a per-contract basis, to give maximum cleaning effect.
FIG. 3 CLEANING PATTERN

1.5 Operating Cycle
The operating cycle begins with the IK-lM in the fully-retracted (reset) position.
When power is applied to the drive motor, the carriage moves forward. A trip pin
on the carriage operates the poppet valve linkage to open the poppet valve, thus
admitting blowing medium to the cleaning element. The carriage continues its
forward movement until it operates the front limit switch via a trip bracket on a
guide assembly fitted to the carriage. This action reverses the drive motor
direction, thus reversing the carriage movement.
As the carriage reaches its retracted position, the trip pin again operates the valve
linkage this time to close the valve. The trip bracket operates the rear limit switch
to stop the sootblower at the reset position. The complete cycle takes place in
approximately 3.25 minutes .
1.6 Identification
Each sootblower in an installation is identified by a serial number and a position
number, both of which are marked on the sootblower nameplate.
A list of the serial numbers of the sootblowers in the installation is given on the
Equipment Identification Form; the position of each sootblower is indicated against
the relevent serial number. Any features, which vary from sootblower to
sootblower, are also indicated against the serial number.
175
SECTION 2
SECTION 2
COMPONENT DESCRIPTION
General
The IK1M-TE sootblower comprises a number of sub-assembly components. This
Section describes the function of these components and their relationship to each
other. A comprehensive breakdown of the components is given in Section10
('Parts Identification').
2.1 ELECTRICAL
2.1.1 Electrical Components (Fig.4)
Electrical components on the sootblower comprise a drive motor, forward and reset
limit switches and terminal box containing start and reverse push-buttons.
The wiring between the drive motor, limit switches and terminal box is part of
Diamond Power supply. The interconnecting wiring from the sootblower to the
electric control panel is not part of Diamond Power supply. To complete the
electrical link up between the sootblower and the control panel a typical or
customised interconnecting schematic diagram is normally supplied by Diamond
Power for this purpose.
2.1.2 Function
When the drive motor is energised (from the control panel) or local start push-
button it drives the carriage forward. As the carriage approaches the limit of its
forward travel, a trip bracket on the guide assembly fitted to the carriage, makes
contact with the forward limit switch. This action reverses the drive motor
FIG.4
REFER TO ELECTRICAL COMPONENTS – SCHEMATIC DIAGRAM
As the carriage approaches its fully retracted position, the trip bracket again makes
contact, this time with the reset limit switch. This action stops the drive motor.
The sootblower can also be retracted at any point during forward travel by pressing
the local retract push-button.
176
1 2 3 4 5 6
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CAUTION $ 8 8 8 % ( /60 =0/.;& & C01.
* ISOLATE ELSEWHERE BEFORE 8 8 % ( 1)D .37& & C01.
ACCESSING ANY TERMINALS ( 8 8 8% 8 /60 & 0-,-7 4+-7)5& %)1" & -%7 ,! 4-0-)1. 0 .=75 /4 " FG
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8 > @ ? ( > @ ? * SOOTBLOWER MAY START 8 8 8% $ /60 & 0-,-7 4+-7)5& $%)1" & -%7 ,! 4-0-)1. 0 .=75 /4 " FG
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NOTES A /60 0/.; 6C175 "4
A 1)D .37 6C175 "4
1. EARTHING BY CUSTOMER TO MEET LOCAL AND GOVERNMENT REGULATIONS A .7"C& ',, ;-/ )0 /"/.) 510
AN EARTH CONNECTION IS PROVIDED INSIDE THE TERMINAL BOX FOR CONNECTION OF EARTH
CORES IN MULTI-CORE INTERCONNECTING CABLES.
8 A /60 0/.; 6C175 "4
$ A 1)D .37 6C175 "4
2. A CABLE HELIX OR OTHER MEANS OF CABLE MOVEMENT MUST BE ALLOWED BETWEEN 8( %' 1/, F3/" & 1""14-1. "17 )7-1. B-7 6 B
1" 45-!!-.=
STANDING STEELWORK AND SOOTBLOWER TO ALLOW FOR BOILER EXPANSION. ( I ' 8 % ",-./0 612 /44C& & $& -77/0& +-75 B
-2-.=4
I ' (8 % ",-./0 01)D 44C 7 ",-./04 /4 " FG
;
3. ANY CABLE VOLTAGES SHOWN ARE ACTUAL VOLTS CARRIED BY CORES, THEY DO NOT ' I 8 8 % 34563771. 44C& 7/"7&
SHOW SIZE OR RATING OF CABLES.
I 8 8 % 3456371. 44C& "4 &
4. SOOTBLOWER IS SHOWN IN REST POSITION WITH LSR ACTUATED. I 8 8 % 34563771. .4 "7&
I 8 8 % 34563771. .4 "7&
5. INTERNAL WIRING ON SOOTBLOWER IS BY DPSL. ! " " # $" %& '( $")
INTERCONNECTING CABLE AND GLANDS TO SOOTBLOWER IS NOT BY D.P.S.L. * *# %& +" , /44C1BI !/"74 1.0C
!" & ' % (

8 930 ' 8 % +/4 '((( % & 8 8 % : /;; ; !" # # #
#
# #
)*+ ",-./0 12& 34563771. $% %
1 2 3 4 5 6
177
SECTION 2
2.2 MOUNTING
2.2.1 Beam (Fig.1)

The beam is a fabricated assembly comprising a pressed-steel canopy with front
and rear bulkhead plates. It provides support and protection for the sootblower
mechanism. Lugs, welded to the canopy, provide lifting points and can also be
used to support the rear end of the sootblower in service. The front end is
supported via the front bulkhead. A stop bar (Fig.5) is welded to the underside of
the beam interior near the front bulkhead to bring the carriage to a halt should
malfunctioning of the front limit switch occur.
2.2.2 Front Support (Fig.5)

The IK-lM is supported at the front (boiler end) via a mounting flange welded, on
site, to a wallsleeve (provided by the customer) in the boiler wall. The arrangement
is shown below.
FIG.5 FRONT SUPPORT ARRANGEMENT
The mounting flange is supplied as part of the sootblower assembly and is bolted
to the sootblower front bulkhead via a wallbox arrangement.
2.2.3 Wallbox (Fig.5)

The wallbox, in addition to providing a front mounting point for the sootblower,
forms a seal around the lance tube via rear and front seal plates contained within
the wallbox to prevent leakage of boiler gases.
178
SECTION 2
2.2.3.1 Scavenging Air (Fig.5A)
Boiler gases are prevented from escaping to atmosphere by pressurising the
wallbox. A hand-operated gate valve is provided at the sealing air entry to the
wallbox. The valve is connected to the sealing air line and adjusted to maintain
adequate sealing air within the wallbox. A connection on the sealing air line runs
to the air relief valve to provide a scavenging function.
FIG. 5A SCAVENGING AIR ARRG'T
2.2.4 Rear Support (Fig.5B)

The sootblower is supported at the rear by a support bar, screwed rod and support
plate arrangement assembled, on-site, to the structural steelwork. The rear support
consists of a support bar which is secured between two side plates welded to the
sides of the beam.
FIG.5B ADJUSTABLE REAR SUPPORT
Screwed rods located within the support bar are assembled onto the structural
steelwork to allow for vertical adjustment as required. The side plates incorporate
an elongated hole to assist positioning and to allow for boiler expansion in the
horizontal plane. The side plates also incorporate a circular hole for use during the
handling process. The supporting steelwork is not supplied by Diamond Power, but
design information is given on the Installation drawing.
FORM 14335/1 AUGUST 2005
179
SECTION 2
2.3 MECHANICAL
2.3.1 Carriage and Drive Mechanism (Fig.6)

The IK-lM is driven by a totally-enclosed 0.55 kW (3/4hp) electric motor, using a
drop-cord as the power supply. The motor is flange-mounted to the carriage
housing and drives the carriage via a worm reduction gear and drive nut
arrangement housed within the carriage.
FIG. 6 DRIVE ARRANGEMENT
The drive nut traverses a stationary leadscrew as it rotates and thus propels the
carriage. Direction and extent of travel are controlled by limit switches, as
described in paragraph 2.5. The lance hub forms part of the carriage assembly. The
lance tube is flange-mounted to the hub and travels with it.
Where the element has to be rotated as it travels, a chain and sprocket drive
arrangement is used to rotate the lance hub.
Where the element is of the non-rotating type, the hub drive arrangement is
omitted.
2.3.2 Guide Assembly (Fig.7)

A guide assembly, comprising a mounting plate and two guide blocks, is bolted to
the carriage housing. A guide tube which runs the length of the beam, is located at
one end in the front bulkhead. The opposite end of the guide tube is retained by
two cotter pins on either side of the rear bulkhead.
180
SECTION 2
2.3.2 Guide Assembly (Fig.7) (Cont’d)

As the carriage travels forward, the guide assembly slides along the supporting
guide tube. A trip bracket, bolted to the forward guide block, actuates the limit
switches which control the travel of the sootblower.
FIG.7 GUIDE ASSEMBLY

2.3.3 Leadscrew (Fig.8)
The leadscrew is supported by the front and rear bulkheads. Under normal
operating conditions, the leadscrew is prevented from rotating by a locking pin
which passes through the right hand pillow block of the poppet valve mechanism.
As the carriage drive nut rotates, it traverses the stationary leadscrew.
FIG.8 LEADSCREW ARRANGEMENT
When the locking pin is removed, the leadscrew can be rotated to drive the
carriage manually. A square tang is provided on the end of the leadscrew for
attaching a ratchet wrench. Collars, pinned to the leadscrew prevent axial
movement of the leadscrew during forward and reverse travel.
181
SECTION 2
2.4 BLOWING MEDIUM

2.4.1 Poppet Valve (Fig.9)
The poppet valve controls the flow of blowing medium to the element and is
operated automatically by a cam and trigger, as described in paragraph 2.4.2. It is
connected to the blowing medium supply by a companion flange designed to suit
the blowing medium pipework. The valve is flange-mounted to the sootblower rear
bulkhead by four studs and nuts which also connect it to the feed tube (paragraph
2.4.4), as shown in Figure 12.
The IKlM may be fitted with a 40, 60, or 120 bar poppet valve, depending upon
the pressure of the blowing medium. The valve body is supplied in carbon steel for
standard applications, and in a chrome molybdenum alloy for higher ternperature
applications.
The arrangement of components within the valve body is shown in Figure 9 below
FIG.9 SECTIONAL VIEW OF POPPET VALVE

The valve seat is of flexible construction to allow for thermal expansion. The stem
and disc assembly in the valve comprises a stem and a flexible valve disc. On 40
and 60 bar applications, the valve disc is loosely attached to the stem by a
screwed retainer and lockwasher. On 120 bar poppet valves, the disc is retained
on the valve stem by a welded plug. A slight play, in both cases, ensures positive
sealing of the disc on the seat. The sealing face of the valve has a hard deposited
surface to minimise wear.
The valve stem is positioned by a guide which is screwed into the valve body. An
adjustable pressure control disc is screwed onto the lower part of the guide and is
held in position by a lock pin. The upper part of the stem guide contains the valve
stem packing which seals around the stem to prevent leakage of the blowing
medium. A packing nut, screwed onto the stem guide, compresses the packing
through a packing washer. The packing nut also supports the valve spring which
acts on the stem through a valve yoke. The valve yoke secures the spring retainer
and is located in a groove on the upper part of the stem.
The poppet valve inlet, outlet, stem guide, and lock pin are fitted with gaskets to
prevent leakage of blowing medium.

182
SECTION 2
2.4.2 Poppet Valve Operation (Fig.10)

The poppet valve is operated automatically via a cam and offset trigger
arrangement. As the carriage moves forward, a trip pin mounted on the side of the
carriage, actuates the cam, thus pulling the valve trigger forward. The trigger
pivots on bearings in each of two pillow blocks bolted to the rear bulkhead.
Movement of the trigger depresses the valve stem, thus opening the valve and
admitting blowing medium to the feed tube.
FIG.10 POPPET VALVE LINKAGE

The position of the trip pin on the carriage can be altered to vary the valve-opening
position. Provision is made, also, for adjusting the engagement of the pin with the
cam by increasing or decreasing the length of the linkage operating arm.
2.4.3 Air Relief Valve (Fig.11)
The poppet valve is fitted with an air relief valve which screws into the poppet
valve body. The air relief valve allows air to be drawn into the poppet valve
between blowing cycles, thus preventing corrosive gases from being drawn into
the poppet valve, feed tube, and lance tube as the blowing medium condenses.
FIG.11 AIR RELIEF VALVE

When the poppet valve is operated to admit blowing medium to the feed tube, the
air relief valve closes to prevent escape of blowing medium.

183
SECTION 2
2.4.4 Feed Tube (Fig.12)

Blowing medium is admitted to the feed tube when the poppet valve opens at the
start of the cleaning cycle and passes through it into the lance tube. The feed tube
is telescoped inside the lance tube in the fully-retracted position; the blowing
medium is sealed by packing in a gland in the carriage hub. The outside diameter of
the feed tube is highly-polished to minimise packing wear as the lance hub slides
over it during the cleaning cycle.
FIG.12 FEED TUBE AND PACKING
The feed tube is made of stainless steel, hence no maintenance is required. The
end of the feed tube is sealed against the gasket in the poppet valve outlet by a
clamping plate which also secures the valve to the rear bulkhead.
2.4.5 Lance Tube

The lance tube directs the flow of blowing medium to the element. The flanged end
of the lance tube is bolted to the hub on the carriage, as shown in Figure 12, and
moves with it. The other end of the lance tube is generally supplied prepared for
welding to the element on-site; a screwed adapter may be fitted where required.
Once connected to the lance tube, the element moves with it.
184
SECTION 2
2.4.6 Lance Tube Support (Fig.13)

The lance tube normally rotates as it travels and is supported by rollers mounted on
shafts welded to the front bulkhead. The roller shafts are angled to ensure that full
rolling contact is made between the rollers and the lance tube as it travels.
FIG.13 LANCE TUBE SUPPORT
Where the IK-lM is used to drive a rake-type (non-rotating) element, a single or

double profile roller is required.
2.4.7 Element (Fig.3)

The element is designed to clean the heating surface using a series of nozzles
arranged to suit the particular operation. The size and number of nozzles are
determined by the cleaning requirement. Normally, the element is welded to the
end of the lance tube on site.
Blowing medium is directed at the area to be cleaned by the nozzles as the element
traverses the boiler tubes. This action removes slag, ash, or any other deposits
from the area to be cleaned.
Suitable supports should be provided for the cleaning element, as illustrated on the
Installation Drawings.
185
SECTION 2

2.5.1 Limit Switches (Fig.14)
Limit/Proximity switches, one directly mounted on the sootblower beam and one
mounted on a rail, control forward and reverse travel. The front switch (LSF)
reverses the sootblower at full extension, while the rear switch (LSR) stops the
sootblower in the reset position.
FIG.14 LIMIT/PROXIMITY SWITCH OPERATION

A sequence switch, when fitted, operates the next sootblower in turn. Travel limits
can be altered by adjusting the position of the switches on the mounting rail. The
switches are actuated by a trip bracket on the guide assembly fitted onto the
carriage (Fig.7).
2.6 MANUAL OPERATION (Fig.15)

For maintenance purposes, or in an emergency, the sootblower carriage can be
operated manually by turning the square tang on the end of the leadscrew. During
normal operation, the leadscrew is locked to prevent rotation but can be released
by removing the securing nut and locking pin. Once the securing nut is removed
and the locking pin withdrawn from the leadscrew, the square tang can be turned
with a ratchet wrench.
BALL / POPPET VALVE
FIG.15 SQUARE TANG FOR MANUAL OPERATION

Turning the square tang counter-clockwise, results in the carriage travelling
forward; conversely, turning the square tang clockwise, results in the carriage
returning towards the normal fully-retracted position.
186
SECTION 3
SECTION 3
INSTALLATION INSTRUCTIONS
General
Installation drawings are supplied with each set of sootblowers; these drawings
generally show the location of the sootblowers, overall dimensions, method of
mounting, extent of Diamond Power supply, and connections to be made.
Reference should be made to the Job Sheets (Section 12) for step-by-step
installation instructions.
3.1 Location
Each sootblower is identified on the appropriate installation drawing by a serial
number; this number is marked on the sootblower nameplate. Care must be taken
to ensure that each sootblower is installed in its correct location, by referring to
the relevant drawing.
3.2 Mounting
The IK-lM is supplied complete with a mounting flange which must be welded on-
site to a sleeve in the boiler wall. It must also be supported at the rear via the
lifting lugs. Reference should be made to the relevant installation drawings for full
mounting details.
When lifting the sootblower into position, the lifting lugs on the beam should be
used (Section 14).
NOTE: Do not use a sling around the beam or the protruding lance tube, as this
may cause damage and subsequent malfunctioning.
The IK-lM is normally supplied complete with a companion flange prepared for
welding on-site to the blowing medium supply pipework. The pipework is not
normally supplied by Diamond Power but must conform to any specification laid
down in the contract paperwork. The basic requirements are that it must be
designed and installed to avoid straining the sootblower and have a drainage slope
of at least 1 in 25 downwards from the companion flange.
The supply pipework must be blown out to remove all scale, weld bead, etc., upon
completion of installation work. A sheet metal deflector must be inserted between
the sootblower poppet valve inlet and the companion flange before this operation
to ensure that debris does not reach the valve seat.
3.5 Lubrication
Reference should be made to the Lubrication Chart in Section 7.
3.6 Electrical
Power and control connections must be made to the terminal box. Reference
should be made to the electrical control details in Section 2 for the connections
required.
MAY 1998 FORM 13249
187
SECTION 4
SECTION 4
COMMISSIONING
General
Commissioning should be carried out in three stages: (1) Inspection; (2) Functional
Checks; and (3) Pre-Operational Checks as briefly described in the following
paragraphs. Reference should be made to the Job Sheets at the back of this
manual for more detailed instructions, and to the commissioning check list for a
summary and further references.

Immediately prior to operating the sootblower for the first time, an inspection
should be made to ensure that it has been properly installed, that all connections
(electrical, steam, and air, where appropriate) have been made, that it has been
lubricated as specified in the installation instructions, and that it has not sustained
any damage since installation.
Once the above inspection has been made and any further work required
completed, the sootblower can be operated as described in paragraph 4.2.

Functional checks should be made before the furnace comes on-load (i.e. without
blowing medium) to ensure that the sootblower mechanism is operating correctly.
The sootblower should initially be operated manually to check for freedom of
movement and correct functioning of the mechanism, as described in Job Sheet 7.
Where the sootblower is an electrically-driven model, it should be operated from
the local control to check for correct direction of motor rotation and correct
operation of limit switches. Power consumption should also be compared (where
possible) with the normal starting and full load current, as stated on the motor
rating plate.
The sootblower is now ready to be checked with the furnace on-load, as described
in the following paragraph.
4.3 Stage 3 - Pre-Operational Checks (Fig.16)

The final stage in commissioning involves checking for blowing medium leakage,
setting the blowing pressure, and setting the wallbox sealing pressure, where
applicable. This can only be carried out with the furnace on-load and all services
available (i.e. power, blowing medium, and sealing air).
The check for leakage is particularly important where superheated steam is used as
the blowing medium. and should be made before, and during, initial operation of
the sootblower. Any leakage must be eliminated before moving to the next stage
of commissioning.
The recommended blowing pressure is given on the Equipment Identification Form

at the front of this manual.
MAY 1998 FORM 13840
188
SECTION 4
4.3 Stage 3 - Pre-Operational Checks (Fig.16) (Cont’d)

The actual blowing pressure must be checked under normal operating conditions,
i.e. with blowing medium available at normal pressure and temperature, nozzle in
place, and the air relief valve in good working order. Blowing pressure can be
checked by connecting a suitable pressure gauge to the air relief valve, as shown
below.
FIG.16 CHECKING THE BLOWING PRESSURE
The blowing pressure is controlled by raising or lowering the pressure control disc,
thus increasing or decreasing the gap between the valve seat and the disc; the gap
is set at approximately 2.5 mm (0.1in) on assembly. Adjustment is made by
disconnecting the air relief valve and removing the lock pin coupling, and then
rotating the pressure control disc. The pressure control disc must be locked in
position after adjustment by replacing the lock pin coupling. The lock pin should
engage one of the deep grooves in the pressure control disc; each groove
represents approximately 0.2 mm (0.08 in) vertical movement of the pressure
control disc.
The sootblower should be operated through several complete cycles, with steam
on, to check that it is functioning correctly before finally putting it into service.
FORM 13840 MAY 1998
189
SECTION 5
SECTION 5
OPERATING INSTRUCTIONS
General
The IK1M Sootblower can be operated from a remote panel or from push-buttons
mounted on the sootblower terminal box or an individual starter box. Once started,
the sootblower automatically completes its operating cycle and returns to the rest
position ready for a further cycle.
Provision is made, also, for manual operation (Section 6.)

When the sootblowers are installed on a small boiler, the steaming capacity should
be maintained at over 50% and the draft fans should be operating at a high rate of
flow during the sootblowing period. This ensures that the amount of cleaning
medium blown in is small compared to the amount of gases passing through the
boiler, and also that the deposits removed by the sootblowers are carried through
the boiler. If the firing rate is low, the sootblowing may agitate combustibles in the
furnace and cause puffing.
On larger boilers, these precautions are not normally necessary, as the amount of
cleaning medium blown in is usually small compared to the amount of gases
passing through.

When a steam generator is first placed into service, the tube surfaces have an
immunity to ash and slag adherence. Consequently, it will appear, at first, that the
recommended blowing pressures are higher than required. During this period,
lasting for a few weeks, it may not be necessary to operate the sootblower very
often. Later, after the tube surfaces have acquired a coating of residual slag, the
deposits of slag and ash will be more difficult to clean and the recommended
pressures will be more than likely required.
Before commencing blowing, reference should be made to the operating
precautions given in paragraph 5.1. Normal recommended practice is to clean the
boiler in the direction of the gas flow. The units nearest to the furnace operate
first, followed by the superheater and economiser units. If heavy accumulations are
to be removed, a few of the units in the rear passes of the boiler should be
operated interchangeably with those in the first pass. This eliminates a heavy
accumulation in the boiler output area. If a 'straight-through' schedule is employed,
it is possible that accumulation removed from the superheater region will pile up in
the economiser area. These recommendations are general ones, operating
experience with the individual boiler is the most accurate guide.
190
SECTION 6
SECTION 6
MAINTENANCE INSTRUCTIONS
General
Maintenance instructions in this Section are grouped under the following headings
for convenience: Operational Checks; Periodic Inspection; Annual Maintenance; and
Major Overhaul. A maintenance schedule for each group is provided in Section 8,
and Job Sheets, detailing the action to be taken, are provided in Section 12.
Lubricants, which should be kept readily available for maintenance purposes, are
listed in Section 7.
Checks should be made when the sootblower is operating to detect malfunctioning
or blowing medium leakage. With the exception of blowing medium leakage, these
checks are normally made by the operator.
The sootblower should be inspected periodically to ensure that :-
(a) All mechanisms are functioning correctly.
(b) All moving parts are adequately lubricated.
(c) Blowing medium is not leaking.
(d) Feed tube surface is in good condition.
(e) Lance tube/Element/Rake Arrg't surfaces are in good condition.
(f) Blowing pressure is correct.
The frequency of inspection will depend on operating conditions, but should be at
least once per month.
The IK1M Sootblower should be inspected annually for deterioration of all critical
parts; these should be renewed, where necessary. Packing and lubricants should be
renewed and mechanisms checked and adjusted, where necessary.
NOTE: Components on the carriage assembly which are sealed for life, should only
similar parts, which should be discarded and renewed.
Critical parts include the following:-
(a) Poppet Valve, including Air Relief Valve.
(b) Feed Tube.
(c) Lance Tube, Element or Rake Arrg't.
(d) Front Support Rollers.
(e) Limit Switches.
(f) Drive Nut.
(g) Guide Nuts
191
SECTION 6
6.4 Major Overhaul

The IK1M Sootblower should be dismantled every three years for inspection and
renewal of all wearing parts. Seals, packing and lubricants should be renewed at
this overhaul. Wall sleeves and supporting steelwork should also be checked, and
renewed if unserviceable.
NOTE Components on the carriage assembly which are sealed for life should only
similar parts, which should be discarded and renewed.
6.5 Manual Operation (Fig.17)

During maintenance, or in an emergency, the Sootblower carriage can be operated
manually by using the retraction handle. After first removing the protective cap on
the end of the gear reducer, the drive pin can next be removed and the square tang
can now be turned with the handle. With the drive motor thus disconnected,
turning the square tang clockwise results in the carriage travelling forward and the
lance tube going into the boiler. Conversely, turning the square tang counter-
clockwise results in the carriage returning towards the fully-retracted position.
FIG.17 LOCATION OF SQUARE TANG FOR MANUAL OPERATION
The following important information should also be noted:-

(a) The blowing medium pressure should be 'On' when the sootblower is operated
manually to cool the lance tube until it is retracted.
(b) The sootblower must always be returned to the retracted position after manual
operation to re-set the limit switches.
192
SECTION 7
SECTION 7
LUBRICATION
General
To maintain the efficiency of the IK-1M Sootblower, it is essential that periodic
checks are carried out at the lubrication points listed in this Section.
7.1 Carriage
The worm set cavity of the carriage, is factory-lubricated and sealed for life. When
the carriage requires dismantling, the lubricant should be renewed as follows :-
Carriage:- Worm Set Cavity – 385 – 400g (13.6 - 14.fl.oz.) of Tivela GL 00 or
Rocol “Sapphire Extreme”.
Moving components of the Carriage run in sealed bearings and therefore do not
require lubrication.
7.2 Drive Chain

The drive chain should be lubricated at least once a year with light machine oil.
7.3 Leadscrew
The ends, only, of the leadscrew should be lubricated annually to prevent
corrosion. On no account should the surfaces on which the drive nut and guide
assembly travel be lubricated; these components do not require lubrication and may
be harmed by grit or ash adhering to any lubricant applied.
The general lubrication points are illustrated below.
Bolt Heads and Threads: ------------------Molykote Thred-Gard, or any other
suitable anti-seize Compound.
LUBRICATION POINTS - IK1M SOOTBLOWERS
193
SECTION 7
IK1M LUBRICATION CHART
COMPONENT LOCATION LUBRICATION PART TO BE FREQUENCY MEANS OF LUBRICANT LUBRICANT

POINT LUBRICATED LUBRICATION ROCOL SHELL
(1) Under Worm Gear Fill with
and Shaft Sealed for 385 - 400g Sapphire Tivela
Carriage Sootblower Gearing
Cavity Life (13.6 – 14.0.fl. oz) Extreme GL 00
Beam
(2) At Rear of Light Light
Drive Chain Chain Links Chain Spray or Brush
Carriage Machine Oil Machine Oil
(3) Rotates
Ends only of Ends only of Light Light
Leadscrew through Annually Brush
Leadscrew Leadscrew Machine Oil Machine Oil
Carriage
194
SECTION 8
SECTION 8
MAINTENANCE SCHEDULE
General
Sootblower controls are normally arranged to protect the plant and the sootblower
from damage in the event of a fault developing, by rendering the sootblower
inoperative until the fault is rectified.
The Maintenance Schedule, in the following paragraphs, is designed to minimise
loss of use of the sootblower by forming the basis of a system of preventive
maintenance which identifies parts of the sootblower requiring attention before
they deteriorate to such an extent as to render the sootblower inoperative.
Action to be taken in the event of a fault developing is given against each item,
either directly, or by reference to a Job Sheet.

Points to be checked are as follows:-
1. Check the amperage as each sootblower operates and compare the readings
obtained with the full load current as shown on motor rating plate. Excessive
current consumption, or fluctuating readings, indicates a sootblower fault,
which should be investigated as soon as possible.
2. Check that the sootblower operates through its full cycle - failure to do so may
be due to either a mechanical fault in the sootblower itself, or an external fault,
such as inadequate blowing medium supply.

Frequency of this inspection will depend on operating conditions, but should not be
less than once per month. Points to be checked are: -
1. All mechanisms are functioning as described in Section 2.
2. Blowing pressure is correct; refer to Job Sheet 4.
3. Blowing medium is not leaking; refer to Job Sheet 5.
4. All moving parts are adequately lubricated; refer to Section 7.

Routine maintenance should be carried out annually, with the sootblower in situ
and all services connected, but isolated as specified on the relevant Job Sheet.
The IK1M Sootblower should be inspected and dismantled as required for renewal,
if necessary. As a preliminary to this operation, the sootblower should be run and
checked for any malfunctioning, as described in paragraphs 8.1 and 8.2.
Dismantling and Reassembly instructions are given on the relevant Job Sheets in
Section 12.
Gaskets and packing seals should be renewed at this stage. Reference should be
made to Section 7 for details of lubrication required.
195
SECTION 8
8.3 Routine Maintenance (Cont’d)

Critical parts, which should be examined in more detail at this overhaul, are as
follows: -
1. Lance Tube - Check for corrosion, surface damage, and straightness.
2. Element / Rake Arrg't - Check for cracking and corrosion.
3. Feed Tube - Check for corrosion, surface damage, and straightness.
4. Carriage - Check for overheating and noisy running.
5. Guide Assembly - Examine for damage and wear.
6. Poppet Valve - Dismantle.
A. Valve Stem and Disc Assembly - Check for wear and renew if necessary.
B. Valve Seat - Check for wear and lap if necessary.
C. Reassemble using new packing and gaskets.
7. Air Relief Valve - Pressure Test. Ensure that the disc, spring and seat are in good
condition
8. Limit Switches - Check for correct operation (Section 12).
9. Motor - Check for overheating and freedom of movement.
10. Drive Nut - Check for wear; renew if necessary.
Upon completion of Routine Maintenance, the sootblower should be
decommissioned as described in Section 4.
8.4 Major Overhaul

The IK1M Sootblower should be inspected every three years and dismantled for
renewal of all wearing parts, if necessary. As a preliminary to this operation, the
sootblower should be run and checked for any malfunctioning, as described in
paragraphs 8.1 and 8.2. Dismantling and Reassembly instructions are given on the
relevant Job Sheets in Section 12.
Gaskets, packing, seals, and lubricants, when required should be renewed at this
stage.
The procedure for examining critical parts is similar to that given for Routine
Maintenance.
Upon completion of a Major Overhaul, the sootblower should be recommissioned as
described in Section 4.
196
SECTION 9
SECTION 9
OPTIONAL TOOLS
Certain jobs described in the Maintenance Section can best be accomplished using
tools developed for the job. These tools are listed below and are available from
Diamond Power. To order, quote the revelant part number and quantity required.
Lapping Equipment for Poppet Valve
Valve Seat Protector Assembly
Poppet Valve Maintenance Tool (Spanner)
Poppet Valve Maintenance Tool (Depressing Tool)
Feed Tube Packing Tool Assembly
Wrench for Manual Operation
Test Pressure Gauge Assembly
197
SECTION 9
LAPPING EQUIPMENT FOR POPPET VALVE
1 395111-1123 Wobble Stick 1
2 313641-1125 Lapping Disc, Serrated Face (Series 40) 1

3 313641-2123 Lapping Disc, Plain Face (Series 40) 1

198
SECTION 9
VALVE SEAT PROTECTOR ASSEMBLY
(PART No. 310925-1029 - SERIES 40)

(PART No. 310925-2026 - SERIES 60)
(PART No. 392443-1129 - SERIES 120)
1 863015-2800 Nut 1
2 311938-1113 Stem 1
3 311936-1115 Spacer (Series 40) 1

311936-2113 Spacer (Series 60) 1
393444-1128 Spacer (Series 120) 1
4 311937-1114 Disc (Series 40) 1

311937-2112 Disc (Series 60) 1
Not Applicable Disc (Series 120) -
199
SECTION 9

(SPANNER)
1 312227-1129 Valve Packing Nut Spanner 1
200
SECTION 9

(DEPRESSING TOOL)
1 307025-1024 Valve Spring Depressing Tool 1
201
SECTION 9
FEED TUBE PACKING TOOL ASSEMBLY
(Part No. 308191-1012 - Graphite Foil Packing)

(Part No. 308191-2010 - Teflon Packing
1 307762-0114 Spring Clip (2-3/8"in o/d Feed Tube) 1
2 306761-0117 Body (Graphite Foil Packing) 1

3 327425-1127 Body (Teflon Packing) 1
202
SECTION 9
WRENCH FOR MANUAL OPERATION
1 909305-0017 Ratchet Wrench 1

2 901412-0006 Socket Extension (Not Illustrated) 1
203
SECTION 9
TEST PRESSURE GAUGE ASSEMBLY
1 398023-000A Pressure Gauge 1
204
SECTION 10
SECTION 10
PARTS IDENTIFICATION
Part Numbers for spares ordering purposes can be identified by referring to the Parts
Identification pages in this Section. The contract number and the sootblower serial
number should be quoted when ordering spares.
The main assemblies and sub-assemblies of the Parts Lists are arranged in the
following order:
IK-lM Main Assembly.

Carriage Assembly.
Lance Joint and Packing Assembly.
Blowing Medium Turn-on Assembly.
Poppet Valve Assembly.
Air Relief Valve Assembly.
Electric Control Assembly.
Electric Control/Wiring Assembly.
Terminal Box Assembly. (As Required)
Front Bulkhead/Roller Assembly. (As Required)
Guide Assembly.
Low Noise Wallbox Assembly c/w Adaptor. (As Required)
Wallbox/Seal Plate Assembly. (As Required)
Wallbox and Scavenge Line Assembly. (As Required)
Scavenging Air Line and Piping Assembly (As Required)
Scavenging Air Assembly. (As Required)
Piping Assembly. (As Required)
Guard Assembly. (As Required)
Acoustic Cover Assembly (As Required)
Rear Support Assembly. (As Required)
205
SECTION 10
SECTION 10
CONTRACT No.N10865
IK1M-TE MAIN ASSEMBLY 1 398299-000A 15442
398742-0043 2 398271-ASRBYT "
2A N10865-861 "
3 FF1DA0-0133 "
4 M3000E-0132 "
JET TUBE ELEMENT MAT’L: Low Alloy 4A JE528 "
5 398339-A000 "
6 397218-010A "
7 397247-A100 "
8 397769-0001 "
8A N10865-2-613 "
9 398565-1C00 "
10 395635-1039 "
10A 907923-0003 "
10B Not Applicable "
10C Not Applicable "
11 397257-000B "
12 397243-010D "
13 395608-4044 "
28 398535-000A "
29 397802-R2A2 "
30 397556-DDN1 "
31 350256-010A "
32 397473-J120 (6-off) "
33 397474-010A (12-off) "
36 Not Applicable "
37 398496-000A "
38 Not Applicable "
CARRIAGE ASSEMBLY 22 395595-1128 15327

398271-ASRBYT 23 395596-1127 "
24 395602-1145 "
25 395586-1020 "
26 395589-1126 "
27 396337-000A "
28 397197-010A "
29 875603-3215 "
30 875005-4030 "
31 Not Applicable "
32 395585-1146 "
33 398336-010A "
35-39 Not Applicable "
( PAGE 1 of 3 ) FORM 14017
206
SECTION 10
SECTION 10
CONTRACT No.N10865
CARRIAGE ASSEMBLY (Cont’d) 40 0903-801 (Tivela) 15327
398271-ASRBYT 41 395598-1034 "
42 879006-3502 "
LANCE JOINT & PACKING ASSY 10 346160-1134 13205

395608-4044
BLOWING MEDIUM TURN-ON ASSY 39 398305-0400 15376

398339-A000
POPPET VALVE ASSEMBLY 1 *398580-RAA0 14895/1

397802-R2A2 2 344381-1033 "
* (Welded with Item 1) 3 309786-1128 "
* (Fitted with Item 1) 4 394197-1123 "
11 393802-1122 "
22 397474-010A "
23 397473-J090 "
25 398325-010A "
26 Not Applicable "
AIR RELIEF VALVE ASSY 1 Not Applicable 14302

397257-000B 2 941402-0001 "
ELECTRIC CONTROL ASSEMBLY 1 398348-S0002 14864

397769-0001 5&6 * "
*Refer to Wiring Diagram 7 398494-A1500 "
8 - 11 * "
12 875608-3216-(2-off) "
13 398360-010A (4-off) "
14 879016-3200 (6-off) "
15 875611-3237 (4-off) "
16 398360-010B (6-off) "
19 * "
20 849515-8909 "
22 879006-4002 "
23 - 25 * "
26 849534-8903 "
27 - 38 * "
TERMINAL BOX ASSEMBLY 1 875003-3525 15486

398348-S0002 2 875003-3530 "
3 Not Applicable "
6 Not Applicable "
( PAGE 2 of 3 ) FORM 14017
207
SECTION 10
SECTION 10
CONTRACT No.N10865
FRONT BULKHEAD ASSEMBLY 2 395570-1135 (2-off) 15479
398535-000A
FRONT ROLLER ASSEMBLY 1 395636-1137 13210

395635-1039
GUIDE ASSEMBLY 1 397235-000A 14304

397247-A100 2 397242-010A "
WALLBOX & SCAVENGE LINE ASSY 1 397704-010A 15417

398565-1C00 2 396940-010C "
3 397448-000D "
17 RT012709CA (1900mm) "
( PAGE 3 of 3 ) FORM 14017
208
SECTION 10
IK1M MAIN ASSEMBLY DRG. NO. 398742-0043
PART. NO.
209
SECTION 10
IK1M MAIN ASSEMBLY DRG. NO. 398742-0043

PART. NO.
1 Beam Arrg't 1
2 Carriage Assembly 1
2A Motor 1
3 Feed Tube 1
4 Lance Tube 1
4A Steam / Air Lance / Rake Extension (Not Illustrated)1
5 Blowing Medium Turn- On Assembly 1
6 Leadscrew 1
7 Guide Assembly 1
8 Electric Control Assembly 1
8A Electric Control / Wiring Assembly (Not Illustrated) 1
9 Mounting Flange / Wallbox Assembly) 1
10 Roller, Front Support As Req’d
10A Circlip (Not Illustrated) As Req’d
10B Shaft, Front Support (Not Illustrated) 1
10C Set Screw (Not Illustrated) 1
11 A.R.V/ Pressure Switch / Gauge Mounting Assy 1
12 Locating Collar, Lead Screw 1
13 Lance Joint and Packing Assembly 1
14 873607-4841 Cotter Pin 2
15 397243-010A Locating Collar, Lead Screw 1
16 397245-010A Locking Pin, Lead Screw 1
17 873651-4042 Roll Pin 1
18 398704-010A Emblem 2
19 391750-1128 Warning Tag 1
20 398695-010A Nameplate 1
21 864501-8903 Gripnail 4
22 875005-4016 Screw, Hex Hd M8 x1.5 – 16 lg 4
24 398553-010A Top Cover Plate 1
25 398252-000A Leadscrew Clamp Assy 1
26 871014-4841 Bolt, Hex Hd M12 x 1.75 – 65 lg 1
27 873013-4800 Nut, Nylock M12 x 1.75 1
28 Bulkhead Assy, Bolt-On 1
29 Poppet Valve Assembly 1
* 30 Companion Flange (Not Illustrated) 1
* 31 Gasket (Not Illustrated) 1
* 32 Stud (Not Illustrated) As Req’d
* 33 Nut (Not Illustrated) As Req’d
* 34 909305-0017 Ratchet Wrench (Not Illustrated)** 1
* 35 901412-0006 Socket Extension (Not Illustrated)** 1
36 Guard Assembly (Not Illustrated) 1
37 Rear Support Assembly (Not Illustrated) 1
38 Scavenging Air Assy (Not Illustrated) 1
* Items Supplied Loose Item 37 fitted to rear lifting lugs at site ** Per Boiler Set
FORM 15442 AUGUST 2005
210
SECTION 10
PART. NO.
211
SECTION 10

PART. NO.
Item No. Part. No. Description No. Off

1 395658-1148 Housing 1
2 395590-1123 Bearing Carrier 1
3 395591-3128 Gasket, Bearing Carrier 1
4 395591-4126 Gasket, Bearing Carrier As Req'd
5 343831-1130 Gasket, Motor Flange 1
6 395648-1133 Collar,Motor Shaft 1
7 395647-2124 Key 1
9 901110-0040 Ball Bearing 2
10 901110-0125 Ball Bearing 2
11 901110-0105 Ball Bearing 1
14 907655-0007 Expansion Plug 1
15 875005-4430 Hex Hd Screw 4
16 879016-4400 Lockwasher 4
17 344093-4135 Key 1
18 875005-3520 Hex Hd Screw 8
19 879016-3500 Lockwasher 8
20 395603-1128 Key 1
21 901416-8900 Seal 1
22 Worm Gear 1
23 Worm Shaft 1
24 Drive Nut 1
25 Sprocket Arrg't 1
26 Sprocket 18T 1
27 Chain Arrg't 1
28 Locking Plate 1
29 Screw 2
30 Hex Hd Screw 8
31 Hub, Sprocket 1
32 Lance Hub 1
33 Trip Pin 1
34 941401-0009 Pipe Plug As Req’d
35 Hub Arrg’t 1
36 Rotary Union 1
37 Nipple 1
38 Coupling 1
39 Torque Bracket Arrg’t 1
40 Lubrication As Req’d
41 Chain Guard Arrg’t 1
42 Plain Washer 2
212
SECTION 10
LANCE JOINT AND PACKING ASSEMBLY DRG. NO. 395608-1040

PART. NO.
1 395647-1126 Key 8 x 8 x 19 1
2 395609-1122 Flange 1
3 907923-0016 Retaining Ring, External 1
4 395610-1137 Gasket, Lance Tube 1
5 395638-1135 Bushing, Front 1
6 873015-4400 Nut, Hex M10 x 1.5 2
7 873008-4400 Nut, Hex, Locknut M10 2
8 879006-4400 Washer, Form A, M10 2
9 395615-1124 Stud, Gland Packing 2
10 Packing 1
11 395611-1037 Packing Gland Arrg't 1
13 875005-4437 Screw, Hex Hd M10 x 1.5 – 45Lg 6
213
SECTION 10
BLOWING MEDIUM TURN-ON ASSEMBLY DRG. NO. 398339-0042
PART. NO.
214
SECTION 10
PART. NO.
1 907948-8901 Rod End 1

2 907948-8900 Rod End 1
3 869068-0012 Washer, 1.5 x 0.75 x 16G 1
4 398333-000A Cam Arrg't 1
5 398646-000A Mounting Arrg’t 1
6 901118-0054 Oilite Bearing 2
7 398301-010B Spacer, Poppet Valve Trigger 1
8 871014-4840 Hex Hd Bolt M12 x 1.75 x 60 lg 4
9 879006-4802 ‘C’ Washer M12 8
10 873651-3233 Roll Pin ø5 x 35 lg 2
11 879006-4800 Washer Form-A M12 2
13 875005-4836 Hex Hd Screw M12 x 1.75 X 40 lg 8
14 397729-000A Trigger Shaft Arrg't 1
15 873024-5200 Aerotight Hex Nut M16 x 2.0 1
16 398649-010A Bearing Retainer, Poppet Valve Mounting 1
17 398334-000A Pivot Block Arrg’t 1
18 869006-8904 Washer 30 OD x 22 ID x 16G 2
19 398301-010A Spacer, Poppet Valve Trigger 1
20 876004-8904 Hex Hd Bolt M16 x 2.0 x 90 lg 1
21 879006-5200 Washer, Form-A M16 1
22 873015-5200 Hex Nut M16 x 2.0 1
23 398302-010A Spacer, Poppet Valve Cam 1
26 304634-0117 Gasket, Feed Tube 1
28 395875-1129 Clamping Plate, Feed Tube 1
30 875005-4433 Hex Hd Screw M10 x 1.5 – 35 lg 2
31 873015-4800 Hex Nut M12 x 1.75 4
32 301235-0116 Pin, Poppet Valve Yoke 1
33 863603-1716 Cotter Pin, Split Ø2 x 15 1
34 875007-3516 Screw, M6 1.0 x 16 Lg 3
35 873651-4042 Roll Pin, Ø8 x 70 Lg 1
36 876006-4410 Grub Screw, M10 x 1.5 x 10 Lg 4
37 398651-010A Plate, Lead Screw Locking Bracket 1
38 398804-010A Block, Lead Screw Locking 1
39 Adjusting Rod 1
215
SECTION 10

PART. NO.
NOTES
1. Assemble adjusting rod and rod ends with equal thread engagement at each end.
For reference the nominal engagement will be 23mm.
2. Adjustment at final assembly is achieved by loosening the locking nut and rotating
the adjusting rod. Re-tighten the locking nut when adjustment is correct.
3. Apply Molykote Gn+ to threads and head of screws and torque to 41Nm (30 lb.ft)
4. Apply Molykote Gn+ to threads and faces of poppet valve nuts and torque to
75Nm (55 lb.ft). For each nut, bend up only ONE tab of the locking washer.
5. When poppet valve is correctly aligned with the feed tube, drill Ø5 through the
bulkhead (via existing Ø5 holes in mounting plate) and fit Ø5 roll pins.
NOTE: It is possible that misalignment / distortion of the rear bulkhead will cause
the lance to lose contact with the front rollers when the poppet valve mounting is
tightened. If this is the case then adjust the four M10 grub screws to compensate.
6. Assemble all threads with Molykote Gn+.
7. Assemble rod ends with Molykote Gn+ on the bores.
8. Install Oilite Bearing flush with inside surface of Poppet Valve Mounting.
9. Install Oilite Bearing flush with small diameter face of Bearing Retainer.
10. The Trigger Assembly should be fitted by inserting the non-lever end
through the larger hole in the Poppet Valve Mounting Bracket as shown. Then fit a
washer (detail 3) before inserting the lever end into the Oilite Bearing within the
smaller hole of the Poppet Valve Mounting Bracket. Finally fit the bearing retainer
c/w Oilite Bearing.
11. When the valve is fully open ensure there is a minimum gap of 0.25mm between
the valve spring coils.
216
SECTION 10
POPPET VALVE ASSEMBLY (IR2G) / (IK1M) / (DOPV) DRG. NO. 397802-0042
PART. NO.
OCTOBER 2006 FORM 14895/1
217
SECTION 10
POPPET VALVE ASSEMBLY (IR2G) / (IK1M) / (DOPV) DRG. NO. 397802-0042

PART. NO.
1 Valve Body 1
2 Valve Stem and Disc Arrg't 1
3 Flexible Valve Seat 1
4 Pressure Control Disc 1
5 Not Applicable Trigger Arrg’t 1
6 Not Applicable Valve Yoke Pin 1
7 Not Applicable Cotter Pin 1
8 Not Applicable Trigger Pin 1
9 Not Applicable Cotter Pin 1
11 Lock Pin Plug 1
13 301142-0118 Valve Yoke 1
14 301808-0113 Valve Spring Retainer 1
15 302051-0115 Valve Spring 1
16 302032-0119 Packing Nut 1
17 302027-0116 Packing Washer 1
18 398443-010A Valve Stem Packing 1
19 342928-1136 Valve Stem Guide 1
20 301167-2114 Valve Stem Washer 1
21 396774-0121 Adjustable Pressure Tag 1
22 Nut 4
23 Stud / Hex Soc Hd Screw 4
24 Not Applicable Adaptor 1
25 Locking Washer, Poppet Valve Nut 2
26 Plug, G3/4 1
NOTES:
1. Valve Stem Guide, Lock Pin and Plug threads to be coated with ‘Molykote Gn Plus’
(907145-0002)
3. Valves to be hydro tested to procedure – QA 002
6. This clearance dimension should be set between the bottom face of the packing
nut hex and the top face of the valve stem guide hex. Increasing this dimension
above 8mm can cause the spring to hard stop when the valve is fully open.
Decreasing this dimension below 3.5mm may cause problems with the valve stem
packing.
FORM 14895/1 OCTOBER 2006
218
SECTION 10
AIR RELIEF VALVE ASSEMBLY DRG. NO. 397257-0034

PART. NO.
1 Street Elbow 1
2 Male Stud Coupling 1
3 341245-1027 Air Relief Valve Arrg't 1
4 935923-8400 Nipple 1
5 937817-8400 Tee Piece 1
6 936220-8400 Plug 1
7 935924-8461 Nipple 1
8 349569-010D Adaptor 1
10 396774-0121 Adjustable Pressure Control Tag 1
DECEMBER 1996 FORM 14302
219
SECTION 10
ELECTRIC CONTROL ASSEMBLY DRG. NO. 397769-0043
PART. NO.
220
SECTION 10
ELECTRIC CONTROL ASSEMBLY DRG. NO. 397769-0043

PART. NO.
1 Terminal Box/Assembly 1
5 Cable Gland Pg13.5 2
6 Limit Switch 2
7 Mounting Rail 1
8 Cable 3-core (Length as req’d) As Req’d
9 Cable 5-core (Length as req’d) As Req’d
10 Cable Gland Pg16 2
11 Cable Looped 4-core (Length as req’d) 1
12 Screw M5 0.8 x 16 lg 2
13 Nut As Req’d
14 Lockwasher M5 As Req’d
15 Screw M5 x 0.8 – 45 lg 4
16 Nut 6
19 Nut M6 2
20 Cable Clip 1
22 Washer M8 4
23 Proximity Switch (Rear) (IFM) 1
24 Adaptor, Motor M20 x Pg16 1
25 Proximity Switch (Front) (IFM) 1
26 Grommet Strip 4
27 Screw M6 x 1.0 x 35 lg 4
28 Washer M6 As Req’d
29 Screw, Hex Hd M6 x 1.0 x 16 lg 1
30 Screw M5 x 0.8 – 30 lg 2
31 Proximity Switch (Front) (Telemechanique) 1
32 Gland M20 2
33 Gasket 2
34 Proximity Switch (Rear) (Siemens) 1
35 Proximity Switch (Front) (Siemens) 1
36 Proximity Switch (Front & Rear) (Namur) 2
37 Proximity Switch (Front & Rear) (Ersce) 2
38 Proximity Switch (Front & Rear) (Siemens) 2
221
SECTION 10
ELECTRIC CONTROL / WIRING ASSEMBLY PART. NO. N10865-2-613
(REV B) DRG. NO. 396600-1723
SEPTEMBER 2006 (CONTRACT N10865)
222
SECTION 10
ELECTRIC CONTROL / WIRING ASSEMBLY PART. NO. N10865-2-613

(REV B) DRG. NO. 396600-1723
Item No. Part No. Description Qty.
1 * Electric Motor 1
2 * Entry, Motor, M25 -
3 841402-0071 Cable Gland M25 2
4 * Entry 25.4 mm dia clearance hole (for M25) -
5 841402-0079 Locknut M25 1
6 849518-8949 Cable, Motor, 4-core -
7 841405-0116 Limit Switch, LSR & LSF - Ersce 2
8 * Entry M20 -
9 848300-9784 Terminal Cross Connector, 3 way 1
10 875007-3236 Screw, M5 x 0.8 – 40 lg Soc Hd 4
11 879011-3200 Washer, M5 Serrated 4
12 * CP20 Rail -
13 * CP20 Fixings -
14 * Entry 20.4mm dia clearance hole (for M20/Pg13.5) -
15 841402-0067 Cable Gland M20 2
16 841402-0078 Locknut M20 2
17 841404-0014 Cable, Limit Switch, 3-core, Hi-temp silicon 1
18 841404-0015 Cable, Limit Switch, 5-core, Hi-temp silicon 1
19 907506-8901 Warning Label, “Steam Sootblower” 1
21 * Cable Gland By others
22 * Locknut By others
24 * Cable Gland By others
25 * Locknut By others
26 847313-9208 VCI Foam Square, Corrosion Protection 2
27# 398348-S0002 Terminal Box Assembly, RH 1
28# 398743-AA10 Terminal Block Assembly 1
29# 841420-0002 Pushbutton Assy, Start, RED 1
30# 841420-0001 Pushbutton Assy, Reverse, GREEN 1
31# 841420-0010 Pushbutton Insert, RED 1
32# 841420-0011 Pushbutton Insert GREEN 1
N10865-2-613 Electrical Parts Assembly, RH Sootblower

N10865TB Terminal Box Assembly, populated
Assy of # parts only

* Shown for reference only
(CONTRACT N10865) SEPTEMBER 2006
223
SECTION 10
TERMINAL BOX ASSEMBLY (RITTAL) DRG. NO. 398348-0140

PART. NO.
1 Screw, Slt Hd Csk M6 x 1.0 - 25lg As Req’d

4 873015-3500 Hex Nut M6 8
6 Nylon Spacer 4
7 875006-3500 Washer, Form A, M6 4
8 841406-0009 Terminal Box 1
224
SECTION 10
FRONT BULKHEAD ASSEMBLY. DRG. NO. 398535-0028

PART. NO.
1 398389-010A Front Bulkhead Plate (Bolt-on) 1

2 395570-1135 Shaft As Req’d
225
SECTION 10
FRONT ROLLER ASSEMBLY DRG. NO. 395635-1039

PART. NO.
1 Roller 1
2 901110-0058 Ball Bearing 1
226
SECTION 10
GUIDE ASSEMBLY DRG. NO. 397247-0037

PART. NO.
1 Guide Block Arrg't 1

2 Guide Tube 1
3 875005-4425 Screw 2
4 879016-4400 Lockwasher 2
5 873651-8900 Roll Pin 2
6 873607-4841 Cotter Pin 2
227
SECTION 10
WALLBOX AND SCAVENGE LINE ASSEMBLY DRG. NO. 398565-0047
PART. NO.
228
SECTION 10
WALLBOX AND SCAVENGE LINE ASSEMBLY DRG. NO. 398565-0047

PART. NO.
1 Wallbox Housing 1
2 Seal Plate 1
3 Seal Arrg’t 1
4 397703-010A Wallbox Flange 1
5 875005-4444 Hex Hd Screw M10 x 1.50 – 80 lg 4
6 871014-4852 Hex Hd Bolt M12 x 1.75 –120 lg 4
7 873015-4800 Hex Nut M12 x 1.75 8
9 941414-0010 Reducing Tee 1
10 932500-8902 Hosetail ½”BSPT 1
11 902210-8903 Hose Clip 2
12 931403-0012 90° Elbow 1
13 841414-0067 Adapter 1
14 941416-0015 Nipple 1
15 941401-0012 Plug 1
16 931403-0005 Rubber Hose (Cut to suit) As Req’d
17 Copper Tube (Cut to suit) As Req’d
18 902225-0005 Clamp, Copper Tube 1
19 873015-3200 Hex Nut 1
20 879016-3200 Lockwasher 1
21 875005-3220 Hex Hd Screw M5 x 0.8 – 20 lg 1
22 941406-0001 90° Elbow ½” x ½” 1
23 873651-3220 Roll Pin 0.5 x 20 lg 1
FORM 15417 SEPTEMBER 2003
229
SECTION 10
REAR SUPPORT ASSEMBLY DRG. NO. 398496-0025

PART. NO. 398496-000A
1 398496-010A Rear Support Bar 1

2 RZ240130KC-0250 Screwed Rod 2
3 873015-6000 Hex Nut M24 4
4 879006-6000 Washer M24 4
5 863607-2240 Cotter Pin 3/16”x 2” lg 2
6 869006-3600 Plain Washer 2
230
SECTION 11
SECTION 11
It is recommended that stocks of the items listed in this Section be maintained as

follows:
1. Running Maintenance
Quantities shown in column 1 should be regarded as a minimum initial stock level
until actual usage is established through operating experience.
2. Incurred Maintenance
Diamond sootblowers are designed to operate for long periods with the minimum of
maintenance and spares usage; component parts do not normally require replacement
unless a breakdown occurs due to accident or misuse. It is recommended, however,
that a stock of the items listed be maintained to minimise downtime should a
breakdown occur, recommended quantities are shown in column 2.
3. Major Overhaul
When the boiler is off-load for a major overhaul, sootblowers should be inspected for
wear or damage as indicated in Section 8, and parts replaced as necessary. Items
which are normally replaced at this stage are indicated by a quantity in column 3.
The items listed in this Section should be adequate for normal use but the
quantities stocked may have to be adjusted to take account of severe usage or
delays in obtaining replacements .
The assembly headings indicate where the items listed are used. Since headings
and items appear in the same order as shown in the Parts Identification Section of
the Instruction Manual, part numbers of related items can be readily identified.
The quantities recommended have been calculated per ten sootblowers. These
quantities may require to be adjusted to correspond with the actual number of
sootblowers in use.
231
SECTION 11

EQUIPMENT TYPE :- IK1MTE SOOTBLOWER 1. Running Maintenance

(Positive Pressure) 2. Incurred Maintenance
DESCRIPTION PART NO QUANTITY

1 2 3
MAIN ASSEMBLY 398742-0043
Electric Motor N10865-861 - 1 -
Feed Tube FF1DA0-0133 - 1 -
Lance Tube M3000E-0132 - 1 -
Element: Mat’l: Low Alloy JE528 - 1 -
Gasket (Companion Flange) 350256-010A - 2 10
CARRIAGE ASSEMBLY 398271-ASRBYT

Gasket, Bearing Carrier 395591-3128 - 1 -
Gasket, Bearing Carrier 395591-4126 - 1 -
Gasket, Motor Flange 343831-1130 - 1 -
Key 395647-2124 - 1 -
Ball Bearing 901110-0040 - 2 -
Ball Bearing 901110-0125 - 2 -
Ball Bearing 901110-0105 - 1 -
Key 344093-4135 - 1 -
Key 395603-1128 - 1 -
Seal 901416-8900 - 1 -
Worm Gear 395595-1128 - 1 -
Worm Shaft 395596-1127 - 1 -
LANCE JOINT & PACKING ASSY 395608-4044

Bushing 395638-1135 - 1 10
Packing (Solid Ring) 346160-1134 - - 10
Packing (Split Ring) 396741-010A 10 10 10
Gland 395611-1037 - 1 -
Key 395647-1126 - 1 10
Gasket 395610-1137 - 1 10
BLOWING MEDIUM TURN-ON ASSY 398339-A000

External Retaining Ring 907920-9005 - 1 -
Gasket, Feed Tube 304634-0117 - 1 -
232
SECTION 11

EQUIPMENT TYPE :- IK1MTE SOOTBLOWER 1. Running Maintenance

(Positive Pressure) 2. Incurred Maintenance
DESCRIPTION PART NO QUANTITY

1 2 3
POPPET VALVE ASSEMBLY 397802-R2A2
Valve Stem and Disc Arrg't 344381-1033 - 2 5
Flexible Valve Seat 309786-1128 - 2 -
Pressure Control Disc 394197-1123 - 2 -
Lock Pin Plug 393802-1122 - 2 -
Lock Pin Washer 930711-9034 - 2 10
Valve Yoke 301142-0118 - 2 10
Valve Spring Retainer 301808-0113 - 2 10
Valve Spring 302051-0115 - 2 10
Packing Nut 302032-0119 - 2 -
Packing Washer 302027-0116 - 2 -
Valve Stem Packing 398443-010A 10 10 10
Valve Stem Guide 342928-1136 - 2 -
Valve Guide Washer 301167-2114 - 2 10
Nut 397474-010A - 4 -
Stud 397473-J090 - 4
Locking Washer 398325-010A - 2 20
AIR RELIEF VALVE ASSEMBLY 397257-000B

Air Relief Valve 341245-1027 - 2 -
Copper Washer 930711-9034 - 1 10
(REF) ELECTRIC CONTROL ASSEMBLY 397769-0001 (Per Wiring Diagram N10856-2-613)

Limit Switch (Forward) 841405-0116 - 1 -
Limit Switch (Reverse) 841405-0116 - 1 -
FRONT ROLLER ASSEMBLY 395635-1039

Roller 395636-1137 - 2 20
Bearing 901110-0058 - 2 20
WALLBOX & SCAVENGE LINE ASSY 398565-1C00

Seal Plate 396940-010C - 1 -
FORM 13218 (Page 2 of 2)
233
SECTION 12
SECTION 12
JOB SHEETS
JOB SHEET TITLE

NO
1 IK1MTE Installation Procedure.

2 Commissioning Check List.
3 Blowing Medium Turn-On Linkage - Adjusting Procedure.
4 Poppet Valve - Checking / Setting the Blowing Pressure.
5 Pressure Sealing Points - Checking Procedure.
6 Limit Switches - Renewal and Adjustment.
7 Checking the Electrical Operation.
8 Manual Operation.
9 Feed Tube Packing - Split Ring : Adjusting the Packing Gland.
10 Feed Tube Packing - Split Ring : Renewal.
11 Poppet Valve - Removal from Sootblower.
12 Poppet Valve - Dismantling.
13 Poppet Valve - Valve Stem Packing : Adjusting Procedure.
14 Poppet Valve - Valve Stem Packing : Renewal.
15 Poppet Valve - Tools and Equipment for Lapping the Valve Seat.
16 Poppet Valve - Valve Seat Lapping Procedure.
17 Poppet Valve - Seat Renewal.
18 Poppet Valve - Reassembly Procedure.
19 Poppet Valve - Replacing on the Sootblower.
20 Lance Tube Gasket - Adjusting Procedure.
21 Lance Tube Flange Gasket - Renewal.
22 Lance and Feed Tube - Removal.
23 Carriage - Removal and Replacement.
24 Carriage - Dismantling and Reassembly.
25 Wallbox - Dismantling.
234
JOB SHEETS
The information within the job sheets are
of a general nature and are not intended to
cover every individual sootblower system.
WARNING
Before all adjustments, repairs and tests
are undertaken the control room should be
notified. The appropriate local permits
should be taken out and all safety
precautions taken.
NOTE
Refer to the yellow coloured warning sheet
at the front of the Instruction manual for
general information regarding important
Installation, Commissioning, Operating and
Maintenance instructions.
FORM 15325
235
SECTION 12

SOOTBLOWER TYPE : IK1M SHEET
1. Remove all straps and packing from the sootblower.
2. Inspect the sootblower for possible damage from shipment

or storage.
3. Check that the sootblower is complete. Packing List
4. Determine the location and mounting position of the Inst. Drg

sootblower in the installation.
5. Position and weld the wallsleeve to the boiler wall.. Inst. Drg
6. Bolt the mounting flange to the front bulkhead.
7. Lift the sootblower into position using the lifting lugs

provided on top of the beam.
8. Position the sootblower with the wall sleeve located in the

mounting flange recess.
9. Position and bolt the rear support to the supporting

steelwork.
10. Weld the mounting flange to the wall sleeve.
11. Connect the blowing medium supply pipework to the

sootblower.
NOTE
The supply pipework is not provided by Diamond Power
and must be carefully installed to prevent undue stress on
the sootblower. To ensure correct drainage of condensate,
refer to the installation drawing.
12. Bolt the companion flange to the poppet valve inlet flange.
13. Position and weld the blowing medium supply pipework to

the companion flange.
14. Unbolt the companion flange from the poppet valve flange.
236
SECTION 12

15. Insert a sheet metal deflector between the companion

flange and the sootblower.
16. Blow out the blowing medium supply pipework to remove

all scale, weld bead, etc.
17. Remove the deflector and insert the companion flange

gasket.
18. Bolt the companion flange to the sootblower valve inlet

flange, compressing the gasket evenly between the
flanges. Tighten the studs in the sequence shown in the
following illustration.
NOTE
The use of a torque wrench is not manditory but the
approximate torque value of a properly tightened stud is as
follows:-
80 - 100 Nm for M20 studs (40 and 60 Bar Valves)
125 – 140 Nm for M24 studs (120 Bar Valves)
STUD TIGHTENING SEQUENCE

NOTE
Series 60 and 120 poppet valve installations have eight
flange studs.
19. Observe the alignment of the beam assembly; check for

any bends, twists, or other distortions.
20. Connect the element (normally supplied loose) to the lance Inst Drg
and check for straightness.
237
SECTION 12

21. Make the power and control connections to the sootblower Section 2
terminal box; ensure there are no loose terminals or wiring.
22. Leave the sootblower ready for commissioning, with the

power off and the blowing medium supply isolated.
238
SECTION 12

SOOTBLOWER TYPE : IK1M SERIES SHEET
JOB SHEET TITLE : COMMISSIONING 1 of 2
1. Isolate the sootblower from the blowing medium and

power supply.
2. Inspect the sootblower to ensure that installation work has

been done as specified on the Installation Job Sheet, that
power and blowing medium is available, and that any
lubrication required has been carried out.
3. Check that the sootblower can be operated safely without

affecting any other equipment, and obtain any permit
required.
4. Arrange the sootblower for manual operation and ensure Job Sheet 8
that the carriage is fully retracted.
5. Check the position of the limit switch arms; they should be Job Sheet 6
at right angles to the centre line of the sootblower except
when in contact with the trip bar; adjust if necessary.
6. Ensure that all moving parts of the sootblower are free to

move, particularly the leadscrew, guide bar, and front
support rollers, if fitted.
7. Move the carriage forward until the integral trip pin Job Sheet 3
engages the blowing medium turn-on linkage and adjust if
necessary.
8. Move the carriage forward until it contacts the front limit Job Sheet 6
switch. Check the travel against that specified on the
Installation Drawing and adjust the limit switch position if
necessary. Retract the sootblower fully on completion of
this step.
9. Turn on the blowing medium supply and check for leakage Job Sheet 5
and correct as necessary.
10. Check the blowing pressure and adjust if necessary. Job Sheet 4
239
SECTION 12

JOB SHEET TITLE : COMMISSIONING 2 of 2
11. Check the electrical operation. Job Sheet 7
12. Run the sootblower through a complete cycle and check:-
(1) That it reverses automatically when the front limit

switch is tripped.
(2) That it stops when the rear limit switch is tripped.
(3) That the poppet valve operates satisfactorily.

power supply and leave it ready for operation.
240
SECTION 12

JOB SHEET TITLE : BLOWING MEDIUM TURN-ON LINKAGE
1 of 1
ADJUSTING PROCEDURE
CAUTION
Do not operate the blowing medium turn-on linkage by
hand with the poppet valve under pressure.

power supply.
2. Move the carriage forward manually and note the position

of the cam as the trip pin engages. The correct position is
shown below.
3. If the cam engagement position is incorrect, adjust it by

shortening or lengthening the poppet valve adjusting rod.
4. To adjust the length of the adjusting rod, loosen the

locking nut and rotate the adjusting rod. Re-tighten the
locking nut when the adjustment is correct.
5. Re-connect the blowing medium and power supply.
241
SECTION 12

JOB SHEET TITLE : POPPET VALVE
1 of 2
(CHECKING/SETTING THE BLOWING PRESSURE)
NOTE
The Blowing pressure can only be set under normal working
conditions, i.e. with blowing medium available.
1. Check that the sootblower is in the fully-retracted position.
2. Check that the poppet valve is in the closed position.
5. Determine the blowing pressure.
6. Remove the 3/8"in BSPT blanking plug from the air relief
valve.
7. Connect a suitable pressure gauge to the air relief valve Section 4

outlet.
8. Remove the lock pin plug from the poppet valve, and coat the
threads with an anti-seize compound, replace the lock pin.
MAY 1998 FORM 14306
242
SECTION 12

JOB SHEET TITLE : POPPET VALVE
2 of 2
(CHECKING/SETTING THE BLOWING PRESSURE)
10. Open the poppet valve by running the sootblower carriage

forward manually, and note the pressure gauge reading.
11. Run the sootblower back manually to the fully-retracted

position, ensuring that the poppet valve closes.
12. Remove the lock pin plug.
13. Using a screwdriver inserted through the tapped lock pin

side hole, rotate the pressure control disc clockwise to
lower or anti-clockwise to raise, thus decreasing or
increasing the blowing pressure between the valve seat and
the valve disc.
14 Replace the lock pin plug after adjustment has been

completed, ensuring that it seats in one of the deep flutes
in the disc.
15. Repeat steps10-14 until the recommended blowing pressure

is obtained.
17. Remove the pressure gauge.
18. Replace the blanking plug.
19. Turn on the blowing medium supply
FORM 14306 MAY 1998
243
SECTION 12

JOB SHEET TITLE : PRESSURE SEALING POINTS
1 of 1
(CHECKING PROCEDURE)
NOTE
A check should be made for leakage at the pressure sealing
points listed below. This should be carried out by operating
the sootblower with the blowing medium on.
1. Poppet Valve to Companion Flange :

2. Feed Tube to Poppet Valve :

3. Lance Tube :
If leakage is detected, tighten the retaining bolts which Job Sheets
secures the lance tube flange to the lance hub. If leakage 21 and 22
persists after further tightening, renew the gasket.
4. Feed Tube Packing :

Check for leakage. If leakage is detected, tighten the Job Sheet 11
packing gland to eliminate the leakage. This should be
carried out when the feed tube is at its hottest condition.
Do not tighten the packing gland more than is necessary as
this will shorten the packing life and increase the load on
the motor. If the leakage persists, renew the packing.
5. Poppet Valve Stem Packing :

Check for leakage. If leakage is detected, tighten the brass Job Sheet 15
packing nut beneath the valve spring by turning it in a
clockwise direction until the leakage has been eliminated. If
the leakage persists, renew the packing.
244
SECTION 12

JOB SHEET TITLE : LIMIT SWITCHES:
1 of 2
RENEWAL AND ADJUSTMENT
3. Unscrew the cable gland and connecting cable from the

faulty limit switch, noting the correct wire termination
points.
4. Remove the two mounting screws, lockwashers, and nuts

which secure the faulty limit switch to the mounting rail;
remove the limit switch from the mounting rail.
NOTE
Before removing the faulty limit switch, mark its position
on the mounting rail. When replacing the rear limit switch,
it is important that it cannot be overrun by the trip bracket
on the guide assembly fitted to the carriage.
5. Select a new limit switch and install it in the reverse order

to that given for removal. Ensure that the wires are fitted
to the same termination points and that the switch is
positioned within the marking points on the mounting rail.
245
SECTION 12

JOB SHEET TITLE : LIMIT SWITCHES:
2 of 2
RENEWAL AND ADJUSTMENT
6. Adjustment Procedure
6.1 Check that the contact roller engages correctly with the
trip bracket on the carriage. The angular position of the
roller crank can be altered by loosening the adjusting
screw, turning the crank until the roller makes contact, and
then tightening the screw.
6.2 Check for correct travel by ensuring that the limit switch Inst. Drg.
(front or rear) is located the correct distance along the
mounting rail. The switch can be adjusted by loosening the
two mounting screws and moving the limit switch towards
the front or rear of the sootblower.
6.3 Operate the sootblower manually to check that the limit Job Sheet 8
switches operate correctly when actuated by the carriage
trip bracket. Care must be taken to ensure that the trip
bracket does not overrun the rear limit switch.
7. Reconnect the power supply and test-run the sootblower
8. Reconnect the blowing medium supply.
246
SECTION 12

JOB SHEET TITLE : CHECKING THE ELECTRICAL OPERATION 1 of 1
1. Switch on the power supply.
2. Run the sootblower forward, manually, for a short distance Job Sheet 8
but not far enough to clear the rear limit switch.
3. Depress the ‘START’ push-button on the control panel.
4. Check the motor rotation, the sootblower should travel

forward. If the motor rotation is wrong, correct it as
follows
4.1 Switch off the power supply.
4.2 Remove the terminal box cover.
4.3 Change over the power wires.
4.4 Replace the terminal box cover.
4.5 Switch on the power supply.
4.6 Depress the 'START' push-button again, and re-check as in

Step 4.
5. Run the sootblower forward through its complete cycle.
6. At the end of the cycle, check that the sootblower is in the

retracted position, with the blowing medium and power
supply disconnected.
247
SECTION 12

NOTE
Each sootblower can be operated manually during
maintenance or in an emergency.
If a fault develops with a set of sootbiowers during
automatic sequential operation, those in use should retract
automatically. If they fail to do so for any reason, such as
power failure, motor stalled, etc.; immediate action must
be taken to manually withdraw the sootblowers involved.
This is carried out by attaching a ratchet wrench to the Section 9.
square tang on the rear bulkhead
Manual operation is as follows:
2. Unscrew the securing nut and withdraw the locking pin

from the leadscrew collar; this action disconnects the
drive.
3.
Attach a ratchet wrench to the square tang. Turning the
square tang clockwise results in the carriage returning
towards the normally fully-retracted position.
Conversely, turning the square tang counter-clockwise

results in the carriage travelling forward and the lance tube
going into the boiler.
248
SECTION 12

3. NOTE: (a) The sootblower must always be returned to the

Cont’d retracted position after manual operation, to
reset the limit switches.
(b) If the poppet valve is ‘ON’, blowing medium

pressure will prevent easy removal of the locking
pin on the leadscrew collar. In this case, the
wrench should be used to turn the square tang and
apply pressure in a clock-wise direction; this will
then allow removal of the pin. Do not apply more
than 75 NM (55 lbs.ft.) of torque to the square
tang.
4.
After retraction has been completed, replace the locking
pin in the collar, securing it with the nut.
5.
Re-connect the power supply.
249
SECTION 12

JOB SHEET TITLE : FEED TUBE PACKING:- (SPLIT RING)
1 of 2
3. Tighten the two packing gland nuts, just enough to prevent

leakage. The position of the packing gland nuts is shown in
the illustration below.
NOTE
The feed tube packing, which provides a seal between the
stationary feed tube and the translational lance hub, is
compressed in the stuffing box by the adjustable packing
gland surrounding the feed tube. The gland can be
tightened until the gland shoulder butts against the end of
the lance hub.
On applications where superheated steam is used as the

blowing medium, tighten the packing gland when the feed
tube is at its hottest condition, as described in Step 3. This
procedure will increase the life of the packing and prevent
over-tightening due to thermal expansion.
4. If persistant leakage occurs, and further tightening does

not stop it, add additional packing up to a maximum of
three rings.
250
SECTION 12

2 of 2
5. Adding Additional Packing
5.1 Remove the nuts which secure the packing gland to the
lance hub. Slide the packing gland towards the rear
bulkhead.
5.2 Fit new additional split-ring packing into the stuffing box, Section 9
using the optional packing tool.
5.3 Replace the packing gland.
5.4 Replace the packing gland nuts, and hand-tighten them

only.

251
SECTION 12

1 of 2
RENEWAL
3. Move the carriage forward, manually, a short distance, to Job Sheet 8

obtain working clearance.
4. Remove the two packing gland nuts and two locknuts

which hold the packing gland in position.
6. Remove the old packing rings with a flexible packing hook.

Direct the hook at the bore of the stuffing box to avoid
damaging the feed tube.
7. Carefully clean the carriage hub stuffing box, packing

gland, and all components. A solvent may be required to
remove any traces of gum.
8. Inspect the feed tube and stuffing box for scratches, nicks,
or wear.
9. Repair or renew any damaged parts.
252
SECTION 12

2 of 2
RENEWAL
10. Lay out each packing ring in the correct sequence and
direction for installation.
11. Using both hands, and with the diagonal cut held upward,
fit the first packing ring on the feed tube.
12. Gently insert the packing ring into the stutting box.
13. Clamp a feed tube packing tool around the feed tube, with Section 9.
the bevelled end towards the stuffing box; gently press the
packing ring into place.
14. Repeat the procedure with the remaining packing rings,

indexing each diagonal cut 90° with the preceding ring.
15. Insert the last packing ring, and reverse the packing tool,
placing the square end towards the stuffing box; firmly
press the packing ring into position.
16. Remove the packing tool and slide the packing gland into
position.
17. Tighten the gland nuts evenly until the packing is slightly
compressed; maximum torque is 10 NM (7 lbs.ft.).
21. Adjust the packing gland, if necessary.
253
SECTION 12

1 of 1
REMOVAL FROM SOOTBLOWER.

3. Disconnect the air relief valve from the scavenging air line
(if fitted).
4. Remove the yoke cotter pin and withdraw the valve yoke
pin from the yoke.
5. Disconnect the poppet valve at the companion flange.
6. Disconnect the poppet valve at the valve outlet flange.
7. Remove the poppet valve from the sootblower.
254
SECTION 12

JOB SHEET TITLE : POPPET VALVE:- DISMANTLING
1 of 1
NOTE
This Job Sheet covers partial dismantling of the poppet
valve in preparation for valve seat lapping or renewal.
Dismantling procedure is as follows.
2. Depress the valve spring just enough to allow removal of

the yoke .
Remove the yoke and release the spring tension.

3.
Lift off the valve spring retainer and the valve spring.
4.
Remove the valve stem and disc assembly.
5. Job Sheet 13
Remove the packing nut and packing washer.
6. Section 9
Remove the packing from the valve stem.
7.
255
SECTION 12

1 of 2
NOTE
If leakage occurs at the valve stem at the top of the poppet
valve body, this is an indication that the valve stem packing
nut requires tightening, or that the valve stem packing should
be renewed.
1. Using the valve packing spanner, turn the brass packing nut Section 9
beneath the valve spring in a clockwise direction, tightening
just enough to prevent leakage. Overtightening will shorten the
packing life and may cause the valve stem to bind. The
packing nut should be torqued to 23 NM (17 lbs.ft.) maximum.
Refer also to note 6.
2. If persistant leakage occurs, and further tightening does not Job Sheet 14
stop it, renew the packing.
256
SECTION 12

2 of 2
NOTES:

packing.

shown.
257
SECTION 12

1 of 2
1. Isolate the sootblower from the power supply to prevent the

automatic operation of the sootblower.

NOTE
To prevent the valve stem and disc assembly from falling into
the poppet valve, the valve stem should be held up during this
operation.
6. Lift off the spring retainer and the spring; then remove the Job Sheet 13
packing nut, packing washer, and old packing from the valve
stem.
7. Insert the new packing, staggering the splits in the rings by Sections
90°. Use only the packing specified in the Parts list. 10 and 11
8. Seat each ring separately.
9. Reassemble the poppet valve in the reverse order to that given Job Sheet 18
for dismantling.
CAUTION
Tighten the packing just enough to ensure that the spring is Job Sheet 13
not coil bound when the valve is fully open. A valve packing
spanner, for turning the packing nut, is available for this
operation. The packing nut should be torqued to 23 NM (17
lb.ft) maximum. Refer also to note 6.
258
SECTION 12

2 of 2
NOTES:

packing.

shown.
259
SECTION 12

SOOTBLOWER TYPE : IK1M Series SHEET
JOB SHEET TITLE : POPPET VALVE : Tools and Equipment
1 of 1
Needed for Lapping the Valve Seat.
NOTE
The tools and equipment required for lapping are as follows:-
1. One disc is serrated, for rough lapping, and the other disc is
plain, for finishing and burnishing. The surfaces of both discs
must must be kept lapped flat; a lapping machine, or surface
plate , can be used to maintain the disc surfaces.
2. Lapping Compounds:- Section 9

3. Lapping Equipment:- Section 9

Wobble stick, manually-operated valve grinder, or small
capacity air motor with flexible shaft.
4. Inspection Equipment:-
Blue block - for checking flatness.
An unused lapping disc, which is absolutely flat, can also be
used.
Prussian blue - to determine high and low markings.

260
SECTION 12

1 of 2
2. Charge an unused serrated lapping disc with Hyprez 45 Section 9

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

surface at the end of each cycle.
5. Charge an unused plain lapping disc with Hyprez 14

compound.
6. Finish lap for two-five minute cycles, checking the valve seat
surfaces at the end of each cycle.
8. Charge the plain lapping disc with Hyprez 3 compound Section 9
9. Burnish-lap for five minutes.
11. Cover the surface of a blue block with a very thin uniform
coating of Prussian blue.
12. Place the blue block carefully on the lapped seat.
13. Applying finger pressure only, move the blue block back and
forth slightly.
14. Carefully remove the blue block.
15. Inspect the lapped seat. If the dye transfer is uniform, the seat
is satisfactory; if not uniform, then the seat is not flat and the
complete lapping procedure must be repeated.
16. After the lapping procedure is completed, clean the valve body
with white spirit, using a small bristle brush.

261
SECTION 12

2 of 2
17. Dry the body with air, or by wiping. Special care should be
taken to remove all minute particles of fuzz and paper shreds.
18. Reassemble the valve in the reverse order to that given for Job Sheet 18
dismantling.

262
SECTION 12

2. Remove the old seat by machining the weld away. Avoid Poppet Valve
removing material from the shoulder under the seat, as this Assembly.
shoulder positions the new seat to the correct depth in the body. Section 10
3. Assemble and position the new seat into the body, using a seat Section 9
protector. The protector, in addition to preventing injurious
material from reaching the seat, locates the seat correctly in
relation to the valve stem guide. Care should be taken to ensure
that the pressure control disc is correctly orientated. Tighten the
locknut finger-tight to hold down the seat during welding.
4. Select an approved welding rod and hold it at approximately 85°,

to deposit more metal on the seat than on the body. Two 2.4mm
(3/32”in) diameter rods should be used per seat.
* Equivalent to AWS 5.18 Class ER-70s-G or BS2901 Part1(1970) A18. *MIG wire
* Equivalent to AWS E7028 or BS639 (1976) E5144H. * Welding Rod
5. Using D.C. welding equipment set at 82-92 amperes (reverse

polarity), start welding at 90° from the point of least clearance
between the body and the seat. Make a single pass weld only,
with no initial tacking. Proceed towards the point of least
clearance.

263
SECTION 12

6. Overlap 13-19mm (1/2”in - 3/4”in) between rod applications.

Clean the slag from the welded area between applications.
7. Upon completion of welding, chip off any remaining slag from

the weld.
8. Ensuring that the sealing surfaces are protected, carefully wire

brush the valve body.
9. Laap the valve seat to ensure a flat surface. Job Sheet 16
10. Reasemble the valve in the reverse order to that given for Job Sheet 18
dismantling.

264
SECTION 12

1 of 1
REASSEMBLY PROCEDURE
NOTE
This procedure covers reassembly after partial dismantling for
seat-lapping or renewal. The valve should be reassembled in
clean conditions to reduce the possibility of grit being trapped
between the sealing faces.
The reassembly procedure is as follows :
1. Place the poppet valve on its side.
2. Install the stem and disc assembly, taking care to ensure that
the sealing faces are clean and undamaged.
NOTE
Maintain firm contact between the sealing faces during the
subsequent steps.
3. Insert the new valve stem packing, staggering the splits in the
rings by 90°; seat each ring separately.
4. Replace the packing washer.
5. Replace the packing nut and screw it down hand tight only;
adjust on assembly.
6. Place the valve body in an upright position.
7. Replace the valve spring, valve spring retainer and valve yoke.
NOTE
If the valve is not to be put into service immediately, the inlet
and outlet should be sealed to protect the internals.
10. Replace the poppet valve on the sootblower. Job Sheet 19

265
SECTION 12

1 of 2
REPLACING ON THE SOOTBLOWER.
1. Ensure that the sootblower is isolated from the power

supply and that the blowing medium supply is shut off.
2. Ensure that the valve inlet and outlet sealing surfaces are
clean and undamaged.
3. Fit a new feed tube gasket to the valve outlet flange.
4. Position the poppet valve on the sootblower with the four

studs projecting through the rear bulkhead.
5. Ensure that the feed tube retaining ring groove is clean and
the edges free from burrs.
6. Ensure retaining ring is fully seated in the groove with the

sharpest edge of the retaining ring installed towards the
rear bulkhead.
7. Push the feed tube through the rear bulkhead until it makes
contact with the feed tube gasket.
8. Slide the feed tube clamping plate along the feed tube
ensuring that the counter bore in the clamping plate
engages squarely over the retaining ring.
NOVEMBER 2001 FORM 14859/1
266
SECTION 12

2 of 2
REPLACING ON THE SOOTBLOWER.
9. Loosely fit the locking washers and securing nuts which

retains the poppet valve to the mounting and clamping plates
via the rear bulkhead.
10. Locate and tighten the two screws of the clamping plate in
turn by torquing them in small increments to 41 Nm (30
lb.ft.) maximum. This procedure will ensure that the clamping
plate is pulled squarely on to the retaining ring compressing
the feed gasket between the poppet valve and the end of the
feed tube.
11. Tighten the poppet valve locking washers and securing nuts
in turn by torquing them in small increments to 75 Nm (55 lb.
ft) maximum. For each nut, bend up only one tab of the
locking washer.
12. Re-connect the poppet valve trigger to the yoke with the pin
and cotter pin.
13. Fit a new companion flange gasket.
14. Re-connect the companion flange to the poppet valve.
15. Re-connect the scavenging air line to the air relief valve. (if fitted)
17. Test-run the sootblower, checking for leaks.
18. Reset the blowing pressure. Section 4
FORM 14859/1 NOVEMBER 2001
267
SECTION 12

JOB SHEET TITLE : LANCE TUBE FLANGE GASKET- 1 of 1
ADJUSTING PROCEDURE
NOTE
The lance tube flange gasket is compressed between the
lance hub and the lance tube flange by tightening the
retaining bolts as follows:-
1. Tighten the six bolts in the sequence shown in the

illustration below. The bolts should be torqued to 23 Nm
(17 ft. lbs.)
NOTE
The torque figure given applies to bolts coated with anti- Section 7
2. If persistant leakage occurs and further tightening does not

stop it, renew the gasket.
268
SECTION 2

JOB SHEET TITLE : LANCE TUBE FLANGE GASKET :-
1 of 2
RENEWAL
1. Ensure that the carriage is in the fully-retracted position.
rear bulkhead; remove the poppet valve.
5. Remove the feed tube retaining ring.
6. Slide the feed tube to the rear of the sootblower, ensuring

that the feed tube and lance tube are supported securely.
7. Remove the six bolts and lockwashers which secure the

lance tube flange to the lance hub flange.
8. Move the lance tube forward far enough to clear the

carriage hub.
9. Remove the existing lance tube flange gasket.
10. Examine the locating face at the lance hub and lance tube
flange.
269
SECTION 12

JOB SHEET TITLE : LANCE TUBE FLANGE GASKET :-
2 of 2
RENEWAL
11. Clean and remove any loose particles of dirt or existing

gasket, as applicable.
12. Install the new gasket.
13. Reasemble in the reverse order to that given for

dismantling.
NOTE
Coat the threads of the six lance hub flange bolts with
anti-seize compound before reassembly, and torque to 23
NM (17 lb/ft).
The torque figure given applies to bolts coated with anti-

270
SECTION 12

JOB SHEET TITLE : LANCE AND FEED TUBE :- 1 of 2
REMOVAL
NOTE
This Job Sheet should be used in conjunction with Job
Sheet No.23 Carriage Removal and Replacement.
3. Remove one of the front support rollers. Fig 13
4. Move the carriage forward manually to obtain sufficient Job Sheet 8

access to feed tube clamping bolts and nuts.
5. Remove the four nuts which clamp the feed tube to the
poppet valve via the mounting plate and slide the clamping
plate forward.
6. Remove the feed tube retaining ring.
7. Push the feed tube forward and remove the clamping plate.
8. Disconnect the air relief valve from the scavenging air line.
9. Remove the yoke cotter pin and withdraw the valve yoke Job Sheet 11
pin from the yoke.
10. Remove and aside the poppet valve assembly.
271
SECTION 12

JOB SHEET TITLE : LANCE AND FEED TUBE :- 2 of 2
REMOVAL
11. Withdraw the feed tube via the rear bulkhead plate.
12. Support the lance tube.
13. Remove the six bolts and lockwashers from the lance hub
flange.
14. Withdraw the lance tube via the rear bulkhead plate.
15. Inspect the lance and feed tube, repair or renew as

required.

dismantling again in conjunction with Job Sheet 23.
NOTE
Coat the threads of the six lance hub flange bolts with
anti-seize compound before reassembly, and torque to 23
NM (17 lb/ft).
The torque figure given applies to bolts coated with anti-

17. Re-connect the blowing medium supply.
18. Re-connect the power supply.
272
SECTION 12

JOB SHEET TITLE : CARRIAGE :- 1 of 2
REMOVAL AND REPLACEMENT
NOTE
This Job Sheet covers the removal of the carriage from the
sootblower for inspection and overhaul, or for the
replacement of a spare carriage. Dismantling for overhaul is
covered by Job Sheet 24.

power supply.
2. Disconnect the power supply cable from the motor.
3. After disconnection, arrange slings to support the lance

and carriage.
4. Tension the slings to take the weight of the carriage.
5. Remove the two roll pins at the rear bulkhead and

withdraw the guide tube.
6. Remove the screw from the leadscrew support tube at the

rear bulkhead.
7. Remove the roll pin which secures the collar to the

leadscrew.
8. Withdraw the leadscrew by unscrewing it through the

carriage drive nut.
9. Disconnect the four nuts which secure the feed tube

clamping plate to the poppet valve.
10. Slide the feed tube forward to expose the feed tube
retaining ring.
11. Remove the feed tube retaining ring and clamping plate.
12. Slide the feed tube through the gland and into the lance
tube.
MAY 1998 FORM 13281/1
273
SECTION 12

JOB SHEET TITLE : CARRIAGE :- 2 of 2
REMOVAL AND REPLACEMENT
13. Disconnect the six screws which secure the lance to the
carriage.
14. Slide the lance and feed tube forward to clear the carriage.
15. Lower the carriage onto the gantry.
16. Remove the carriage to the bench for inspection and

overhaul.
17. Re-assemble in the reverse order to that given for removal.
18. Re-connect the power supply cable to the motor.
FORM 13281/1 MAY 1998
274
SECTION 12

JOB SHEET TITLE : CARRIAGE:- 1 of 2
DISMANTLING AND REASSEMBLY
1. Remove the four screws and lockwashers which secure

the motor to the housing. Save the screws for re-use, but
discard the lockwashers. Withdraw the motor; save the
collar and the key for re-use.
2. Remove and discard the expansion plug and the circlip;

withdraw the worm shaft.
NOTE
To avoid damage to the worm gear, ensure that it is free to
rotate as the worm is withdrawn.
3. Remove the chain guard and chain (if fitted).
4. Remove the eight screws and lockwashers which secure

the bearing carrier to the housing and withdraw the bearing
carrier complete with its bearing; save the gaskets for re-
use.
5. Withdraw the drive nut complete with its bearing and

worm wheel; the worm wheel and drive nut can now be
examined and renewed if necessary.
6. Remove the bearing from the carrier for examination and or

replacement, as required. The seal should be discarded.
7. Remove the retaining ring and pull off the flange.
8. Remove the retaining ring at the front end of the lance

hub, and withdraw the lance hub, complete with the hub
and the bearing, from the carriage housing.
9. Remove the retaining ring which secures the hub and

bearing to the lance hub; the bearing can now be removed
from the lance hub for examination.
10. Examine the guide nuts and renew if necessary.
275
SECTION 12

JOB SHEET TITLE : CARRIAGE:- 2 of 2
DISMANTLING AND REASSEMBLY
11. Reassembly - General

Before reassembly, all parts should be cleaned and Section 7
examined for wear or damage. New oil seals, expansion
plugs, and lockwashers should be used. The worm gear
cavity should be packed with grease as specified in the
lubrication chart.
The procedure to be adopted is generally the reverse of

that used in dismantling but, if a new worm gear or drive
nut is fitted, the drive nut end play relative to the housing
must be checked to ensure that it is within the limits,
0.127 mm to 0.508mm (0.005 in. to 0.020 in). The end
play can be varied by adjusting the gasket thickness
between the bearing carrier and the housing. Gaskets, are
available in two thicknesses, 0.381 mm and 0,787 mm
(0.015 in. and 0.031 in).
If a new sprocket (when applicable) requires to be fitted,

remove the wire from the cap screws before dismantling.
NOTE
On reassembly torque cap screws to 5.6 Nm (5Oin lbs.);
torque pattern one time round only and rewire cap screws
together in pairs.
12. After reassembly, test-run and check for noise and leaks.
276
SECTION 12

JOB SHEET TITLE : WALLBOX - DISMANTLING.
1 of 2
(POSITIVE PRESSURE)

4. Attach a sling around the lifting points at the front and rear
of the sootblower.
5. Remove the four nuts, washers and bolts which connects Section 10
the welded wallsleeve and flange to the sootblower. F15417
6. Reposition the sootblower to separate it from the wallsleeve

and flange arrangement.
7. Remove the seal plate from the wallbox.
8. Check that there is enough slack on the control and power

cables to allow the sootblower to be pulled back until the
lance is clear of the wallbox. If not, it may be necessary to
disconnect the cables at the sootblower terminal box.
MARCH 2006 FORM 14856/2
277
SECTION 12

JOB SHEET TITLE : WALLBOX - DISMANTLING.
2 of 2
(POSITIVE PRESSURE)
9. Slacken or remove the four seal plate adjusting screws.
10. Re-assemble the wallbox using existing / new parts as

follows.
11. Re-ssemble the seal plates to the wallbox with the

machined face of the front seal plate towards the wallbox
flange.
12. Apply dow corning 744 silicone sealant to the faces of the
wallbox housing.
13. When the M12 mounting bolts are tightened the wallbox
seal plates must be adjusted to give the correct clearance
by turning the four(4) M10 seal plate adjusting screws
clockwise until there is no seal plate movement. Turn each
screw counter-clockwise by I flat (1/6th turn). Check that
the seal plates are free to move.
14 Wallbox Renewal
14.1 Disconnect the sealing air supply from the wallbox.
14.2 Remove the weld between the wallbox and the wallsleeve
14.3 Remove the wallbox housing.
14.4 Position and weld a replacement wallbox to the wallsleeve.
15 Re-install the sootblower in the reverse order to that given

for removal paying particular attention to steps 11-13.
16. Reconnect the sealing air supply to the wallbox.
17 Turn on the blowing medium supply.
18 Reconnect the power supply.
19 Test run the sootblower.
FORM 14856/2 MARCH 2006
278
SECTION 13
SECTION 13
FAULT FINDING
Sootblower fails to start. (1) No power voltage:

a. No power to starter Check power supply.
b. Overload tripped or Renew heater.
heater burned out.
c. Open circuit between Check contiuity.
starter and motor.
(2) Motor winding open or Test and rectify circuit.

shorted.
(3) One power line open: Re-establish continuity.

a.The overload relay has
operated without the
motor having started
because of a single-
phase condition.
(4) Forward contactor fails Check continuity.

to operate:
a. No voltage from panel
on lines A and B.
b. No signal from panel
on line D.
c. If operated manually,
‘START’ push-button
fails to make contact.
d. Overload contacts
are open.
e. The coil has burned
out.
f. Loose wire in forward
coil circuit.
AUGUST 1996 (PAGE 1 of 3) FORM 13283
279
SECTION 13
SECTION 13
FAULT FINDING
Sootblower jams or fails Drive motor overloaded:

to travel. (1) Element fouling on Re-align internal bearing in hot and
boiler internals. cold positions.
(2) Feed tube packing is too Adjust the packing gland.

tight.
(3) Valve stem fouling - Dismantle the poppet valve and

binding in valve guide. inspect the valve stem.
Re-new the stem if it is damaged.
(4) Worm gear stripped. Dismantle carriage and renew

gear.
(5) Pipework is incorrectly Inspect pipework and re-run if it

supported, strain trans- is necessary.
mitted to sootblower.
(6) Drive nut failure. Dismantle carriage and renew

drive nut.
Sootblower fails to stop. (1) Limit switch has not op- Tighten the trip lever.
erated,trip lever loose.
(2) The limit switch has Free or re-new the limit switch.
jammed.
(3) Forward / Reverse Inspect contactor and adjust if

contactor has failed to necessary.
operate.
280
SECTION 13
SECTION 13
FAULT FINDING
Blowing medium fails to (1) Poppet valve stem is Dismantle the poppet valve and
turn off. sticking in guide. inspect the valve stem. Re-new
stem if faulty.
(2) Valve yoke is broken or Dismantle the poppet valve and

detached from valve stem re-new the valve yoke.
(3) Valve spring broken. Dismantle poppet valve and renew

spring.
(4) Valve disc loose on the Dismantle the poppet valve and
valve stem. inspect the valve disc.
Re-new the disc if necessary.
(5) Operating pin broken. Re-new pin.
(6) Cam and pin are out of Re-align and re-new if necessary.
alignment.
Lance tube fails to rotate (1) Sprocket teeth stripped. Renew sprocket.
although the motor runs.
(2) Hub key sheared. Renew hub key.
(3) Chain broken. Rejoin chain or renew.
Boiler tube abrasion or (1) Blowing pressure too Re-set to recommended blowing
baffle erosion present high. pressure.
upon internal inspection.
(2) Excess moisture present Increase temperature of blowing

in blowing medium. medium.
(3) Element out of alignment. Re-align element.
281
SECTION 14
SECTION 14
STORAGE, HANDLING, AND INSPECTION
DURING STORAGE
General
Damage resulting from improper handling on site, site storage, or storage
maintenance is not the responsibility of the equipment supplier. Because of the
many variables involved in site storage, however, there is always the possibility
of some damage occurring, particularly to electrical equipment on sootblowers.
This risk can be minimised by observing the instructions given in the following
paragraphs and the handling details given in paragraphs 14.2.1 and 14.2.2
14.1 STORAGE
14.1.1 Initial Receipt at Site

On receipt at site, it is recommended that IK-1M sootblowers should be removed
from their crates or boxes, all polythene wrappings removed, and the equipment
then stored in a dry building where temperature and humidity are controlled to
prevent condensation. Sootblowers should be stored the correct way up and not
on their sides.

Each sootblower should be placed on timber battens of sufficient thickness to
keep all parts of the equipment well clear of the ground. The battens should be
placed under the main beams at approximately one third of the length in from
each end. Equipment may be stacked up to three units high, in double rows, by
placing timber battens across each pair directly above the ground support
battens. To allow for inspection, electrical boxes should face outwards.

The feed tube packing and the poppet valve stem packing should be removed
and, if undamaged by removal, stored for reinstatement prior to commissioning.
The method of doing this and the part numbers for replacements are included in
the relevant sections of this manual.
14.2 HANDLING

Sootblowers which are packed in boxes or crates must be handled by slinging the
boxes. using two slings. Boxes and crates supplied are specially reinforced for the
purpose. A fork lift truck should not be used for handling IK-1M sootblowers .
282
SECTION 14
14.2.2 Handling Unpacked Equipment (Figure 18)

Sootblowers should only be moved by slinging from the lifting points provided on
the top of the beam. Use of a two-point sling or fork lift truck is likely to cause
damage and prevent proper operation when installed.
FIG.18 TYPICAL SLINGING ARRANGEMENT
14.3.1 Frequency
IK-1M sootblowers should be inspected at monthly intervals. with particular care
being given to ensuring that the closures (tape, caps. etc.) on all openings remain
intact.
283

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1

SECTION TITLE PAGE

SECTION TITLE PAGE

11 RECOMMENDED SPARES LIST 97

12 JOB SHEETS 101

13 FAULT FINDING 160

SECTION TITLE PAGE

14 STORAGE, HANDLING, & INSPECTION DURING STORAGE 163

FIGURE TITLE PAGE

1 IK - 545B Sootblower - Overall View 18

SECTION TITLE PAGE

1 GENERAL DESCRIPTION 174

2 COMPONENT DESCRIPTION 176

3 INSTALLATION INSTRUCTION 187

SECTION TITLE PAGE

5 OPERATION INSTRUCTIONS 190

6 MAINTENANCE INSTRUCTIONS 191

8 MAINTENANCE SCHEDULE 195

9 OPTIONAL TOOLS 197

10 PARTS IDENTIFICATION 205

11 RECOMMENDED SPARES LIST 231

12 JOB SHEETS 234

13 FAULT FINDING 279

SECTION TITLE PAGE

14 STORAGE, HANDLING, & INSPECTION DURING STORAGE 282

FIGURE TITLE PAGE

1 IK1M Sootblower - Overall View 173

(Customised to suit) Contract No. N10865

Diamond Power Specialty Limited

Diamond Contract No :- N10865

Customer Order No :- 07461-49100-A610-00

Blowing Pressure :- 12.9 kg/cm2 (2nd SH Inlet))

Equipment Supplied :- 27 - Diamond IK545B (Electric Motor Driven)

Site :- Rabigh, Saudi Arabia

POSITION SERIAL UNIT CUSTOMER TAG

LSB A B66501 2 B2HCB01AN301

LSB A B66508 3 B3HCB01AN301

LSB A B66515 4 B4HCB01AN301

LSB A B66522 5 B5HCB01AN301

(PAGE 1 of 2) FORM 13519

Diamond Contract No :- N10865

Customer Order No :- 07461-49100-A610-00

Blowing Pressure :- 12.9 kg/cm2 (2nd SH Inlet))

Equipment Supplied :- 27 - Diamond IK545B (Electric Motor Driven)

Site :- Rabigh, Saudi Arabia

POSITION SERIAL UNIT CUSTOMER TAG

LSB A B66536 7 B7HCB01AN301

LSB A B66543 8 B8HCB01AN301

LSB A B66550 9 B9HCB01AN301

(PAGE 2 of 2) FORM 13519

READ THIS MANUAL

This equipment may be operated by remote control

Isolate from power and blowing medium supply before working on

To avoid personal injury or damage to equipment during installation,

OCTOBER 1993 FORM 14148

OCTOBER 2002 (PAGE 1 OF 3) FORM 14274

11 RECOMMENDED SPARES LIST

OCTOBER 2002 (PAGE 2 OF 3) FORM 14274

14 STORAGE, HANDLING, & INSPECTION DURING STORAGE

OCTOBER 2002 (PAGE 3 OF 3) FORM 14274

1 IK-545B Sootblower - Overall View

NOVEMBER 1999 FORM 14275

FIG.2 CLEANING PRINCIPLE